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Fiber Metal Laminate Structures - from Laboratory to Application Overview and Selected Items Contents Presented to the Royal Aerospace Society Hamburg Branch at Hamburg University of Applied Sciences, 29.10.2009 Download this file from http://hamburg.dglr.de Presented by Dr. Thomas Beumler Airbus Deutschland GmbH Fiber Metal Laminate Structures - from Laboratory to Application Overview and Selected Items Contents • Advantage of Bonded Structures • Why Fiber Metal Laminates ? • Towards A380 Certification - From Laboratory to Application / Selected Items © AIRBUS DEUTSCHLAND GmbH. document. All Confidential rights and proprietary reserved. Beumler, EDSAS Page 2 Advantage of Bonded Structures WW2: The Havilland Mosquito First time bonding of wood to metal in a high loaded primary structure. The start of metal bonding. © AIRBUS DEUTSCHLAND GmbH. document. All Confidential rights and proprietary reserved. Beumler, EDSAS Page 3 Crack Bridging Metal Bonded Structures (Fokker, Boeing, Lockheed, Douglas, Airbus Saab, ...) Metal Technology 1st Metal Laminates application F-27 Metal Reinforced Composites (Schliekelmann/Bijlmer) Fiber Metal Laminate Concept, Delft FML Technology Fiber Metal Laminates 1st FML application, ARALL on C-17 Development of „Standard-Glare“ A380 Carbon Fiber Reinforced Plastics Composite Technology F-18 B787 Glas Fiber Reinforced Plastics De Bruijne application F-27 Laminated wood (Fokker, de Havilland) 1900 1920 1940 1960 1980 2000 2020 © AIRBUS DEUTSCHLAND GmbH. document. All Confidential rights and proprietary reserved. Beumler, EDSAS Page 4 Advantage of Bonded Structures Advantage of bonded structures compared with riveted or integral structures: • Multiple load path structures • ... allows to join materials tailored to their specific tasks • ... without introduction of fatigue sensitive items (i.e. holes) • ... leading to high stress allowables and therefore low weight structures. • Static advantage: Large load carrying width between skin and stiffener increases onset-of-buckling load. © AIRBUS DEUTSCHLAND GmbH. document. All Confidential rights and proprietary reserved. Beumler, EDSAS Page 5 Advantage of Bonded Structures Example Residual Strength of bonded stringer stiffened panel: Allowable stress with bonded stringer ~20% > riveted stringer. Allowable stress with bonded stringer 50% > integral panel. © AIRBUS DEUTSCHLAND GmbH. document. All Confidential rights and proprietary reserved. Beumler, EDSAS Page 6 Advantage of Bonded Structures Example Comparison of load carrying width: buckling of riveted and bonded panel: Riveted structure b rivet brivet Bonded structure bbond bbond © AIRBUS DEUTSCHLAND GmbH. document. All Confidential rights and proprietary reserved. Beumler, EDSAS Page 7 Contents • Advantage of Bonded Structures • Why Fiber Metal Laminates ? • Towards A380 Certification - From Laboratory to Application / Selected Items © AIRBUS DEUTSCHLAND GmbH. document. All Confidential rights and proprietary reserved. Beumler, EDSAS Page 8 MSD Phenomenon in Riveted Joints ALOHA incident • Disbond of longitudinal joint (cold bond film adhesive) • Aluminium skin stress increased, skin fatigued (MSD) and failed under internal pressure load • Separation of panels © AIRBUS DEUTSCHLAND GmbH. document. All Confidential rights and proprietary reserved. Beumler, EDSAS Page 9 Crack Bridging Fatigue cracks occur in aluminium layers only, starting in outer aluminium layers Fibers stay intact and bridge the fatigue crack 50 45 Smax = 120 MPa R= 0.05 Aluminium 2024 T3 - 2mm W= 140 mm 40 L = 580 mm f = 10 Hz 2a0 = 5 mm 35 30 GLARE 4B - 4/3 - 0.5 LT a 25 (mm) 20 GLARE 3 - 3/2 - 0.3 L 15 10 5 0 0 20 40 60 80 100 120 140 160 180 200 N (kcycles) Slow crack growth rate and high residual strength compared to aluminium © AIRBUS DEUTSCHLAND GmbH. document. All Confidential rights and proprietary reserved. Beumler, EDSAS Page 10 Sizing Cases Consider: Today 60% to 80% of the pressurized fuselage shells are designed by F&DT. Fatigue Crack Propagation Static Ground Load Cases Damage Tolerance (LDC) Static Flight Load Cases © AIRBUS DEUTSCHLAND GmbH. document. All Confidential rights and proprietary reserved. Beumler, EDSAS Page 11 Controlling the Damage with FML‘s DT Material + DT Design High Design Allowables for high Performance and Damage Tolerance for Maintenance → Flexibility for Maintenance Plan Repairs of Dents, Scratches, Scribe Marks, etc. © AIRBUS DEUTSCHLAND GmbH. document. All Confidential rights and proprietary reserved. Beumler, EDSAS Page 12 Contents • Advantage of Bonded Structures • Why Fiber Metal Laminates ? • Towards A380 Certification - From Laboratory to Application / Selected Items © AIRBUS DEUTSCHLAND GmbH. document. All Confidential rights and proprietary reserved. Beumler, EDSAS Page 13 FML Certification Tasks for A380 Information flow in