Composites Research and Technology for Aerospace Vehicles_OHP

8/11/2019 Composites Research and Technology for Aerospace Vehicles_OHP

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Composites Research and Technology

For Aerospace Vehicles

Mark J. Shuart

NASA Langley Research Center

Presented at the Aerospace Materials 1999 Conference & Exhibition

September 9-10, 1999

Toulouse, France


2/22

Todays Lessons Learned

Materials and Structures Technology Development

Future Materials and Structures Applications

Outline


3/22

Lessons Learned

1. Materials development in conjunction with product development creates undue risks.

2. Experienced materials and processing engineers should be included in the design

phase and must be readily available to correct problems in production processes.

3. Manufacturing process scale-up development tests should be conducted to optimize the

production processes.

4. Co-curing and co-bonding are preferred over secondary bonding which requires near

perfect interface fit-up.

5. Mechanically fastened joints require close tolerance fit-up and shimming to assure a

good fit and to avoid damage to the composite parts during assembly.

6. Dimensional tolerances are more critical in composites than in metals to avoid damage

to parts during assembly. Quality tools are essential to the production of quality parts.

7. Selection of the tool material depends on part size, configuration, production rate,

quantity, and company experience.

8. Tool designers should anticipate the need to modify tools to adjust for part springback,

ease of removal, or maintain dimensional control of critical interfaces.

Lessons Learned

1. Materials development in conjunction with product development creates undue risks.

2. Experienced materials and processing engineers should be included in the design

phase and must be readily available to correct problems in production processes.

3. Manufacturing process scale-up development tests should be conducted to optimize the

production processes.

4. Co-curing and co-bonding are preferred over secondary bonding which requires near

perfect interface fit-up.5. Mechanically fastened joints require close tolerance fit-up and shimming to assure a

good fit and to avoid damage to the composite parts during assembly.

6. Dimensional tolerances are more critical in composites than in metals to avoid damage

to parts during assembly. Quality tools are essential to the production of quality parts.

7. Selection of the tool material depends on part size, configuration, production rate,

quantity, and company experience.

8. Tool designers should anticipate the need to modify tools to adjust for part springback,

ease of removal, or maintain dimensional control of critical interfaces.

Materials, Processes, and Manufacturing


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Lessons Learned:

1. Design and certification requirements for composite structure are generally more

complex and conservative than for metal structure.

2. Successful programs have used the building-block approach with arealistic schedule that allows for a systematic development effort.

3. The use of basic laminates containing 0/90/+45/-45 plies with a minimum of 10% of the

plies in each direction is well suited to most applications.

4. Mechanical joints should be restricted to attachment of metal fittings and situationswhere assembly or access is impractical using alternative approaches.

5. Large, co-cured assemblies reduce part count and assembly costs but may require

complex tooling.

6. Structural designs and the associated tooling should be able to accommodate design

changes associated with the inevitable increases in design loads.

7. Understanding and properly characterizing impact damage would eliminate confusion in

the design process and permit direct comparison of test data.

Structural Design, Analysis, and Testing


5/22

Lessons Learned:

1. Automated processes can help to reduce QC costs.

2. Inspection and quality control should focus on aspects of the process and part that havea direct bearing on part performance.

3. Determine and understand the effects of defects on part performance.

4. Supportability should be addressed during design so that composite

structures are inspectable, maintainable and repairable.5. Most damage to composite structure occurs during assembly or routine maintenance of

the aircraft.

6. Repair costs are much higher than for metal structures.

7. Improved Standard Repair Manuals are needed for in-service maintenance and repair.8. Special long-life and low-temperature curing repair materials are required.

9. Moisture ingestion and aluminum core corrosion are recurring supportability problems

for honeycomb structures.

Quality Control, NDE/I, and Supportability


6/22

800800

700700600600

500500

400400

300300

200200

100100

00

DryDryweight,weight,

klbklb

8%8%1%1% 7%7%1%1%

STSSTS

technologytechnologyAdvancedAdvanced

subsystemssubsystems

32%32%

5%5%

55%55%

8%8%

Dual-fuelDual-fuel

PropulsionPropulsion

50%50%

8%8%

40%40%

6%6%

Weight reduction from technology applicationWeight reduction from technology application

Weight reduction from vehicle resizingWeight reduction from vehicle resizing

Major Weight & Cost Reductions are Possible fromMajor Weight & Cost Reductions are Possible from

Advanced Airframe Structures and Materials!Advanced Airframe Structures and Materials!

