Quantitative thermal imaging analysis of aircraft materials: through skin sensing (Invited Paper)

Thermal non-destructive testing (NDT) is commonly used for assessing aircraft structures. This research work evaluates the potential of pulsed -- transient thermography for locating fixtures beneath aircraft skins in order to facilitate accurate automated assembly operations. Representative aluminium and carbon fibre aircraft skin-fixture assemblies were modelled using thermal modelling software. The assemblies were also experimentally investigated with an integrated pulsed thermographic evaluation system, as well as using a custom built system incorporating a miniature un-cooled camera. Modelling showed that the presence of an air gap between skin and fixture significantly reduced the thermal contrast developed, especially in aluminium. Experimental results show that fixtures can be located to accuracies of 0.5 mm.

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.

Macro-Fiber Composite Actuators for Flow Control of a Variable Camber Airfoil

This research employs solid-state actuators for delay of flow separation seen in airfoils at low Reynolds numbers. The flow control technique investigated here is aimed for a variable camber airfoil that employs two active surfaces and a single four-bar (box) mechanism as the internal structure. To reduce separation, periodic excitation to the flow around the leading edge of the airfoil is induced by a total of nine piezocomposite actuated clamped-free unimorph benders distributed in the spanwise direction. An electromechanical model is employed to design an actuator capable of high deformations at the desired frequency for lift improvement at post-stall angles. The optimum spanwise distribution of excitation for increasing lift coefficient is identified experimentally in the wind tunnel. A 3D (non-uniform) excitation distribution achieved higher lift enhancement in the post-stall region with lower power consumption when compared to the 2D (uniform) excitation distribution. A lift coefficient increase of 18.4% is achieved with the identified non-uniform excitation mode at the bender resonance frequency of 125 Hz, the flow velocity of 5 m/s and at the reduced frequency of 3.78. The maximum lift (Clmax) is increased 5.2% from the baseline. The total power consumption of the flow control technique is 639 mW(RMS).

Modeling the growth of LT and TL-oriented fatigue cracks in longitudinally and transversely pre-strained Al 2524-T3 alloy

The aluminum alloy 2524 (Al-Cu-Mg) was developed during the 90s mainly to be employed in aircraft fuselage panels, replacing the standard Al 2024. In the present analysis the fatigue crack growth (FCG) behavior of 2524-T3 was investigated, regarding the influence of three parameters: load ratio, pre strain and crack plane orientation of the material. The pre strain of aluminum alloys is usually performed in order to obtain a more homogeneous precipitates distribution, accompanied by an increase in the yield strength. In this work, it was evaluated the resistance of Al 2524-T3 sheet samples to the fatigue crack growth, having L-T and T-L crack orientations. FCG tests were performed under constant amplitude loading at three distinct positive load ratios. The three material conditions were tested: as received(AR), pre strained longitudinally (SL) and transversally (ST) in relation to rolling direction. In order to describe FCG behavior, two-parameter kinetic equations were compared: a Paris-type potential model and a new exponential equation introduced in a previous work conducted by our research group. It was observed that the exponential model, which takes into account the deviations from linearity presented by da/dN versus AK data, describes more adequately the FCG behavior of Al 224-T3 in relation to load ratio, pre strain effects and crack plane orientation. © 2011 Published by Elsevier Ltd.

The role of aircraft panel materials in cabin fires and their properties. Final report.

Federal Aviation Administration, Washington, D.C.

Evaluation technique for determining wheel performance in the grinding of aerospace materials

Nickel-based super alloys are used in a variety of applications in which high-temperature strength and resistance to creep, corrosion, and oxidation are required, such as in aircraft gas turbines, combustion chambers, and automotive engine valves. The properties that make these materials suitable for these applications also make them difficult to grind. Grinding systems for such materials are often built around vitrified cBN (cubic boron nitride) wheels to realize maximum productivity and minimum cost per part. Conditions that yield the most economical combination of stock removal rate and wheel wear are key to the successful implementation of the grinding system. Identifying the transition point for excessive wheel wear is important. The aim of this study is to compare the performance of different cBN wheels when grinding difficult-to-grind (DTG) materials by determining the 'wheel wear characteristic curve', which correlates the G-ratio to the calculated tangential force per abrasive grain. With the proposed methodology, a threshold force per grit above which the wheel wear rate increases rapidly can be quickly identified. A comparison of performance for two abrasive product formulations in the grinding of three materials is presented. The obtained results can be applied for the development of grinding applications for DTG materials.

Empirical models for quantification of machining damage in composite materials

Dissertação para obtenção do Grau de Doutor em Engenharia Mecânica

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.

Airplane materials compatibility with blends of fossil kerosene jet a1 with biokerosenes from babassu, palm kernel and coconut oils

El desarrollo de bioqueroseno de diferentes orígenes y su uso creciente, hacen necesario el estudio de la compatibilidad estos nuevos combustibles con los materiales y recubrimientos con los que se encuentra en contacto. Por tanto, el presente proyecto estudia la compatibilidad de los bioquerosenos mezclados en diferentes proporciones con queroseno mineral, para evaluar posteriormente su compatibilidad con diferentes polímeros y composites presentes en la estructura de un avión.Currently there is a big interest to increase the sources of alternative fuels for aviation to get a reduction of their carbon footprint and the deep energetic dependence from fossil fuels of different countries. Although there are studies about how to produce this alternative fuel and how to accomplish the standards for a good performance in the aircraft turbines, there are no studies about how these fuels could affect the different materials of airplanes. In this context this work describes the compatibility of biokerosene blends of coconut, babassu and palm kernel with commercial Jet A-1 testing airplane polymeric materials, metals and composites. As a conclusion, all material samples show a good compatibility with the fuel blends tested.

Flight loads analysis of a maneuvering transport aircraft

The paper provides a method applicable for the determination of flight loads for maneuvering aircraft, in which aerodynamic loads are calculated based on doublet lattice method, which contains three primary steps. Firstly, non-dimensional stability and control derivative coefficients are obtained through solving unsteady aerodynamics in subsonic flow based on a doublet lattice technical. These stability and control derivative coefficients are used in second step. Secondly, the simulation of aircraft dynamic maneuvers is completed utilizing fourth order Runge-Kutta method to solve motion equations in different maneuvers to gain response parameters of aircraft due to the motion of control surfaces. Finally, the response results calculated in the second step are introduced to the calculation of aerodynamic loads. Thus, total loads and loads distribution on different components of aircraft are obtained. According to the above method, abrupt pitching maneuvers, rolling maneuvers and yawing maneuvers are investigated respectively.

Full-scale fire testing of seat component materials.

Mode of access: Internet.

Investigation of feasibility of utilizing available heat resistant materials for hypersonic leading edge applications.

"Volumes I through VIII are unclassified while volume IX is classified secret."

Utilization of yttrium in gettering oxygen and nitrogen in columbium base materials /

Work performed at CANEL.

Investigation into more complete use of structural materials through a study of the stress-temperature-time conditions of a re-entry vehicle

Mode of access: Internet.

Development of a corrosion-resistant bearing steel for service in aircraft at temperatures up to 1000 F

"Materials Laboratory, Contract no. AF33(616)-5428, Phase B, Project no. 7351."