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N O T I C E

THIS DOCUMENT HAS BEEN REPRODUCED FROM MICROFICHE. ALTHOUGH IT IS RECOGNIZED THAT

CERTAIN PORTIONS ARE ILLEGIBLE, IT IS BEING RELEASED IN THE INTEREST OF MAKING AVAILABLE AS MUCH

INFORMATION AS POSSIBLE

https://ntrs.nasa.gov/search.jsp?R=19800009838 2018-05-27T10:07:19+00:00Z

If

MR a

i

l!1 CONTRACT NAS1-15069

Advanced Composite AileronFor L-1011 Transport Aircraft

,DLR 003

QUARTERLY TECHNICAL REPORT - NO. 2

This report is for the period 22 December 1973 through 24 March 1978

Lockheed CorporationLockheed-California Company

Post Office Box. 551Burbank, California 91520

(NASA-CR-lb2663) ADVANCED COMFOR L-1011 TFANSi;GET A ILI CRAFTTechaicdl Report, 21 Dec. 19731978 (Lock heed-c.dli forma Co.,

r 54 p HC A04/MF A01

POSITE AILch0N N8J-18103^uacteriy24 Ndl.

Blirbar i k.) OnclasC:>CL 1 1 C ;-J/24 3s566

I.

14 April 1978

Prepared for Langley Research Center

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LR 28559

CONTRACT NAS1-15069

Advanced Composite AileronFor L-1011 Transport Aircraft

DLR 003

QUARTERLY TECHNICAL REPORT — NO.

This report is for the period 22 December 1973 through 24 March 1978

Lockheed Corporation

Lockheed-California CompanyPost Office Box 551

Burbank, California 91520

Approved By. ^ JF.C. EnglishProgram Manager

14 April 1978

Prepared for Langley Research Center

Page intentionally left blank

LR 28559

FOREWORD

This report was prepared by the Lockheed-California Company, Lockheed

Corporation, Burbank, California, under contract NAS1-15069. It is the second

quarterly technical report covering work completed between 22 December 1977

and 24 March 1978. The program is sponsored by the National Aeronautics and

Space Administration (NASA), Langley Research Center. The Program Manager

for Lockheed is Mr. Fred C. English. Mr- Louis F. Vosteen is Project Manager

for NASA, Langley. The Technical Representative for NASA, Langley is

Mr. Herman L. Bohon.

LOCKHEEDf.JtiIAM N^. COY /.N^

Page intentionally left blank

LR 28559

SUMMARY

The activities performed in this reporting period end documented in this

report are associated with Task I - Engineering Development, and Task II -

Design and Analysis of the Advanced Composite Aileron (ACA) program. Task I

activities included the completion of design assessment and material evalua-

tion. The ae f:ail deign of the aileron has been initiated as part of Task II.

Design and evaluation of alternate concepts for the major subcomponents

of the ACA was completed. From this array of subcomponents aileron assemblies

were formulated and evaluated. Based on these analyses a multirib assembly

with graphite tape/syntactic core covers, a graphite tape front spar, and a

graphite fabric ribs was selected for development in the remainder of the ACA

program. A weight savings of 29.1% (40.8 pounds per aileron) is currently

being predicted for the ACA. Engineering cost anaiyoes indicate that the pro-

duction cost of the ACA will be 7.3% less than the current aluminum aileron.

Fabrication, machining, and testing of the material evaluation specimens

for the resin screening program was completed at Lockheed-California Company

and Avco. These test results lead to the selection of Narmco 5208 resin for

the ACA.

Task II activities initiated during this reportin g quarter include the

detail design of the ACA, construction of a three-dimensional finite element

model for structural analysis, and formulation of detail plans for material

verification and process development.

