Composite Material Aircraft Electromagnetic Properties and Design Guidelines

373 Pages·2012·15.59 MB·English

II
COMPOSITE MATERIAL AIRCRAFT
ELECTROMAGNETIC PROPERTIES
AND
DESIGN GUIDELINES
BI'KEN , .A. ,
W. G.D . ...FF
1). Rt. PFLUGA
NA AL AIR SYSTEM COMlMANI,
7_,
*
LIJ U.S. I)EIAR'rMENT OF rl-E NAVY
8 02 OO|
UNCLASSIFIED
r~~I *CVftITV CLAI~iPiCA7ION OF 1.115 PAGE W1. D*1ýA#0eI 041,d___________________
"REPORT DOCUMENTA.TION PAGE ... D&FoRZAD CIONMS.L TIRCTUICNT ISNSFORM
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4. TIIC (ant' al . TYPE OF 09PORT A P"IRIO COvI.g.
Composite Material Aircraft Electromagnetic Jan 19"1
Properties and Design Guidelines
"6.
PERFORMING ORS. REPORT NUNSIIR
50 - 5779
7 ,AIT4OR(.J '. CONTRACT OR GRANT "NUMSrR(aj
'J.Birken R. Wallenberg H00019-79-C-0634
W." Duff
D.tPflug
,. PIqrOAIgNO OROANIZATION NAME AND ADORLIS 10. PROORAM CLE[INT,PROJ[CT. TASK
Atlantic Research Corporation ARIA A wORK UNIT NUMIIRI
5390 Cherokee
Alex'andria, VA 22314
I). CONTROLLING OPFICINAM9 AND ACOF4Rl IS. REPORT DATE
Naval Air Systems Comand
ATTN: J. A. Birken (AIR-5161D) , WNU MIIPOF PAGIS
Washington, D. C. 20361 369
IA. MONITORING AGINCY NAMI A ADORoIffIerent frm ControlDli O1hat) IL 89CUMITY CLASS, (of this report
"UNCLASSIFIED
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DISTRIBUTION STATEMENIT (of Athi oepeal)
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APPROVED FOR PUBLIC RELEAS,
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17. DISllT RIUU ION TATEIMINT (of tie abo(cid:127) el ,1119,1011 i &look 10, It EiltltAm t 0e0# I0 er-U '
Aircraft-Electr.maIarin0 c t
,., • ', IS. KIY WOROS (CenEMu. pci aeae;.e aid.~It e~ee~aca m(cid:127).llei atlyI bok ,.mll) _,
-Advanced Composite Aircraft
Electromagnetic Pulse (EMP) Composite Material Avionics
-Lightnng Composite Aircraft Safety Sblid State Devices
.Radar Electromagnetic Testing
E lectromagnetic Compatibility Communication
g\t rnn.inW ar'fare CoU2uters
2W A" STRACT (Cocntlinue oni @votes Sid Idnfsesea p a41*n Idd enhity by bleak nAumb.,)'
This document collects and primarily suimariezes aircraft advanced composite
material electromagnetic properties, and seconda.rily, aumarizes composite material
mechanicalj thermal, environmental fabricattonpropertiss noting their ramifications
on electromagnstic performance. It then overvie(cid:127). the electromagnetic sub-discipline
of threats.external to internal aircraft coupling, component and subsystems suscepta
, .bility, protective methods as veil as test and evaluation of small sample to total
aircraft composite material electromagnetic performance. The sub-disciplines
: constitute a partioned set of independent variables which allow the reader to locate
' hig -aea of interest in one section of the book. (man other side)
DD , 1473 o0TION OF, INOVY 5IS1 oUOLITS .. CLAssimI
-lCURITY CL A$11VICATION OF THIS PACE f'4in Dole ,nIOeP00
The sub-discipline are then combined to perform total aircraft electromnagnetic
system performance noting the protective methods, advantages and penalties.
