Advanced Technology Composite Fuselage-Structural Performance PDF Download

Author: National Aeronautics and Space Administration (NASA)
Publisher: Createspace Independent Publishing Platform
ISBN: 9781722925130
Category :
Languages : en
Pages : 102

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Book Description
Boeing is studying the technologies associated with the application of composite materials to commercial transport fuselage structure under the NASA-sponsored contracts for Advanced Technology Composite Aircraft Structures (ATCAS) and Materials Development Omnibus Contract (MDOC). This report addresses the program activities related to structural performance of the selected concepts, including both the design development and subsequent detailed evaluation. Design criteria were developed to ensure compliance with regulatory requirements and typical company objectives. Accurate analysis methods were selected and/or developed where practical, and conservative approaches were used where significant approximations were necessary. Design sizing activities supported subsequent development by providing representative design configurations for structural evaluation and by identifying the critical performance issues. Significant program efforts were directed towards assessing structural performance predictive capability. The structural database collected to perform this assessment was intimately linked to the manufacturing scale-up activities to ensure inclusion of manufacturing-induced performance traits. Mechanical tests were conducted to support the development and critical evaluation of analysis methods addressing internal loads, stability, ultimate strength, attachment and splice strength, and damage tolerance. Unresolved aspects of these performance issues were identified as part of the assessments, providing direction for future development. Walker, T. H. and Minguet, P. J. and Flynn, B. W. and Carbery, D. J. and Swanson, G. D. and Ilcewicz, L. B. Langley Research Center COMPOSITE STRUCTURES; FUSELAGES; TRANSPORT AIRCRAFT; STRUCTURAL DESIGN; PERFORMANCE PREDICTION; COMPOSITE MATERIALS; MANUFACTURING; DATA BASES; STRUCTURAL FAILURE; DAMAGE ASSESSMENT; LOADS (FORCES); AEROELASTICITY; TOLERANCES (MECHANICS); DESIGN ANALYSIS; PREDICTION ANALYSIS TECHNIQUES; STABILITY...

Author: National Aeronautics and Space Administration (NASA)
Publisher: Createspace Independent Publishing Platform
ISBN: 9781722924478
Category :
Languages : en
Pages : 190

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Book Description
The goal of Boeing's Advanced Technology Composite Aircraft Structures (ATCAS) program is to develop the technology required for cost-and weight-efficient use of composite materials in transport fuselage structure. Carbon fiber reinforced epoxy was chosen for fuselage skins and stiffening elements, and for passenger and cargo floor structures. The automated fiber placement (AFP) process was selected for fabrication of stringer-stiffened and sandwich skin panels. Circumferential and window frames were braided and resin transfer molded (RTM'd). Pultrusion was selected for fabrication of floor beams and constant-section stiffening elements. Drape forming was chosen for stringers and other stiffening elements cocured to skin structures. Significant process development efforts included AFP, braiding, RTM, autoclave cure, and core blanket fabrication for both sandwich and stiffened-skin structure. Outer-mold-line and inner-mold-line tooling was developed for sandwich structures and stiffened-skin structure. The effect of design details, process control and tool design on repeatable, dimensionally stable, structure for low cost barrel assembly was assessed. Subcomponent panels representative of crown, keel, and side quadrant panels were fabricated to assess scale-up effects and manufacturing anomalies for full-scale structures. Manufacturing database including time studies, part quality, and manufacturing plans were generated to support the development of designs and analytical models to access cost, structural performance, and dimensional tolerance. Wilden, K. S. and Harris, C. G. and Flynn, B. W. and Gessel, M. G. and Scholz, D. B. and Stawski, S. and Winston, V. Langley Research Center COMPOSITE STRUCTURES; MANUFACTURING; FUSELAGES; TRANSPORT AIRCRAFT; SANDWICH STRUCTURES; RESIN TRANSFER MOLDING; DATA BASES; FABRICATION; EPOXY MATRIX COMPOSITES; CARBON FIBERS; STIFFENING; STRINGERS; TOOLING; PULTRUSION; PANELS; DIMENSIONAL STABILITY; SKIN (STRUCTURAL MEMBER); BRAIDED CO...

