NASA Technical Reports Server (NTRS) 19950022608: Third NASA Advanced Composites Technology Conference, volume 1, part 1

498 Pages·31 MB·English

by  NASA Technical Reports Server (NTRS)

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Volume I
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NASA Conference Publication 3178
Part 1
Third NASA
Advanced
Composites
Conference
Technology
Volume I
Compiled by
John G. Davis, Jr.
Langley Research Center
Hampton, Virginia
Herman L. Bohon
Lockheed Engineering & Sciences Company
Hampton, Virginia
Proceedings of a workshop sponsored by the
National Aeronautics and Space Administration,
Washington, D.C., and the Department of
Defense, Washington, D.C., and held in
Long Beach, California
June 8-11, 1992
N/kSA
National Aeronautics and
Space Administration
Office of Management
Scientific and Technical
Information Program
1992
PREFACE
This document is a compilation of papers presented at the Third NASA
Advanced Composites Technology (ACT) Conference held at Long Beach,
California, June 8-11, 1992.
The ACT Program is a major multi-year research initiative to achieve a
national goal of technology readiness to introduce composite materials
into primary structure of production aircraft before the end of the decade.
This initiative is carried out through a cooperative program between
industry, universities, and the government conducting research in materials
processing, analysis development, innovative designs, and manufacturing
methodology. Conference papers recorded results of research in the ACT
Program in the specific areas of automated fiber placement, resin transfer
molding, textile preforms, and stitching as these processes influence design,
performance, and cost of composites in aircraft structures. These papers are
published as Volume I in this document.
Conference papers were also presented on the new initiative Design and
Manufacturing of Low Cost Composites (DMLCC) sponsored by the
Department of Defense. These papers are published in Volume II of this
document.
The use of trademarks or manufacturers' names in this publication does
not constitute endorsement, either expressed or implied, by the National
Aeronautics and Space Administration.
John G. Davis, Jr.
Herman L. Bohon
!!!
PRECEDING P.,_GE _LAi_K l'JOiF|L|VIED
CONFERENCE ORGANIZATION
_H1,5.0.E: Structures Technology Progam Office
Structures Directorate
NASA Langley Research Center
Hampton, Virginia 23665-5225
General Chairman Technical Chairman Administrative Assistant
John G. Davis, Jr. Herman L. Bohon Smart E. Pendleton
NASA Langley Research Center Lockheed Engineering Lockheed Engineering
and Science Company and Science Company
Session Organizers
v
John G. Davis, Jr. NASA Langley Research Center
James H. Starnes, Jr. NASA Langley Research Center
Norman L Johnston NASA Langley Research Center
David Beeler Wright Laboratory
iv
SESSION OUTLINE
THIRD NASA ADVANCED COMPOSITES TECHNOLOGY CONFERENCE
(Volume I, Part 1)
Composites in Transport Aircraft
Chairman: John G. Davis, Jr., NASA Langley Research Center
SESSION H (Volume I, Part 1)
Advanced Composites Technology Overview
Chairman: John G. Davis, Jr., NASA Langley Research Center
SESSION III (Volume I, Part 1)
Textile Technology
Chairman: Charles E. Harris, NASA Langley Research Center
SESSION IV (Volume II)
Design and Manufacturing of Low Cost Composites
Chairmen: Paul Pirrung and Richard Holzwarth, Wright Laboratory
SESSION V (volume I, Part 1)
RTM/Stitched Technology
Chairman: Norman J. Johnston, NASA Langley Research Center
SESSION VI (Volume I, Part 2)
Materials Technology
Chairman: H. Benson Dexter, NASA Langley Research Center
SESSION VII (Volume I, Part 2)
Automated Fiber Placement Technology
Chairman: William T. Freeman, Jr., NASA Langley Research Center
SESSION VIII (Volume I, Part 2)
Design/Analysis Technology
Chairman: James H. Starnes, Jr., NASA Langley Research Center
V
CONTENTS
Preface
• ° ° • ° . ° ° ° • • • • • . • • • ° ° ° ° • ° • • ° ° • • • • ° • ° • m..°
Conference Organization ............................ iv
Session Outline
• • , • ° , , • • • • • • • . . , , • • • • . * • • • • * . • . V
Volume I, Part 1
SESSION I
COMPOSITES IN TRANSPORT AIRCRAFT
Session Chairman: Charles P. Blankenship
NASA Langley Research Center
Impact of Composites on Future Transport Aircraft ................ 3:'
Robert H. Kinder
Challenges and Payoff of Composites in Transport Aircraft: 777 Empennage
and Future Applications ............................. 25
John Quinlivan
SESSION H
ADVANCED COMPOSITES TECHNOLOGY OVERVIEW
Session Chairman: John G. Davis, Jr.
