A review on the development and properties of continuous fiber/epoxy/aluminum hybrid composites for aircraft structures

Weight reduction and improved damage tolerance characteristics were the prime drivers to develop new family of materials for the aerospace/ aeronautical industry. Aiming this objective, a new lightweight Fiber/ Metal Laminate (FML) has been developed. The combination of metal and polymer composite laminates can create a synergistic effect on many properties. The mechanical properties of FML shows improvements over the properties of both aluminum alloys and composite materials individually. Due to their excellent properties, FML are being used as fuselage skin structures of the next generation commercial aircrafts. One of the advantages of FML when compared with conventional carbon fiber/epoxy composites is the low moisture absorption. The moisture absorption in FML composites is slower when compared with polymer composites, even under the relatively harsh conditions, due to the barrier of the aluminum outer layers. Due to this favorable atmosphere, recently big companies such as EMBRAER, Aerospatiale, Boing, Airbus, and so one, starting to work with this kind of materials as an alternative to save money and to guarantee the security of their aircrafts.

Artificial Immune Systems with Negative Selection Applied to Health Monitoring of Aeronautical Structures

In this paper we present a system for aircraft structural health monitoring based on artificial immune systems with negative selection. Inspired by a biological process, the principle of discrimination proper/non-proper, identifies and characterizes the signs of structural failure. The main application of this method is to assist in the inspection of aircraft structures, to detect and characterize flaws and decision making in order to avoid disasters. We proposed a model of an aluminum beam to perform the tests of the method. The results obtained by this method are excellent, showing robustness and accuracy.

Hygrothermal effects on damping behavior of metal/glass fiber/epoxy hybrid composites

Continuous fiber/metal laminates (FML) offer significant improvements over current available materials for aircraft structures due to their excellent fatigue endurance and low density. Glass fibers/epoxy laminae and aluminum foil (Glare) are commonly used to obtain these hybrid composites. The environmental factors can limit the applications of composites by deteriorating the mechanical properties during service. Usually, epoxy resins absorb moisture when exposed to humid environments and metals are prone to surface corrosion. Therefore, the combination of the two materials in Glare (polymeric composite and metal). can lead to differences that often turn out to be beneficial in terms of mechanical properties and resistance to environmental influences. In this work. The viscoelastic properties. such as storage modulus (E') and loss modulus (E'), were obtained for glass fiber/epoxy composite, aluminum 2024-T3 alloy and for a glass fiber/epoxy/aluminum laminate (Glare). It was found that the glass fiber/epoxy (G/E) composites decrease the E' modulus during hygrothermal conditioning up to saturation point (6 weeks). However, for Glare laminates the E' modulus remains unchanged (49GPa) during the cycle of hygrothermal conditioning. The outer aluminum sheets in the Glare laminate shield the G/E composite laminae from moisture absorption. which in turn prevent, in a certain extent, the material from hygrothermal degradation effects. (c) 2005 Elsevier B.V. All rights reserved.

Damping behavior of continuous fiber/metal composite materials by the free vibration method

Fiber metal laminates (FML) offer significant improvements over current available materials for aircraft structures due to their excellent mechanical characteristics and relatively low density. Non-destructive testing techniques are being used in the characterization of composite materials. Among these, vibration testing is one of the most used tools because it allows the determination of the mechanical properties. In this work, the viscoelastic properties such as elastic (E') and viscous (E) responses were obtained for aluminum 2024 alloy; carbon fiber/epoxy; glass fiber/epoxy and their hybrids aluminum 2024 alloy/carbon fiber/epoxy and aluminum 2024 alloy/glass fiber/epoxy composites. The experimental results were compared to calculated E modulus values by using the composite micromechanics approach. For all specimens studied, the experimental values showed good agreement with the theoretical values. The damping behavior, i.e. The storage modulus and the loss factor, from the aluminum 2024 alloy and fiber epoxy composites can be used to estimate the viscoelastic response of the hybrid FML. (c) 2005 Elsevier Ltd. All rights reserved.