I

v

LOCKHEEDCw^i.ONrai^ CJUNwNr

Page intentionally left blank

LR 28559

TABLE OF CONTENTS

FOREWORD

SUMMARY

LIST OF FIGURES

LIST OF TABLES

INTRODUCTION

TASK I - ENGINEERING DEVELOPMENT, DESIGN ASSESSMENT

ALTERNATE CONCiPTS

Rib Backup Fittings

Main Ribs

Aileron Assembly

Concept/Materials Interactive Study

SELECTED ACA DESIGN CONCEPT

TASK 1 - ENGINEERING DEVELOPMENT, MATERIAL EVALUATION

STRUCTURAL SCREENINGS TESTS

PRODUCIBILITY SCREENING TESTS

SELECTED MATERIALS

:ASK II - DESIGN AND ANALYSIS, COMPONENT DEFINITION

DETAIL DESIGN

STRUCTURAL ANALYSIS

NASTRAN Model

Development of Material Verification Test Plans

Weight Status

MATERIALS AND PRODUCIBILITY ANALYSIS

TASK II - DESIGN AND ANALYSIS, PROCESS DEVELOPMENT ANDVERIFICATION

PROCESS DEVELOPMENT

REFERENCES

Section

1

2

2.1

2.1.1

2.1.2

2.1.3

2.1.4

2.2

3

3.1

3.2

3.3

4

4.1

4.2

4.2.1

4.2.2

4.2.3

4.3

5

5.1

Page

iii

v

ix

xi

1-1

2-1

2-1

2-1

2-2

2-3

2-4

2-8

3-1

3-1

3-12

3-13

4-1

4-1

4-1

4-1

4-2

4-9

4-9

5-1

5-1

R-1

viiLOCKHEEDC.LIIOM A Co.:-

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LR 28559

LIST OF FIGURES

Page

Advanced Composite Aileron - Program Master Schedule 1-2

Aluminum Diefcrged Hinge and Actuator Fitting 2-3

L-1011 Inboard Aileron Concept No. 1 2-5

L-1021 Inboard Aileron Concept No. 2 2-6

Selected ACA Concept and Materials 2-9

Dynamic Flexure Test Results 3-11

Male Tool Rubber Bag 3-17

Female Tool Rubber Bag 3-17

ACA Basic Design Drawing 4-3

Composite Aileron Finite Element Kodel 4-7

Actuator and Hinge Support Stations 4-8

Weight Time History 4-12

Figure

1-1

2-1

2-2

2-3

2-4

3-1

3-2

3-3

4-1

4-2

4-3

4-4

ixLOCKHEEDCALIFORNIA COMOANY

Page intentionally left blank

Page

Rib Backup Fitting Evaluation Matrix 2-2

Main Rib Evaluation Matrix 2-4

Aileron Assembly Evaluation Matrix 2-7

Concept/Materials Refinement 2-8

Composite Aileron: Weight Breakdown 2-10

Quantitative Screening Tests for Combinations ofResins and Reinforcements 3-2

Process Development for Structural Screening -Syntactic and Honeycomb 3-4

Structural Screening Test Panels 3-5

Material Screening - Solid Laminate Test Results 3-7

Material Screening of Graphite/Syntactic -Summary of Test Results 3-8

Material Screening of honeycomb Sandwich Test Specimens 3-9

Ranking of Quantitative Screening Test Results 3-10

Materials Producibility Evaluations 3-13

Producibility Evaluations - Specimen Test Results 3-15

Weight Status Report 4-10

Summary of Weight Changes 4-11

Table

2-1

2-2

2-3

2-4

2-5

3-1

3-2

3-3

3-4

3-5

3-6

3-7

3-8

3-9

4-1

4-2

LR 28559

LIST OF TABLES

xiLOCKHEEDC ­ 1ron NI& COMPAN,

LQ 28559

SECTION 1

INTRODUCTION

The broad objective of NASA's Aircraft Energy Efficiency (ACEE) Compo-

site Structures Program is to accelerate the use of composite materials in

aircraft structures by developing technology for early introduction of struc-

tures made of these materials into commercial transport aircraft. This pro-

gram, one of several which are collectively aimed toward accomplishing the

broad objective, has the specific goal to demonstrate the weight and cost-

saving nw-ential of secondary structures constructed of advanced composite

materials. The secondary structure selected for the program is the inboard

aileron of the Lockheed L-1011 aircraft.

The scope of this program is to design, fabricate, qualify, and certifi-

cate a composite inboard aileron; to test selected subcomponents to verify

the design; to fabricate and test two ground test articles; to fabricate and

install ten shipsets of inboard ailerons; and to gather flight service data

on the ten shipsets of composite ailerons.

The Lockheed-California Company is teamed with Avco Aerostructures Divi-

sion of Avco Corporation. Lockheed will design the aileron, conduct the ma-

terials, concept verification, and ground tests, and evaluate in-flight

service experience. Avco will develop manufacturing processes, fabricate

test specimens, and fabricate the ground test and flight articles.

As shown on the master schedule, Figure 1-1, the program will be con-

ducted in six consequential tasks. Task I, Engineering Development, and Task

II, Design and Analysis, are the portions of the program wherein the compo-

site aileron design will be formulated and subcomponents fabricated and

tested to verify design concepts and fabrication procedures. During Task

# III, Manufacturing Development, and Task IV, Ground Test and Flight Checkout,r

I

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LR 28559

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production quality manufacturing tools will be constructed, ;Vnd t%V full-

scale ailerons will be fabricated and tested. A ?roduction run ten (10)

shipsets will be fabricated during Task V, Aileron Manufacture, to provide

manufacturing and cost information. In Task VI, Plight Service, inspection

and maintenance data will be gathered on the ten shipsets of ailerons to dem-

onstrate that they can be economically operated in routine service. The work

performed during this program is intended to provide the data required to

progress toward a production commitment.

This report describes work accomplished during the second three-month

period of the program. The two principal subtasks within Task 1 of the ACA

program are design assessment and materials evaluation. Activities within

these subtasks which have been completed during this reporting period are

documented in Sections 2 and 3, respectively. Task II of the program has

been initiated. Engineering and planning efforts during this reporting

period are discuFied in Sections 4 and 5.

