Composite Structures ? The First 100 Years - Department of ...
Composite Structures ? The First 100 Years - Department of ...
Composite Structures ? The First 100 Years - Department of ...
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<strong>Composite</strong> <strong>Structures</strong> – <strong>The</strong> <strong>First</strong><br />
<strong>100</strong> <strong>Years</strong><br />
Billy Roeseler, Branko Sarh, and Max Kismarton<br />
Originally prepared for ICCM-16 Kyoto, Japan<br />
9 July 2007<br />
Added content from John Quinlivan, Joe Sutter, Damon Roberts,<br />
(Insensys,) GE, and Boeing 787 Program for <strong>Composite</strong> Design<br />
Tutorial, Stanford University 28 Sept 2009
<strong>Composite</strong>s <strong>The</strong>n and Now<br />
Two or more materials combined to<br />
perform some useful purpose<br />
Exhibits the best properties <strong>of</strong> the<br />
individual materials plus additional<br />
qualities that the individual materials do<br />
not exhibit alone<br />
Examples<br />
Mud and straw<br />
Steel-reinforced concrete<br />
Fibers embedded in a plastic resin matrix<br />
Oriented Strand Board (OSB)
1943 Popular Mechanics Prediction
<strong>Composite</strong>s Provide Higher<br />
Strength and Stiffness<br />
Specific<br />
Ultimate<br />
Tension,<br />
UTS1<br />
(KSI / pci)<br />
Vectran HS<br />
S-glass<br />
Quartz<br />
Kevlar 29<br />
E-glass<br />
Vectran M<br />
Titanium<br />
Aluminum<br />
Steel<br />
Zylon AS<br />
Dyneema<br />
T-800<br />
Zylon<br />
T-700G<br />
M30J<br />
Spectra 900 AS4D<br />
AS4<br />
T-400H<br />
Kevlar 149 T-300G<br />
Kevlar 49<br />
T300<br />
T-<strong>100</strong>0<br />
M30S<br />
M30<br />
Boron<br />
0 200 400 600 800 <strong>100</strong>0 1200 1400<br />
HM<br />
M35J<br />
M40J<br />
Specific Modulus, E1/ rho (MSI / pci)<br />
M46J<br />
Specific<br />
Fiber Properties Dry<br />
(no resin)<br />
Tension ONLY<br />
M50J<br />
M55J<br />
M5<br />
M60J<br />
Fig 2
Fiberglass Primary <strong>Structures</strong> -<br />
Rotor Blades (1964 flight test)
MASS Governor Volpe inspects<br />
Autocopter 1966
767 and Entry Door Spring 1978
Fiberglass Primary Structure in Service<br />
1984
Joe Sutter 1982
1982 Prediction<br />
Joe Sutter
Rational Growth <strong>of</strong> Aerospace Usage<br />
<strong>of</strong> <strong>Composite</strong> <strong>Structures</strong><br />
Percent <strong>of</strong> <strong>Composite</strong><br />
60<br />
50<br />
40<br />
30<br />
20<br />
10<br />
Gripen<br />
Eur<strong>of</strong>ighter<br />
F-22<br />
7E7<br />
OV-22<br />
F-35<br />
AV-8B<br />
ATR72<br />
A400M<br />
707<br />
A380<br />
767 ATR42 F/A-18 E/F<br />
L1011 757 A340 A330-200<br />
DC-10<br />
A320<br />
777<br />
DC-9<br />
737-300 A310<br />
MD-11<br />
747-400<br />
0<br />
1940 1960 1980 2000 2020<br />
B-2<br />
AH-66<br />
LCA<br />
Boeing<br />
Non-Boeing
Damage Tolerant Design<br />
Design<br />
Load<br />
Level<br />
Ultimate<br />
1.5 Factor<br />
<strong>of</strong> Safety<br />
Limit<br />
Allowable<br />
Damage Limit<br />
(ADL)<br />
~ Maximum load<br />
per lifetime<br />
Critical Damage<br />
Threshold<br />
(CDT)<br />
Increasing Damage Severity<br />
Continued<br />
safe flight
LCPAS Compression Panel Test<br />
Summary<br />
Normalized Gross Failure Stress (Ksi)<br />
70<br />
60<br />
50<br />
40<br />
30<br />
