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Optimisation of assembly processes for Adhesive bonded Brackets onto the airframe structure

Airbus-Marco Chacin PhD, Ana De-Lozoya Nombela, Mark Burrows
Cranfield University-Jose Angel Gonzalez-Domingo, Philip Webb
  • Technical Paper
  • 2019-01-1855
To be published on 2019-09-16 by SAE International in United States
Aircraft manufacturers use adhesive bonded brackets (ABB) to support wire harnesses, looms and sensors. Using ABBs eliminates the necessity to drill holes in the airframe and significantly reduces the assembly time. Such brackets are installed manually on the airframes in numerous locations using high strength epoxy based adhesives. In addition, the application of adhesive onto bracket is carried out manually. Thus it's time consuming and quality relies on operator’s skill sets to apply a certain quantity of adhesive using a predefined pattern, both of which are commonly not controlled. On the other hand, removing the damaged brackets by manual operations tend to cause dents and scratches in metallic airframes and delamination in composites. Prior research indicates that the brackets can be removed by heating them. But, they are not recommendable to aerospace manufacturers due to the longer process times. Therefore, it is vital to find a solution or methods to remove the ABBs without damaging any airframes. The scope of this research encompasses all the areas of design, technology and product development enabling a multi-disciplinary…
 

Low cost, fireproof, and light aircraft interior

Sardou Societe Anonyme-Max Sardou
  • Technical Paper
  • 2019-01-1857
To be published on 2019-09-16 by SAE International in United States
Low cost, fireproof, and light aircraft interior Fire is a dramatic issue in aircraft nowadays, especially with composite air crafts. An additional issue is the dangerous use of flammable Li-Ion batteries in a lot of appliances. we propose in order to avoid dramas to produce aircraft interiors, fire doors, cargo bay walls, as well than cargo container able to contain a fire inside them, with our ceramic composite called TOUGHCERAM ®. We have developed a low-cost, ceramic, damage tolerant, this ceramic is flexible between minus 100°C and plus 350°C. TOUGHCERAM ® poly-crystalize between 60°C and 110°C and can be reinforced with fibbers like carbon or basalt one. TOUGHCERAM ® survive 90 minutes to a propane 1900°C torches. TOUGHCERAM ® does not burn, nor smoke. In this paper we will explain how it is possible to develop a fully mineral ceramic offering such unique mechanical and fire properties.
 

The benefits of using Composite Bearings in Aircraft Shock Absorbers

Trelleborg Sealing Solutions-Brian Bowen, Torben A. Andersen
  • Technical Paper
  • 2019-01-1898
To be published on 2019-09-16 by SAE International in United States
This paper will use actual examples from aircraft recently introduced into service, to describe the main advantages of changing from the currently used metallic bearings, to composite bearings. Abstract: The introduction of composite bearing in a recently introduced twin aisle aircraft has resulted in: • Weight saving, by replacing bronze bearings with plastic bearings • Lowering of the particle count in the shock absorber oil, (Reduced contamination with metal particles) leading to reduced wear on seals and bearings. Qualification testing showed that Composite Bearings are able to provide longer service life than bronze bearings.
 

Development Of Multi-Material Overhead Stowage Systems For Commercial Aircrafts By Using New Design and Production Methods

3D Systems GmbH-Gunnar Fick
Composite Technology Center / CTC GmbH-Marc Fette
  • Technical Paper
  • 2019-01-1858
To be published on 2019-09-16 by SAE International in United States
The relevance of innovative and functional lightweight components for aircrafts has risen significantly during the recent years. In this context, modern lightweight materials as well as cost-efficient and time-saving manufacturing technologies are required for a future aircraft production. The so called Hybrid SMC Technology and the SMC-Foam-Sandwich Technology are promising approaches for the cost-efficient and time-saving manufacturing of lightweight, geometrically complex and functional aircraft components. Both technologies have been used for the development of a new generation overhead stowage system. It is realized by sidewalls made out of enhanced SMC technologies with directly implemented metallic load introduction elements and regular sandwich structures that can be assembled by a quick-assembly principle. Due to the glass fibers in the shape of chopped long fibers with no predominant direction in SMC material, continuous carbon fiber tailored fiber placement (TFP) fabrics were integrated to increase mechanical properties. Because of several load introduction points in the demonstration part, carbon fiber loops are a good and efficient possibility to transfer these loads. The challenge in the virtual design process of SMC…
 

Care and Repair of Advanced Composites, 3rd Edition

Keith B. Armstrong
Airbus-Francois Museux
  • Book
  • R-461
To be published on 2019-07-01 by SAE International in United States
No Abstract Available.
 