LOCKHEED 1"3C.L I. 0 11N - . COMP.-'

F

LR 28559

SECTION 2

TASK I - ENGINEERING DEVELOPMENT, DESIGN ASSESSMENT

The objective of the design assessment subtask within Task I was to

select a design concept for the ACA with the greatest potential for meeting

the program objectives. The approach used for this activity was to define

the design criteria, develop alternate designs, evaluate the alternatives

against the cost and weight objectives, and select the best alternative.

Design criteria and several of the alternate concepts for the subcomponents

of the ACA were discussed in Quarterly Report Nu:.iber 1 (Reference 1). The

remainder of the subcomponent alternate concepts, the assembly evaluation,

and the selected design for the ACA are presented in the following

paragraphs.

2.1 ALTERNATE CONCEPTS

Alternate concepts were designed and evaluated for covers, front and

rear spars, main and intermediate ribs, and rib backup fittings. Combinations

of these subcomponents were then assembled and these assemblies evaluated

to ma;:e the final concept selection. The design and evaluation of the covers,

spars, and ribs was reported in Quarterly Technical Report No. 1 (Reference 1).

During this reporting period the evaluation of the rib backup fittings, the

main ribs with the backup fittings included, and the aileron assemblies was

completed.

2.1.1 Rib Backup Fittings

Three designs for the rib backup fitting were evaluated; a graphite tape

bathtub, a graphite fabric bathtub, and a dieforged aluminum bathtub. The

evaluation matrix for the rib backup fitting is shown in Table 2-1. As a

LOCKHEED 2-1cAuroft— A COUP-

LR 28559

TABLE 2-1. RIB BACKUP FITTING EVALUATION MATRIX

COMPONENT BACK-UP FITTING

CONCEPT BATHTUB

MATERIAL ALUMINUM #3 GR — TAPE /1 GR — CLOTH 82

Weight (lb) 0.70 0.48 0.52

Cost Ratio 0.18 1.00 1.07

Tooling andManufacturingProcesses Good Poor Poor

Inspectability Good Fair Fair

ImpactResistance Good Good Good

EnvironmentalSensitivity Fair Good Good

Haintainability Fair Fair Fair

Repairability Nct applicable O Not applicable O Not applicable `3

Remarks r(D Replace Fitting Ol Replace Fitting `" Replace Fitting

consequence of its very low cost as compared to the composite designs, the

dieforged aluminum fitting was selected for the assemblies. A drawing of

this part is shown in Figure 2-1.

2.1.2 Main Ribs

The main rib designs and their evaluation were discussed in Quarterly

Technical Report No. 1 (Reference 1). Three main ribs are included in the

aileron assembly. The main ribs at 1AS 57 and IAS 102 are connected to hinge/

actuator fittings through the spar web. The main rib at IAS 107 is connected

to an actuator fitting. Rib backup fittings are used to facilitate trans-

mission of the concentrated loads from the rib web and caps. The rib backup

fitting in the current metal aileron is a full-depth fitting designed to

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LR 28559

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Figure 2-4. Aluminum Dieforged Hinge and Actuator Backup Fitting

(All dimensions shown in inches)

transmit the rib web shear as well as the rij cap loads. Two of these fittings

nre required per main rib. For the composite designs, the aluminum bathtub

fitting was selected, since the composite rib web is flanged ac the spar inter-

face to transmit the web shear. Four bathtuL fittings are required for the

composite main ribs at IAS 57 and IAS 102, and three are used at IAS 107. A

comparison of a typical aluminum main rib subassembly with the composite main

rib designs is shown in Table 2-2. Concepts ail and #2 were selected for evalua-

tion in assemblies because of their low cost and weight compared Co the other

designs which were evaluated.

2.1.3 Aileron Assembly

The preliminary evaluation of the cover concepLs led to the selection of

two concepts for evaluation as ACA assemblies. They are graphite tope/

syntatic core with five intermediate ribs, and Kevlar honeycomb sandw:Ch with

no intermediate ribs. The two cover concerts were then combined wit`i

2-36

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LR 28559

TABLE 2-2. MAIN RIB $VALUATION MATRIX

STIFF-CONCEPT PLAIN WEB ENED

CONCEPT NO. 1 2 3 4 5

MATERIAL ALUMINUM GRAPHITE GRAPHITE GRAPHITE GRAPHITE GRAPHITE .AND TAPE CLOTH TAPE TAPE TAPECONSTRUCTION (7.5 SYNTACTIC kEVLAR 49 (7.5

MILS/ CORE CLOTH MILS/PLY) I 5 MILS/ CORE. PLY)

PF.Y) (5 MILS/PLY)

WEIGHT (LB)* 5.44 3.51) 3.49 3.35 3.56 3.48COST RATIO* 1.00 0.92 0.98 1.01 1.02 1.05

*Includes Rib Backup Fittings

preliminary selections for each of the subcomponents evaluated, The two

resultant assemblies are shown in Figures 2-2 and 2-3. The evaluation of

these assemblies, shown in Table 2-3, led to the selection of the multirib

concept for the ACA.