20<br />
10<br />
X<br />
3I-1<br />
1J-3<br />
3B-3<br />
X<br />
X<br />
X X<br />
X<br />
X X<br />
X<br />
X<br />
5 10 15 20 25 30 20 30 40 50 60<br />
11-5<br />
End load N x (Kip/in.) Shear Stiffness Ratio Gt/N x<br />
LCPAS 1982 (2220-3)<br />
Rhodes and Williams 1981 (5208)<br />
Aluminum (7150)<br />
Impact damage ½ in. –diameter metal impactor<br />
3J-1<br />
1B-1<br />
3B-3<br />
11-5<br />
27%<br />
Mass Reduction<br />
3B-3<br />
8%<br />
X<br />
3I-1<br />
3J-1
LCPAS Wing Sizing Based on Test<br />
Results<br />
Component<br />
Upper Surface<br />
Lower Surface<br />
Spars<br />
Total<br />
(Panels + Spars)<br />
<strong>The</strong>oretical<br />
Mass<br />
Reduction (%)<br />
24<br />
49<br />
40<br />
38
Boeing Structural Aluminum Alloy<br />
Improvements<br />
Fracture<br />
Toughness<br />
K aap,Ksi √ in<br />
200<br />
150<br />
<strong>100</strong><br />
50<br />
0<br />
2024-T3<br />
• 777 Fuselage<br />
2024-T351<br />
2XXX-T3<br />
Old<br />
Technology<br />
Lower Wing<br />
• 767<br />
• 757<br />
• 737<br />
• 747-400<br />
• 777<br />
2324-T39<br />
2224<br />
7075-T651<br />
7178-T651<br />
Upper Wing<br />
• 767<br />
• 757<br />
• 737-300<br />
-400, -500<br />
• 747-400<br />
40 60 80 <strong>100</strong><br />
7150<br />
Typical Yield Strength, Ksi<br />
7150<br />
Goodness<br />
Upper Wing<br />
• 737-700,-800<br />
• 777<br />
7055<br />
• 777 Body Stringers
Specific Strength Of Wing Bending<br />
Materials<br />
Specific Strength<br />
Stress / Density<br />
(Ksi / pci)<br />
900<br />
850<br />
800<br />
750<br />
700<br />
650<br />
600<br />
550<br />
500<br />
Spruce<br />
Goose<br />
DC-3<br />
B-47<br />
DC-7<br />
B-52<br />
Comet<br />
Helicopters<br />
737<br />
747<br />
Military<br />
7075<br />
2024<br />
7150<br />
757<br />
767<br />
1930 1950 1970 1990 2010 2030 2050<br />
Year<br />
Wind Energy<br />
IACC<br />
7055<br />
2324<br />
2224<br />
Commercial<br />
Tails<br />
777-wing<br />
Commercial<br />
Wings<br />
UAVs<br />
Metallics<br />
<strong>Composite</strong>s
Setting New Levels <strong>of</strong> Leadership<br />
Less fuel used<br />
Lower emissions<br />
Quieter for communities,<br />
crews, and passengers<br />
Fewer hazardous materials<br />
Less waste in production
Opening a New Era in Fuel Efficiency<br />
Fuel consumption per seat<br />
20%<br />
Better<br />
787<br />
225 SEATS 275 SEATS<br />
200 SEATS 250 SEATS 300 SEATS<br />
Current<br />
Twins<br />
Current<br />
Quads<br />
Fuel consumption per trip<br />
350 SEATS 400 SEATS<br />
450 SEATS<br />
500 SEATS<br />
550 SEATS
Addressing the Market’s Needs<br />
(2006-2025)<br />
Regional jets<br />
Single-aisle<br />
Twin-aisle<br />
747 and larger<br />
23%<br />
3%<br />
13%<br />
61%<br />
27,200<br />
airplanes<br />
4%<br />
10%<br />
45%<br />
2.6 trillion<br />
delivery dollars*<br />
*In year 2005 dollars<br />
41%
<strong>Composite</strong> Solutions Applied<br />
Throughout the 787<br />
Carbon laminate<br />
Carbon sandwich<br />
Other composites<br />
Aluminum<br />
Titanium<br />
Titanium/steel/aluminum<br />
Titanium<br />
15%<br />
Steel<br />
10%<br />
Aluminum<br />
20%<br />
Other<br />
5%<br />
<strong>Composite</strong>s<br />
50%
Partners Across <strong>The</strong> Globe Are Bringing<br />
<strong>The</strong> 787 Together (2007 data)
787 Final Assembly Flow<br />
Everett, Wash.
