Composite Structures The First 100 Years

Transcription

1 Composite Structures The First 100 Years Billy Roeseler, Branko Sarh, and Max Kismarton Originally prepared for ICCM-16 Kyoto, Japan 9 July 2007 Added content from John Quinlivan, Joe Sutter, Damon Roberts, (Insensys,) GE, and Boeing 787 Program for Composite Design Tutorial, Stanford University 28 Sept 2009

2 Composites Then and Now Two or more materials combined to perform some useful purpose Exhibits the best properties of the individual materials plus additional qualities that the individual materials do not exhibit alone Examples Mud and straw Steel-reinforced concrete Fibers embedded in a plastic resin matrix Oriented Strand Board (OSB)

3 1943 Popular Mechanics Prediction

4 Composites Provide Higher Strength and Stiffness Zylon AS Dyneema Zylon HM T-1000 Specific Fiber Properties Dry (no resin) Tension ONLY Specific Ultimate Tension, UTS1 (KSI / pci) Vectran HS S-glass Kevlar 29 T-800 T-700G M30J Spectra 900 AS4D AS4 T-400H Kevlar 149 T-300G Kevlar 49 T300 M30S M30 M35J M40J M46J M50J M55J M5 M60J Quartz E-glass Boron Vectran M Titanium Aluminum Steel Specific Modulus, E1/ rho (MSI / pci) Fig 2

5 Fiberglass Primary Structures - Rotor Blades (1964 flight test)

6 MASS Governor Volpe inspects Autocopter 1966

7 767 and Entry Door Spring 1978

8 Fiberglass Primary Structure in Service 1984

9 Joe Sutter 1982

10 1982 Prediction Joe Sutter

11 Rational Growth of Aerospace Usage of Composite Structures Percent of Composite Gripen Eurofighter F-22 7E7 OV-22 F-35 AV-8B A400M ATR72 A ATR42 F/A-18 E/F L A340 A DC-10 A DC A310 MD B-2 AH-66 LCA Boeing Non-Boeing

12 Damage Tolerant Design Design Load Level Ultimate 1.5 Factor of Safety Limit ~ Maximum load per lifetime Continued safe flight Allowable Damage Limit (ADL) Critical Damage Threshold (CDT) Increasing Damage Severity

13 LCPAS Compression Panel Test Summary Normalized Gross Failure Stress (Ksi) I-1 1J-3 3J-1 3B-3 1B-1 3B-3 27% Mass Reduction 3B-3 X X X X X X X X X 8% X 3I-1 3J-1 10 X End load N x (Kip/in.) LCPAS 1982 (2220-3) Rhodes and Williams 1981 (5208) Aluminum (7150) Impact damage ½ in. diameter metal impactor Shear Stiffness Ratio Gt/N x

14 LCPAS Wing Sizing Based on Test Results Component Upper Surface Lower Surface Spars Total (Panels + Spars) Theoretical Mass Reduction (%)

15 Boeing Structural Aluminum Alloy Improvements Fracture Toughness K aap,ksi in T3 777 Fuselage 2024-T351 2XXX-T3 Old Technology Lower Wing T T T651 Upper Wing , Goodness Upper Wing , Body Stringers Typical Yield Strength, Ksi

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17 Specific Strength Of Wing Bending Materials 900 Wind Energy UAVs 850 IACC 800 Specific Strength Stress / Density (Ksi / pci) Spruce Goose B-52 Helicopters Military 7055 Commercial Tails Commercial Wings wing DC-3 B-47 DC-7 Comet Year Metallics Composites

18 Setting New Levels of Leadership Less fuel used Lower emissions Quieter for communities, crews, and passengers Fewer hazardous materials Less waste in production

19 Opening a New Era in Fuel Efficiency 225 SEATS 275 SEATS 200 SEATS 250 SEATS 300 SEATS 350 SEATS 400 SEATS 450 SEATS Fuel consumption per seat 20% Better Current Twins Current Quads 500 SEATS 550 SEATS 787 Fuel consumption per trip

20 Addressing the Market s Needs ( ) Regional jets Single-aisle Twin-aisle 747 and larger 23% 3% 13% 4% 10% 61% 45% 41% 27,200 airplanes 2.6 trillion delivery dollars* *In year 2005 dollars

21 Composite Solutions Applied Throughout the 787 Carbon laminate Carbon sandwich Other composites Aluminum Titanium Titanium/steel/aluminum Titanium 15% Steel 10% Aluminum 20% Other 5% Composites 50%

22 Partners Across The Globe Are Bringing The 787 Together (2007 data)

23 787 Final Assembly Flow Everett, Wash.

24 Increased Use of Composites Over Time % 50% 757/767 3% 747 1% Materials Composite Steel Titanium Aluminum Miscellaneous

25 Validation Process Ensures Safety, Reliability Proven Certification process, validated by positive service experience Boeing design objectives typically exceed minimum regulatory requirements Assemblies Airplanes Static Test Fatigue Test Ground & Flight Tests Material Specimens Elements Components Increasing Levels of Complexity

26 Static Test Airframe Moves To Testing Rig 25 April 2008

27 787 Airframe Static Test

28 Composites Also On Jet Engines

29 Composites at Work with Wind Turbines (Vestas V90)

30 BOR 90, Newest Carbon Fiber Flying Machine, Anacortes, WA

31 Composites at Sea with the Maltese Falcon

32 Damon Roberts Insensys, Ltd

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34 Maltese Falcon Rig Engineering and Build Structural Overview Bending moment at deck 17,000,000 Nm Torque at deck 1,200 knm Height 58m Sail area on each spar 800 sqm Elliptical spar 1.8m by 1.1m max, tapering to 0.6 by 0.4m at top and reducing to 1.1m diam at deck Open slot down compression face

35 Maltese Falcon main spar, note slot for furling sails Masts

36 Maltese Falcon Rig Cured in 4 pieces, secondary bonded together

37 Maltese Falcon Rig Stepping

38 Real Time Display in Wheel House, Maltese Falcon

39 Improvements in Specific Strength During the First 100 Years of Composites AL Ti Steel Wood Plastic Glass CFRP Nano Fibers Zylon, dry Spectra lines GR fiber, dry Vectran, dry Specific Strength, Log (ksi/pci) Autocopter B-52 B-47 Uni, Rod Uni, Spring AL High Pressure Tanks Wind Energy Oil Drilling Metals DC-7 Comet DC-3 Corvette AL AL ladders Chop Fiber Year

40 Diverse Modes of Transportation ( ) ( ) Automobile Commercial AC Using Hub Commercial AC Advanced Flying Automobile Travel Time (Hours) AFA Driving Mode + Automobile ( ) ( ) ( ) ( ) ( ) ( ) Commercial w Hub Commercial AC 1.0 AFA Flight Mode Flight Destination (Miles)

41 On the Land, In the Sky, On the Sea: The Best Is Yet to Come