2.1.4 Concept/Materials Interactive Study

Materials trade studies indicated advantages for both graphite fabric

and graphite preplied tape for the various subcomponents of the ACA. Con-

sequently, design iterations were required to determine the interaction between

design concepts and material form and to determine the best combination of

both. Subcomponent designs described in this report and the previous report

(Reference 1) were used to develop aileron assemblies using: all-graphite

preplied tape, assembly concept #3; all-graphite fabric, assembly concept #4;

and the best combination of tape and fabric, assembly concept #5. The results

of this study are summarized in Table 2-4.

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TABLE 2-4. CONCEPT/MATERIALS REFINEMPNT

COMPONENT

ASSEMBLY COP*CEPT NUMBER

DESCRIPTION #2 #3 #4 #5

Cover Tape #3 Tape #3 Fabric #10 Tape #3

Front Spar Tape & Fabric #1 Tape #4 Fabric #5 Tape #4

Intermediate Fabric #2 Tape #6 Fabric #2 Fabric #2and End Ribs

Main Ribs Tape #1 Tape #1 Febrie #2 Fabric #2

Pear Spar Aluminum Aluminum Aluminum Aluminum

Backup Fitting Aluminum Aluminum Aluminum Aluminum

Weight * (LB) 100.0 98.9 102.4 99.6

Cost Ratio toAluminum .94 - - .93

t Without Design Growth Allowance

2.2 SELECTED ACA DESIGN CONCEPT

A review of the assemblies shown in Table 2-4 showed that concept #5

with fabric ribs and 7.5 mil preplied graphite tape front spar and covers

(with syntactic core) represented the most effective design. The selected

concept is shown in Figure 2-4, and its weight statement is shown in

Table 2-5.

LOCKHEED 2-8CALI.O R -A COMPANY

LR 28559

BACK UP FITTINGSAL. DIE FORGING

REAR SPARCAM ALUMINUM CHANNEL

INTERMEDIATE RIBSOR/EPDXY CLOTH

— MAIN RIBSOR/EPDXY CLOTH

^.. " ^- ^ COVERS^► '^^^^ •' F GRAPHITE/EPDXY TAPE

\J 0AND SYNTACTIC CORE

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FRONT SPAROR/EPDXY TAPE

+BANAL PAGE; 4S

Figure 2-4.- Selected ACA. Concept and Materials

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LR 28559

TABLE 2-5. COMPOSITE AILERON WEIGHT BREAKDOWN

COMPONENT

ALUMINUMBASELINEWT (LBS)

COMPOSITECONCEPT 45WT (LDS)

0Surfaces 39.3 28.7

QRibs 39.3 (20.0)

IAS 57 3.9

102 3.9

107 3.0

INBD Closeout 1.6

OUTBD Closeout 1.6

0Intermediate 6.0

OSpars 15.9 (9.7)

Front 5.8

Rear 3.9

O OFairing and Shroud 16.2 (16.9)

LE Shroud 10.5

INBD Fairing 2.9

OUTBD Fairing 3.5

GT.E. Wedge Assy 12.6 6.0

OAttach Hardware 4.2 2.7

Surface Protection 3.4 (6.1)

©Lightning 2.7

Finish/Sealant 3.4

OExisting FRT Spar Figs 9.5 9.5

Design Crowth Allowance - 5.0

Predicted Weight - Aileron 140.4 104.6

Weight Saving 35.8

2 Weight Saving 25.51

NOTES: OI No fasteners

(D Incl: upper surface fasteners; lover surface platenuts

Q3 Identical to baseline except hi•-loks instead of rivetsfor shroud to spar attachment

O4 Incl: fasteners (bolts and washers)OS Remaining assembly and installation hardware© Aluminum flame spray

2-]0LOCKHEEDCA11.ORNIA GOYP.N'

()RI(,INAI, PAGE IS,%, p( N )R OUA AX

LR 28559

i

SECTION 3

TASK I - ENGINEERING DEVELOPMENT, MATERIAL EVALUATION

The first part of material evaluation activities in Task I consisted

of an initial qualitative screening of candidate prepregs, the results of

which were reported in the First Quarterly Report (Reference 1). Three

resin systems were selected for inclusion in the Task I quantitative

screening tests: Narmco 5208, Fiberite 934, and Hexcel F-263. The quali-

tative screening study also identified three filamentary reinforcement

types as having potential application to the ACA design. These were uni-

directional graphite tape, graphite fabric, and Kevlar 49 fabric reinforce-

meets. The quantitative screening consisted of structural screening tests

performed at Lockheed and producibility screening tests performed at AVCO.