Author: National Aeronautics and Space Administration (NASA)
Publisher: Createspace Independent Publishing Platform
ISBN: 9781723506246
Category :
Languages : en
Pages : 250

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Book Description
The goal of Boeing's Advanced Technology Composite Aircraft Structures (ATCAS) program was to develop the technology required for cost and weight efficient use of composite materials in transport fuselage structure. This contractor report describes results of material and process selection, development, and characterization activities. Carbon fiber reinforced epoxy was chosen for fuselage skins and stiffening elements and for passenger and cargo floor structures. The automated fiber placement (AFP) process was selected for fabrication of monolithic and sandwich skin panels. Circumferential frames and window frames were braided and resin transfer molded (RTM'd). Pultrusion was selected for fabrication of floor beams and constant section stiffening elements. Drape forming was chosen for stringers and other stiffening elements. Significant development efforts were expended on the AFP, braiding, and RTM processes. Sandwich core materials and core edge close-out design concepts were evaluated. Autoclave cure processes were developed for stiffened skin and sandwich structures. The stiffness, strength, notch sensitivity, and bearing/bypass properties of fiber-placed skin materials and braided/RTM'd circumferential frame materials were characterized. The strength and durability of cocured and cobonded joints were evaluated. Impact damage resistance of stiffened skin and sandwich structures typical of fuselage panels was investigated. Fluid penetration and migration mechanisms for sandwich panels were studied. Scholz, D. B. and Dost, E. F. and Flynn, B. W. and Ilcewicz, L. B. and Nelson, K. M. and Sawicki, A. J. and Walker, T. H. and Lakes, R. S. Langley Research Center NASA-CR-4731, NAS 1.26:4731 NAS1-18889; NAS1-20013; RTOP 510-02-13-01...

Author: National Aeronautics and Space Administration (NASA)
Publisher: Createspace Independent Publishing Platform
ISBN: 9781722924836
Category :
Languages : en
Pages : 140

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Book Description
The Advanced Technology Composite Aircraft Structures (ATCAS) program has studied transport fuselage structure with a large potential reduction in the total direct operating costs for wide-body commercial transports. The baseline fuselage section was divided into four 'quadrants', crown, keel, and sides, gaining the manufacturing cost advantage possible with larger panels. Key processes found to have savings potential include (1) skins laminated by automatic fiber placement, (2) braided frames using resin transfer molding, and (3) panel bond technology that minimized mechanical fastening. The cost and weight of the baseline fuselage barrel was updated to complete Phase B of the program. An assessment of the former, which included labor, material, and tooling costs, was performed with the help of design cost models. Crown, keel, and side quadrant cost distributions illustrate the importance of panel design configuration, area, and other structural details. Composite sandwich panel designs were found to have the greatest cost savings potential for most quadrants. Key technical findings are summarized as an introduction to the other contractor reports documenting Phase A and B work completed in functional areas. The current program status in resolving critical technical issues is also highlighted. Ilcewicz, L. B. and Smith, P. J. and Hanson, C. T. and Walker, T. H. and Metschan, S. L. and Mabson, G. E. and Wilden, K. S. and Flynn, B. W. and Scholz, D. B. and Polland, D. R. and Fredrikson, H. G. and Olson, J. T. and Backman, B. F. Langley Research Center COMPOSITE STRUCTURES; FUSELAGES; TRANSPORT AIRCRAFT; COST REDUCTION; SANDWICH STRUCTURES; OPERATING COSTS; COMPOSITE MATERIALS; RESIN TRANSFER MOLDING; WEIGHT REDUCTION; MANUFACTURING; STRUCTURAL DESIGN; TOOLING; DESIGN TO COST; MAINTENANCE; SKIN (STRUCTURAL MEMBER)...

Author: National Aeronautics and Space Administration (NASA)
Publisher: Createspace Independent Publishing Platform
ISBN: 9781722924737
Category :
Languages : en
Pages : 154

