Composite Structures The First 100 Years

Billy Roeseler, Branko Sarh, and Max Kismarton Originally prepared for ICCM-16 Kyoto, Japan 9 July 2007

Added content from John Quinlivan, Joe Sutter, Damon Roberts, (Insensys,) GE, and Boeing 787 Program for Composite Design Tutorial, Stanford University 28 Sept 2009

Composites Then and Now

Two or more materials combined to perform some useful purpose Exhibits the best properties of the individual materials plus additional qualities that the individual materials do not exhibit alone Examples
Mud and straw Steel-reinforced concrete Fibers embedded in a plastic resin matrix Oriented Strand Board (OSB)

1943 Popular Mechanics Prediction

Composites Provide Higher Strength and Stiffness

Zylon Dyneema T-800 Specific Fiber Properties Dry (no resin) Tension ONLY

Zylon AS

HM

T-1000 M30S M5 M35J M40J M46J M50J M55J M60J

Specific Ultimate Tension, UTS1 (KSI / pci)

Vectran HS S-glass Quartz E-glass Kevlar 29

T-700G Spectra 900 AS4D AS4 T-400H T-300G Kevlar 149 Kevlar 49 T300

M30J

M30

Boron

Vectran M Titanium Aluminum Steel

0 200 400 600 800 1000 1200 1400

Specific Modulus, E1/ rho (MSI / pci)

Fig 2

Fiberglass Primary Structures Rotor Blades (1964 flight test)

MASS Governor Volpe inspects Autocopter 1966

767 and Entry Door Spring 1978

Fiberglass Primary Structure in Service 1984

Joe Sutter 1982

1982 Prediction Joe Sutter

Rational Growth of Aerospace Usage of Composite Structures

60 50
Percent of Composite Eurofighter B-2 Gripen AV-8B ATR72 LCA F-22 F-35 A400M AH-66 Boeing 7E7 OV-22 Non-Boeing

40 30 20 10
707

0 1940

A380 767 ATR42 F/A-18 E/F A330-200 L1011 757 A340 DC-10 A320 777 737-300 A310 DC-9 MD-11 747-400

1960

1980

2000

2020

Damage Tolerant Design

Design Load Level

Ultimate
1.5 Factor of Safety

Limit
~ Maximum load per lifetime Continued safe flight

Allowable Damage Limit

Critical Damage Threshold

(ADL)

(CDT)

Increasing Damage Severity

LCPAS Compression Panel Test Summary

70 11-5 11-5 60 27% 50 1J-3 3B-3 40 3I-1 3J-1 3B-3
X X X X X X X X X

Normalized Gross Failure Stress (Ksi)

1B-1

Mass Reduction 3B-3 3I-1 3J-1 8%

X

30

20

10

10

15

20

25

30

20

30

40

50

60

End load Nx (Kip/in.)

LCPAS 1982 (2220-3) Rhodes and Williams 1981 (5208) X Aluminum (7150) Impact damage in. diameter metal impactor

Shear Stiffness Ratio Gt/Nx

LCPAS Wing Sizing Based on Test Results

Component Upper Surface Lower Surface Spars Total (Panels + Spars) Theoretical Mass Reduction (%) 24 49 40 38

Boeing Structural Aluminum Alloy Improvements

200

777 Fuselage
2XXX-T3

150

2024-T3 2024-T351

Lower Wing 767 757 737 747-400 2324-T39 777

2224

Fracture Toughness Kaap,Ksi in

Upper Wing 767 757 737-300 -400, -500 747-400

7150

Goodness

100 Old Technology 7075-T651 50 7178-T651

Upper Wing 737-700,-800 777

7055

777 Body Stringers

7150

0 40 60 80 100

Typical Yield Strength, Ksi

Specific Strength Of Wing Bending Materials

900 850 800
Specific Strength Stress / Density (Ksi / pci)
UAVs Wind Energy IACC

750 700 650 600 550 500 1930

DC-3 B-47 Spruce Goose B-52

Helicopters Military Commercial Tails

7055 7150

Commercial Wings

777-wing
7075

757 767

2324 2224

737 747 DC-7 Comet

2024

Metallics Composites

1950

1970
Year

1990

2010

2030

2050

Setting New Levels of Leadership

Less fuel used Lower emissions Quieter for communities, crews, and passengers Fewer hazardous materials Less waste in production

