Commercial Aircraft Composite Technology PDF
Preview Commercial Aircraft Composite Technology
Ulf Paul Breuer Commercial Aircraft Composite Technology Commercial Aircraft Composite Technology ThiSisaFMBlankPage Ulf Paul Breuer Commercial Aircraft Composite Technology UlfPaulBreuer Institutf€urVerbundwerkstoffeGmbH Kaiserslautern,Germany ISBN978-3-319-31917-9 ISBN978-3-319-31918-6 (eBook) DOI10.1007/978-3-319-31918-6 LibraryofCongressControlNumber:2016939483 ©SpringerInternationalPublishingSwitzerland2016 Thisworkissubjecttocopyright.AllrightsarereservedbythePublisher,whetherthewholeorpartof the material is concerned, specifically the rights of translation, reprinting, reuse of illustrations, recitation, broadcasting, reproduction on microfilms or in any other physical way, and transmission or information storage and retrieval, electronic adaptation, computer software, or by similar or dissimilarmethodologynowknownorhereafterdeveloped. The use of general descriptive names, registered names, trademarks, service marks, etc. in this publicationdoesnotimply,evenintheabsenceofaspecificstatement,thatsuchnamesareexempt fromtherelevantprotectivelawsandregulationsandthereforefreeforgeneraluse. Thepublisher,theauthorsandtheeditorsaresafetoassumethattheadviceandinformationinthis book are believed to be true and accurate at the date of publication. Neither the publisher nor the authors or the editors give a warranty, express or implied, with respect to the material contained hereinorforanyerrorsoromissionsthatmayhavebeenmade. Printedonacid-freepaper ThisSpringerimprintispublishedbySpringerNature TheregisteredcompanyisSpringerInternationalPublishingAGSwitzerland Preface The contents of this book are based on my lectures “Commercial Aircraft Composite Technology” (Verbundwerkstoffe im Flugzeugbau) given to master’s students at the Faculty of Mechanical Engineering, Technical University of Kaiserslautern, Germany, who wish to broaden their specific knowledge about composite material properties and manufacturing-optimised light weight design. The topic is very extensive and comprehensive textbooks only exist for certain areas. I have tried to focus on the central theme of societies’ overall aircraft requirementstospecificmaterialrequirementsandtohighlightthemostimportant advantagesandchallengesofcarbonfibre-reinforcedplastics(CFRP)comparedto conventionalmaterials.Duringtheproductdevelopmentprocess,itisfundamental todecideon“therightmaterialattherightplace”earlyon.Itis,therefore,basicto understandthemainactivitiesandmilestonesofthedevelopmentandcertification processandthesystematicdefiningofclearrequirements.Theprocessofmaterial qualification—verifyingmaterialrequirements—isexplainedindetail.Allstate-of- the-art manufacturing technologies are described, including future perspectives. Especially for composites it is key to understand the interaction of the design scheme, manufacturing technology and resulting material properties. Here I have tried to highlight some key aspects of advanced CFRP design for primary load carrying airframe structures along with selected examples. I have also included a shortchapterontestingaspartofthecertificationprocess—andrepair. Asmoreandmorehigh-performancecompositessuchasCFRParealsousedin other sectors—especially automotive, manufacturing systems engineering, wind power, architecture, sports and leisure and medical engineering—the textbook canalsobeusefulforstudentsandengineersengagedintheseareas. Thebookcloseswithanoutlookonsomeofthelatest developmentsforfuture aircraftthatwepresentlypursueattheInstitutf€urVerbundwerkstoffe(IVW).This last chapter was supported by my assistant researchers Tim Krooß (PPS—PES blends, enabling a material performance close to PEEK at lower cost), Benedikt Hannemann (carbon metal fibre hybrid materials, enabling electrical conductivity v vi Preface andimprovedfailurebehaviour)andMoritzH€ubler(morphingstructuresbyshape memoryalloyintegrationintofibre-reinforcedpolymerstructures). I would like to thank all my old colleagues and friends for their thorough proofreadingandtheirprecioushintsforimprovementstothistext. Kaiserslautern,Germany UlfBreuer Spring2016 Contents 1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 GeneralAirframeMaterialRequirements:TheValueofLightWeight. . . 1 AircraftMarketDevelopment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 NextGenerationAircraftRequirements. . . . . . . . . . . . . . . . . . . . . . . . 10 LighterAirframes:ContributorsandLeverArms. . . . . . . . . . . . . . . . . 14 HistoryofFibreReinforcedAirframeStructure. . . . . . . . . . . . . . . . . . 16 CarbonFibreConsumption. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 EndofLife. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Questions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 References. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 2 Requirements,DevelopmentandCertificationProcess. . . . . . . . . . . 25 DevelopmentProcessandRequirementCascade. . . . . . . . . . . . . . . . . 25 DesignProcessAccordingtoVDI2221. . . . . . . . . . . . . . . . . . . . . . . . 29 LoadCasesandStressing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 DamageToleranceRequirements:The“NoCrackGrowth”Conceptof CFRP. . . . .. . . . . .. . . . .. . . . .. . . . .. . . . . .. . . . .. . . . .. . . . .. . 34 CertificationConcept. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Questions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Exercise:SimplifiedFunctionalAnalysis. . . . . . . . . . . . . . . . . . . . . . . 43 References. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 3 MaterialTechnology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 SelectionCriteria. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 ConventionalandNewAluminiumAlloys. . . . . . . . . . . . . . . . . . . . . . 47 FatigueCrackGrowth. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 FractureToughness(CrackResistanceCurveorR-Curve). . . . . . . . 49 FibreMetalLaminates. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Titanium. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 vii viii Contents CompositeMatrixSystems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 EpoxyResin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 ThermoplasticMatrices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 OtherPolymerMatrices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 CarbonFibres. .. . . . . .. . . . . . .. . . . . . .. . . . . .. . . . . . .. . . . . . .. 56 ThermosetPrepregs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 LaminateProperties. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 MaterialQualification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 MaterialQualificationProcess. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 Questions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Exercise:SecondSourceMaterialQualification. . . . . . . . . . . . . . . . . . 71 References. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 4 ManufacturingTechnology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 PrepregAutoclaveTechnology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 AutomaticTapeLaying(ATL). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 AutomaticFibrePlacement(AFP). . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 Pultrusion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 Skin/StringerIntegration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 AutoclaveProcess. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 CompositeDefects. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 TextileInfusionTechnology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 ThermoplasticCompositeTechnology. . . . . . . . . . . . . . . . . . . . . . . . . 100 FilamentWindingTechnology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111 JoiningandBonding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 BoltedJoints. .. . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. 115 AdhesiveJoining. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119 Welding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122 ManufacturingTechnologySelection. . . . . . . . . . . . . . . . . . . . . . . . . . 123 Questions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127 Exercise:ManufacturingTechnologySelectionandAssessment. . . . . . 129 References. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129 5 Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133 ValidationandVerification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133 TestPyramid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134 Questions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140 References. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140 6 Repair. . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . .. . . 141 MaintenanceProgram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141 CosmeticandStructuralRepair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144 BoltedCFRPRepair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150 BondedCFRPRepair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156 Contents ix Questions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160 Exercise:BoltedCFRPRepair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160 References. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161 7 FlapDesignCaseStudy. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163 GeneralProcedure,ReferenceDesignandTargets. . . . . . . . . . . . . . . . 163 NewDesignConcepts. . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . .. . . . . 167 ShellSandwichDesign. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167 MultiSparDesigninRTM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168 MultiSparDesigninThermoplasticTechnology. . . . . . . . . . . . . . . 173 Evaluation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176 Questions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177 References. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177 8 TailoredWingDesignandPanelCaseStudy. . . . . . . . . . . . . . . . . . 179 WingShapeControlbyAeroelasticTailoring. . . . . . . . . . . . . . . . . . . 179 AeroelasticTailoringHistory. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182 WingStructureStiffnessTailoring. . . . . .. . . . .. . . . .. . . . . .. . . . .. 184 AileronEfficiency. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189 Flutter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191 LiftDistributionandDrag. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192 StrengthProperties. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193 WingPanelConcepts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194 SpecialManufacturingAspects. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200 Questions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209 References. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210 9 NewDevelopments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213 ThermoplasticBlends:LowCostButHighPerformance. . . . .. . . . . .. 213 PolymerBlends. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214 BlendMorphologies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215 PPS-PESBlendDevelopments. . . . . . . . . . . . . . . . . . . . . . . . . . . . 216 ConclusionandOutlook. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219 MetalandCarbonUnited:ElectricalFunctionIntegration. . . . . . . . . . . 220 MetalCarbonFibreComposites.. . . . . . . . .. . . . . . . .. . . . . . . .. . 220 MaterialPreparation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223 AnalyticalEstimations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224 MaterialCharacterisation:MechanicalProperties. . . . . . . . . . . . . . . 226 MaterialCharacterisation:ElectricalLaminateProperties. . . . . . . . . 227 ResultsandDiscussion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231 ConclusionandOutlook. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233 ShapeMemoryAlloyWires:ANewApproachtoMorphing Structures.. . . . . . . . . .. . . . . . . . . . .. . . . . . . . . .. . . . . . . . . . .. . . 234 FunctionIntegration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234 SolidStateActuators. . .. . . . . . .. . . . . .. . . . . .. . . . . .. . . . . . .. 237 ShapeMemoryAlloys. . . . . . . .. . . . . . . .. . . . . . . . .. . . . . . . . .. 238
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