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WE COMBINE INNOVATION WITH EXPERIENCE TO CREATE SOLUTIONS
WELCOME
THANK YOU FOR COMING
WE COMBINE INNOVATION WITH EXPERIENCE TO CREATE SOLUTIONS
Advanced Composites for Multirole Applications in Aeronautics – Project PASSAROManuel Gomes (ISQ)Ricardo Rocha (INEGI)
Portugal Air Summit – Ponte de Sor2019-05-30/31
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The PASSARO project
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Capabilities for Innovative Structural and Functional Testing of Aerostructures
This project has received funding from the Clean Sky 2 Joint Undertaking under the European Union’s Horizon 2020 research programme under Grant agreement No 807083
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The partnership
• 11 partners dealing with different aspects of cockpit optimization• WAL - ADS• For impact protection materials
• INEGI• ISQ
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Presentation Structure
• Background introduction• Requirements/Hazards• Objectives/Approach• Material/Technology selection• Testing/Evaluation
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• Background introduction• Requirements/Hazards• Objectives/Approach• Material/Technology selection• Testing/Evaluation
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Introduction
• Aeronautic industry is one of the most demanding concerning material properties.
• Air frame materials in particular can be under such wide range of service and environmental conditions that are particularly challenging.
• Historically materials usage to this purpose can be leisurely divided in three periods
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The beggining
• Debut of aviation about a century ago, 1903.
• Serious power plant limitations• Light metals mostly unavailable• Domination of natural materials
• Wood• Fabric
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Between wars & beyond
• By the end of WW1 Aluminum start being used in aeronautics
• Reasonable strength and toughness compared to steel
• Low density • For most XX century dominated
aeronautic construction
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Metal Alloys Limitations• Main properties strongly
depend on the chemical composition
• Metal alloys offer limited possibilities for improvement of mechanical properties
• Very little possibilities of reducing density, thus weight
Whatnext
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COMPOSITE MATERIALS
• Different materials• Independently produced• Join together by some physical/chemical means• Optimize combinations of the materials different properties
Not quite a new idea!
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Ancient Composites
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Adobe (mud) bricksZigurat of Ur, Mesopotamia
Japanese Katana (sword)
Composite bow(Traditional long bow, right)
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Modern Composite Families
Metal Matrix Composites (MMC)Metal alloy strengthen with addition of fibers or particles of usually a harder phase
Ceramic Matrix Composites (CMC)Technical ceramic with addition of fibers or particles of usually another ceramic material
Polymer Matrix Composites (PMC)Fibers (random or fabric) usually of high strength material embedded in a more flexible polymeric resin matrix
Sandwich Composites (SC)
Sheets of different metal alloys or composites “glued” together by apolymeric adhesive/resin. Core of a usually light material sandwich between layers of metal or composite materials
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• Background introduction• Requirements/Hazards• Objectives/Approach• Material/Technology selection• Testing/Evaluation
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Fuselage Skin Basic Requirements
• Impact resistance• Electrical conductivity• Electromagnetic
compatibility (EMC)
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strength
toughnessweight
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Main Operational Hazards
• Bird strike• Hail strike• Uncontained engine rotor failure debris (UERF)• Runway contamination• Lightening strike• Foreign object strike
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Bird strike• FAA figures
• 1990 – 1795 strikes• 2014 – 13159 strikes• In this 25 year – 151267
• Of which 37% (54980) caused noticeable damage
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Hail strike / UERF• UERF Not very common …but!• Hail is lighter than birds but
strikes might happen at higher altitudes, thus speeds.
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Runway Contamination
• Concorde accident• Probably the most
well known in recent years
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Lightening Strike
• Aircraft skin must be conductive
• Faraday cage• Allow electric current to
floe along the fuselage and exit
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Foreign Object Strike• Collisions on the ground
• Dropping tools during maintenance
• Potential source of future problems
• Composites maybe more sensitive
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• Background introduction• Requirements/Hazards• Objectives/Approach• Material/Technology selection• Testing/Evaluation
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The Objectives
• Usage of new multifunctional composites to improve• strength and toughness• impact resistance• Reduce weight of airframes• Reduce vibrations from power plants• Reduce cabin noise• Electrical conductivity• Electromagnetic compatibility (EMC)• Effective in both cost and time to implement
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The PASSARO Approach
• Selection of available materials/technologies/simulation models• Improving most promising numerical models• Select most promising materials/technologies• Validate models/technologies with experimental testing• Draw conclusions and suggest improvements
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• Background introduction• Requirements/Hazards• Objectives/Approach• Material/Technology selection• Testing/Evaluation
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Technology Evaluation
• The materials/technologies identified were critically evaluated on the basis of their cost, availability and application feasibility
• Classified in three groups• Low innovation level – Do not require major changes in design.