Evaluation of stitched fabric composite processed by RTM in quasi-static test

Stitched fabrics have been widely studied for potential application in aircraft structures since stitch yarns offer improvements in the out-of-plane mechanical properties and also can save time in the lay up process. The down side of stitch yarns came up in the manufacturing process of fabric in which defects introduced by the needle movement creating fiber-free-zones, fiber breakage and misalignment of fibers. The dry stitched carbon fabric preform has mainly been used in the Resin Transfer Molding (RTM) process which high fiber content is aimed, those defects influence negatively the injection behavior reducing the mechanical properties of final material. The purpose of this research work focused on testing in quasi-static mechanical mode (in-plane tension) of a monocomponent resin CYCOM (R) 890 RTM/carbon fiber anti-symmetric quadriaxial fabric stitched by PE 80Dtex yarn processed by RTM. The evaluation consisted in comparing the scatter of the quasi-static test with the attenuation of ultrasonic maps, which show the path of the resin and possible dry spots considering that interference of yarn in resin flow is detectable in ultrasonic measurement. Microscopic analysis was also considered for further evaluation in case of premature failure. (C) 2011 Published by Elsevier Ltd. Selection and peer-review under responsibility of ICM11

Evaluation of hygrothermal effects on the shear properties of Carall composites

Fiber metal laminates are the frontline materials for aeronautical and space structures. These composites consists of layers of 2024-T3-aluminum alloy and composite prepreg layers. When the composite layer is a carbon fiber prepreg, the fiber metal laminate, named Carall, offers significant improvements over current available materials for aircraft structures. While weight reduction and improved damage tolerance characteristics were the prime drivers to develop this new family of materials, it turns out that they have additional benefits, which become more and more important for today's designers, such as cost reduction and improved safety. The degradation of composites is due to environmental effects mainly on the chemical and/or physical properties of the polymer matrix leading to loss of adhesion of fiber/resin interface. Also, the reduction of fiber strength and stiffness are expected due to environmental degradation. Changes in interface/interphase properties leads to more pronounced changes in shear properties than any other mechanical properties. In this work, the influence of moisture in shear properties of carbon fiber/epoxy composites and Carall have been investigated by using interlaminar shear (ILSS) and Iosipescu tests. It was observed that hygrothermal conditioning reduces the Iosipescu shear strength of CF/E and Carall composites due to the moisture absorption in these materials. (c) 2006 Elsevier B.V. All rights reserved.

Aplicação de redes neurais artificiais na predição de diâmetro e rugosidade durante o processo de furação

Coordenação de Aperfeiçoamento de Pessoal de Nível Superior (CAPES)

Tricot stitched carbon fiber reinforced polymer composite laminates manufactured by resin transfer molding process: C-scan and flexural analysis

Fundação de Amparo à Pesquisa do Estado de São Paulo (FAPESP)

Monitoramento e identificação de falhas em estruturas aeronáuticas e mecânicas utilizando técnicas de computação inteligente

Pós-graduação em Engenharia Mecânica - FEIS

Estudo da propagação de trinca por fadiga sob carregamento de amplitude variável

For engineering projects that require high reliability levels, is often not enough know only physical and chemical material properties. It’s necessary understand the failure mode of these materials in operation to ensure security level in the project and establish more stringent criteria in the analysis of structural integrity. Due to this need, aircraft industry has been using aluminum alloys in their designs and projects. “Currently more than 70% of aircraft structures are built of high strength aluminum alloys among which stand out 7075-T6 and 2024-T3 alloys, which are considered basics for being used in the new alloys development.” (PASTOUKHOV & VOORWALD, 1995). Some years ago ALCOA develops Al 2524 alloy that has emerged as refinement of Al 2024 (Al, Cu. Mg) alloy, with purpose of improve fracture toughness and fatigue resistance on structural components. The present research addresses testing of fatigue crack propagation under variable amplitude loading for Al 2024 alloy, observing the interaction effects from application of overhead blocks and plastic zone at the crack tip and makes an analysis of fracture surface images

Obtenção e caracterização de compósitos via RTM com alta fração de fibras de carbono processados à temperatura ambiente