Of 'ý1
100
Table of Contents
Section Page
1.0 Introduction -'--
2.0 Electromagnetic Threats 2-1
2.1 Natural Threat 2-1
2.1.1 Lightning 2-1
2.1.2 Precipitation Static 2-16
2.2 Friend/Foe Threat 2-19
2.2.1 RF Threat 2-19
2.2.2 EMP Threat 2-26
2.2.3 High Energy Laser, Nuclear Thermal Radiation
and Particle Beam Threat 2-28
2.3 References 2-31
3.0 Composition, Fabrication and Mechanical Properties
of Composite Materials 3-1
3.1 Composition of Composite Materials 3-1
3.1.1 Fibers 3-1
3.1.2 Matrix Materials 3-3
3.2 Fabrication of Composite Materials 3-5
3.2.1 Tape (Prepreg) and Broad Goods Fabrication 3-5
3.2.2 Layup Process 3-5
3.2.3 Laminate Orientation Code 3-5
3.2.4 Composite Fabrication Processes 3-7
3.3 Mechanical Properties 3-9
3.3.1 Composite Fiber Properties 3-9
3.3.2 Compositia Matrix Properties 3-12
3.3.3 Single Laminate Composite Properties 3-12
3.1.4 Croasplied Laminate Composite Properties 3-18
3.4 Environmental Effects on Composite Materials 3-35
3.5 Composite Fatigue 3-35
3.6 References 3-43
4.0 Applications of Composite Materials 4-1
4.1 'Early (pre-1973) Aerospace Composite Materials Applications 4-1
4.2 Recent (post-1973) and Current Aerospace Composite
Material Applications 4-1
4.2.1 Aircraft Systems 4-1
4.2.2 Propulsion Systems 4-8 ..
4.2.3 Space Systems 4-8
4.2.4 Helicopter Systems 4-9
4.2.5 Other Aerospace Applications 4-9
4.3 Problems in Composite Material Applications 4-10
* 4.3.1 Graphite Fiber Release 4-10
4.3.2 Galvanic Corrosion 4-11,
4.3.3 Fabrication Techniques 4-11
4.4 Future Uses of Composite Materials 4-11
- 4.4.1 Future Composite Uses in Aerospace Systems 4-11
4.5 References 4-1b
S•..............".
. . . . . .
Table of Contents
(Continued)
Section PIte
5.0 Intrinsic Material Properties 5-I.
5.1. Material EM Parameters 5-1
5.1.1 Permeabilityk 5-1.
5.1.2 Permittivity
5.1.3 Conductivity 5-2
5.2 Improvement of Intrinsic Parameters 5-12
5.2.1 Doping 5-1.2
5.2.2 Intercalation 5-13
5.3 Thermal Modification of EM Intrinsic Parameters 5-19
5.3.1 Conductivity 5-19
5.4 Environmental Modification of EM Intrinsic Parameters 5-19
5.4.1 Moisture 5-19
5.5 Nonlinear Effects 5-22
5.5.1 High-Field Effects 5-22
5.6 References 5-22
6.0 External-to-Internal Coupling 6-1
6.1 Airframe Shielding Effectiveness 6-1
6.1.1 Shielding Effectiveness - Theoretical Considerations 6-1
"6.1.2 Measured and Predicted Composite Shielding
Effectiveness 6-25
6.1.3 Metallic/Composite Aircraft Weight-Shielding
Tradeoffs 6-33
6.2 Composite Joints 6-41
"6.2.1 Theory 6-41
6,2.2 Effect on Shielding Effectiveness 6-46
6.3 References 6-51
7.0 Component and Subsystem Susceptibility 7-1
7.1 Component and Circuit Susceptibility 7-1
7.1.1 Analog Circuits 7-1 r'.
7.1.2 Digital Circuits 7-2
7.1.3 Semiconductor Devices 7-2
7.1.4 Integrated Circuits 7-9
7.1.5 Electro-Explosive Detonators 7-16
7.2 Subsystem Susceptibility 7-16
7.2.1 Communication and Navigation 7-16
7.2,2 Flight Control Equipment 7-18
7.2.3 Weapons 7-21
7.2.4 Radar 7-21
7.3 References 7-25
8.0 General Analysis and Tradeoff Philosophy 8-1
8.1 Standards and Specifications 8-1
8.2 The System Approach 8-2
8.2.1 Electromagnetic Compatibility (EMC) Program 8-2
8.2.2 Electromagnetic Compatibility (EMC) Plans 8-3
8.2.3 EMC ProgrAm Implementation 8-7
ii
VI
i , " ' " .," - -.
