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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.
Hot-section components of aircraft gas turbine engines are subjected to severe thermal structural loading conditions, especially during the startup and takeoff portions of the engine cycle. The most severe and damaging stresses and strains are those induced by the steep thermal gradients induced during the startup transient. These transient stresses and strains are also the most difficult to predict, in part because the temperature gradients and distributions are not well known or readily predictable and, in part, 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 at the basic as well as the applied level. The three key program elements in the HOST structural analysis program are computations, constitutive modeling, and experiments for each research activity. Also shown are tables summarizing each of the activities.
A joint FAA/NASA program is discussed which is aimed at developing a reliable technology for the design of crashworthy light aircraft. This program encompasses the development of analytical methods, the definition of a survivable crash envelope, and the design of improved seat and restraint systems. A facility for full-scale crash-simulation testing is described along with the test method and results of five full-scale crash tests of twin-engine light aircraft. The major goals of the analytical portion of the program are outlined, including the development and validation of the analytical technique using simplified structural specimens that approximate aircraft components, as well as the mathematical modeling of the complete airframe and its subsequent dynamic analysis by substructuring and matrix reduction techniques.
The development of design load factors are investigated for aerospace and aircraft components and experiment support structures, which are subject to a simultaneous vehicle dynamic vibration and acoustically generated random vibration. The characteristics of the combined acceleration probability density function is determined, and an appropriate percentile level for the combined acceleration is selected. This mechanism is developed and graphical data is provided to select combined accelerations for most popular percentile levels.
The development of design load factors for aerospace and aircraft components and experiment support structures, which are subject to a simultaneous vehicle dynamic vibration (quasi-static) and acoustically generated random vibration, require the selection of a combination methodology. Typically, the procedure is to define the quasi-static and the random generated response separately, and arithmetically add or root sum square to get combined accelerations. Since the combination of a probabilistic and a deterministic function yield a probabilistic function, a viable alternate approach would be to determine the characteristics of the combined acceleration probability density function and select an appropriate percentile level for the combined acceleration. The following paper develops this mechanism and provides graphical data to select combined accelerations for most popular percentile levels.
A Statistical Energy Analysis is used to predict aircraft noise from the structural components. Structural-borne noise is vibration: (1) generated at one location; (2) transmitted by the structure to other locations; and (3) radiated into the cabin as noise. All results are presented in viewgraph format.
The fatigue resistance of a multiaxial braided (3-D) graphite/expoxy composite in both unnotched and post impacted conditions has been evaluated. The material tested is a (+/- 30/0 deg) multiaxial braid constructed from AS4/12K tow graphite fibers and British Petroleum E905L epoxy resin. These materials were braided as dry preforms and the epoxy was added using a resin transfer molding process (RTM). The unnotched and post-impact specimens were tested in compression-compression fatigue at 10 Hz with a stress ratio of R=10. The unnotched tension-tension fatigue specimens were tested at S Hz with a stress ration of R=0.1. Damage initiation and growth was documented through the application of radiography and ultrasonic through transmission (C-scans). Visible inspection of surface and edge damage was also noted to describe the initiation and progression of damage in these materials. The mechanisms leading to damage initiation were established and failure modes were determined. Stiffness and strength degradation were measured as a function of applied cycles. These 3-D braided composite results were compared to strain levels currently used to design primary structure in commercial aircraft composite components made from prepreg tape and autoclave cured.
NASA Langley Research Center is investigating a variety of techniques for mitigating aircraft accidents due to structural component failure. One technique under consideration combines distributed fiber optic strain sensing with an inverse finite element method for detecting and characterizing structural anomalies anomalies that may provide early indication of airframe structure degradation. The technique identifies structural anomalies that result in observable changes in localized strain but do not impact the overall surface shape. Surface shape information is provided by an Inverse Finite Element Method that computes full-field displacements and internal loads using strain data from in-situ fiberoptic sensors. This paper describes a prototype of such a system and reports results from a series of laboratory tests conducted on a test coupon subjected to increasing levels of damage.
The NASA Emergency Locator Transmitter Survivability and Reliability project was initiated in 2013 to assess the crash performance standards for the next generation of emergency locator transmitter (ELT) systems. Three Cessna 172 aircraft were acquired to perform crash testing at the NASA Langley Research Center Landing and Impact Research Facility. Full-scale crash tests were conducted in the summer of 2015 and each test article was subjected to severe, but survivable, impact conditions including a flare-to-stall during emergency landing, and two controlled-flight-into-terrain scenarios. Finite element analyses were performed to numerically simulate the aircraft response to the crash tests. The first test simulated impacting a concrete surface represented analytically by a rigid plane. Tests 2 and 3 simulated impacting a dirt surface represented analytically by an Eulerian grid of bric k elements using a Mohr-Coulomb material model. The objective of this paper is to summarize the test and analysis results for the three full-scale crash tests. Simulation models of the airframe which correlate well with the tests are needed for future studies of alternate ELT mounting configurations.
