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An assessment of the State-of-the-Art in the design and manufacturing of large composite structures has been conducted. The focus of the assessment is large structural components in commercial and military aircraft. Applications of composites are reviewed for commercial transport aircraft, general aviation aircraft, rotorcraft, and military aircraft.
The failure mechanisms in the fatigue of composite materials are analyzed in terms of the requirements for designing fatigue-critical composite structures. Fiber reinforced polymers, fiber reinforced metals, fatigue of composite structures, and composite design considerations are discussed. It is concluded that composite materials offer the engineer the opportunity for tailoring stiffness in different directions for designing dynamic components.
The design of tow-steered composites is one of the most popular and promising topics under the class of variable stiffness structures. In this work, the authors propose a new design framework and tool for the optimization of tow-steered composites. Mechanics of structure genome (MSG) provides accurate computation of plate/shell section properties including thick and highly curved structures. The computed section properties can be directly used in commercial computer-aided engineering tools. Tow-steered composites are modeled through a design framework wherein tow paths are parameterized in a general way and projected onto a finite element mesh, and MSG calculates the local shell/plate properties. The result is a complete workflow from design parameter input to structural performance evaluation. An open-source optimization software package is used to enable constrained optimization of structural stiffness for the broad tow-steered composite design space. Numerical examples are provided to demonstrate the capabilities of this tool and the promise and potential of tow-steered designs that optimize structural performance while satisfying manufacturing constraints.
The design of tow-steered composites is one of the most popular and promising topics under the class of variable stiffness structures. In this work, the authors propose a new design framework and tool for the optimization of tow-steered composites. Mechanics of structure genome (MSG) provides accurate computation of plate/shell section properties including thick and highly curved structures. The computed section properties can be directly used in commercial computer-aided engineering tools. Tow-steered composites are modeled through a design framework wherein tow paths are parameterized in a general way and projected onto a finite element mesh, and MSG calculates the local shell/plate properties. The result is a complete workflow from design parameter input to structural performance evaluation. An open-source optimization software package is used to enable constrained optimization of structural stiffness for the broad tow-steered composite design space. Numerical examples are provided to demonstrate the capabilities of this tool and the promise and potential of tow-steered designs that optimize structural performance while satisfying manufacturing constraints.
In support of the Deep Space Habitat project a number of composite rack prototypes were developed, designed, fabricated and tested to various extents ( with the International Standard Payload Rack configuration, or crew quarters, as a baseline). This paper focuses specifically on a composite rack prototype with a direct tie in to Space Station hardware. The outlined prototype is an all composite construction, excluding metallic fasteners, washers, and their associated inserts. The rack utilizes braided carbon composite tubing for the frame with the sidewalls, backwall and flooring sections utilizing aircraft grade composite honeycomb sandwich panels. Novel additively manufactured thermoplastic joints and tube inserts were also developed in support of this effort. Joint and tube insert screening tests were conducted at a preliminary level. The screening tests allowed for modification, and enhancement, of the fabrication and design approaches, which will be outlined. The initial joint tests did not include mechanical fasteners. Adhesives were utilized at the joint to composite tube interfaces, along with mechanical fasteners during final fabrication (thus creating a stronger joint than the adhesive only variant). In general the prototype was focused on a potential in-space assembly approach, or kit-of-parts construction concept, which would not necessarily require the inclusion of an adhesive in the joint regions. However, given the tie in to legacy Station hardware (and potential flight loads with imbedded hardware mass loadings), the rack was built as stiff and strong as possible. Preliminary torque down tests were also conducted to determine the feasibility of mounting the composite honeycomb panels to the composite tubing sections via the additively manufactured tube inserts. Additional fastener torque down tests were also conducted with inserts (helicoils) imbedded within the joints. Lessons learned are also included and discussed.
Optimum hat-stiffened compression panel designs are determined by a structural synthesis technique. The effects of simplifying assumptions made in the buckling analysis for the optimization program are investigated by a linked plate element program. Optimization results for hat-stiffened graphite-epoxy panels show a 50-percent weight savings over optimized aluminum panels. Composite panels are shown to possess a variety of proportions at nearly constant weight.
