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The long-term durability of those advanced composite materials which are applicable to aircraft structures was discussed. The composite components of various military and commercial aircraft and helicopters were reviewed. Both ground exposure and flight service were assessed in terms of their impact upon composite structure durability. The ACEE Program is mentioned briefly.
Advanced material systems and designs require improved nondestructive evaluation (NDE) techniques for quality control, failure analysis and properties monitoring. Some advanced NDE techniques such as infrared scanning systems, laser holographic applications and the use of the Mossbauer effect are outlined. Applications of these techniques are discussed for evaluating the new space shuttle external insulation materials, aircraft structures and engine components, and precursors to crack initiation and growth.
Manufacturers are developing composite versions of structural components on existing aircraft. Development involves testing of various material options before selecting one and then extensive testing to develop an adequate data base of material strength and stiffness properties. Design options are narrowed through analysis and a varied spectrum of development tests on small and large subcomponents. In parallel with this, a suitable production process including economical ply preparation and cure at high temperature and pressure is evolved, tools are designed and fabricated, and full scale components are then manufactured for ground qualification tests, flight tests, and airline service. The various tests include many that are required by the FAA for flight certification, which must precede airline service. Inspection and repair methods to insure adequate maintenance in service are also developed.
A two page discussion of non-aerospace seating applications and the design of NASA's safety seat cushioning (SSC) is presented. The SSC was designed for both safety and comfort in order to replace polyurethane cushioning which is flammable and produces lethal fumes upon combustion. The SSC is composed of advanced fabric reinforced composites and is lightweight, fire-retardent, and crashworthy. The seat design consists of central elliptical tubular spring supports made of fire-resistant and fatigue-durable composites surrounded by a fire-blocking sheath. The cushioning is made crashworthy by incorporating energy-absorbing, viscoelastic layers between the nested, elliptical-hoop springs. The design is intended to provide comfortable seating that meets aircraft-loading requirements without using the conventional polyurethane materials. The designs of an aircraft seat and structural components of the SSC are also presented.
Recent aerospace industry trends have resulted in an increased demand for real-time, effective techniques for in-flight structural health monitoring. A promising technique for damage diagnosis uses electrical impedance measurements of semiconductive materials. By applying a small electrical current into a material specimen and measuring the corresponding voltages at various locations on the specimen, changes in the electrical characteristics due to the presence of damage can be assessed. An artificial neural network uses these changes in electrical properties to provide an inverse solution that estimates the location and magnitude of the damage. The advantage of the electrical impedance method over other damage diagnosis techniques is that it uses the material as the sensor. Simple voltage measurements can be used instead of discrete sensors, resulting in a reduction in weight and system complexity. This research effort extends previous work by employing finite element method models to improve accuracy of complex models with anisotropic conductivities and by enhancing the computational efficiency of the inverse techniques. The paper demonstrates a proof of concept of a damage diagnosis approach using electrical impedance methods and a neural network as an effective tool for in-flight diagnosis of structural damage to aircraft components.
Compositions of, and processes for fabricating, high-temperature composite materials from phenylethynyl-terminated imide (PETI) oligomers by resin-transfer molding (RTM) and resin infusion have been developed. Composites having a combination of excellent mechanical properties and long-term high-temperature stability have been readily fabricated. These materials are particularly useful for the fabrication of high-temperature structures for jet-engine components, structural components on highspeed aircraft, spacecraft, and missiles. Phenylethynyl-terminated amide acid oligomers that are precursors of PETI oligomers are easily made through the reaction of a mixture of aromatic diamines with aromatic dianhydrides at high stoichiometric offsets and 4-phenylethynylphthalic anhydride (PEPA) as an end-capper in a polar solvent such as N-methylpyrrolidinone (NMP). These oligomers are subsequently cyclodehydrated -- for example, by heating the solution in the presence of toluene to remove the water by azeotropic distillation to form low-molecular-weight imide oligomers. More precisely, what is obtained is a mixture of PETI oligomeric species, spanning a range of molecular weights, that exhibits a stable melt viscosity of less than approximately 60 poise (and generally less than 10 poise) at a temperature below 300 deg C. After curing of the oligomers at a temperature of 371 deg C, the resulting polymer can have a glass-transition temperature (Tg) as high as 375 C, the exact value depending on the compositions.
The ability to extend the valid frequency range for finite element based structural dynamic predictions using detailed models of the structural components and attachment interfaces is examined for several stiffened aircraft fuselage structures. This extended dynamic prediction capability is needed for the integration of mid-frequency noise control technology. Beam, plate and solid element models of the stiffener components are evaluated. Attachment models between the stiffener and panel skin range from a line along the rivets of the physical structure to a constraint over the entire contact surface. The finite element models are validated using experimental modal analysis results. The increased frequency range results in a corresponding increase in the number of modes, modal density and spatial resolution requirements. In this study, conventional modal tests using accelerometers are complemented with Scanning Laser Doppler Velocimetry and Electro-Optic Holography measurements to further resolve the spatial response characteristics. Whenever possible, component and subassembly modal tests are used to validate the finite element models at lower levels of assembly. Normal mode predictions for different finite element representations of components and assemblies are compared with experimental results to assess the most accurate techniques for modeling aircraft fuselage type structures.