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Book Description
Under the NASA-sponsored contracts for Advanced Technology Composite Aircraft Structures (ATCAS) and Materials Development Omnibus Contract (MDOC), Boeing is studying the technologies associated with the application of composite materials to commercial transport fuselage structure. Included in the study is the incorporation of maintainability and repairability requirements of composite primary structure into the design. This contractor report describes activities performed to address maintenance issues in composite fuselage applications. A key aspect of the study was the development of a maintenance philosophy which included consideration of maintenance issues early in the design cycle, multiple repair options, and airline participation in design trades. Fuselage design evaluations considered trade-offs between structural weight, damage resistance/tolerance (repair frequency), and inspection burdens. Analysis methods were developed to assess structural residual strength in the presence of damage, and to evaluate repair design concepts. Repair designs were created with a focus on mechanically fastened concepts for skin/stringer structure and bonded concepts for sandwich structure. Both a large crown (skintstringer) and keel (sandwich) panel were repaired. A compression test of the keel panel indicated the demonstrated repairs recovered ultimate load capability. In conjunction with the design and manufacturing developments, inspection methods were investigated for their potential to evaluate damaged structure and verify the integrity of completed repairs. Flynn, B. W. and Bodine, J. B. and Dopker, B. and Finn, S. R. and Griess, K. H. and Hanson, C. T. and Harris, C. G. and Nelson, K. M. and Walker, T. H. and Kennedy, T. C. and Nahan, M. F. Langley Research Center FUSELAGES; MAINTENANCE; COMPOSITE STRUCTURES; BOLTED JOINTS; BONDED JOINTS; TRANSPORT AIRCRAFT; CIVIL AVIATION; MAINTAINABILITY; STRINGERS; STRUCTURAL WEIGHT; INSPECTION; TRADEOFFS; SKIN (STRUCTURAL MEMBER); ...

Author: Paul A. Lagace
Publisher:
ISBN:
Category :
Languages : en
Pages : 29

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Book Description
Introduction: The aircraft industry continues to pursue the use of advanced composite materials in aircraft structures in order to save weight and produce more efficient, and potentially cost-effective, aircraft. As of the beginning of this work in 1989, advanced composite materials had been applied for over two decades in a number of aerospace structures. Although the list of applications at that time (including aircraft such as the Boeing 757 and 767, the Beech Starship, The Osprey V-22, the F-18, and the AV-8B) represented important engineering achievements, the National Research Council Committee on the Status and Viability of Composite Materials for Aircraft Structures noted in its 1987 report that: "Despite these and other examples, filamentary composites still have significant unfulfilled potential for increasing aircraft productivity [1]." An area identified for application of composite materials, at the time of this work, was primary load-bearing structure in large commercial transports. Although smaller aircraft, such as the Beech Starship, have had primary loadbearing structure, such as wings and fuselages, constructed from composite materials, it is not practical to geometrically scale up a general aviation aircraft into a large transport due to differences such as in the loading indices. There was thus an identified need to pursue further research into the behavior of composite materials and their structures so that increased benefits, such as further reduction in the structural load fraction, can be achieved. Two critical technology areas as related to aircraft are the technologies associated with wings and with fuselages. In considering such applications, an overriding concern is safety. In and of itself, safety is a very wide ranging issues. But, with regard to structure, safety generally deals with the ability of the structure to maintain its integrity while subjected to the loads and environment experienced in operation. A central issue in the case of a primary load-bearing structure is damage. There are three facets to the central issue of damage: damage resistance, which involves the ability of a structure to undergo events without (minimal) damage occurring and which thus addresses the question "how does damage get there"; damage tolerance, which involves the ability of a structure to undergo loading with damage present without failing and which thus addresses the question of "when does damage propagate/cause failure?"; and damage arrest, which involves the ability of a structural configuration to stop propagating damage before such damage causes catastrophic failure and which thus addresses the question "how can the propagating damage be stopped?". Answers to these three questions must be provided in order for a safe structure to be designed. In addressing these issues as they pertain to fuselage configurations made from advanced composite materials, a number of other important technical issues arise. A key issue is that of orthotropy. Due to their inherent orthotropy, composite materials provide the designer the ability to vary the properties of the structure with the structural needs in the various directions of the structure. This "structural tailoring" will affect the damage issues previously enumerated and the designer needs to know how to best tailor the specific fuselage structure to meet the structural needs and to meet the demands placed by the damage issues of resistance, tolerance, and arrest. A further issue deals with the effects of size. Aircraft fuselages are constructed of various dimensions and test articles are often of much smaller size. In order to apply the technology across the entire spectrum of possible sizes, it is necessary to understand the role of scale in the three damage issues. If scaling "laws" or working principles can be established, then the data and lessons learned on one fuselage can be more readily transferred to that of a different geometry and size. A final issue that could be immediately identified was that of configuration and its effects on the three facets of damage. A common structural configuration for aircraft fuselages is that of skin and frame where the underlying frame carries the longitudinal and bending loads while the skin provides the pressure surface and shear capability. In contrast to this typical approach used in metallic airframes, the Beech Starship fuselage has a more monocoque configuration utilizing a sandwich structure with inner and outer graphite/epoxy skins surrounding a Nomex honeycomb core. In this configuration, the sandwich skins provide the bending, longitudinal, pressure, and shear capabilities of the fuselage. In the skin/frame configuration, issues such as the interaction between the skin and the frame and how the skin is attached to the frame must be treated. In the sandwich configuration, issues concerning sandwich construction including debonding of the skins from the honeycomb must be addressed. Again, these need to be addressed in the context of the three facets of damage as to how they affect damage resistance, damage tolerance, and damage arrest. The underlying need is to provide the structural designer with the capability to choose the structural configuration that will most efficiently carry out its mission.