The NASA Emergency Locator Transmitter Survivability and Reliability project was initiated in 2013 to assess the crash performance standards for the next generation of emergency locator transmitter (ELT) systems. Three Cessna 172 aircraft were acquired to perform crash testing at the NASA Langley Research Center Landing and Impact Research Facility. Full-scale crash tests were conducted in the summer of 2015, and each test article was subjected to severe, but survivable, impact conditions including a flare-to-stall during emergency landing and two controlled-flight-into-terrain scenarios. Finite element analyses were performed to numerically simulate the aircraft response to the crash tests. The first test simulated impacting a concrete surface represented analytically by a rigid plane. Tests 2 and 3 simulated impacting a dirt surface represented analytically by an Eulerian grid of brick elements using a Mohr–Coulomb material model. The objective of this paper is to summarize the test and analysis results for the three full-scale crash tests. Simulation models of the airframe that correlate well with the tests are needed for future studies of alternate ELT mounting configurations.
The program involves controlled full scale crash testing, nonlinear structural analyses to predict large deflection elastoplastic response, and load attenuating concepts for use in improved seat and subfloor structure. Both analytical and experimental methods are used to develop expertise in these areas. Analyses include simplified procedures for estimating energy dissipating capabilities and comprehensive computerized procedures for predicting airframe response. These analyses are developed to provide designers with methods for predicting accelerations, loads, and displacements on collapsing structure. Tests on typical full scale aircraft and on full and subscale structural components are performed to verify the analyses and to demonstrate load attenuating concepts. A special apparatus was built to test emergency locator transmitters when attached to representative aircraft structure. The apparatus is shown to provide a good simulation of the longitudinal crash pulse observed in full scale aircraft crash tests.
Technique combines theoretical and empirical aspects of structural components. Experimental and analytical program produces test and analysis procedures for predicting extent of noise generated in aircraft. Purpose of program to develop ways of screening candidate materials considered for noise control and establish test procedures for verifying choice of particular control measure.
The application of composites in aerospace vehicle structures is reviewed. Research and technology program results and specific applications to space vehicles, aircraft engines, and aircraft and helicopter structures are discussed in detail. Particular emphasis is given to flight service evaluation programs that are or will be accumulating substantial experience with secondary and primary structural components on military and commercial aircraft to increase confidence in their use.
An assessment of the risk associated with accidents involving aircraft with carbon fiber composite structural components is examined. The individual fiber segments cause electrical and electronic equipment to fail under certain operating conditions. A Monte Carlo simulation model was used to computer the risk. Aircraft accidents with fire, release of carbon fiber material, entrainment of carbon fibers in a smoke plume transport of fibers downwind, transfer of some fibers/into the the interior of buildings, failures of electrical and electronic equipment, and economic impact of failures are discussed. Risk profiles were prepared for individual airports and the Nation. The vulnerability of electrical transmission equipment to carbon fiber incursion and aircraft accident total costs is investigated.
The primary reason for use of composites is to save structural weight. A well designed composite aircraft structure will usually save 25-30 percent of a well designed metal structure. The weight savings then translates into improved performance of the aircraft in measures of greater payload, increased flying range or improved efficiency - less use of fuel. Composite materials offer technical advantages. Key technical advantages that composites offer are high stiffness, tailored strength capability, fatigue resistance, and corrosion resistance. Low thermal expansion properties produce dimensionally stable structures over a wide range of temperature. Specialty resin 'char' forming characteristics in a fire environment offer potential fire barrier application and safer aircraft. The materials and processes of composite fabrication offer the potential for lower cost structures in the near future. The application of composite materials to aircraft are discussed.
In support of NASA s Habitat Demonstration Unit - Deep Space Habitat Prototype, a number of evolved structural sections were designed, fabricated, analyzed and installed in the 5 meter diameter prototype. The hardware consisted of three principal structural sections, and included the development of novel fastener insert concepts. The articles developed consisted of: 1) 1/8th of the primary flooring section, 2) an inner radius floor beam support which interfaced with, and supported (1), 3) two upper hatch section prototypes, and 4) novel insert designs for mechanical fastener attachments. Advanced manufacturing approaches were utilized in the fabrication of the components. The structural components were developed using current commercial aircraft constructions as a baseline (for both the flooring components and their associated mechanical fastener inserts). The structural sections utilized honeycomb sandwich panels. The core section consisted of 1/8th inch cell size Nomex, at 9 lbs/cu ft, and which was 0.66 inches thick. The facesheets had 3 plys each, with a thickness of 0.010 inches per ply, made from woven E-glass with epoxy reinforcement. Analysis activities consisted of both analytical models, as well as initial closed form calculations. Testing was conducted to help verify analysis model inputs, as well as to facilitate correlation between testing and analysis. Test activities consisted of both 4 point bending tests as well as compressive core crush sequences. This paper presents an overview of this activity, and discusses issues encountered during the various phases of the applied research effort, and its relevance to future space based habitats.
A discussion of modeling plan objectives, followed by a description of the AH-64A aircraft including all general features, major components, and primary and structure definitions are presented. Following the aircraft description, a discussion of the modeling guidelines and model checkout procedure are provided. The NASTRAN finite element analysis is set up to be suitable to predict both static internal loads and vibrations. Finally, the results, schedule, and planned versus actual manhours for this work are presented.