Table of Contents .
(Continued)
Section PRae
8.3 EMC Systems Analysis Procedure Synthesis 8-7
8.3.1 Drivers in Procedure Synthesis 8-7
8.3.2 Guide to EMC Procedure Synthesis 8-15
8.4 Description of Programs and Facilities 8-15
8.4.1 Electromagnetic Compatibility Analysis Center (RADC) 8-16
8.4.2 Intrasystem Analysis Program 8-24
8.4.3 Interference Prediction Process - Number 1 (lIP-l) 8-34
8.4.4 The Cosite Analysis Model (COSAM) 8-35
8.4.5 Specification and Electronfagnatic Compatibility .
,
Analysis Program (SEMCAP) 8-36
8.4.6 Shipboard Electromagnetic Compatibility
Analysis (SEMCA) 8-37
8.5 Data Base Management 8-37
8.5.1 ECAC Data Base Management 8-38
8.5.2 lAP Data Base Management 8-38
8.6 References 8-40
9.0 Measurement Test and Evaluation 9-1
9.1 Techniques for Measuring Intrinsic Parameters 9-1
9.1.1 Permeability 9-1
9.1.2 Permittivity 9-3
9.1.3 Resistivity 9-5
9.1.4 Conductivity 9-7
9.2 EM Shielding Effectiveness Measurement Techniques 9-20
9.2.1 Coupling Between Loops and Probes 9-20
9.2.2 Plane Wave Transmission/Reflection Methods 9-24
9.2.3 Surface Impedance Parameters 9-28
9.2.4 Joint Measurement Techniques 9-32
9.2.5 High Current Injection 9-36
9.2.6 High Voltage Charging-Discharging Phenomena 9-43
9.3 References 9-45
S.•
10.0 Protection Methods and Techniques 10-i
10.1 Present Aircraft Protection Systems 10-1.
10.1.1 Static Dischargers 10-2
10.1.2 Lightning Arresters 10-2
10.1.3 Radome Strips 10-2
10.1.4 Composite Coating Protection Systems l0-.2
10.2 Future Composite Protection-Doping and Intercalation 10-21
10.3 References 10-27
11.0 Design Guidelines 11-1
i1.1 Overview 11-1
11.2 Electromagnetic Design Guidelines 11-3
11.2.1 External Electromagnetic Fields 11-5
11.2.2 Electromagnetic Shielding [Tl(f) and T (f)] 11-5
2
11.2.3 Joint Leakage [T (f)] 11-15
3
11.2.4 Cables [T4(f)] 11-17
11.2.5 Subsystem Susceptibility [T (f)] 11-21 (cid:127).2
5
11.3 Unprotected Aircraft Performance Guidelines 11-23
i~i
List of Illustrations
1.1 Aerospace Avionics Device Technology Trends 1-2
1.2 Electromagnetic System Parameters 1-4 ...
1.3 Peak Open Circuit Voltage Versus Line Length for Three
Threats and Four Coupling-Transmission Line Confipurations,
X- O,05m, Z - 100n 1-5
1.4 Upper Bounds on Peak Power Versus Line Length E..: Three .,.
Threats and Four Coupling-Transmission Line CoafigurationB(cid:127)
