Structures Technology for Future Aerospace Systems PDF
Preview Structures Technology for Future Aerospace Systems
Purchased from American Institute of Aeronautics and Astronautics Structures Technology for Future Aerospace Systems Purchased from American Institute of Aeronautics and Astronautics This page intentionally left blank Purchased from American Institute of Aeronautics and Astronautics Structures Technology for Future Aerospace Systems Edited by Ahmed K. Noor Center for Advanced Computational Technology University of Virginia Volume 188 PROGRESS IN ASTRONAUTICS AND AERONAUTICS Paul Zarchan, Editor-in-Chief Charles Stark Draper Laboratory, Inc. Cambridge, Massachusetts Published by the American Institute of Aeronautics and Astronautics, Inc. 1801 Alexander Bell Drive, Reston, Virginia 20191-4344 Purchased from American Institute of Aeronautics and Astronautics Copyright © 2000 by the American Institute of Aeronautics and Astronautics, Inc. Printed in the United States of America. All rights reserved. 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AIAA is not responsible for any injury or damage resulting from use or reliance, nor does AIAA warrant that use or reliance will be free from privately owned rights. ISBN 1-56347-384-4 Purchased from American Institute of Aeronautics and Astronautics Progress in Astronautics and Aeronautics Editor-in-Chief Paul Zarchan Charles Stark Draper Laboratory, Inc. Editorial Board John D. Binder Michael D. Griffin MathWorks, Inc. Orbital Sciences Corporation Lt. Col. Steven A. Brandt Phillip D. Hattis U.S. Air Force Academy Charles Stark Draper Laboratory, Inc. Luigi De Luca Richard M. Lloyd Politecnico di Milano, Italy Raytheon Electronics Company Leroy S. Fletcher Ahmed K. Noor Texas A&M University NASA Langley Research Center Alien E. Fuhs Albert C. Piccirillo Carmel, California ANSER, Inc. Vigor Yang Pennsylvania State University Purchased from American Institute of Aeronautics and Astronautics This page intentionally left blank Purchased from American Institute of Aeronautics and Astronautics Table of Contents Preface .................................................. xiii Chapter 1 Perspectives on Structures Technology Ahmed K. Noor, Center for Advanced Computational Technology, University of Virginia, NASA Langley Research Center, Hampton, Virginia Introduction ................................................ 1 Major Characteristics of Future Aerospace Systems .................. 10 Autonomy ............................................... 11 Evolvability .............................................. 11 Highly Distributed Systems.................................... 12 Paradigm Change in Structures Technology ........................ 13 Changes in Aerospace Engineering Organizations ..................... 15 Economic Pressures. ........................................ 15 Impact of Advances in Technology ............................... 16 Opportunities Provided by Synergistic Coupling of Structures Technology with Other Technologies ................... 16 Novel Materials Technologies .................................. 16 Multifunctional Structures. .................................... 18 Micro Air Vehicles ......................................... 20 Biologically Inspired Structures ................................. 21 Concluding Remarks......................................... 22 References ................................................ 23 Chapter 2 Affordable Composite Structures William Baron, Air Force Research Laboratory, Dayton, Ohio; Tia Benson Tolle, Air Force Research Laboratory, Dayton, Ohio', Dan Arnold, Boeing, Seattle, Washington', Gary Renieri, Boeing, Saint Louis, Missouri', and Larry Bersuch, Lockheed Martin, Fort Worth, Texas Introduction ............................................... 27 Purpose of the Chapter ....................................... 27 Structural Affordability: Low Cost Plus Performance ................... 28 Background ............................................... 29 Benefits of Composites....................................... 29 Current Use of Composites .................................... 30 Challenges of an "All-Composite" Air Vehicle ....................... 33 Design Freedom Enabled with Composite Structures ................. 36 Design Philosophy. ......................................... 36 Materials and Processes: Enabling for Novel Concepts ................ 38 Materials and Processes Overview ............................... 38 VII Purchased from American Institute of Aeronautics and Astronautics viii Curing Processes........................................... 39 Nonautoclave Low-Temperature/Low-Pressure Curing .................. 40 Electron Beam Processing. .................................... 41 Induction Processing ........................................ 45 Resin Infusion Methods ...................................... 48 Innovative Reinforcements—Discontinuous Fiber Product Forms........... 49 Material Lay-Down Methods. .................................. 50 Emerging Structural Concepts .................................. 52 Three-Dimensional Composites in Aircraft Joints ..................... 52 Three-Dimensional Composite Application for Bulkheads and Frames ....... 57 Bonding of Primary Structure .................................. 58 Skin-Stiffening Concepts ..................................... 