Increased Use <strong>of</strong> <strong>Composite</strong>s<br />
Over Time<br />
747<br />
1%<br />
757/767<br />
3%<br />
787<br />
777 11%<br />
50%<br />
Materials<br />
<strong>Composite</strong><br />
Steel<br />
Titanium<br />
Aluminum<br />
Miscellaneous
Validation Process Ensures Safety,<br />
Reliability<br />
Material<br />
Specimens<br />
Proven Certification process, validated by<br />
positive service experience<br />
Boeing design objectives typically exceed<br />
minimum regulatory requirements<br />
Elements<br />
Assemblies<br />
Components<br />
Increasing Levels <strong>of</strong> Complexity<br />
Airplanes<br />
Static Test<br />
Fatigue Test<br />
Ground & Flight Tests
Static Test Airframe Moves To<br />
Testing Rig 25 April 2008
787 Airframe Static Test
<strong>Composite</strong>s Also On Jet Engines
<strong>Composite</strong>s at Work with Wind Turbines<br />
(Vestas V90)
BOR 90, Newest Carbon Fiber Flying<br />
Machine, Anacortes, WA 2008<br />
www.GGYC.COM
<strong>Composite</strong>s at Sea with the Maltese<br />
Falcon
Damon Roberts Insensys, Ltd
Maltese Falcon Rig Engineering and Build<br />
Structural Overview<br />
Bending moment at deck 17,000,000 Nm<br />
Torque at deck 1,200 kNm<br />
Height 58m<br />
Sail area on each spar 800 sqm<br />
Elliptical spar 1.8m by 1.1m max, tapering to 0.6 by 0.4m<br />
at top and reducing to 1.1m diam at deck<br />
Open slot down compression face
Maltese Falcon main spar, note slot for furling sails<br />
Masts
Maltese Falcon Rig Cured in 4 pieces,<br />
secondary bonded together
Maltese Falcon Rig Stepping
Real Time Display in Wheel House,<br />
Maltese Falcon
Improvements in Specific Strength<br />
During the <strong>First</strong> <strong>100</strong> <strong>Years</strong> <strong>of</strong> <strong>Composite</strong>s<br />
Specific Strength,<br />
Log (ksi/pci)<br />
DC-3<br />
B-47<br />
DC-7<br />
AL ladders<br />
Autocopter<br />
B-52<br />
Comet<br />
Corvette<br />
Chop Fiber<br />
AL Ti Steel Wood Plastic Glass CFRP<br />
AL-7050<br />
4130<br />
747<br />
Spectra lines GR fiber, dry<br />
Uni, Rod<br />
Uni, Spring<br />
767<br />
Year<br />
777<br />
High Pressure Tanks<br />
Wind Energy<br />
AL-7150<br />
787<br />
Zylon, dry<br />
Vectran, dry<br />
Oil Drilling<br />
Nano<br />
Fibers<br />
Metals<br />
1940 1950 1960 1970 1980 1990 2000 2010 2020 2030 2040
Diverse Modes <strong>of</strong> Transportation<br />
Travel Time (Hours)<br />
12.0<br />
11.0<br />
10.0<br />
9.0<br />
8.0<br />
7.0<br />
6.0<br />
5.0<br />
4.0<br />
3.0<br />
2.0<br />
1.0<br />
+ +<br />
() () () ()<br />
Automobile<br />
() () () () Commercial AC Using Hub<br />
<br />
Commercial AC<br />
<br />
Advanced Flying Automobile<br />
AFA Driving Mode<br />
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Automobile<br />
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() () () ()<br />
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AFA Flight Mode<br />
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<strong>100</strong> 200 300 400 500 600 700 800<br />
Flight Destination (Miles)<br />
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Commercial w Hub<br />
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Commercial AC
On the Land, In the Sky, On the Sea:<br />
<strong>The</strong> Best Is Yet to Come
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