Composites and sandwich structures activities at KTH

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Dan Zenkert Division of Lightweight Structures Kungliga Tekniska Högskolan (KTH) Stockholm, Sweden Composites and sandwich structures activities at

1 Dan Zenkert Division of Lightweight Structures Kungliga Tekniska Högskolan (KTH) Stockholm, Sweden Composites and sandwich structures activities at KTH Current aerospace projects o o o o What is going on out there? ALCAS NFFP MOJO Marine related research Car industry activities Educational efforts

JAS 39 Gripen Carbon-Fiber Composite (CFRP) Glass-Fiber Composite (GFRP) Aramid-Fiber Composite (AFRP) From past to present composites at Airbus Stepwise approach Major NASA programs on CFRP primary

2 JAS 39 Gripen Carbon-Fiber Composite (CFRP) Glass-Fiber Composite (GFRP) Aramid-Fiber Composite (AFRP) From past to present composites at Airbus Stepwise approach Major NASA programs on CFRP primary structure for HTP and VTP of civil transports CFRP Spoilers In service trial GFRP fairings CFRP primary structure Fin CFRP flight controls Spoilers, Airbrakes, Rudder CFRP primary structures + HTP, Flaps CFRP primary structures + HTP as fuel tank CFRP primary structures + center wing box CFRP primary structures + bulkhead and keel beam A300 A A A320 A340 A330 A321 A319 A A A A R 2006

3 A320 composite applications A Composite Structures Vertical stabilizer Horizontal stabilizer J-Nose, Fokker Special Products, NL Keel Beam Pressure bulkhead

4 A380 state of the art composites Floor Beams for Upper Deck GLARE in Upper Fuselage Outer Flaps Vertical Tail Plane Section 19.1 J-Nose Horizontal Tail Plane Section 19 Center Wing Box Wing Ribs Rear Pressure Bulkhead 4

5 Composites in Boeing 787 and Airbus A350

Advanced Low-Cost Aircraft Structures - ALCAS ALCAS stands for Advanced Low Cost Aircraft Structures, European project, 58 partners, total budget of 101 Mio The overall objective is to reduce the

The ALCAS project will include: o o o o Evaluations of Technologi

6 Advanced Low-Cost Aircraft Structures - ALCAS ALCAS stands for Advanced Low Cost Aircraft Structures, European project, 58 partners, total budget of 101 Mio The overall objective is to reduce the operating costs of relevant European aerospace products by 15%, through the cost effective application of carbon fibre composites. The ALCAS project will include: o o o o Evaluations of Technologies for Industrial Implementation (e.g. new manufacturing technologies, part reduction, infusion manufacturing of large complex parts) Cost and Design Optimization Sub-component Tests Full Scale Component Tests Advanced Low-Cost Aircraft Structures - ALCAS The work package of KTH contains the formulation and development of a design optimisation methodology for generic composite elements. min DOC of a generic composite element subject to prescribed buckling load strength requirements manufacturing robustness maximum shape distortions draping restrictions...

Advanced Low-Cost Aircraft Structures - ALCAS Optimisation variables o fibre stacking angle o layer thicknesses o boom design o tapering zone design o stiffener configuration o fastener configuration

7 Advanced Low-Cost Aircraft Structures - ALCAS Optimisation variables o fibre stacking angle o layer thicknesses o boom design o tapering zone design o stiffener configuration o fastener configuration o... Prescribed o overall dimensions o load case o failure criteria 300 kn 300 kn simply-supported clamped simply-supported Advanced Low-Cost Aircraft Structures - ALCAS Cost/weight optimization routine works o for continous variables o for smaller examples o optimization of discrete variables problematic Compare optimal solutions for different weight penalties Sensitivity analysis of the chosen variables (robust design) Enhance model by additional constraints o draping o shape distortion o etc 300 kn 300 kn simply-supported clamped simply-supported

x z y x y z Cost Efficient Composite Structures (KEKS) To experimentally investigate parameters determining the drapability of stacks of UD prepreg (RT and hot) To develop constitutive models and FE

8 x z y x y z Cost Efficient Composite Structures (KEKS) To experimentally investigate parameters determining the drapability of stacks of UD prepreg (RT and hot) To develop constitutive models and FE models in order to enable virtual prototyping To describe manufacturability as subset to be used in multidisciplinary optimisation aiming at finding best possible performance at lowest possible price Cost Efficient Composite Structures (KEKS) Drapability Manufacturing Optimisation, Cost Optimisation, Weight, Stress/ Stiffness Shape distortion

Cost Efficient Composite Structures (KEKS) stacking sequence material component geometry KTH NFFP module OUTCOME Optimal stacking sequence Manufacturing description Resulting fibre angles INFLUENCING

9 Cost Efficient Composite Structures (KEKS) stacking sequence material component geometry KTH NFFP module OUTCOME Optimal stacking sequence Manufacturing description Resulting fibre angles INFLUENCING Production Cost optimisation Structural analysis Shape distortion Cost Efficient Composite Structures (KEKS) Bias extension test of carbon/epoxy prepreg at different stacking angles, temperatures and deformation speeds Digital Signal Processing (DSP) using digital cameras to measure deformation FE models development Constitutive modelling of involved parameters Strain field during bias extension testing, layup [15,-15] s

10 Modular Joints for Aircraft Structures - MOJO Preforming of structural elements Attachment and reinforcement of joining elements and infiltration (infusion) Adhesive bonding of other joining elements Completion of assembly Modular Joints for Aircraft Structures - MOJO Pi-Section HT-Section