3.1 STRUCTURAL SCREENING TESTS

The quantitative screening test plan is shown in Table 3-1. This test

plan was designed to determine the following critical factors for selection

of the resin system:

• Retention of 1800F mechanical properties in high-humidity environments

• Retention of mechanical properties after impact damage

• Fabricability and mechanical properties as cocured skins for honey-comb sandwich construction

• Compatibility and mechanical properties as cocured skins forsyntactic epoxy construction

• Resin/fiber interface bond strength with Kevlar 49.

A preliminary process development task was performed prf.or to specimen

fabrication to develop acceptable procedures for test-panel fabrication.

3-1LOCKHEED

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LR 28559

TABLE 3-1. QUANTITATIVE SCREENING TESTS FOR COMBINATIONSOF RESINS AND REINFORCEMENTS

Graphite Graphite Graphite Kevlar

(g) (h) Tape/ (1)Type

Tape Cloth Syntactic Cloth HybridOf

Tat (a)Temperature e A B C A B C A B C A B C A B C

Sandwich Beam(f)3 (f) 3 3 3 (f) 3 3 3Compression RTD 3 3 - - - - - -

Interlaminar(f) (b)

3 3 3(f) 3 3 3

(f) 33 3Tension RTD 3 3 3 ---

Sandwich Beam (c)(b)

Compression(f) (d)

33 3(f) 3 3 3

(f) 33 3After Impact RTD 3 3 3 ---

Laminate 355.40K (1800F)

(b)3 3 3Compression Wet 3 3 3 - - - - - - - - -

Laminate RTD 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3

Short-Beam 219.30K (-650F) - - - -- (b)3 3 3 3 3 3 3 3 3

Shear 'Dry 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3

355.401( (1800F)

Wet

Laminate RTD 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3

Flexure 255.40K (1800F) 3 3 3 3 3 3 (b)3 3 3 3 3 3 3 3 3

Wet

Dynamic Dry 3 3 3 - - - - - - - - - - - -

Mechanical Wet 3 3 3 - - - - - - - - - - - -

Analysis

NOTES

(a) Numbers in temperature column indicate test temperature in degrees Fahrenheit.

Letters: W - wet (7 day immersion at 338.7 0K (150oF), D - dry, and RT - room temperature. i

(b) A syntactic material (Hysol ADX 819) is used for the core.

(c) After impact the sandwich is tested as a beam with the impacted face in compression.

(d) After impact the Graphite tape/syntactic sandwich is tested in edgewise compression

with platen supports.

(e) The letters A, B, and C are the resins (5208, 934 6 F263) selected fr3m qualitative

screening.

(f) Bonded with AF143 adhesive.

(g) Nominal 0.013 cm (5 mils)/cured ply tape, 3000 tow fibers at 35% nominal resin content by

weight.

(h) 24 x 23 8 harness satin bi-directional fabric 0.033 cm (13 mils) /cured ply nominal, 3000

tow fibers, at 35% nominal resin content by weight.

(i) Style 285 Kevlar 49 fabric, 43Z nominal resin content by weight, 0.025 CM (10 mils) /cured

ply nominal.

3-2LOCKHEEDCAII/O.-A COM•ANV

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LR 28559

These activities were summarized in Table 3-5 of the First Quarterly Report

(Reference 1) and an updated summary of further process development activities

since that report is given in Table 3-2. Significant items in the process

development activity include:

e Fabrication of solid laminate graphite, Kevlar 49 and hybrid speci-mens - Acceptable laminates were fabricated using modified vendorcure cycles. The bleeder arrangement was designe3 to achieve mini-mum flow with the 35 percent resin content prepreg system.

e Fabrication of graphite/syntactic panels - The syntactic test panelswere fabricated using the same cure cycles used for solid laminatespecimens with each of the three resins.

e Fabrication of honeycomb panels - Panels were fabricated with graph-ite faces cocured to the Nomex cure, using two procedures: a single-stage cocuring cycle, and prebleeding of the skins prior to cocuring.Excessive resin flow occurred with the single-stage procedure andextensive skin porosity was fouLi in all panels by photopiccographs.The preblec skins had less porosity and resin flow, but in severalinstances graphite interlamirar failures occurred in flatwire tensiletests. In view of these problems and the limited available time forfurther process development, a decision was made to fabricate allhoneycomb test panels with pre-cured, &econdarily bonded skins.

A summary of test panels used in the structural screening tests is

given in Table 3-3, along with results of tests used to verify quality of

the panels.

The structural screening tests have been completed, and test results

are given in Table 3-4 for the solid laminate specimens, is Table 3-5 for

the graphite/syntactic specimens, and in Table 3-6 for the honeycomb test

panels. The dynamic flexure test results on the graphite tape laminate

specimens are shown in Figure 3-1.