The Combined Loads Test System (COLTS) is a new structures test complex that is being developed at NASA Langley Research Center (LaRC) to test large curved panels and cylindrical shell structures. These structural components are representative of aircraft fuselage sections of subsonic and supersonic transport aircraft and cryogenic tank structures of reusable launch vehicles. Test structures are subjected to combined loading conditions that simulate realistic flight load conditions. The facility consists of two pressure-box test machines and one combined loads test machine. Each test machine possesses a unique set of requirements or research data acquisition and real-time data display. Given the complex nature of the mechanical and thermal loads to be applied to the various research test articles, each data system has been designed with connectivity attributes that support both data acquisition and data management functions. This paper addresses the research driven data acquisition requirements for each test machine and demonstrates how an open architecture data system design not only meets those needs but provides robust data sharing between data systems including the various control systems which apply spectra of mechanical and thermal loading profiles.
The ability to extend the valid frequency range for finite element based structural dynamic predictions using detailed models of the structural components and attachment interfaces is examined for several stiffened aircraft fuselage structures. This extended dynamic prediction capability is needed for the integration of mid-frequency noise control technology. Beam, plate and solid element models of the stiffener components are evaluated. Attachment models between the stiffener and panel skin range from a line along the rivets of the physical structure to a constraint over the entire contact surface. The finite element models are validated using experimental modal analysis results.
A composite wing extension was designed for a typical general aviation aircraft to improve lift curve slope, dihedral effect, and lift to drag ratio. Advanced composite materials were used in the design to evaluate their use as primary structural components in general aviation aircraft. Extensive wind tunnel tests were used to evaluate six extension shapes. The extension shape chosen as the best choice was 28 inches long with a total area of 17 square feet. Subsequent flight tests showed the wing extension's predicted aerodynamic improvements to be correct. The structural design of the wing extension consisted of a hybrid laminate carbon core with outer layers of Kevlar - layed up over a foam interior which acted as an internal support. The laminate skin of the wing extension was designed from strength requirements, and the foam core was included to prevent buckling. A joint lap was recommended to attach the wing extension to the main wing structure.
NASA research and development on advanced aeronautical structures technology related to flight safety is reviewed. The effort is categorized as research in the technology base and projects sponsored by the Aircraft Energy Efficiency (ACEE) Project Office. Base technology research includes mechanics of composite structures, crash dynamics, and landing dynamics. The ACEE projects involve development and fabrication of selected composite structural components for existing commercial transport aircraft. Technology emanating from this research is intended to result in airframe structures with improved efficiency and safety.
Inflatable tubular structures that have annular cross sections rigidized with foams, and the means of erecting such structures in the field, are undergoing development. Although the development effort has focused on lightweight structural booms to be transported in compact form and deployed in outer space, the principles of design and fabrication are also potentially applicable to terrestrial structures, including components of ultralightweight aircraft, lightweight storage buildings and shelters, lightweight insulation, and sales displays. The use of foams to deploy and harden inflatable structures was first proposed as early as the 1960s, and has been investigated in recent years by NASA, the U.S. Air Force Research Laboratory, industry, and academia. In cases of deployable booms, most of the investigation in recent years has focused on solid cross sections, because they can be constructed relatively easily. However, solid-section foam-filled booms can be much too heavy for some applications. In contrast, booms with annular cross sections according to the present innovation can be tailored to obtain desired combinations of stiffness and weight through choice of diameters, wall thicknesses, and foam densities. By far the most compelling advantage afforded by this innovation is the possibility of drastically reducing weights while retaining or increasing the stiffnesses, relative to comparable booms that have solid foamfilled cross sections. A typical boom according to this innovation includes inner and outer polyimide film sleeves to contain foam that is injected between them during deployment.
Textile laminates, developed a number of years ago, have recently been shown to be applicable to primary aircraft structures for both small and large components. Such structures have the potential to reduce acquisition costs but require advanced automated processing to keep costs controlled while verifying product reliability and assuring structural integrity, durability and affordable life-cycle costs. Recently, resin systems and graphite-reinforced woven shapes have been developed that have the potential for improved RTM processes for aircraft structures. Ciba-Geigy, Brochier Division has registered an RTM prepreg reinforcement called 'Injectex' that has shown effectivity for aircraft components. Other novel approaches discussed are thermotropic resins producing components by injection molding and ceramic polymers for long-duration hot structures. The potential of such materials and processing will be reviewed along with initial information/data available to date.