The objective of this work was to develop design concepts for a cooled ceramic vane to be used in the first stage of the High Pressure Turbine(HPT). To insure that the design concepts were relevant to the gas turbine industry needs, Honeywell International Inc. was subcontracted to provide technical guidance for this work. The work performed under this contract can be divided into three broad categories. The first was an analysis of the cycle benefits arising from the higher temperature capability of Ceramic Matrix Composite(CMC) compared with conventional metallic vane materials. The second category was a series of structural analyses for variations in the internal configuration of first stage vane for the High Pressure Turbine(HPT) of a CF6 class commercial airline engine. The third category was analysis for a radial cooled turbine vanes for use in turboshaft engine applications. The size, shape and internal configuration of the turboshaft engine vanes were selected to investigate a cooling concept appropriate to small CMC vanes.
Background Genomic islands (GIs) are mobile genetic elements that integrate site-specifically into bacterial chromosomes, bearing genes that affect phenotypes such as pathogenicity and metabolism. GIs typically occur sporadically among related bacterial strains, enabling comparative genomic approaches to GI identification. For a candidate GI in a query genome, the number of reference genomes with a precise deletion of the GI serves as a support value for the GI. Our comparative software for GI identification was slowed by our original use of large reference genome databases (DBs). Here we explore smaller species-focused DBs. Results With increasing DB size, recovery of our reliable prophage GI calls reached a plateau, while recovery of less reliable GI calls (FPs) increased rapidly as DB sizes exceeded ~500 genomes; i.e., overlarge DBs can increase FP rates. Paradoxically, relative to prophages, FPs were both more frequently supported only by genomes outside the species and more frequently supported only by genomes inside the species; this may be due to their generally lower support values. Setting a DB size limit for our SMA ll R anked T ailored (SMART) DB design speeded runtime ~65-fold. Strictly intra-species DBs would tend to lower yields of prophages for small species (with few genomes available); simulations with large species showed that this could be partially overcome by reaching outside the species to closely related taxa, without an FP burden. Employing such taxonomic outreach in DB design generated redundancy in the DB set; as few as 2984 DBs were needed to cover all 47894 prokaryotic species. Conclusions Runtime decreased dramatically with SMART DB design, with only minor losses of prophages. We also describe potential utility in other comparative genomics projects.
Design concepts for fiber-metal matrix composites for advanced gas turbine blades
We report picosecond bunch length measurements using an interferometric method for a 3 MeV electron beam having bunch charge ranging from 1 to 14 pC. The method senses the single-cycle sub-terahertz (THz) pulse emitted by each electron bunch as coherent transition radiation which, in turn, is analyzed using a Michelson-type interferometer, forming an interferogram that is then processed to yield the nominal electron bunch length. This sub-THz coherent radiation intensity was measured using a quasi-optical detector (QOD) operated at room temperature. This experiment was quite challenging since the divergence angle of the sub-THz pulse emitted by the low-energy electron bunch exceeds ±10°, and its pulse energy at the entrance to the detector was as low as 100 pJ. When compared to a conventional helium-cooled silicon composite bolometer designed for frequencies above 0.5 THz, the QOD provided much better signal-to-noise ratio in the ~80 GHz frequency range, which was critical for the successful measurement of the bunch length.
An optimization procedure is developed for addressing the design of composite tilt rotor blades. A comprehensive technique, based on a higher-order laminate theory, is developed for the analysis of the thick composite load-carrying sections, modeled as box beams, in the blade. The theory, which is based on a refined displacement field, is a three-dimensional model which approximates the elasticity solution so that the beam cross-sectional properties are not reduced to one-dimensional beam parameters. Both inplane and out-of-plane warping are included automatically in the formulation. The model can accurately capture the transverse shear stresses through the thickness of each wall while satisfying stress free boundary conditions on the inner and outer surfaces of the beam. The aerodynamic loads on the blade are calculated using the classical blade element momentum theory. Analytical expressions for the lift and drag are obtained based on the blade planform with corrections for the high lift capability of rotor blades. The aerodynamic analysis is coupled with the structural model to formulate the complete coupled equations of motion for aeroelastic analyses. Finally, a multidisciplinary optimization procedure is developed to improve the aerodynamic, structural and aeroelastic performance of the tilt rotor aircraft. The objective functions include the figure of merit in hover and the high speed cruise propulsive efficiency. Structural, aerodynamic and aeroelastic stability criteria are imposed as constraints on the problem. The Kreisselmeier-Steinhauser function is used to formulate the multiobjective function problem. The search direction is determined by the Broyden-Fletcher-Goldfarb-Shanno algorithm. The optimum results are compared with the baseline values and show significant improvements in the overall performance of the tilt rotor blade.