NASA Langley Research Center
Advanced Composites Technology Program .................... 49
John G. Davis, Jr.
Textile Composite Fuselage Structures Development ................. 79
Anthony C. Jackson, Ronald E. Barde, and Robert L. Chu
Application of Composites to Primary Transport Aircraft Structure ........... t
Max Klotzsche
Advanced Composite Fuselage Technology ..................... 97
Larry B. Ilcewicz, Peter J. Smith, and Ray E. Horton
SESSION IH
TEXTILE TECHNOLOGY
Session Chairman: Charles E. Harris
NASA Langley Research Center
Advanced Resin Systems and 3-D Textile Preforms for Low Cost
Composite Structures .............................. 159
J. G. Shukla and T. D. Bayha
Weavability of Dry Polymer Powder Towpreg ................... 175
Maylene K. Hugh, Joseph M. Marchello, Janice R. Maiden,
and Norman J. Johnston
tPresented but not included in thispublication.
vii
PRECEDING PAGE BLANK i'_OT FILMED
Effects of Temperature and Humidity Cycling on the Strengths of
Textile Reinforced Carbon/Epoxy Composite Materials ............... 191
Roberto J. Cano and Keith W. Furrow
Mechanical Characterization of 2-D, 2-D Stitched, and
3-D Braided/RTM Materials ........................... 209
Jerry W. Deaton, Susan M. Kullerd, and Marc A. Portanova
Performance of Resin Transfer Molded Multiaxial Warp Knit Composites ....... 231
H. Benson Dexter and Gregory H. Hasko
Experimental and Analytical Characterization of Triaxially Braided
Textile Composites ............................... 263
John E. Masters, Mark J. Fedro, and Peter G. Ifju
Cross-Stiffened Continuous Fiber Structures .................... 287
John R. Ewen and Jim A. Suarez
An Engineering Model of Woven Composites Based on Micromechanics ........ 309
W. C. Carter, B. N. Cox, M. S. Dadkhah, and W. L. Morris
Cost Model Relationships Between Textile Manufacturing Processes
and Design Details for Transport Fuselage Elements ................ 323
Stephen L. Metschan, Kurtis S. Wilden, Garrett C. Sharpless,
and Rich M. Andelman
SESSION IV
DESIGN AND MANUFACTURING OF LOW COST COMPOSITES*
Session Chairmen: Paul Pirrung and Richard Holzwarth
Wright Laboratory
SESSION V
RTM/STITCHED TECHNOLOGY
Session Chairman: Norman J. Johnston
NASA Langley Research Center
Development of RTM and Powder Prepreg Resins for Subsonic Aircraft
Primary Structures ............................... 345
Edmund P. Woo, Michael R. Groleau, James L. Bertram, Paul M. Puckett,
and Shawn J. Maynard
Analytical Modeling and Sensor Monitoring for Optimal Processing of
Advanced Textile Structural Composites by Resin Transfer Molding ......... 361
Alfred C. Loos, John D. MacRae, Vincent H. Hammond, David E. Kranbuehl,
Sean M. Hart, Gregory H. Hasko, and Alan M. Markus
A Designed Experiment in Stitched/RTM Composites ................ 381
Larry C. Dickinson
*Appears in Volume H.
oil
vnl
The Effects of Aircraft Fuel and Fluids on the Strength Properties of
Resin Transfer Molded (RTM) Composites ................... 399
Anthony Falcone and Marvin B. Dow
Effects of Thermal and Moisture Cycling on the Internal Structure
of Stitched RTM Laminates ........................... 415
Jeff Walker, Lance Roundy, and Jon Goering
The Combined Effect of Glass Buffer Strips and Stitching on the
Damage Tolerance of Composites ......................... 433
Susan M. Kullerd
Progress in Manufacturing Large Primary Aircraft Structures Using
the Stitching/RTM Process ............................ 453
Alan Markus, Patrick Thrash, and Kim Rohwer
Test Results From Large Wing and Fuselage Panels ................. 481
Ram C. Madan and Mike Voldman
Volume I, Part 2*
SESSION VI
MATERIALS TECHNOLOGY
Session Chairman: H. Benson Dexter
NASA Langley Research Center
Characterization and Development of Materials for Advanced
Textile Composites ............................... 505
J. Timothy Harmess, Timothy L. Greene, and Leo E. Taske
The Effects of Specimen Width on Tensile Properties of Triaxially
Braided Textile Composites ........................... 523
John E. Masters, Peter G. Ifju, Christopher M. Pastore,
and Alexander E. Bogdanovich
In Situ Processing Methods for Composite Fuselage Sandwich Structures ....... 537
Hossein Saatchi, Bill Durako, Dick Reynolds, Ernest Dost, and Kurtis Willden
The Effect of Mixed Mode Precracking on the Mode I Fracture
Toughness of Composite Laminates ........................ 547
Prashanth Shankar, Williard D. Bascom, and John A. Naim
Master Plot Analysis of Microcracking in Graphite/Epoxy and
557
Graphite/Peek Laminates ............................