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Heat Transfer Enhancement in Stagnation Region of Aero-Engine Inlet Vanes due to Ejection Slot and Anisotropic Heat Conduction

AECC Commercial Aircraft Engine Co., Ltd-Kun Yang, Hongkui Zhou
Beihang University-Peng Ke, Jie Liu, Lukas Schaeflein
Published 2019-06-10 by SAE International in United States
Ice protection is important for aero-engine induction system, such as the inlet vanes. For the ice protection of such parts manufactured with low thermal conductivity polymer-based composite material, the combined heating method using interior jet impingement and exterior ejection film has certain advantages. The simulation model coupling CFD with solid heat conduction was developed and solved with the anisotropic thermal conductivities model to investigate the heat transfer enhancement in the stagnation region of aero-engine inlet vanes due to ejection slot and anisotropic heat conduction, which is related to the curved geometry, ejection slots and anisotropic heat conduction.The temperature distribution and heat flux ratio between the stagnation region on outside surface and the impingement region inside were calculated and analyzed for the configuration with different ejection angle and different materials. The results show that ejection slots and anisotropic heat conduction plays important roles of the heat transfer process. For the same ejection angles, the larger the thermal conductivity, the higher the temperature at stagnation point and the better ice protection. For the same material property, the…
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Aero-Engine Inlet Vane Structure Optimization for Anti-Icing with Hot Air Film Using Neural Network and Genetic Algorithm

Beihang University-Jie Liu, Peng Ke
Published 2019-06-10 by SAE International in United States
An improved anti-icing design with film heating ejection slot and cover for the inlet part of aero-engine was brought out, which combines the interior jet impingement with the exterior hot air film heating and shows promising application for those parts manufactured with composite materials. A hybrid method based on the combination of the Back Propagation Neural Network (BPNN) and Genetic Algorithm (GA) is developed to optimize the anti-icing design for a typical aero-engine inlet vane in two dimensions. The optimization aims to maximize the heating performance of the hot air film, which is assessed by the heating effectiveness. The film-heating ejection angle and the cover opening angle are the two geometric variables to be optimized. Numerical model was established and validated to generate training and testing samples for BPNN, which was used to predict the objective function and find the optimal design variables in conjunction with the GA. The optimal values of the film-heating ejection angle and the cover opening angle were 24.3° and 5°, respectively, which were achieved at a given heat flow rate…
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Computational Simulation of an Electrically Heated Ice Protection System for Composite Leading Edges of Aircraft

Gyeongsang National University-Prince Raj Lawrence Raj, Hojin Jeong, Rene Roy, Jin-Hwe Kweon, Rho Shin Myong
Published 2019-06-10 by SAE International in United States
The performance of an electrically heated aircraft ice protection system for a composite leading edge was evaluated. The composite leading edge of the model is equipped with a Ni alloy resistance heater. A state-of-the-art icing code, FENSAP-ICE, was used for the analysis of the electrothermal de-icing system. Computational results, including detailed information of conjugate heat transfer, were validated with experimental data. The computational model was then applied to the composite leading edge wing section at various metrological conditions selected from FAR Part 25 Appendix C.
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Industrial Framework for Identification and Verification of Hot Spots in Automotive Composite Structures

SAE International Journal of Materials and Manufacturing

Chalmers University of Technology, Sweden-Leif E. Asp
Volvo Car Corporation, Sweden-Henrik Molker, Renaud Gutkin
  • Journal Article
  • 05-12-02-0009
Published 2019-05-16 by SAE International in United States
In this article, a framework for efficient strength analysis of large and complex automotive composite structures is presented. This article focuses on processes and methods that are compliant with common practice in the automotive industry. The proposed framework uses efficient shell models for identification of hot spots, automated remodelling and analysis of found hot spots with high-fidelity models and finally an automated way of post-processing the detailed models. The process is developed to allow verification of a large number of load cases in large models and still consider all potential failure modes. The process is focused on laminated composite primary structures. This article highlights the challenges and tools for setting up this framework.
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Composite Fuel Tanks, Fuel System Design Considerations

AE-5A Aerospace Fuel, Inerting and Lubrication Sys Committee
  • Aerospace Standard
  • AIR5774
  • Current
Published 2019-05-16 by SAE International in United States
This SAE Aerospace Information Report (AIR) is a compilation of engineering references and data useful to the technical community that can be used to ensure fuel system compatibility with composite structure. This AIR is not a complete detailed design guide and is not intended to satisfy all potential fuel system applications. Extensive research, design, and development are required for each individual application.
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