Author: National Aeronautics and Space Administration (NASA)
Publisher: Createspace Independent Publishing Platform
ISBN: 9781722947118
Category :
Languages : en
Pages : 146

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Book Description
Relationships between manufacturing costs and design details must be understood to promote the application of advanced composite technologies to transport fuselage structures. A team approach, integrating the disciplines responsible for aircraft structural design and manufacturing, was developed to perform cost and weight trade studies for a twenty-foot diameter aft fuselage section. Baseline composite design and manufacturing concepts were selected for large quadrant panels in crown, side, and keel areas of the fuselage section. The associated technical issues were also identified. Detailed evaluation of crown panels indicated the potential for large weight savings and costs competitive with aluminum technology in the 1995 timeframe. Different processes and material forms were selected for the various elements that comprise the fuselage structure. Additional cost and weight savings potential was estimated for future advancements. Ilcewicz, L. B. and Walker, T. H. and Willden, K. S. and Swanson, G. D. and Truslove, G. and Metschan, S. L. and Pfahl, C. L. Unspecified Center AIRCRAFT DESIGN; COMPOSITE STRUCTURES; DESIGN ANALYSIS; FUSELAGES; MANUFACTURING; TECHNOLOGY ASSESSMENT; TRANSPORT AIRCRAFT; AIRCRAFT STRUCTURES; ALUMINUM; COMPOSITE MATERIALS; COST REDUCTION; KEELS; PANELS...

Author: Committee on New Materials for Advanced Civil Aircraft
Publisher: National Academies Press
ISBN: 0309588782
Category : Technology & Engineering
Languages : en
Pages : 99

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Book Description
The major objective of this book was to identify issues related to the introduction of new materials and the effects that advanced materials will have on the durability and technical risk of future civil aircraft throughout their service life. The committee investigated the new materials and structural concepts that are likely to be incorporated into next generation commercial aircraft and the factors influencing application decisions. Based on these predictions, the committee attempted to identify the design, characterization, monitoring, and maintenance issues that are critical for the introduction of advanced materials and structural concepts into future aircraft.

Author: Ahmed Khairy Noor
Publisher: AIAA
ISBN: 9781563471162
Category : Technology & Engineering
Languages : en
Pages : 544

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Book Description
Drawn from early volumes of Aerospace America and its antecedents, this book rescues the insights, concerns, and dreams of dozens of structural engineers for the next generation of aerospace scientists and engineers. Written by eminent individuals in structures, this book provides accessible source material for university-level design courses in aerospace engineering. The first paper in Structures Technology deals with new structures for future aerospace systems and provides a contrast between our current thinking and past technology plans. Succeeding papers are historical reports covering materials and structures, general structures technology, aircraft structures, space structures, and structural dynamics technology. You will also find sections covering structural configurations, thermal protection systems, subsonic aircraft, supersonic and hypersonic vehicles and structures for space systems.

Author: D. J. Watts
Publisher: BiblioGov
ISBN: 9781289144708
Category :
Languages : en
Pages : 186

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Book Description
A study was conducted to define the technology and data needed to support the introduction of advanced composites in the future production of fuselage structure in large transport aircraft. Fuselage structures of six candidate airplanes were evaluated for the baseline component. The MD-100 was selected on the basis of its representation of 1990s fuselage structure, an available data base, its impact on the schedule and cost of the development program, and its availability and suitability for flight service evaluation. Acceptance criteria were defined, technology issues were identified, and a composite fuselage technology development plan, including full-scale tests, was identified. The plan was based on composite materials to be available in the mid to late 1980s. Program resources required to develop composite fuselage technology are estimated at a rough order of magnitude to be 877 man-years exclusive of the bird strike and impact dynamic test components. A conceptual composite fuselage was designed, retaining the basic MD-100 structural arrangement for doors, windows, wing, wheel wells, cockpit enclosure, major bulkheads, etc., resulting in a 32 percent weight savings.