GLARE Technology Program environment GTP Working Groups M&P Qualification Material Properties Durability Methods Static GLARE Certification Methods F&DT Group (WG3B) Design Guidelines Conducts working sessions with Industrial Manufacturing European and US AA‘s. NDI Invites specialists for support. A380 stressmen, designers Directs tasks to cluster. Repairs & SRM and manufacturing specialists Presents results from cluster. Specialties define tasks for cluster and use cluster know-how for aircraft strength justification and aircraft structural certification. Cluster conduct technical tasks according to A380-800 milestone planing. Task results required for aircraft sizing and design,strength justification and aircraft certification. © AIRBUS DEUTSCHLAND GmbH. document. All Confidential rights and proprietary reserved. Beumler, EDSAS Page 14 Material Characterisation for Certification GLARE® has been qualified and certified as a metal under consideration of 6 characteristic and important properties: 1) Ductility. The material has the capability to yield and to absorb energy with gradual and predictable strength degradation. The ductility is mainly dependent on the aluminium type applied. 800 700 600 500 400 300 Prepreg stress [MPa] 200 2024T3 GLARE 100 yield x 1.5 0 012345 strain [%] Stress-strain diagram Standard-GLARE © AIRBUS DEUTSCHLAND GmbH. document. All Confidential rights and proprietary reserved. Beumler, EDSAS Page 15 Material Characterisation for Certification 2) Oxidation. The laminate is as sensitive to corrosion as the applied metal. 3) The sensitivity to fatigue (crack initiation). 4) Electrical conductivity. Similar as for monolithic aluminium. © AIRBUS DEUTSCHLAND GmbH. document. All Confidential rights and proprietary reserved. Beumler, EDSAS Page 16 Material Characterisation for Certification 5) Machining processes are not equal but quite similar to monolithic aluminium. 6) Environmental influences due to diffusion into the prepreg are limited to drilled holes and damages. 0,700,12 0,600,10 0,08 0,50 re-organisation 0,06 0,40 test site 0,04 moisture level used for qualification 0,300,02 0,200,00 weight gain [g] weight gain [g] -0,02 0,10 -0,04 -0,060,00 -0,10-0,08 0 1224364860 exposure time [month] 8-1-P 8-2-P 8-3-PH 8-4-PH 8-1-P 8-2-P 8-3-PH 8-4-PH 8-18-H 8-19-H 70°C/85%RH © AIRBUS DEUTSCHLAND GmbH. document. All Confidential rights and proprietary reserved. Beumler, EDSAS Page 17 FML Certification Both „Standard GLARE“ and „HSS-GLARE“ have been certified as metal under JAR/FAR without a Special Condition. © AIRBUS DEUTSCHLAND GmbH. document. All Confidential rights and proprietary reserved. Beumler, EDSAS Page 18 FML Tasks for A380 Information flow in GTP environment GTP Working Groups M&P Qualification Material Properties Durability Methods Static GLARE Certification Methods F&DT Group (WG3B) Design Guidelines Conducts working sessions with Industrial Manufacturing European and US AA‘s. NDI Invites specialists for support. A380 stressmen, designers Directs tasks to cluster. Repairs & SRM and manufacturing specialists Presents results from cluster. Specialties define tasks for cluster and use cluster know-how for aircraft strength justification and aircraft structural certification. Cluster conduct technical tasks according to A380-800 milestone planing. Task results required for aircraft sizing and design,strength justification and aircraft certification. © AIRBUS DEUTSCHLAND GmbH. document. All Confidential rights and proprietary reserved. Beumler, EDSAS Page 19 Controlling the Damage … • … on Structural Level • … on Material Level Material Level through material properties → JAR 25.613(a,b,c,d) Structural Level through design features → design values, JAR 25.613(e) Under strict consideration of JAR 25.1529: Continuous Airworthiness © AIRBUS DEUTSCHLAND GmbH. document. All Confidential rights and proprietary reserved. Beumler, EDSAS Page 20 Damage Tolerance on Material Level Slow fatigue crack propagation rates Variable Amplitude Crack Propagation 100 Test 1049-3 Matl 2024 90 Test 1049-4 Matl 2024 Test 1049-5 Matl 2524 Test 1049-6 Matl 2524 80 Test 1519-1 Matl 2098 lean Test 1519-2 Matl 2098 lean Test 1519-3 Matl 2098 lean 70 Test CDP4.5 UF HSS-GLARE3 Test CDP4.5 LF HSS-GLARE3 Test CDP4.5 UR HSS-GLARE3 60 Test CDP4.5 LR HSS-GLARE3 50 A330-300 SR flight spectrum according to finite element CQUAD4 580031, Smax. = 140 MPa 40 detectable crack length (general visual) Crack Propagation [mm] [mm] Propagation Propagation Crack Crack 30 20 10 General visual crack length can not be reached in the fatigue case with the representative spectrum, GVI of GLARE panels just for accidental damage case. 0 0 30000 60000 90000 120000 150000 180000 210000 240000 270000 300000 N [flights] © AIRBUS DEUTSCHLAND GmbH. document. All Confidential rights and proprietary
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