A structural assessment by integrating finite-element methods (FEM) and a nondestructive evaluation (NDE) of two flywheel rotor assemblies is presented. Composite rotor A is pancake like with a solid hub design, and composite rotor B is cylindrical with a hollow hub design. Detailed analyses under combined centrifugal and interference-fit loading are performed. Two- and three-dimensional stress analyses and two-dimensional fracture mechanics analyses are conducted. A comparison of the structural analysis results obtained with those extracted via NDE findings is reported. Contact effects due to press-fit conditions are evaluated. Stress results generated from the finite-element analyses were corroborated with the analytical solution. Cracks due to rotational loading up to 49 000 rpm for rotor A and 34 000 rpm for rotor B were successfully imaged with NDE and predicted with FEM and fracture mechanics analyses. A procedure that extends current structural analysis to a life prediction tool is also defined.
The continuing development of PMR-15 composite materials and their associated design properties is pacing the implementation of this technology on commercial aircraft. The guidelines that the FAA has issued regarding the certification of advanced composite structures are very significant with respect to future PMR-15 research and development activities. The FAA has issued an advisory circular dated 1-5-83 concerning guidelines for composite aircraft structures. Of particular significance to PMR-15 technology development is the reliance on combined environmental exposure and component testing, coupled with the stipulation that reliance on previous experience be limited to where common structures and materials have been used for a similar function. Critical environmental exposures for commercial propulsion structures include 50,000 cycle service life, exposure to skydrol, moisture and other fluids, and nacelle fire conditions.
The results of an assessment of the state-of-the-art in the design and manufacturing of large composite structures are described. The focus of the assessment is on the use of polymeric matrix composite materials for large airframe structural components. such as those in commercial and military aircraft and space transportation vehicles. Applications of composite materials for large commercial transport aircraft, general aviation aircraft, rotorcraft, military aircraft. and unmanned rocket launch vehicles are reviewed. The results of the assessment of the state-of-the-art include a summary of lessons learned, examples of current practice, and an assessment of advanced technologies under development. The results of the assessment conclude with an evaluation of the future technology challenges associated with applications of composite materials to the primary structures of commercial transport aircraft and advanced space transportation vehicles.
Residual elements from scrap steel recycling, most notably copper, are known to result in hot shortness during thermomechanical processing and casting. As the concentration of copper and other residuals in steel scrap streams increases, Electric Arc Furnace (EAF) scrap recycling heats commonly use pig iron to dilute residuals below current limits. This work focuses on establishing residual element tolerant compositions and concomitant processing windows that can simultaneously mitigate issues from residuals during thermomechanical processing and, if possible, use these residuals to improve properties, yielding a more sustainable steel manufacturing pathway with a substantially smaller carbon footprint.
Elastic wave propagation and attenuation in a model fiber matrix was investigated. Damping characteristics in graphite epoxy composite materials were measured. A sound transmission test facility suitable to incorporate into NASA Ames wind tunnel for measurement of transmission loss due to sound generation in boundary layers was constructed. Measurement of transmission loss of graphite epoxy composite panels was also included.
For abstract, see N78-18133.
A comparison of program estimates of wing weight, material distribution. structural loads and elastic deformations with actual Northrop F-5A/B data is presented. Correlation coefficients obtained using data from a number of existing aircraft were computed for use in vehicle synthesis to estimate wing weights. The modifications necessary to adapt the WADES code for use in the ACSYNT program are described. Basic program flow and overlay structure is outlined. An example of the convergence of the procedure in estimating wing weights during the synthesis of a vehicle to satisfy F-5 mission requirements is given. A description of inputs required for use of the WADES program is included.