AdvancedAdvanced

TPSTPSAl-Al-LiLi

tankstanksCompositeComposite

structuresstructuresCompositeCompositeLH2 tankLH2 tank

Predicted Weight Savings from Incorporation of

Advanced Technologies


7/22

Advancements

In Composite

Technology

1960 1970 1980 1990 2000

Skybond

703, 710

P13N,

PMR-15,

LARC-160

NR150 K3BBMIs:

5250

5260

LARC-PETI-5 Processable Organic- Inorganic Matrices

Improved Fab.

Processes

Low Energy CuresHighestHighest

Thermally StableThermally Stable

PlPl

Low FlowLow Flow

ThermoplasticThermoplastic

PlsPls

High FlowHigh Flow Thermoset PlsThermoset Pls

IntermediateIntermediate

Temp. HighTemp. High

FlowFlow BMIsBMIs

ImprovedImproved BMIsBMIs

ImprovedImproved

ThermoplasticThermoplastic PlsPls

Advanced Resins

Evolution of Composite Resin Development:

Intermediate & High Temperature Resins


8/22

Computationally Designed Materials and Structures


9/22

Nano / Macro

PolymerChain

Poly(imide/inorganic)Blend

Polyamide Acid

Alkyl Inorganic

Poly(amide acid)/inorganicSolution

Imidization

Low-cost, stitched

textile preforms

Magnetic Field to

Shape/PositionMaterial

E-Beam Sourcesfor Curing

Finished CompositeFuselage Barrel Section

High performanceresin with nanophase

Tooless, RTM Processing with E-Beam Curing, with High

PerformanceNanophaseResins& TextilePreforms

Toolless, RTM Processing with

E- Beam Curing, with High

Performance Nanophase Resins

& Textile Preforms

ComputerProcess Control

NanophaseStructure

Polymer

Chain

InorganicCrystal Lattice

Low-Cost Composites Processing of the Future


10/22

BucklingLo

ad

Load

Weight

Length/Width

Deflection

Strength

Global Shell

Stiffened

PanelLocal

DetailedStresses

Local Panel Details

Analysis Methodology Predicted Behavior

Global/Local Analysis for Predicting

Structural Behavior


11/22

UltrasonicsThermal

Eddy CurrentSTS SRBSTS SRB

CompositeComposite

NozzleNozzle

STS SSMESTS SSME

CombustorCombustor

LinerLiner

Bantam/Bantam/

PathfinderPathfinder

Composite TankComposite Tank

B-757 Fuselage

X-Ray

Tomography

Advancing NDE Technologies TowardAdvancing NDE Technologies Toward

Complex StructuresComplex Structures


12/22

System Test, Launch

& Operations

System/Subsytem

Development

Technology

Demonstration

Technology

Development

Research to Prove

Feasibility

Basic Technology

Research

TRL 9TRL 9TRL 9

TRL 8TRL 8TRL 8

TRL 7TRL 7TRL 7

TRL 6TRL 6TRL 6

TRL 5TRL 5TRL 5

TRL 4TRL 4TRL 4

TRL 3TRL 3TRL 3

TRL 2TRL 2TRL 2

TRL 1TRL 1TRL 1

Design,

Build, Test,

Fly

AdvancedDevelopment

Focused

Technology

Research

NASA Technology Readiness Levels (TRL)


13/22

Cryotanks

Sandwich construction (TRL=4)

Nonautoclave curing (TRL=3)

Nondestructive evaluation (TRL=4)

Vehicle health monitoring (TRL=3)

Integrated TPS / cryoinsulation (TRL=2)

Leading Edges / Nose Caps

Refractory composites (TRL=9)

Hot-structure control surfaces (TRL=5)

Thermal Protection System

High temperature metallics (TRL=5)

Refractory composites (TRL=4)

Advanced flexible insulation (TRL=6)

Primary Structure

High-temperature metal composites (TRL=4)

Noncircular composite shell structures (TRL=3)

Joints and attachment techniques (TRL=4)

Nondestructive evaluation (TRL=4)

Manufacturing technology (TRL=4)

Assessment of Technology Needs for an RLV


14/22

Typical Reentry Temperature History

0

400

800

1200

1600

100 4100 8100 12100 16100Time (sec.)