X w 0.5m, Z - 1000 1-6
1.5 Wunsch Constant Versus Line Length for Three Threats and
Four Coupling-Transmission Line Configurations, X 1-7
1.6 Top View of F-14 Using Triangular Patch Data Base0
of Reference 4 1-8
1.7 Side View of F-14 Using Triangular Patch Data Base :1
of Reference 4 1-9
1.8 Comparison of Surface Current Density with MRC/EMA
Code and Surface Patch Model Used in This Report 1-11
1.9 Skin Current Density JS on Edge No. 29 for Near-Strike
Lightning Excitation an(cid:127) Different Rise Times, T 1-12
1.10 Skin Current Density on Edge No. 29 of Triangular Patch
Model of F-14 Aircraft for Various Rise Times T of
Incident NEMP 1-13
1.11 Transfer Impedance Shielding of S'tructural Materials and
Protective Electromagnetic Coatings 1-14
1.12 Improvement Protective Coatings Provided Relative to
8-ply Graphite/Epoxy 1-14
1.13 Weight Penalty Imposed by Protective Coatings 1-15
1.14 Weight/Shielding Figure of Merit of EM Protective Coatings 1-15 •
2.1 Thundercloud Profile Showing Charge Centers and Temperature
and Pressure Gradients (after (1)) 2-2
2.2 Current Waveform (not to scale) for a Lightning Flash to Ground 2-5 ,.
2.3 Radiated Lightning Spectrum Normalized to 10 km (an EMP spectrum ,
is inluded for comparison) 2-6
2.4 Radiated Lightning Spectrum Normalized to One Statute Mile 2-6
2.5 Triangular Lightning Current Waveform. 2-8
2.6 Space Shuttle Lightning Current Waveform 2-8
*1
2.7 Double Exponential Lightning Current Waveform 2-8
2.8 Triple Exponential Lightning Current Waveform 2-10
2.9 Quadruple Exponential Lightning Current Waveform 2-10
2.10 Spectrum of Space Shuttle Current Lightning Waveform 2-11
2.11 Spectrum of Space Shuttle Current Lightning Waveform 2-12
2.12 Exponential Current Lightning Waveforms 2-12 ,
2.13 Superposition of All Lightning Current Waveforms 2-13
2.14 Lightning Attachment 2-15
2.,.5 Swept Stroke Phenomenon 2-15
2.16 Aircraft Lightning Strike Zones 2-15
2.17 Lightning Strike Zones 2-15
2.18 Noise Spectrum Properties 2-18
2.19 Noise Spectrum Properties 2-18
2.20 Current Pulses Resulting from Streamers of Several Lengths 2-18
iv
LisL. of Illustrations
(Continued)
2.21 RF Environment (10 kHz - 100 MHz) 2-20
2.22 RF Environment (100 - I GHz) 2-21
2.23 RF Environment (1 - 10 GHz) 2-21
2.24 RF Environment (10 - 100 GHz) 2-21
2.25 EMP Time Domain Waveform 2-27 6
2.26 EMP in Frequency Domain 2-27
2.27 Back-face Temperature of Graphite/Epoxy Substrate for Several
Pulse Fluence Levels 2-30
2.28 Laser Energy Density Necessary to Produce a Level of Stress
for Two Failure Modes 2-30
3.1 Fiber-reinformced Composite Material 3-2
3.2 PAN Fiber Graphitization Process 3-4
3.3 Graphite Fiber Tow 3-4
3.4 Boron Fiber Manufacturing Process together with a Boron
Cross-section 3-4
3.5 Tape (prepreg) and Broad Goods Fabrication Processes 3-6 '
3.6 Symmetrical Balanced Layup 3-6 I..
3.7 Composite Fiber Densities Compared to Aircraft Metals 3-10
3.8 Tetisilo Strength and Modules of Various Composite Fibers
3-10
and Metals
3.9 Stress-strain Curves for Composite Fibers 3-11
3.10 Specific Tensile Strength and Modules for Various Composite
Fibers and Metals 3-1.1
3.11 Longitudinal Tensile Strength for Various Single Laminte
Composites at Room Temperature (RT) and 350*F) 3-13
3.12 Transverse Tensile Strength for Various Single Laminate
Composites at Room Temperature (RT) and 350*F 3-13
3.13 Diagonal Tensile/Compressive Strength for Various Single
Laminate Composites at Room Temperature (RT) and 350OF 3-13
3.14 Longitudinal Compressional Strength for Various Single
Laminate Composites at Room Temperature (RT) and 350*F 3-13
3.15 Transverse Commissional Strength for Various Single
Laminate Compositeu at Room Temperature (RT) and 350*F 3-14
3.16 In-plane Shear Strength for Various Single Laminate
Composites at Room Temperature (RT) and 350'F 3-14
3.17 Interlaminar Shear Strength for Various Single Laminate
Composites at Room Temperature (RT) and 350OF 3-14
3.18 Diagonal In-plane Shear Strength for Various Single
Laminate Composites at Room Temperature (RT) and 350*F 3-14
3.19 Longitudinal Tensile/compression Modulus for Various Single
Laminate Composites at Room Temperature (RT) and 350*F 3-15
3.20 Transverse Tension/Compression Modulus for Various Single
Laminate Composites at Room Temperature (RT) and 350*F 3-15
3.21 Diagonal Tension/compression modulus for Various Single
Laminate Composites at Room Temperature (RT) and 350"F 3-15
3.22 In-plane Shear Modulus for Various Single Laminate Composites
at Room Temperature (RT) and 350OF 3-15 .