The National Aeronautics and Space Administration (NASA) Armstrong Flight Research Center (AFRC) (Edwards, California, U.S.A.) has been flying various types of aircraft, including experimental ones requiring structural modifications. Many of these aircraft aren’t typically certified by the Federal Aviation Administration (FAA) or the Department of Defense (DoD), but NASA can provide its own airworthiness certification utilizing a riskbased approach. The AFRC has established review processes and procedures to identify hazards, manage risks associated with flight programs, ensure safe flight operations, and satisfy programmatic requirements. The Aerostructures Branch at AFRC developed guidelines for the structural safety of flight, covering experimental aircraft, new components, payloads, and modifications. These guidelines detail structural design, analysis, instrumentation, ground testing, and flight-test operational aspects. The guidelines are followed for defining the airworthiness plan throughout the life cycle of a project. The guidelines can be tailored to the risk posture of each individual project. This paper documents the details of the structural airworthiness plan for the X-57 aircraft, including existing, modified, and newly developed structures. Additionally, it covers the design requirements and load cases specific to the X-57 aircraft.
Hot section components of aircraft gas turbine engines are subjected to severe thermal structural loading conditions, especially during the start up and take off portions of the engine cycle. The most severe and damaging stresses and strains are those induced by the steep thermal gradients induced during the start up transient. These transient stresses and strains are also the most difficult to predict, in part because of the temperature gradients and distributions are not well known or readily predictable, and also because the cyclic elastic viscoplastic behavior of the materials at these extremes of temperature and strain are not well known or readily predictable. A broad spectrum of structures related technology programs is underway to address these deficiencies. One element of the structures program is developing improved time varying thermal mechanical load models for the entire engine mission cycle from start up to shutdown. Another major part of the program is the development of new and improved nonlinear 3-D finite elements and associated structural analysis programs, including the development of temporal elements with time dependent properties to account for creep effects in the materials and components.
This project included both research and education objectives. The goal of this project was to advance innovative research and education objectives in theoretical and computational probabilistic structural analysis, reliability, and life prediction for improved reliability and safety of structural components of aerospace and aircraft propulsion systems. Research and education partners included Glenn Research Center (GRC) and Southwest Research Institute (SwRI) along with the University of Texas at San Antonio (UTSA). SwRI enhanced the NESSUS (Numerical Evaluation of Stochastic Structures Under Stress) code and provided consulting support for NESSUS-related activities at UTSA. NASA funding supported three undergraduate students, two graduate students, a summer course instructor and the Principal Investigator. Matching funds from UTSA provided for the purchase of additional equipment for the enhancement of the Advanced Interactive Computational SGI Lab established during the first year of this Partnership Award to conduct the probabilistic finite element summer courses. The research portion of this report presents the cumulation of work performed through the use of the probabilistic finite element program, NESSUS, Numerical Evaluation and Structures Under Stress, and an embedded Material Strength Degradation (MSD) model. Probabilistic structural analysis provided for quantification of uncertainties associated with the design, thus enabling increased system performance and reliability. The structure examined was a Space Shuttle Main Engine (SSME) fuel turbopump blade. The blade material analyzed was Inconel 718, since the MSD model was previously calibrated for this material. Reliability analysis encompassing the effects of high temperature and high cycle fatigue, yielded a reliability value of 0.99978 using a fully correlated random field for the blade thickness. The reliability did not change significantly for a change in distribution type except for a change in distribution from Gaussian to Weibull for the centrifugal load. The sensitivity factors determined to be most dominant were the centrifugal loading and the initial strength of the material. These two sensitivity factors were influenced most by a change in distribution type from Gaussian to Weibull. The education portion of this report describes short-term and long-term educational objectives. Such objectives serve to integrate research and education components of this project resulting in opportunities for ethnic minority students, principally Hispanic. The primary vehicle to facilitate such integration was the teaching of two probabilistic finite element method courses to undergraduate engineering students in the summers of 1998 and 1999.
The development of graphite-epoxy composite structures for use on commercial transport aircraft is considered. Six components, three secondary structures, and three primary structures, are presently under development. The six components are described along with some of the key features of the composite designs and their projected weight savings.
The powered lift configurations under present development for STOL aircraft are the externally blown flap (EBF), involving direct jet impingement on the aircraft flaps, and the upper surface blown (USB), where the jet flow is attached on the upper surface of the wing and directed downwards. Towards the goal of developing scaling laws to predict unsteady loads imposed on the structural components of these STOL aircraft from small model tests, the near field fluctuating pressure behavior for the simplified cases of a round free cold jet and the same jet impinging on a flat plate was investigated. Examples are given of coherences, phase lags (giving convection velocities), and overall fluctuating pressure levels measured. The fluctuating pressure levels measured on the flat plate are compared to surface fluctuating pressure levels measured on full-scale powered-lift configuration models.