Development of Stitched, Braided and Woven Composite Structures in the ACT Program and at Langley Research Center (1985 to 1997)
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NASA/TP-97-206234 Development of Stitched, Braided and Woven Composite Structures in the ACT Program and at Langley Research Center (1985 to 1997) Summary and Bibliography Marvin B. Dow and H. Benson Dexter Langley Research Center, Hampton, Virginia National Aeronautics and Space Administration Langley Research Center Hampton, Virginia 23681-2199 November 1997 The use of trademarks or names of manufacturers in this report is for accurate reporting and does not constitute an official endorsement, either expressed or implied, of such products or manufacturers by the National Aeronautics and Space Administration. Available from the following: NASA Center for AeroSpace Information (CAS1) National Technical Information Service (NTIS) 800 Elkridge Landing Road 5285 Port Royal Road Linthicum Heights, MD 21090-2934 Springfield, VA 22161-2171 (301) 621-0390 (703) 487-4650 Contents Abstract .......................................................................... 1 Introduction ....................................................................... 1 NASA Langley Research in Textile Composites .......................................... 2 Advanced Material Forms .......................................................... 2 Woven Preforms ................................................................. 2 Multiaxial Knitted Preforms ........................................................ 2 Braided Preforms ................................................................. 2 Powder-Coated Braided Preforms .................................................... 3 Stitched Preforms ................................................................. 3 Resin Flow Processes and Models .................................................... 3 Mechanics of Textile Preform Composites ............................................. 3 NASA ACT Program (1988-97) ....................................................... 4 Lockheed Martin Textile Structures Development ....................................... 4 Wing and Fuselage Concepts ...................................................... 4 Textile Subcomponents for Fuselage Panels ........................................... 4 Textile Fuselage Structures ........................................................ 5 Northrop Grumman Textile Structures Development ..................................... 5 Wing Spars .................................................................... 5 Cross-Stiffened Window Belts ..................................................... 5 Fuselage Side Panel .............................................................. 5 McDonnell Douglas Stitched Wing Development ....................................... 6 Approach to Wing Development .................................................. 6 Wing Stub Box ................................................................. 6 Semi-Span Wing ............................................................... 6 Advanced Stitching Machine ...................................................... 7 Semi-Span Wing Tests ........................................................... 7 Full-Scale Wing Development ................................................... 7 Future Wing Manufacturing ....................................................... 7 Concluding Remarks ................................................................ 8 References ........................................................................ 9 Appendix A--Definition of Textile Terms .............................................. 31 Appendix B--Bibliography of Composites Reports ....................................... 32 Langley Textiles Research .......................................................... 33 Braiding and Weaving Technology .................................................. 33 Test Methods for Textile Laminates ................................................. 34 Tests of Braided and Woven Laminates and Elements ................................... 36 Tests of Stitched Laminates and Elements ............................................ 39 Resin Processing and Modeling Technology .......................................... 43 Mechanics of Textile Materials and Structures ......................................... 45 Overviews and Summaries ........................................................ 48 iii ACT Textile Composites Program .................................................... 50 Dow Chemical Company - RTM Resins .............................................. 50 Lockheed Martin - Material and Structural Concepts .................................... 50 Lockheed Martin - Fabrication Studies ............................................... 51 Northrop Grumman - Material and Structural Concepts .................................. 53 Rockwell - Mechanics of Materials Studies ........................................... 53 McDonnell Douglas - Structural Design and Analysis ................................... 54 McDonnell Douglas - Manufacturing Methods Development ............................. 56 McDonnell Douglas - Advanced Stitching Machine Development ......................... 58 McDonnell Douglas - Stitched Laminate Test Results ................................... 58 McDonnell Douglas and Langley - Structural Tests and Analyses .......................... 59 ACT Program Overviews ......................................................... 61 Other Textile Composites Research ................................................... 62 Mechanics of Materials and Structures ............................................... 62 Manufacturing Studies ............................................................ 65 Experimental Studies ............................................................. 69 Fatigue Studies .................................................................. 71 Overviews and Summaries ........................................................ 72 Author Index ..................................................................... 73 iv List of Figures Figure 1. Carbon-epoxy upper aft rudder for DC-10 transport aircraft ......................... 12 Figure 2. Elements of the Langley Research Center investigation of textile composite materials and structures ................................................................... 12 Figure 3. Advanced textile material forms--biaxial knit, multiaxial knit and triaxial weave ........ 13 Figure 4. Advanced textile material forms--multiaxial warp knit, triaxial braid, three-dimensional braid and knitted stitched .......................................................... 13 Figure 5. Schematic of multiaxial warp knitting machine ................................... 14 Figure 6. Compression strength data for composite laminates reinforced with multiaxial warp knit carbon tow preforms .............................................................. 14 Figure 7. Photograph of a 2-D triaxial braiding machine (typ.) ............................... 15 Figure 8. Schematic of process for making stitching-reinforced composites .................... 15 Figure 9. Process steps for making the stitched preform for a damage-tolerant stiffened panel ...... 16 Figure 10. Schematic of resin film infusion (RFI) process .................................. 16 Figure 11. Elements of processing science for textile reinforced composites .................... 17 Figure 12. Elements of Langley mechanics of textile-reinforced-composite materials program ..... 17 Figure 13. Application of textile reinforced composites in transport fuselage structures. (Lockheed Martin contract) ........................................................ 18 Figure 14. Three-dimensional integrally woven preform (epoxy-powder-coated tow) for a fuselage panel window belt component ...................................................... 18 Figure 15. Completed fuselage panel window belt component ............................... 19 Figure 16. Completed braided and woven window frames .................................. 19 Figure 17a. Honeycomb-stiffened fuselage side panel with joggled braided frames .............. 20 Figure 17b. Honeycomb-stiffened fuselage side panel with constant-section braided frames ....... 20 Figure 18. Woven preform (carbon-PEEK tow) for a wing Y-spar. (Northrop Grumman contract) ....................................................................... 21 Figure 19. Cross-stiffened fuselage window belt component ................................ 21 Figure 20. Picture frame shear test of cross-stiffened fuselage window belt component ........... 22 Figure 21. Cross-stiffened woven/stitched fuselage side panel ............................... 22 Figure 22a. Stitched/RFI wing panel in Langley 1,200-kip machine for discrete damage tolerance test ............................................................................ 23 Figure 22b. Stitched/RFI wing panel in Langley 1,200-kip machine for damage repair test ........ 23 Figure 23. Stitched/RFI upper cover for wing stub box test component ........................ 24 Figure 24. Assembly of wing stub box test component ..................................... 24 Figure 25. Stitched/RFI wing stub box test set-up at the Langley Structures and Materials Laboratory ...................................................................... 25 Figure 26. Design features of stitched/RFI semi-span wing ................................. 25 Figure 27. Main landing gear attachment test article for stitched/RFI wing ..................... 26 Figure 28. Advanced stitching machine at Huntington Beach Facility ......................... 26 Figure 29.