Structures Technology for Future Aerospace Systems

443 Pages·2000·35.07 MB·English

by  Ahmed K Noor (ed.)

Purchased from American Institute of Aeronautics and Astronautics

Structures Technology for Future
Aerospace Systems
Purchased from American Institute of Aeronautics and Astronautics

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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

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ISBN 1-56347-384-4
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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
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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
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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
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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