3.23 Diagonal In-plane Shear Modulus for Various Single Laminate
Composites at Room Temperature (RT) and 350OF 3-1.6
3.24 Loagitudinal Poisson's Ratio for Various Single Laminate
Composites at Room Temperature (RT) and 350*F 3-16
vS
List of Illustrations
(Continued)
3.25 Transverse Poisson's Ratio for Various Single Laminate
Composites at Room Temperature (RT) and 350*F 3-16
3.26 Diagonal Poisson's Ratio for Various Single Laminate
Composites at Room Temperature (RT) and 350*F 3-16
3.27 Longitudinal Thermal Expansion Constant for Various Single
Laminate Composites at Room Temperature (RT) and 350*F 3-17
3.28 Transverse Thermal Expansion Constant for Various Single
Laminate Composites at Room Temperature (RT) and 350°F 3-17
3.29 Diagonal Thermal Expansion Constant for Various Single
Laminate Composites at Room Temperature (RT) and 350*F 3-17
3.30 Single Laminate Composite Densities at Room Temperature (RT)
3-18
and 350OF
3.31 Longitudinal Tension Stress-Strain Curve for Various Single
Laminate Composites at Room Temperature (solid lines) and
3-1.9
350*F (dotted lines)
3,32 Transverse Tension Stress-Strain Curve for Various Single
Laminate Composites at Room Temperature (solid lines) and
3-19
3501F (dotted lines)
3.33 Diagonal Tension Stress-Strain Curves for Various Single
Laminate Composites at Room Temperature (solid lines).and 350')F 3-19
3.34 Bending Stress-Strain Curve for Kevlar 49/Epoxy Compared to
Graphite/Epoxy and Aluminum 3-19
3,35 Boron/Epoxy Tensile Strength Curves for the. [Oi/+45j/ 90]
Laminate Family 3-20
3.36 Boron/Epoxy Compressive Strength Curves for the [Oi/+45j/90k]
Laminate Family 3-20
3.37 Boron/Epoxy In-plane Shear Strength and Modulus Curves
[0i/+45j/90k] Laminate Family 3-21
3.38 Boron/Epoxy Extensional Modulus Curves for the [0i/+45j/ 90k] 3.2
Laminate Family 3-21
3,39 Boron/Epoxy Poisson's Ratio Curves for the [Oi/+ 45j/ 90k] 3-22
Laminate Family
3.40 Boron/Epoxy Thermal Expansion Coefficient Curves for the
[Oi/+ 45J/ 90k] Laminate Family 3-22
3.41. High-Strength Graphite/Epoxy Tensile Strength Curves for the
[0i/+45j/9Ok] Laminate Family 3-23
3.42 High-Strength Graphite/Epoxy Compressive Strength Curves for
the [Oi/+ 45j/9 0k] Laminate Family 3-23
3.43 Shear Strength Curves for the High-Strength Graphite/Epoxy
(0[/+451/90k] Laminate Family at Room Temperature (RT) and 350*F 3-24
3.44 ESx[Otei/n+s4i65nj/9a0l kIM odulus Curves for the High-Strength Graphite/Epoxy
Laminate Family 3-24
3-45 Shear Modulus Curves for the High-Strength Graphite/Epoxy
[Oi/±J/ 90k] Laminate Family at Room Temperature (RT) and 350'F 3-24
3.46 Poisson's Ratio Curves for the High-Strength Graphite/Epoxy
[Oi/± 45j/ 90k] Laminate Family 3-25
3.47 Thermal Expansion Coefficient Curves for the High-Strength
Graphite/Epoxy [Oi/+ 45j/90k] Laminate Family 3-25
3.48 Tensile Strength Curves for the Hligh-Modulus Graphite/Epoxy
