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8/11/2019 Composites Research and Technology for Aerospace Vehicles_OHP
1/22
Composites Research and Technology
For Aerospace Vehicles
Mark J. Shuart
NASA Langley Research Center
Presented at the Aerospace Materials 1999 Conference & Exhibition
September 9-10, 1999
Toulouse, France
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Todays Lessons Learned
Materials and Structures Technology Development
Future Materials and Structures Applications
Outline
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Lessons Learned
1. Materials development in conjunction with product development creates undue risks.
2. Experienced materials and processing engineers should be included in the design
phase and must be readily available to correct problems in production processes.
3. Manufacturing process scale-up development tests should be conducted to optimize the
production processes.
4. Co-curing and co-bonding are preferred over secondary bonding which requires near
perfect interface fit-up.
5. Mechanically fastened joints require close tolerance fit-up and shimming to assure a
good fit and to avoid damage to the composite parts during assembly.
6. Dimensional tolerances are more critical in composites than in metals to avoid damage
to parts during assembly. Quality tools are essential to the production of quality parts.
7. Selection of the tool material depends on part size, configuration, production rate,
quantity, and company experience.
8. Tool designers should anticipate the need to modify tools to adjust for part springback,
ease of removal, or maintain dimensional control of critical interfaces.
Lessons Learned
1. Materials development in conjunction with product development creates undue risks.
2. Experienced materials and processing engineers should be included in the design
phase and must be readily available to correct problems in production processes.
3. Manufacturing process scale-up development tests should be conducted to optimize the
production processes.
4. Co-curing and co-bonding are preferred over secondary bonding which requires near
perfect interface fit-up.5. Mechanically fastened joints require close tolerance fit-up and shimming to assure a
good fit and to avoid damage to the composite parts during assembly.
6. Dimensional tolerances are more critical in composites than in metals to avoid damage
to parts during assembly. Quality tools are essential to the production of quality parts.
7. Selection of the tool material depends on part size, configuration, production rate,
quantity, and company experience.
8. Tool designers should anticipate the need to modify tools to adjust for part springback,
ease of removal, or maintain dimensional control of critical interfaces.
Materials, Processes, and Manufacturing
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Lessons Learned:
1. Design and certification requirements for composite structure are generally more
complex and conservative than for metal structure.
2. Successful programs have used the building-block approach with arealistic schedule that allows for a systematic development effort.
3. The use of basic laminates containing 0/90/+45/-45 plies with a minimum of 10% of the
plies in each direction is well suited to most applications.
4. Mechanical joints should be restricted to attachment of metal fittings and situationswhere assembly or access is impractical using alternative approaches.
5. Large, co-cured assemblies reduce part count and assembly costs but may require
complex tooling.
6. Structural designs and the associated tooling should be able to accommodate design
changes associated with the inevitable increases in design loads.
7. Understanding and properly characterizing impact damage would eliminate confusion in
the design process and permit direct comparison of test data.
Structural Design, Analysis, and Testing
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Lessons Learned:
1. Automated processes can help to reduce QC costs.
2. Inspection and quality control should focus on aspects of the process and part that havea direct bearing on part performance.
3. Determine and understand the effects of defects on part performance.
4. Supportability should be addressed during design so that composite
structures are inspectable, maintainable and repairable.5. Most damage to composite structure occurs during assembly or routine maintenance of
the aircraft.
6. Repair costs are much higher than for metal structures.
7. Improved Standard Repair Manuals are needed for in-service maintenance and repair.8. Special long-life and low-temperature curing repair materials are required.
9. Moisture ingestion and aluminum core corrosion are recurring supportability problems
for honeycomb structures.
Quality Control, NDE/I, and Supportability
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800800
700700600600
500500
400400
300300
200200
100100
00
DryDryweight,weight,
klbklb
8%8%1%1% 7%7%1%1%
STSSTS
technologytechnologyAdvancedAdvanced
subsystemssubsystems
32%32%
5%5%
55%55%
8%8%
Dual-fuelDual-fuel
PropulsionPropulsion
50%50%
8%8%
40%40%
6%6%
Weight reduction from technology applicationWeight reduction from technology application
Weight reduction from vehicle resizingWeight reduction from vehicle resizing
Major Weight & Cost Reductions are Possible fromMajor Weight & Cost Reductions are Possible from
Advanced Airframe Structures and Materials!Advanced Airframe Structures and Materials!