Materials

Structural

Concepts

Experimental

Validation

Analyses

Advanced

Tanks

Wings

Airframe

A Complete Integrated Structures and

Materials Program for RLV Airframe Systems


15/22

1. Application-Specific Aero-space Programs Affordable Point-to-Point Personal Aircraft

Large Transport Aircraft (e.g., Blended-Wing Body)

Sensorcraft Lunar/Mars Transportation Vehicles for Human Exploration

2. Brilliant Products and Systems

Multifunctional Materials and Structures

Highly-Integrated Instruments and Structures for Sensorcraft

Ultra-Smart Materials and Structures Radiation Effects and Radiation Shielding Materials

3. Computing, Design, and Analysis Methods and Tools

Optical, Quantum, and Biological Computers Fully Immersive Concept-To-Flight Design Environment

Flexible Integration of Modeling and Design Techniques

Intelligent agents, Fuzzy, and Nondeterministic Analysis Methods

4. Experimental Methods and Test Techniques

Remote access to facilities and laboratories through virtual reality

Automated, Digitally-Controlled Testing Techniques

Programs, Products, and Services for 2009


16/22

Structures & Materials Skills Evolution

Classical metals, polymers, ceramics, and composites development

skills transitioning to nano-, smart-, functionally graded,

multifunctional, environmentally friendly, computational, and biomimicdesigned M&S systems

Classical applied mechanics, dynamics, aeroelasticity, and

computational methods skills transitioning to multidisciplinarycomputational aero-servo-thermal-structure-materials methodology;

and mathematically nondeterministic, nonlinear, fuzzy, probabilistic,

design and analysis tools

Traditional point-by-point external diagnostic sensors skills

transitioning to intelligent, distributed, in-situ diagnostic, and self-healing systems.


17/22

Areas of Expertise at

NASA Langley Research Center

AoE 1. Develop advanced materials and processing technologiesto enable

the fabrication of low-cost and high-performance structural concepts for

aerospace applications.

AoE 2. Conduct research and technology development that accurately and

efficiently predict behavior, durability and damage tolerance,evaluates

concepts, and validatesperformance of advanced materials and structures for

aerospace structural applications.

AoE 3. Conduct research and technology development for advanced sensors,

intelligent systems, and ground operationsto ensure structural integrity,

reliability, and safety for aerospace vehicles.

AoE 4. Conduct research and technology development to quantify and control

aeroelastic response, unsteady aerodynamicflow phenomena, and

structural dynamicsbehavior for aerospace vehicles.


18/22

New materials, processing, structural concepts, and

sensors will enable dramatically improved applications

Reusable launch vehicles and future spacecraft will

demonstrate advanced materials and structures

technologies

Concluding Remarks


19/22

Coupon Testingfor Material

Properties

Design Conceptsand AnalysisDevelopment

ManufacturingProcess

Developmentand Scale-up

ConceptDemonstration atComponent Level

Full-ScaleStructuralVerification

Mechanical Properties

H2 Permeability tests (4 in. x 4 in.)

Flatwise Tension Tests

(2 in. x 2 in.)

Gr-Ep/Foam Panel

(LaRC TEEK HH)

Thermally Cycled PMC/Foam Insulation

Fluted Core Splice Joint

Development of Advanced Cryotank and Airframe

Structures Building-Block Approach


20/22

Atomic Oxygen Resistance

High Specific Strength

Selected for ProSEDS

Flight Demonstration

Tethers for Propellant-Free

Propulsion

Solar Thermal Propulsion

Upperstage

Low Color, Low Solar Absorption

High Reflectivity

Selected for Primary Collector on

Boeings SOTV

Application of LaRC-Developed Materials


21/22

Cargo hold and fuel tank explosions

Modify Aircraft Landing Dynamics Facility (high load, high speed, larger tires)*

High-temperature and cryo-temperature capability for COLTS*

Electro-Magnetic upgrade to TDT*

Hypersonic flow simulation (ARC Jet)

Nano-sensor facility*

In-Situ Materials Processing Lab

Laser Deposition Fabrication Lab

High-conductivity property characterization

Advanced automated materials manufacturing lab

Biochemistry Lab*

Large graphitization fabrication facility

Free-form fabrication facility Large brazing fabrication facility

Rapid prototyping fabrication lab

3-D virtual reality computational test lab*

*Facilities located at LaRC

New/Enhanced Facilities Required for 2009


22/22

Autoclave & Vacuum Hot Press

Curing

AdvancementsIn Composite

Technology

1960 1970 1980 1990 2000

Carbon,

Boron,

S-Glass

BrittleEpoxies:

MY-720

ERL-0510T300/5208,

T300/3501-6

Rubber Toughening:

Thermoplastic Studies

Toughened

Epoxies

Textile

Preforms

Affordable Processing

E-Beam Cures

Non-Autoclave Curing

RFI/Stitched Preforms

Evolution of Composite Resin Development: Epoxies

Composites Research and Technology for Aerospace Vehicles_OHP

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