[Oi/+ 45j/90k] Laminate Family 3-26
3.49 Compressive Strength Curves for the High-Modulus Graphite/Epoxy
[Oi/+45./90k] Laminate Family 3-26 4-
3.50 Shear S8rength Curves for the High-Modulus Graphite/Epoxy
[0i/+45-1/90k] Laminate Family at Room Temperature (R'r) And 3500F 3-27
vi
List of Illustrations
(Continued)
Figure
__
3.51 Extensional Modulus Curves for the High-Modulus Graphite/Epoxy
[0i/+45j/ 90k] Laminate Family 3-27
3.52 Shear Modulus Curves for the High-Modulus Graphite/Epoxy
[0i/+45j/90k] Laminate Family at Room Temperature and 350*F 3-27
3.53 Poisson's Ratio Curves for the High-Modulus Graphite/Epoxy
[Oi/+ 451/90k] Laminate Family 3-28
3.54 Thermal Expansion Coefficient Curves for the High-Modulus
Graphite Epoxy [Oi/+ 45j/9 0k] Laminate Family 3-28
3.55 Tensile Strength Curves for the Intermediate Strength
Graphite Epoxy [Oi/+ 45j/90k] Laminate Family 3-29
3.56 Compressive Strength Curves for the Intermediate-Strength
Graphite/Epoxy [Oi/± 45j/ 90k] Laminate Family 3-29
3.57 Shear Strength Curves £or the Intermediate-Strength
Graphite/Epoxy [01/+45j/90k1 Laminate Family 3-30
3.58 Extensional Modulus Curves for the Intermediate Strength
Graphite/Epoxy ([i/+ 45j/ 90k] Laminate Family 3-30
3.59 Shear Modulus Curves for the Graphite/Epoxy [oi/+45j/ 90k]-.3-3
Laminate Family at Room Temperature (RT) and 350F 3-30
3.60 Poisson's Ratio Curve for the Intermediate-Strength
Graphite/Epoxy [Oi/± 4.5j/90k] 3-31
3.61 Thermal Expansion Coefficient Curves for the Intermediate-
Strength Graphite/Epoxy [Oi/+ 45j/ 90k] Laminate Family 3-31
3.62 Longitudinal Tensile Strength for the [0/60) Boron/Epoxy and
Graphite/Epoxy Laminate at Room Temperature (RT) and 3500F 3-32
3.63 Transverse Tensile Strength for the (0/60] Boron/Epoxy and
Graphite/Epoxy Crossplied Laminates at Room Temperature (RT)
and 350'F 3-32
3.64 Longitudinal Compressive Strengths for the [0/60] Boron/Epdxy
and Graphite/Epoxy Crossplied Laminates at Room Temperature (RT)
and 3500F 3-32
3.65 Transverse Compressive Strengths for the [0/60] Boron/Epoxy and
Graphite/Epoxy Crossplied Laminates at Room Temperature (RT) and
350OF 3-32
3.66 In Plan Shear Strengths for the [0/601 Boron/Epoxy and
Graphite/Epoxy CrossplLed Laminates at Room Temperature (RT)
and 350*F 3-33
3.67 Tension/Compression Modulus for the [0/60] Boron/Epoxy and
Graphite/Epoxy Crossplied Laminates at Room Temperature (RT)
and 350eF 3-33
3.68 In-Plane Shear Modulus for the [0/601 Boron/Epoicy and 0
Graphite/Epoxy Crossplied Laminates at Room Temperature (RT)
and 350OF 3-33
3.69 Poisson's Ratio for the (0/60] Boron/Epoxy and Graphite/Epoxy
Crossplied Laminates at Room Temperature (RT) and 350*F 3-33
3.70 Thermal Expansion Constants for the [0/60] Boron/Epoxy and
Graphite/Epoxy Crossplied Laminates at Room Temperature (RT)
and 350OF 3-34
'3.71. Denisites for [2/60] Boron/Epoxy and Graphite//Epoxy Crossplied
Laminates 3-34
vii