AdvancedAdvanced
TPSTPSAl-Al-LiLi
tankstanksCompositeComposite
structuresstructuresCompositeCompositeLH2 tankLH2 tank
Predicted Weight Savings from Incorporation of
Advanced Technologies
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Advancements
In Composite
Technology
1960 1970 1980 1990 2000
Skybond
703, 710
P13N,
PMR-15,
LARC-160
NR150 K3BBMIs:
5250
5260
LARC-PETI-5 Processable Organic- Inorganic Matrices
Improved Fab.
Processes
Low Energy CuresHighestHighest
Thermally StableThermally Stable
PlPl
Low FlowLow Flow
ThermoplasticThermoplastic
PlsPls
High FlowHigh Flow Thermoset PlsThermoset Pls
IntermediateIntermediate
Temp. HighTemp. High
FlowFlow BMIsBMIs
ImprovedImproved BMIsBMIs
ImprovedImproved
ThermoplasticThermoplastic PlsPls
Advanced Resins
Evolution of Composite Resin Development:
Intermediate & High Temperature Resins
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Computationally Designed Materials and Structures
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Nano / Macro
PolymerChain
Poly(imide/inorganic)Blend
Polyamide Acid
Alkyl Inorganic
Poly(amide acid)/inorganicSolution
Imidization
Low-cost, stitched
textile preforms
Magnetic Field to
Shape/PositionMaterial
E-Beam Sourcesfor Curing
Finished CompositeFuselage Barrel Section
High performanceresin with nanophase
Tooless, RTM Processing with E-Beam Curing, with High
PerformanceNanophaseResins& TextilePreforms
Toolless, RTM Processing with
E- Beam Curing, with High
Performance Nanophase Resins
& Textile Preforms
ComputerProcess Control
NanophaseStructure
Polymer
Chain
InorganicCrystal Lattice
Low-Cost Composites Processing of the Future
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BucklingLo
ad
Load
Weight
Length/Width
Deflection
Strength
Global Shell
Stiffened
PanelLocal
DetailedStresses
Local Panel Details
Analysis Methodology Predicted Behavior
Global/Local Analysis for Predicting
Structural Behavior
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UltrasonicsThermal
Eddy CurrentSTS SRBSTS SRB
CompositeComposite
NozzleNozzle
STS SSMESTS SSME
CombustorCombustor
LinerLiner
Bantam/Bantam/
PathfinderPathfinder
Composite TankComposite Tank
B-757 Fuselage
X-Ray
Tomography
Advancing NDE Technologies TowardAdvancing NDE Technologies Toward
Complex StructuresComplex Structures
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System Test, Launch
& Operations
System/Subsytem
Development
Technology
Demonstration
Technology
Development
Research to Prove
Feasibility
Basic Technology
Research
TRL 9TRL 9TRL 9
TRL 8TRL 8TRL 8
TRL 7TRL 7TRL 7
TRL 6TRL 6TRL 6
TRL 5TRL 5TRL 5
TRL 4TRL 4TRL 4
TRL 3TRL 3TRL 3
TRL 2TRL 2TRL 2
TRL 1TRL 1TRL 1
Design,
Build, Test,
Fly
AdvancedDevelopment
Focused
Technology
Research
NASA Technology Readiness Levels (TRL)
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Cryotanks
Sandwich construction (TRL=4)
Nonautoclave curing (TRL=3)
Nondestructive evaluation (TRL=4)
Vehicle health monitoring (TRL=3)
Integrated TPS / cryoinsulation (TRL=2)
Leading Edges / Nose Caps
Refractory composites (TRL=9)
Hot-structure control surfaces (TRL=5)
Thermal Protection System
High temperature metallics (TRL=5)
Refractory composites (TRL=4)
Advanced flexible insulation (TRL=6)
Primary Structure
High-temperature metal composites (TRL=4)
Noncircular composite shell structures (TRL=3)
Joints and attachment techniques (TRL=4)
Nondestructive evaluation (TRL=4)
Manufacturing technology (TRL=4)
Assessment of Technology Needs for an RLV
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Typical Reentry Temperature History
0
400
800
1200
1600
100 4100 8100 12100 16100Time (sec.)