Table 3-7 gives the ranking of test results for the three candidate sys-

tems. Narmco 5208 and Fiberite 934 have generally superior mechanical pro-

perties to Hexcel F-263. The 180 0F wet flexure, short-beam shear, and com-

pression values in the graphite tape laminates show the Hexcel F-263 system to

be more affected by this environment than the other systems. The 180 0 E wet

data on the graphite fabric laminates also show the Hexcel system with lower

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LR 28559

TABLE 3-5. MATERIAL SCREENING OF GRAPHITE/SYNTACTIC - SUMWyOF TEST RESULTS

TYPE OF TEST 5208 934 F263Compression RTD KSI 73.8

THICK IN .071.072.072

55.5.084

Compression RTD KS'I 58.7 56.0after impact41.3

54.6

Flexure®45.0 39.4

RTD STR KSI 122.5 143.9 114.9MOD HSI 7.4 8.2 7.1THICK IN . 077 .070 .082180W STR KSI 119.7 120.8

MOD HSI 10.8 10.6104.310,3THICK IN .073 .063 .082

Short-BeamShear

RTD PSI "'789& 317®

65D PSI 3542 2690®

1614

1520THICK180W

INPSI 2143& 2259A 1309THICKIN •069 .073 .083

Interlam. Tension RTD PSI® 2212 2190 1580Density

g/cc 1.20 1.31 1.08

NOTE: • Average of three tests

• Nominal Thickness - . 020 each face + . 040 core - . 080 total• © Span- to-thickness ratio - 32

• ® Coef. of variation >.10%

I

• ® Coef. of variation >20%

• L4^j Most failure modes graphite to syntactic.

I• ® Least Damage

• ® Nost Damage

• LaYuP: (45/0/135/0/bYN)s

• RTD ' Room temperature tests unconditioned• 18OW - 180 OF tests after 7 days immersior. in distilled water

at 150OF

A

LR 28559

TABLE 3-6. MATERIAL SCREENING OF HONEYCOMB SANDWICH TEST SPECIMENS

SANDWICH BEAM COMPRESSION

COMPRESSIVE STRENGTH (ksi)PANEL

CONTROL AFTER IMPACT **CONSTRUCTION RESIN

Graphite Tape Skins (0, Narmco 39.3 38.2

4521 90, 1352); 1/8 - 4.0PCF Nomex core, 5/8 in.

5208

thick. Fiberite 50.6 37.4934

Hexcel 46.6 33.3F-263

Kevlar-49 Fabric Skins (45, Narmco 20.5 18.1

0, 135, 45); 1/8 - 4.0 PCF 5208Nomex core, 5/8 in. thick.

Fiberite 19.2 16.8934

Hexcel 19.9 16.9F-263

Graphite Tape/Kevlar-49 Narmco 26.4 26.8

Hybrid Skins (Ok , 452G , 52081352G , Ok); 1/8 - 4.0 PCFNomex core,-5/8 in. Fiberite 25.8 25.8

thick. 934

Hexcel 26.4 24.3F-263

V**Impacted at 2. ft lb with 1.0 in. di; sphere

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values. Narmco 5208 and Fiberite 934 are more closely comparable, but on

balance Narmco system holds an edge in hot, wet properties and in general

mechanical properties. The Kevlar 49 data provides less distinction between

the three systems, but th.Q elimination of Kevlar 49 from the design concepts

made this data of less significance in the resin selection.

The dynamic flexure curves provide the clearest ranking of the three

resins, with Narmco 5208 significantly superior in the dry condition and

after moisture exposure. The relative superiority of Narmco 5208 in this

property increases with increased temperature and moisture exposure.

The graphite/syntactic test data also showed Narmco 5208 and Fiberite

934 having superior mechanical properties over Hexcel F-263, particularly

in short-beam shear. Fiberite 934 showed some higher values than Narmco

5208 in flexure and short-beam shear. In summary, the syntactic panels

must be considered as not clearly differentiating between the three candi-

date resins, but the data does demonstrate compatibility of the syntactic

system with the three candidate resins.

The honeycomb sandwich test panels were impacted at a two foot pound

energy level using a steel rod and residual sandwich beam compression

properties were determined. The results showed a greater proportional drop

occurred with the graphite faced panels than with the Kevlar 49 or hybrid

faced panels. Beam compression values after impact on the graphite panels

were comparable for the three resins, and the results did not indicate any

significant differences in impact resistance of the three candidate resins.

3.2 PRODUCIBILITY SCREENING TESTS

The producibility aspects of the three candidate resin systems were

evaluated by Avco. Flat plates, sections of the rib configuration, and

sandwich plates were fabricated. During fabrication the tack, backing peper

adhesion, bleed characteristics, drilling and sawing characteristics, and

drapability were evaluated. The results of this evaluation, shown in

Table 3-8, do not indicate a clear-cut producibility superiority of one sys-

tem over the other two.

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Coupons fcr physical and mechanical property tests were machined from

each of the parts described in Table 3-8. Data from fiber-volume measure-

ments, short-beam shear, flexure, and flatwise tensile tests is presented

in Table 3-9. In general, this data indicated that the 5208 system had

the highest mechanical properties.

In evaluation of qualitative data, no one material was significantly

better than the others. However, the following observations were;

• Fabric layup is easier than tape layup.

• All specimens were preplied prior to layup and drapability isbetter with fabric than tape.