Opening a New Era in Fuel Efficiency

225 SEATS 200 SEATS 275 SEATS 300 SEATS 350 SEATS 400 SEATS 450 SEATS 250 SEATS

Fuel consumption per seat

500 SEATS

Current Quads
550 SEATS

20% Better

Current Twins

787
Fuel consumption per trip

Addressing the Markets Needs

(2006-2025)

Regional jets Single-aisle Twin-aisle 747 and larger

3% 13% 23%

10%

4%

41%
61%

45%

27,200 airplanes

2.6 trillion delivery dollars*

*In year 2005 dollars

Composite Solutions Applied Throughout the 787

Carbon laminate Carbon sandwich Other composites Aluminum Titanium Titanium/steel/aluminum

Other Steel 5% 10% Titanium 15% Aluminum 20% Composites 50%

Partners Across The Globe Are Bringing The 787 Together (2007 data)

787 Final Assembly Flow Everett, Wash.

Increased Use of Composites Over Time

787 777 757/767 747
1%
11%
50%

3%

Materials
Composite Steel Titanium Aluminum Miscellaneous

Validation Process Ensures Safety, Reliability

Proven Certification process, validated by positive service experience Boeing design objectives typically exceed minimum regulatory requirements
Assemblies Airplanes

Static Test Fatigue Test Ground & Flight Tests

Material Specimens Elements Components

Increasing Levels of Complexity

Static Test Airframe Moves To Testing Rig 25 April 2008

787 Airframe Static Test

Composites Also On Jet Engines

Composites at Work with Wind Turbines (Vestas V90)

BOR 90, Newest Carbon Fiber Flying Machine, Anacortes, WA 2008

www.GGYC.COM

Composites at Sea with the Maltese Falcon

Damon Roberts Insensys, Ltd

Maltese Falcon Rig Engineering and Build Structural Overview

Bending moment at deck 17,000,000 Nm Torque at deck 1,200 kNm Height 58m Sail area on each spar 800 sqm Elliptical spar 1.8m by 1.1m max, tapering to 0.6 by 0.4m at top and reducing to 1.1m diam at deck Open slot down compression face

Maltese Falcon main spar, note slot for furling sails

Masts

Maltese Falcon Rig Cured in 4 pieces, secondary bonded together

Maltese Falcon Rig Stepping

Real Time Display in Wheel House, Maltese Falcon

Improvements in Specific Strength During the First 100 Years of Composites

AL Ti Steel Wood Plastic Glass CFRP
Nano Fibers Zylon, dry Spectra lines Uni, Rod Uni, Spring Autocopter B-47 B-52 AL-7050 4130
High Pressure Tanks

GR fiber, dry

Vectran, dry

Specific Strength, Log (ksi/pci)

Oil Drilling

Wind Energy

Metals
747 767 777 AL-7150 787

DC-7 Comet DC-3 Corvette Chop Fiber AL ladders

1940

1950

1960

1970

1980

1990

2000

2010

2020

2030

2040

Year

Diverse Modes of Transportation

12.0 11.0 10.0 9.0 Travel Time (Hours) 8.0 7.0 6.0 5.0 4.0 3.0 2.0 1.0 100 200

AFA Driving Mode

()

Automobile () Commercial AC Using Hub Commercial AC Advanced Flying Automobile

+ + + + +

Automobile ()

+
() () () ()

Commercial w Hub

( )

+ +

+

Commercial AC
AFA Flight Mode

300 400 500 600 Flight Destination (Miles)

700

800

On the Land, In the Sky, On the Sea: The Best Is Yet to Come