John A. Naim, Shoufeng Hu, and Jong Song Bark
Establishing the Relationship Between Manufacturing and Component
Performance in Stretch Formed Thermoplastic Composites ............. 571
Michael H. Santare, R. Byron Pipes, A. J. Beaussart, D. W. Coffin,
B. J. O'Toole, and S. F. Shuler
*These papers are presented in NASA CP-3178, Volume I, Part 2.
ix
Novel Cost Controlled Materials and Processing for Primary Structures ........ 591
S.J. Dastin
The Effects of Design Details on Cost and Weight of Fuselage Structures ....... 601
G. D. Swanson, S. L. Metschan, M. R. Morris, and C. Kassapoglou
SESSION VH
AUTOMATED FIBER PLACEMENT TECHNOLOGY
Session Chairman: William T. Freeman, Jr.
NASA Langley Research Center
Automated Fiber Placement--Evolution and Current Demonstrations ......... 625
Carroll G. Grant and Vernon M. Benson
Response of Automated Tow Placed Laminates to Stress Concentrations ........ 649
Douglas S. Cairns, Larry B. Ilcewicz, and Tom Walker
Mechanical Characterization of Two Thermoplastic Composites
Fabricated by Automated Tow Placement ..................... 665
Larry C. Dickinson and Jerry W. Deaton
Manufacturing Scale-up of Composite Fuselage Crown Panels ............ 689
K. Willden, M. Gessel, C. Grant, and T. Brown
Dimensional Stability of Curved Panels With Cocured Stiffeners and
Cobonded Frames ............................... 705
G. E. Mabson, B. W. Flynn, G. D. Swanson, R. C. Lundquist,
and P. L. Rupp
Tension Fracture of Laminates for Transport Fuselage
Part H: Large Notches ............................. 727
T. H. Walker, L. B. Ilcewicz, D. R. Polland, and C. C. Poe, Jr.
Impact Damage Resistance of Composite Fuselage Structure, Part 2 .......... 759
Ernest F. Dost, Scott R. Finn, Daniel P. Murphy, and Amy B. Huisken
Design, Analysis, and Fabrication of a Pressure Box Test Fixture for
Tension Damage Tolerance Testing of Curved Fuselage Panels ............ 789
P. J. Smith, J. B. Bodine, C. H. Preuss, and W. J. Koch
Global Cost and Weight Evaluation of Fuselage Keel Design Concepts ......... 807
B. W. Flynn, M. R. Morris, S. L. Metschan, G. D. Swanson,
P. J. Smith, K. H. Griess, M. R. Schramm, and R. J. Humphrey
SESSION VIII
DESIGN/ANALYSIS TECHNOLOGY
Session Chairman: James H. Statues, Jr.
NASA Langley Research Center
Design and Evaluation of a Foam-Filled Hat-Stiffened Panel Concept
for Aircraft Primary Structural Applications .................... 839
Damodar R. Ambur
X
A Study of Structurally Efficient Graphite-Thermoplastic Trapezoidal-
Corrugation Sandwich and Semi-Sandwich Panels ................. 859
Dawn C. Jegley
A Weight-Efficient Design Strategy for Cutouts in Composite
Transport Structures .............................. 879
S. G. Russell, J. Hangen, and T. E. Palm
Effects of Cutouts on the Behavior of Symmetric Composite Laminates
Subjected to Bending and Twisting Loads ..................... 899
C. B. Prasad, M. J. Shuart, N. J. Bains, and M. Rouse
Buckling Analysis of Curved Composite Sandwich Panels Subjected
to Inplane Loadings .............................. 919
Juan R. Cruz
ISPANmInteractive Stiffened Panel Analysis---A Tool for Quick
Concept Evaluation and Design Trade Studies ................... 933
John W. Hairr, William J. Dorris, J. Edward Ingrain, and Bharat M. Shah
Technology Integration Box Beam Failure Study .................. 951
M. J. Shuart, D. R. Ambur, D. D. Davis, Jr., R. C. Davis,
G. L. Farley, C. G. Lotts, and J. T. Wang
A Global/Local Analysis Method for Treating Details in Structural Design ....... 967
Mohammad A. Aminpour, Susan L. McCleary, and Jonathan B. Ransom
IPACS---Integrated Probabilistic Assessment of Composite Structures:
Code Development and Applications ....................... 987
C. C. Chamis and Michael C. Shiao
xi