Implementable in short term. Reduced risk to implement.• Medium innovation level – Significant improvement on the state of
the art. Some changes in design philosophy. Significant risk for manufacturing or certification.
• High innovation – disruptive improvement on the state of the art. Require new design concepts for the fuselage. Very high risk for implementation.
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Materials/Technologies ReviewMaterials/Fibers
Carbon fibers
Aramid fibers
Glass Fibers
Polypyridobisimidazole (M5)
HPPE
Spider/silkworm silk
Natural fibers
UHMWPE
Ceramics
Aluminum
Honeycombs / Foams
Non-Newtonian polymers
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Technologies/Desings
Woven fabrics
3D textile reinforced
Sandwich structures
Cores (honeycomb, auxetic)
Fiber orientation & stacking
HybridizationLaminates
fibers
Resins
C. Metal foams
Nano filled C.
Shape memory alloys
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Final Testing/Evaluation
Materials
Carbon fibers
Aramid fibers
UHMWPE
Ceramics
Aluminum
Non-Newtonian polimers
Design solutions
Woven fabrics
3D textile
Stacking sequence/orientation
Hybrid laminates
Hybrid fibers
Nano filled composites
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• Background introduction• Requirements/Hazards• Objectives/Approach• Material/Technology selection• Testing/Evaluation
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Certification Strategy
• Certification of aircraft components is a complex process regulated by strict rules stablish by agencies like EASA or FAA
• The process follows a standard stepwise scheme based on testing
• More recently certification by design is acceptable in some instances
• FEA modelling is crucial
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Composite Testing Requirements
• Complex materials• Several components with different interactions• Different response to stresses• Ultimately the material might be “unique”• Data for modelling is more difficult to obtain than in metal alloys
• Material elements behavior• Cohesive elements behavior• Small specimens laboratory testing
• Overall composite solution behavior under impact• Larger coupons impact tests (element level)
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Coupon Level Tests
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MODEL PROPERTY TEST STANDARD
Material Elements
Model
Tensile strength and modulus 0ºASTM D3039
Tensile strength and modulus 90º
Compressive strength and modulus 0º ASTM D6641
Compressive strength and modulus 90º
In-plane shear strength and modulus ASTM D3518
Longitudinal tensile fracture toughness In-house method
Longitudinal compressive fracture toughness In-house method
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Coupon Level Tests
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MODEL PROPERTY TEST STANDARD
Cohesive Elements
Model
Interlaminar shear strength EN 2563
Interlaminar fracture toughness energy -mode I ASTM D5528
Interlaminar fracture toughness energy -mode II ASTM D7905
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Impact Tests – element level
• High and medium energy impacts• Speed up to 200 m/s• Energy in excess of 1000 J
• Steel and ice (hail) projectiles• Mass up to 100 g
• Damage characterization• Visual• Advanced NDT (digital X-ray, phased array)
• Models calibration
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Impact Tests – element level
• Compressed air cannon• Smooth bore• 3-4 meters long• 108 mm diameter• 10 bar max pressure
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Impact Tests – element level
• Projectiles• Steel and ice spheres• Sabot driven
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Impact Tests – element level• Test Coupons
• 300x300 mm• Gripped by steel frames• Attached to steel beam
structure
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Impact Tests – element level• Test set-up
• Two high speed video cameras
• One ballistic chronograph
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Cannon Firing
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Steel Sphere Impact Without Perforation
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Steel Sphere Impact With Perforation
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Ice Sphere Impact Without Perforation
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Damage characterization by C-Scan
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Manuel Gomes – [email protected] Rocha - [email protected]
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THANK YOUFor your attention