• 48-inch fabric uses less labor to cut the composite than 12-inch tape.

• During layup, errors are more easily correctable with fabric thantape.

• Fabric materials with same resin content exhibit handling propertiesof tape materials of less resin content; this is a result of themethod of resin impregnation. This condition is more pronouncedwith older materials.

• The surface finish on tape is better than with fabric.

• Syntactic sandwich panels are much easier to layup than honeycombsandwich panels.

• The Kevlar panels are more difficult to cut and machine than graphite.

• The 285 Kevlar weave has good drapability on double-curved surfaces.The corners on the sandwich panels can be formed without slittingand lapping the corners.

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In summary, the evaluation to date of the materials tested indicates

that the fabric material with the Narmco 5208 resin is superior from a manu-

facturing producibility standpoint for the L-1011 advanced composite aileron.

As part of the producibility screening tests, Avco has made a prelim-

inary evaluation of tooling techniques for the channel section ribs to be

used for the aileron assembly. Graphite fabric ribs were made using both

male and female tooling. Conventional bagging approaches and formed rubber

bags (see Figures 3-2 and 3-3) were used on both tools. In addition, several

ribs were made in a female tool using a formed rubber block in conjunction

with a conventional vacuum bag.

Parts made in a female tool using a conventional vacuum bag or a formed

rubber bag showed evidence of bridging and porosity in the radii of the rib.

Parts made in the male tool showed no evidence of bridging in the radii;

however, the parts did have a large dimensional variance. The dimensional

problems using a male tool appear to be correctable to a large extent by

tool development; however, the accumulation of tolerances to the outside

mold liues for the ribs and spar could be a problem. Ribs fabricated using

the female tool in conjunction with a rubber block and conventional bagging

showed no evidence of bridging or porosity in the radii.

A preliminary evaluation of the tooling techniques investigated indi-

cates that the female tool using a rubber block and conventional bag is the

best method for fabricating the ribs and spar of the aileron. Additional

process development activities will be conducted during Task II to firmly

establish th q fabrication approach.

3.3 SELECTED MATERIALS

In addition to the data from the structural scu ppning tests, other

factors entered into the selection of the resin system. These included

the results of the Producibility Screening tests performed at Avco. Addi-

tional factors were available data base and processing history at Lockheed;

and availability of the system i-. preplied tape form, which proved to be

an essential factor in reducing production costs.

3-16LOCKHEEDC^II.OAMi• GOY.^ p v 0

LR 28559

Figure 3-2. Male Tool Rubber Bag

Figure 3-3. Female Tool Rubber Bag

ORIGINAL PAGE IS

3-17

OF POOR QUAI.TI'YJLOCKHEED I

LR 28559

Consideration of all this information led to the decision to use

Narmco's 5208 prepreg system in the ACA program, with the selected rein-

forcement forms of 1.5 mil unidirectional tape and bidirectional 13 mil,

satin weave graphite fabric. The basic reasons for this selection are

summarized as follows:

• Superior hot, wet properties of 5208

• Equivalent processability of 5208 to the other candidate systems

• Availability of 5208 allowables data from the Advanced CompositeVertical Fin (ACVF) Program NASA Contract NAS1-14000.

• Development of processing experience at Lockheaa with 5208 fromthe ACVF program

• Narmco's position as the only one of the candidate suppliers tomake a firm commitment for development of preplying capability.

3-]8LOCKHEEDCAL I FOR M1. COMPAMW

LR 28559

SECTION 4

TASK II - DESIGN AND ANALYSIS, COMPONENT DEFINITION

Component definition, which is the design and analysis of the selected

ACA concept, has been initiated during the reporting period. Activities

within component definition are reported under the headings detail design,

structural analysis, and material and producibility analysis.

4.1 DETAIL DESIGN

The basic design and interface requirements drawing has been completed.

This drawing (Figure 4-1) defines existing parts which will be used

unchanged, interchangeability requirements, electrical bonding and

grounding, drainage, smoothness and gaps, and identifies new detail parts,

assemblies, and installations; it is for design control only, and authorizes

no fabrication or tooling.

Detail design activity for the covers has been initiated. Alternate

approaches to the intersection of the rib doublers and spar doublers are

curre being investigated. Results of these studies will be included in

the next technical report.

4.2 STRUCTURAL ANALYSIS

The activities reported within this task include: development of the

NASTRAN finite element model, development of the material test plans fcr

design allowables, and the weight history and current status of the ACA.

4.2.1 NASTRAN Model

Based on the selected design concept a NASTRAN three-dimensional Finite

Element Model (FEM) of the aileron is being developed. The purpose of the FEM

LOCKHEED 4-1

CALIFORN I A COM;ANV

LR 28559

Is to determine internal loads, deflections, and structural influence

coefficients (SIC's). The model includes a representation of the actuators.

The Lockheed- developed anisotropic quadrilateral membrane element, a linear

stress function element, is used to model the surfaces and webs.

