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The Future for Advanced Structural Materials and Computational Design
Frank Doerner,
Vice President – Materials, Processes & Structures Technologies
Boeing Research & Technology
05 October 2011
Discussion Topics
• Background
• Complexity driving costs and
development cycle time
• Computational methods applications
• Increased computational methods for
materials & structures
• Need holistic system
Key Drivers for Aerospace Structures
• Affordability
– Technology development costs
– Design and non-recurring costs
– Operations costs • Reduce weight - Lower fuel burn
• Maintenance - Repair
– Environmental – carbon footprint to
build, operate and dispose
• Performance
– Safety
– Payload & range
• Speed to market
– Leverage new technology
LU 2 in NDI
Aerospace Complexity
Complexity Driving Longer Development Cycles
Launch Order – 1990
Delivered – 1995
Launch Order – 2004
Delivered – 2011
Launch Order – 1978
Delivered – 1982
767
777
787
Complexity Drives Analysis Demands for
Airframe Structure
0
10
20
30
40
50
60
70
Stress
Weights
M&P
Time
Non-recurring
Analysis
Hours / lb of
Airframe
Complexity Drives Increased Building Block
Testing to Provides Data for Structural Analysis
Analysis validation
Design-value
development
Material property
evaluation
Component
tests
Sub-component tests
Structural elements tests
Allowable development
Material specification development
Material screening and selection
Full-
scale
tests
Tier 1
Tier 3
Tier 2
1980s 2000s
2 2
15 2
2,500 25
10,000 500
100,000 5,000
~ size of structural test
programs
Major growth
in cost & time
Expanding Design Space is Rapidly Increasing
Complexity P
erf
orm
an
ce
(we
igh
t re
du
cti
on
)
Material Combinations, Fiber Orientations,
Manufacturing Techniques, . . .
Isotropic
“One Choice”
Today
100’s of
Choices “Billions”
of Choices
Traditional Structural
Methods & Tools Can’t
Keep Up with Expanding
Design Space
Going Forward
Computational Methods Widely Used in Other
Engineering Disciplines
Effort
Elapsed Time
90% Drawing Release
1990 1993
1997
2000
Computational Effect on Product Design Cycle
Certify and Qualify New Materials & Structures
Faster
Goal is to Provide a Modeling, Simulations and Analysis
Approach Supported by Experience, Test and Demonstration
Time to Insertion Readiness
Time to Insertion Readiness Reduced by 55%
A A A A A A
A A A A A A
Traditional Test Supported by Analysis Approach
Materials & structures designed, analyzed, and
qualified in digital form, with requirements driven by
system & life-cycle requirements
• Reduced time and cost
• Increased design space
• Increased performance
Constituent Design
Material Configurations
Element Design
Sub-Component Designs
Component Designs
• Material Development • Process Development
Molecular Modeling
Material Models
Computational Allowables
Failure Modeling
Virtual Testing & Sim
Computational Design Values
• Producibility • Accept/Reject
• NDT Standards
• Mechanical Props • Knock-downs • Environmental • Effects of Defects
• Structural Performance
• Damage Tolerance • Static & Fatigue • Analysis Validation
• Design Values • DaDT • Analysis Validation
Full Scale
• Static • GVT • Fatigue • Flight
Vehicle
Atoms to Aircraft – Applying Computational
Methods Down the Structural Value Chain
Constituent Design
Material Configurations
Element Design
Sub-Component Designs
Component Designs
• Material Development • Process Development
Molecular Modeling
Material Models
Computational Allowables
Failure Modeling
Virtual Testing & Sim
Computational Design Values
• Producibility • Accept/Reject • Assembly
• NDT Standards
• Mechanical Props • Knock-downs • Environmental • Effects of Defects
• Structural Performance
• Damage Tolerance • Static & Fatigue • Analysis Validation
• Design Values • DaDT • Analysis Validation
Full Scale
• Static • GVT • Fatigue • Flight
Vehicle
Atoms to Aircraft
0
0.03
0.06
0.09
0.12
0.15
0.18
0.21
0 0.02 0.04 0.06 0.08 0.1 0.12 0.14 0.16 0.18 0.2 0.22
Strain, in/in
Str
ess
, G
Pa
Simulation Experimental
Molecular Modeling & Predictive Laminate
Performance
Structural Materials also Need Multi-Functional
Performance
Electrical Thermal Acoustic
Structural
Manufacturing Processing Effects
• Producibility limits
• Inspection Standards
• Quality & Effects of Defects
• Process Tolerances
• Manufacturing Scale-up
• Assembly Tolerances
Constituent Design
Material Configurations
Element Design
Sub-Component Designs
Component Designs
• Material Development • Process Development
Molecular Modeling
Material Models
Computational Allowables
Failure Modeling
Virtual Testing & Sim
Computational Design Values
• Producibility • Accept/Reject
• NDT Standards
• Mechanical Props • Knock-downs • Environmental • Effects of Defects
• Structural Performance
• Damage Tolerance • Static & Fatigue • Analysis Validation
• Design Values • DaDT • Analysis Validation
Full Scale
• Static • GVT • Fatigue • Flight
Vehicle
• Producibility
• Inspection Standards
• Quality & Effects of
Defects
• Process Tolerances
• Electromagnetic
effects
• Effects of
Lightning Strikes
• Flammability
Performance
• Assembly
Tolerances Build-
ups – GD&T
• Quality & Effects of
Defects
Linking Modeling & Simulation of Other Effects
Summary
• Complexity drives increased costs
and longer development
• Computational methods must be
extended to routinely handle
complex application design spaces
• Material properties must be linked to structural
simulations seamlessly
• Modeling and simulation activities should be linked
into a more holistic system