11 Modular Joints for Aircraft Structures - MOJO BiTeam 3D weaving Corvette Visby LOA: 72 metres Beam: 10.4 metres Weight: 600 metric tonnes Hull ( 150 metric tonnes) o 25% of total weight o Carbon fibres T700 ( kg) o Vinylester resin ( kg) o PVC foam core ( kg)

12 Trends in Structural Materials 1970 Landsort Visby NSC / YSNY - Magnetic Signature - Shock Resistance - Maintenance Cost Glass Fibre Polyester PVC-foam Wet Lay-up Structural margins Low cost materials - Radar signature - Weight reduction - Magnetic Signature - Shock Resistance - Maintenance Cost Carbon / Glass Fibre Vinyl ester PVC-foam / balsa Vacuum infusion Weight optimization More Expensive materials - Fire resistance - Vulnerability Reduction - Ballistic protection - Damage tolerance - Radar signature - Weight reduction - Magnetic Signature - Shock Resistance - Maintenance Cost Carbon / Glass Fibre Variety of matrix systems Variety of core materials / adhesives Vacuum infusion / Resin film Infusion Weight optimization & Quality Assurance More expensive materials Vision for NSC LOA: m Displacement: tonnes Hull: All composite (sandwich)

13 Vision for NSC LOA: m Displacement: tonnes Hull: Steel or composite Vision for NSC LOA: m Displacement: tonnes Hull: Steel or composite

Vision for NSC LOA: 100-110 m Displacement: 1700-2200 tonnes Hull: All composite (sandwich) Design challenges Larger ships o Design with

14 Vision for NSC LOA: m Displacement: tonnes Hull: All composite (sandwich) Design challenges Larger ships o Design with respect to global loads rather than local loads Use new materials o CFRP means stiffness design strength design o Fire resistant materials more brittle! o Compatibility between materials Thinner face sheets o wrinkling failure becomes active constraint o local impact - robustness Strength design o requires more in-depth knowledge of failure modes o QA o Damage tolerance, NDI, repair Weapon effects o Fragment protection o Blast

15 Aims of Product Definition Phase Hull structure and materials Create a new hull concept Based on Corvette Visby properties Low cost Low weight Low signatures Increased fire resistance Reduced vulnerability Present focus Ballistic Protection Blast Resistance Fire Performance Signature Control Structural Load Bearing Capacity Etc. Fire is that a problem? Matrix systems Phenolics Cyanate Ester Phthalonitrile Silicone Resin Geopolymer Modar Nano Composites Bisphenol C Etc. Core Materials Balsa Comfire, Glass Foam Aluminum Foam C-Foam Carbon Foam Phenolic Foam Parabeam 3D Glass weave Structiso 3D Glass Webcore Etc.

16 New materials qualification spiral Environmental impact Fire Price Process Strength Environmental resistance New material A- Screening B- Qualification C Rules of use Fragment protection -

17 Fragment protection - Blast resistance -

18 Blast resistance - Possible Material Selection Hull Shell Plating, Main deck : Carbon / Vinylester / PVC-foam - Superstructure, Internal Decks and Bulkheads : Glassfiber / Phenolics / Balsa Joints : Bonded, Prefabricated Composite Profiles

examination Our implementation of CDIO Specialization, year 4 Project based CDIO course Course x

19 Student Projects Specification Design and build an aircraft that can fly level flight on solar power with a pay-load of 2 kg Invent-designbuild project experience Team based Link courses New examination Our implementation of CDIO Specialization, year 4 Project based CDIO course Course x FEA Composites Sandwich Fluid mech. Thesis Course y Naval arch. Comp.Manuf. Design and optimisation time

20 Training device for astronauts Formula Student composite chassis Composite monocoque o Save weight o Increase stiffness o Appealing design

Marathon KTH Agilis Project format Invent-design-build project experience

21 Student Project 2006 Shell Eco Marathon KTH Agilis 14 students Composite monocoque o Save weight o Integral design New type of engine (HCCI) Shell Eco Marathon KTH Agilis Project format Invent-design-build project experience Team based Link courses New examination CDIO syllabus Conceive Design Implement Operate

22 Shell Eco Marathon KTH Agilis Conceive Shell Eco Marathon KTH Agilis Conceive

23 Shell Eco Marathon KTH Agilis Conceive Shell Eco Marathon KTH Agilis Design dx( t) 2 F x + 2δ + ω0 x( t) = g( t) dt

24 Shell Eco Marathon KTH Agilis Design L : F R1 2 F L R2 2 + L 2 F static,1l F acc,1l = 0 Shell Eco Marathon KTH Agilis Implement

25 Shell Eco Marathon KTH Agilis Implement Shell Eco Marathon KTH Agilis Operate

26 Shell Eco Marathon KTH Agilis Operate Shell Eco Marathon KTH Agilis Operate

27 Publicity SVT Rapport (c:a 2 minutes) twice TV4 Nyhetsmorgon, TV8 SR P1 och P3 Metro, Aftonbladet Ny Teknik, Motor.. Urban Concept Cars

28 Urban Concept Cars Winner 2006: 810 km/litre

Crashworthiness of an Electric Prototype Vehicle Series

Crashworthiness of an Electric Prototype Vehicle Series Schluckspecht Project Collaboration for Crashworthiness F. Huberth *, S. Sinz *+, S. Herb *+, J. Lienhard *+, M. Jung *, K. Thoma *, K. Hochberg