The general layout of the model is shown in Figure 4-2. The models

for the actuator and hinges are shown in Figure 4-3. Auxiliary stations

at models 1100, 1300, 1700, 2000, 2300 do include rib panels, or rib

caps. They have been included in the model to provide additional detail

for the stress pattern in the surfaces.

4.2.2 Development of Material Verification Test Plans

The material evaluation (Task I) IeJ to the selection of preplied

T300/5208 graphite/epoxy tape for the covers :nd spars and T300/5208

24 x 23 x 8HS graphite fabric/epoxy for the ribs. A hybrid of fabric and

tape was selected for the main rib caps.

The tape selected for the aileron is 7.5 mils/ply. The unidirectional

tape properties, developed as part of Lockheed's Advanced Composite Vertical

Fin ACVF Program NASA Contract NAS1-1400, will be used to compute laminate

properties.

The ply level propert i es for T300/5208 24 x 23 x 8HS graphite fabric/

epoxy will be developed by tests of 00 and +450 fabric laminates. For ply

level allowables 30 replicates will be tested at room temperature, dry

to establish a sufficient statistical base to compute 'B' basis allowables;

10 replicates each tested at -65 0F and 1800F(wet) will establish environmental

adjustment factors; and 5 replicates each at fiber volume extremes (outside

of specification limits) will determine the effect of high or low fiber

volumes on properties. The question of whether the dry or wet state is

most critical for a given test mode (tension, compression, or shear) at

-650F will be determined by testing 5 replicates each for both conditions

and testing 5 more replicates for the critical state. The results of these

tests will be used to develop ply-level allowables for fabric so that

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4-7LOCKHEEDC0.4-1

LR 28559

STATION:

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Figure 4-3. Actuator and Hinge Support Stations

4-8LOCKHEEDCALIFORN IA COMVAN•

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LR 28559

unnotched laminate properties can be computed using Lockheed's laminate

strength preaittion computer program.

Laminate characterization test results will be used to verify the

predicted properties for tape, fabric, and hybrid laminates. The "B" basis

allowables will be determined for these laminates (using a sample size of 30)

with a circular notch. These data will be related to average unnotched lam-

inate properties to obtain adjustment factors for the combined effects of

data scatter, notch effects, and environmental effects. The adjustment

factors will be determined for tape, fabric, and hybrid laminates. The data

determined from the laminated tests for laminate tape will be supplemented

by the ACVF tape laminate test results so that a broad range of laminate

orientations will be represented.

The detail test plans for the ply-level tests and laminate tests will

be presented at a later date in a revised edition of the ancillary test

plan.

4.2.3 Weight Stitus

The current weight status is shown in Table 4-1. A weight saving of

25.5 percent (35.8 pounds including a 5-lb growth allowance) is currently

being predicted. Without the growth allowance, a weight saving of 29.1

percent (40.8 pounds) is anticipated. Composite material utilization is

currently predicted to be 65.1 percent of the redesigned aileron weight.

A summary of weight changes from the previous Quarterly Report will be

presented in a format as indicated in Table 4-2. A weight-time history

for the composite aileron is provided in Figure 4-4.

4.3 MATERIALS AND PRODUCIBILITY ANALYSIS

Preliminary material specifications have been prepared for the three

material forms selected for the ACA:0.0075 in/ply graphite tape prepreg,

24 x 23 x 8HS graphite fabric prepreg, and syntactic epoxy. These

specification are as follows:

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C-22-1379/112 "Graphite Fiber Non-Woven Tape, 350 KSIStrength, 33 MSI Modulus, 350OF Curing.Epoxy Impregnated, Low Resin Content,7.5 Mils/Ply

C-22-1388 (Basic) "Graphite Woven Fabric, Resin Impregnated,General Specification for

C-22-1388/11 "Graphite Woven Fabric, 24 x 23 8 HarnessSatin Weave, 33 MSI Modulus, 350 OF Curing,Epoxy Impregnated

C-28-1387 "Syntactic Epoxy Core Material"

These draft specifications fully define all test requirements and procedures,

and define all qualitative and workmanship requirements. The initial batches

of material for Task II are being procured to these specifications on a

target basis. These batches will be used for qualification tests, after

which the specifications will be modified as necessary and formally released.

4-13LOCKHEEDC•11.O1^Ni• COM I^NY II

LR 28559

SECTION 5

TASK II - DESICN AND ANALYSIS PROCESS DEVELOPMENT AND VERIFICATION

The process development and verification activities for the selected ACA

design concept and materials will be conducted by Avco.

5.1 PROCESS DEVELOPMENT

The detail plans for development of the manufacturing processes for the

ACA have been completed and are shown in Table 5-1. Process development will

be coordinated with design and ane.ysis to verify selection of fabrication

procedure.

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REFERENCES

1. Griffin, C. F., et al, "Advanced Composite Aileron For L-1011 TransportAircraft" Quarterly Technical Report #1, LR 28426, 23 January 1978.

LOCKHEED R-1CALIFORNIA COM%ANV