65 Three-Dimensional Structure Analysis and Certification ............... 71 Testing of Three-Dimensional Woven Preforms. ...................... 72 Needs for Certification of Three-Dimensional Structure ................. 74 Affordable Considerations for Ballistic Survivability. ................. 74 Description of Ballistic Event .................................. 75 Conventional Design Practice .................................. 76 Design Considerations for "All-Composite" Structure. .................. 78 Novel Airframe Configurations ................................. 81 Structural Definition ........................................ 81 Unitized Composite Structure .................................. 82 Primary Sandwich Structure ................................... 84 Innovative Structural Layouts .................................. 87 Future Outlook for Composite Airframe Structures................... 88 References ................................................ 89 Chapter 3 Aging Systems and Sustainment Technology John W. Lincoln, Aeronautical Systems Center, Wright-Patterson Air Force Base, Ohio Historical Background. ....................................... 93 Introduction.............................................. 93 Aging Commercial Aircraft Research at the Federal Aviation Administration Technical Center. .............................. 96 Aging Commercial Aircraft Research at National Aeronautics and Space Administration Langley Research Center. ................... 101 Aging Military Aircraft Research in the United States Air Force. .......... 104 Aging Military Aircraft Research in the United States Navy ............. 110 Widespread Fatigue Damage .................................. Ill Introduction............................................. Ill Damage Tolerance Assessment Process ........................... Ill Technology for Assessment of Widespread Fatigue Damage ............. 118 Case Study on Aging Aircraft and Widespread Fatigue Damage. .......... 121 Corrosion ................................................ 125 Repair. .................................................. 133 Introduction............................................. 133 Metallic Repairs .......................................... 133 Composite Repairs ........................................ 134 Purchased from American Institute of Aeronautics and Astronautics IX Future Actions ............................................. 137 Introduction............................................. 137 United States Air Force Actions ................................ 138 Conclusions .............................................. 140 References ............................................... 140 Chapter 4 Extreme Environment Structures Donald B. Paul, Christopher L. Clay, Brett Harber, and Harold Croop, Air Force Research Laboratory, Dayton, Ohio', and David Glass and Steven Scotti, NASA Langley Research Center, Hampton, Virginia Introduction .............................................. 145 Actively Cooled Structures ................................... 147 Introduction............................................. 147 Design Requirements and Conditions ............................ 147 Design Development ....................................... 148 Refractory and Ceramic Composite Development .................... 149 Refractory and Ceramic Composite Development (Recent Activities) ....... 151 NARloy-Z Development. .................................... 152 Haynes 188 Development.................................... 153 Molybdenum Rhenium Development ............................ 154 Copper Graphite Development. ................................ 159 Copper Microcomposite Development. ........................... 159 Test Facilities ............................................ 159 Air Force Research Laboratory Hydrogen Facility .................... 160 General Applied Sciences Laboratory Panel Oxidation and Erosion Test Facility. ..................................... 160 Rocketdyne Material and Structure Thermal Validation Rig. ............. 161 Thermal Protection Systems. .................................. 161 BlanketTPS............................................. 163 Tile TPS ............................................... 164 Stand-Off TPS ........................................... 164 Hot Structure for High-Speed Vehicles........................... 166 Introduction............................................. 166 Two-Dimensional Carbon-Carbon Control Surface ................... 167 Three-Dimensional Carbon-Carbon Wing Box ...................... 169 Titanium Matrix Composite Hot Structure ......................... 170 Heat-Pipe-Cooled Leading Edges for Hypersonic Vehicle Airframes ..... 172 Introduction............................................. 172 Operation. .............................................. 174 Half-Scale Hastelloy-X Leading-Edge Component ................... 177 Haynes 188 Leading Edge "D-Shaped" Heat Pipe .................... 179 Niobium Heat-Pipe Leading-Edge Subcomponent.................... 180 Niobium Nosecap Vapor Chamber .............................. 181 Hastelloy-X Leading-Edge-Shaped Heat Pipe ...................... 183 Refractory-Composite Heat-Pipe-Cooled Leading Edge ................ 185 Straight Heat Pipes Embedded in Carbon/Carbon .................... 188
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