Materials
Structural
Concepts
Experimental
Validation
Analyses
Advanced
Tanks
Wings
Airframe
A Complete Integrated Structures and
Materials Program for RLV Airframe Systems
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1. Application-Specific Aero-space Programs Affordable Point-to-Point Personal Aircraft
Large Transport Aircraft (e.g., Blended-Wing Body)
Sensorcraft Lunar/Mars Transportation Vehicles for Human Exploration
2. Brilliant Products and Systems
Multifunctional Materials and Structures
Highly-Integrated Instruments and Structures for Sensorcraft
Ultra-Smart Materials and Structures Radiation Effects and Radiation Shielding Materials
3. Computing, Design, and Analysis Methods and Tools
Optical, Quantum, and Biological Computers Fully Immersive Concept-To-Flight Design Environment
Flexible Integration of Modeling and Design Techniques
Intelligent agents, Fuzzy, and Nondeterministic Analysis Methods
4. Experimental Methods and Test Techniques
Remote access to facilities and laboratories through virtual reality
Automated, Digitally-Controlled Testing Techniques
Programs, Products, and Services for 2009
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Structures & Materials Skills Evolution
Classical metals, polymers, ceramics, and composites development
skills transitioning to nano-, smart-, functionally graded,
multifunctional, environmentally friendly, computational, and biomimicdesigned M&S systems
Classical applied mechanics, dynamics, aeroelasticity, and
computational methods skills transitioning to multidisciplinarycomputational aero-servo-thermal-structure-materials methodology;
and mathematically nondeterministic, nonlinear, fuzzy, probabilistic,
design and analysis tools
Traditional point-by-point external diagnostic sensors skills
transitioning to intelligent, distributed, in-situ diagnostic, and self-healing systems.
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Areas of Expertise at
NASA Langley Research Center
AoE 1. Develop advanced materials and processing technologiesto enable
the fabrication of low-cost and high-performance structural concepts for
aerospace applications.
AoE 2. Conduct research and technology development that accurately and
efficiently predict behavior, durability and damage tolerance,evaluates
concepts, and validatesperformance of advanced materials and structures for
aerospace structural applications.
AoE 3. Conduct research and technology development for advanced sensors,
intelligent systems, and ground operationsto ensure structural integrity,
reliability, and safety for aerospace vehicles.
AoE 4. Conduct research and technology development to quantify and control
aeroelastic response, unsteady aerodynamicflow phenomena, and
structural dynamicsbehavior for aerospace vehicles.
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New materials, processing, structural concepts, and
sensors will enable dramatically improved applications
Reusable launch vehicles and future spacecraft will
demonstrate advanced materials and structures
technologies
Concluding Remarks
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Coupon Testingfor Material
Properties
Design Conceptsand AnalysisDevelopment
ManufacturingProcess
Developmentand Scale-up
ConceptDemonstration atComponent Level
Full-ScaleStructuralVerification
Mechanical Properties
H2 Permeability tests (4 in. x 4 in.)
Flatwise Tension Tests
(2 in. x 2 in.)
Gr-Ep/Foam Panel
(LaRC TEEK HH)
Thermally Cycled PMC/Foam Insulation
Fluted Core Splice Joint
Development of Advanced Cryotank and Airframe
Structures Building-Block Approach
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Atomic Oxygen Resistance
High Specific Strength
Selected for ProSEDS
Flight Demonstration
Tethers for Propellant-Free
Propulsion
Solar Thermal Propulsion
Upperstage
Low Color, Low Solar Absorption
High Reflectivity
Selected for Primary Collector on
Boeings SOTV
Application of LaRC-Developed Materials
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Cargo hold and fuel tank explosions
Modify Aircraft Landing Dynamics Facility (high load, high speed, larger tires)*
High-temperature and cryo-temperature capability for COLTS*
Electro-Magnetic upgrade to TDT*
Hypersonic flow simulation (ARC Jet)
Nano-sensor facility*
In-Situ Materials Processing Lab
Laser Deposition Fabrication Lab
High-conductivity property characterization
Advanced automated materials manufacturing lab
Biochemistry Lab*
Large graphitization fabrication facility
Free-form fabrication facility Large brazing fabrication facility
Rapid prototyping fabrication lab
3-D virtual reality computational test lab*
*Facilities located at LaRC
New/Enhanced Facilities Required for 2009
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Autoclave & Vacuum Hot Press
Curing
AdvancementsIn Composite
Technology
1960 1970 1980 1990 2000
Carbon,
Boron,
S-Glass
BrittleEpoxies:
MY-720
ERL-0510T300/5208,
T300/3501-6
Rubber Toughening:
Thermoplastic Studies
Toughened
Epoxies
Textile
Preforms
Affordable Processing
E-Beam Cures
Non-Autoclave Curing
RFI/Stitched Preforms
Evolution of Composite Resin Development: Epoxies
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