After confirming the high specific mechanical properties of composite materials by scientific studies conducted over the last decades, one of the challenges of this new class of materials is the ability to achieve mass production at a more affordable cost, which has become indispensable. The Resin Transfer Molding (RTM) is an excellent method for manufacturing composite materials. Despite being a process widely used by international companies in the production of high performance structural composites, only a short time the national aviation industry has shown interest in implementing this type of processing to more complex structures and greater structural responsibility. In aeronautical projects, the reproducibility and the relative low cost of this process, several studies have been performed in Brazil for learning and perfecting this technique. This process is suitable for producing polymer components both simple as complex geometry, and allows to achieve consistent thickness, with high quality finish and without limiting range. Polymeric composite components for the high mechanical stress applications such as aircraft structures, satellites, etc., require a strict control of volume fractions of the composite constituents, beyond the knowledge of their mechanical and thermal properties. Therefore, in this experimental work degree study on the mechanical, thermal and of porosity composites processed by RTM processed characterization was performed. This characterization was performed targeting a possible aerospace application of this composite material. For the production of composites, process equipment (RTM RTM injector Radius 2100cc) was used. The processed carbono/epoxy composites were characterized via flexure tests mechanically and thermally analysis via DMA, DSC and TGA. To determine the volume fraction of fibers, the composite samples were analyzed via matrix digestion (ASTM D3171) ... (Complete abstract click electronic access below)

A metallurgical study of aluminium alloys used as aircraft components

The effects of heat treatment on morphologies and microstructures of Al 2024 and Al 7050 alloys, used as aircraft components, were studied by metallographic techniques. Light microscopy (LM) and quantitative image analysis were used to characterize the precipitate dispersion and morphology for these alloys. The application of the scanning electron microscopy (SEM) and energy dispersive spectroscopy (EDS) combined techniques for studying these multiphase systems makes it possible to distinguish and quantify the different phases in the surface structure. Xray diffraction also permitted a qualitative comparison of the structures before and after heat treatments.

Experimental Active Vibration Control in Truss Structures Considering Uncertainties in System Parameters

Fundação de Amparo à Pesquisa do Estado de São Paulo (FAPESP)

Robust control to parametric uncertainties in smart structures using linear matrix inequalities

The study of algorithms for active vibrations control in flexible structures became an area of enormous interest, mainly due to the countless demands of an optimal performance of mechanical systems as aircraft and aerospace structures. Smart structures, formed by a structure base, coupled with piezoelectric actuators and sensor are capable to guarantee the conditions demanded through the application of several types of controllers. This article shows some steps that should be followed in the design of a smart structure. It is discussed: the optimal placement of actuators, the model reduction and the controller design through techniques involving linear matrix inequalities (LMI). It is considered as constraints in LMI: the decay rate, voltage input limitation in the actuators and bounded output peak (output energy). Two controllers robust to parametric variation are designed: the first one considers the actuator in non-optimal location and the second one the actuator is put in an optimal placement. The performance are compared and discussed. The simulations to illustrate the methodology are made with a cantilever beam with bonded piezoelectric actuators.

Fatigue Behavior of Weld Repaired AISI 4130 Aeronautic Steel Used in Critical Flight Safety Structures

Since the 1950s, fatigue is the most important project and operational consideration for both civil and military aircrafts. For some aircraft models the most loaded component is one that supports the motor: the Motor Cradle. Because they are considered critical to the flight safety the aeronautic standards are extremely rigorous in manufacturing them by imposing a zero index of defects on the final weld quality (Safe Life), which is 100% inspected by Non-Destructive Testing/NDT. This study has as objective to evaluate the effects of up to four successive TIG welding repairs on the axial fatigue strength of an AISI 4130 steel. Tests were conducted on hot-rolled steel plate specimens, 0.89 mm thick, with load ratio R = 0.1, constant amplitude, at 20 Hz frequency and in room temperature, in accordance with ASTM E466 Standard. The results were related to microhardness and microstructural and geometric changes resulting from welding cycles.