Inspection interval optimization for aircraft composite structures with dent and delamination damage

The optimization of inspection intervals for composite structures has been proposed,but only one damage type,dent damage,has been addressed so far.The present study focuses on the two main damage types of dent and delamination,and a model for optimizing the inspection interval of composite structures is proposed to minimize the total maintenance cost on the premise that the probability of structure failure will not exceed the acceptable level.In order to analyze the damage characteristics and the residual strength of the composite structure,the frequency,energy,size,and depth of the damage are studied,and the situation of missing detection during the inspection is considered.The structural residual strength and total maintenance cost are quantified corresponding to different inspection intervals.The proposed optimization method relieves the constraints in previous simulation methods,and is more consistent with the actual situation.Finally,the outer wing of aircraft is taken as an example,and with the historical cases and experimental data,the optimization method is verified.The optimal inspection interval is shorter than the actually implemented inspection interval,and the corresponding maintenance cost is reduced by 23.3%.The result shows the feasibility and effectiveness of the proposed optimization method.

Damage to aircraft composite structures caused by directed energy system: A literature review

This paper presents a comprehensive review of the research studies on direct energy system effect on aircraft composite structures to develop a good understanding of state-of-the-art research and development in this area.The review begins with the application of composite materials in the aircraft structures and highlights their particular areas of application and limitations.An overview of directed energy system is given.Some of the commonly used systems in this category are discussed and the working principles of laser energy systems are described.The experimental and numerical studies reported regarding the aircraft composite structures subject to the effect of directed energy systems,especially the laser systems are reviewed in detail.In particularly,the general effects of laser systems and the relevant damage mechanisms against the composite structures are reported.The review draws attention to the recent research and findings in this field and is expected to guide engineers/researchers in future theoretical,numerical,and experimental studies.

Robotic compliant assembly for complex-shaped composite aircraft frame based on Gaussian process considering uncertainties

Robots are finding increasing application in aircraft composite structure assembly due to their flexibility and the growing demand of aircraft manufacturers for high production rates.The contact force of the composite frame in a robotic assembly of the aircraft composite fuselage panel can hardly be controlled due to the multi-surface variable contact stiffness caused by compliance and complex shape with multiple mating surfaces.The paper proposes a robotic assembly system for the aircraft composite fuselage frame with a compliant contact force control strategy using the Gaussian process surrogate model.First,a robotic assembly system is introduced,and the global coordinate system transformation model is built.Then,a compliant force control architecture is designed to generate the desired output force.Subsequently,a Gaussian process surrogate model with uncertainties is utilized to model the complicated relationship between the robot’s output force and the normal contact force acting on the mating surface of the composite frame.Furthermore,an optimal contact force control strategy is implemented to improve the contact quality.Finally,an experiment demonstrates that the proposed methodology can ensure that the contact force on each surface is within the limit of the engineering specification and uniformly distributed,improving the quality compared to the traditional assembly process.

Smart Manufacture Process and Structure for Composite Materials

It is difficult to ensure the manufacturing process of composites for the reason that there are complicated processes during curing process of composites. The cure cycle has a significant effect on the quality of the finished part. The traditional cure cycle based on empirical approach could not ensure the quality of cured products because of unstabilized performance, high cost of production and low efficiency. As complex intelligent manufacturing systems are developed increasingly in industry, the necessity of more user friendly operation system is becoming progressively importance for their utilization and market value. This paper introduces some of the recent technological advances in the intelligent manufacturing systems that will influence the design and development of relevant industry.

Field-assisted tunneling enabled pressure-sensitive composites/sensors for smart concrete structures

Spiky spherical nickel powder with sharp nano-tips on its surface is a kind of excellent fillers for developing pressure-sensitive cement-based composites/sensors for traffic detection,structural health monitoring,and border and military security.The sharp nano-tips on the surface of spiky spherical nickel particles can induce field emission and tunneling effects,which leads to the ultrahigh pressure-sensitive responses of the cement-based composites.In this paper,we systematically introduce research on nanotip-induced ultrahigh pressure-sensitive cement-based composites/sensors,with attentions to their pressure-sensitive property and sensing mechanism,pressure-sensitive characteristic model,and smart structure system for traffic detection.

Application of Monodisperse Thermo-Responsive Composite Microgels with Core-Shell Structure Based on Au@Ag Bimetallic Nanorod as Core in Surface Enhanced Raman Spectroscopy Substrate

The monodisperse Au@Ag bimetallic nanorod is encapsulated by crosslinked poly( N-isopropylacrylamide)( PNIPAM) to produce thermo-responsive composite microgel with well-defined core-shell structure( Au@ Ag NR@ PNIPAM microgel)by seed-precipitation polymerization method using butenoic acid modified Au @ Ag NRs as seeds. When the temperature of the aqueous medium increases from 20℃ to 50℃,the localized surface plasmon resonance( LSPR) band of the entrapped Au @ Ag NR is pronouncedly red-shifted because of the decreased spatial distances between them as a result of shrinkage of the microgels,leading to their plasmonic coupling. The temperature tunable plasmonic coupling is demonstrated by temperature dependence of the surface enhanced Raman spectroscopy( SERS) signal of 1-naphthol in aqueous solution. Different from static plasmonic coupling modes from nanostructured assembly or array system of noble metals,the proposed plasmonic coupling can be dynamically controlled by environmental temperature. Therefore, the thermo responsive hybrid microgels have potential applications in mobile LSPR or SERS microsensors for living tissues or cells.

Successes and challenges in non-destructive testing of aircraft composite structures

Composite materials are increasingly used in the aerospace industry.To fully realise the weight saving potential along with superior mechanical properties that composites offer in safety critical applications,reliable Non-Destructive Testing(NDT)methods are required to prevent catastrophic failures.This paper will review the state of the art in the field and point to highlight the success and challenges that different NDT methods are faced to evaluate the integrity of critical aerospace composites.The focus will be on advanced certificated NDT methods for damage detection and characterization in composite laminates for use in the aircraft primary and secondary structures.

A refined finite element method for bending analysis of laminated plates integrated with piezoelectric fiber-reinforced composite actuators

This research presents a finite element formulation based on four-variable refined plate theory for bending analysis of cross-ply and angle-ply laminated composite plates integrated with a piezoelectric fiber-reinforced composite actuator under electromechanical loading. The four-variable refined plate theory is a simple and efficient higher-order shear deformation theory, which predicts parabolic variation of transverse shear stresses across the plate thickness and satisfies zero traction conditions on the plate free surfaces. The weak form of governing equations is derived using the principle of minimum potential energy, and a 4-node non-conforming rectangular plate element with 8 degrees of freedom per node is introduced for discretizing the domain. Several benchmark problems are solved by the developed MATLAB code and the obtained results are compared with those from exact and other numerical solutions, showing good agreement.

Damage Monitoring in Composite Stiffened Skin Using Fiber Bragg Grating under Tensile and Three-Point Loading

One of the problems associated with loading a fully composite structure with joints is that the loads are not linear through the neutral axis of the structure but are collinear; this induces additional moment and creates a load in the normal direction, which is typically a critical load because it can create delamination and can only be withstood if it is small. Another problem is that the structure is difficult to inspect using conventional methods because of limited accessibility. With fiber Bragg grating （FBG）, the problem can potentially be solved in structures with a stiffness mismatch. The model used to represent the problem above is a composite stiffened skin with two loading cases： tensile and three-point bending. Additionally, FBG is used to monitor and characterize the delamination caused by both loading cases. Finite element modeling （FEM） with traction versus separation theory is performed to determine the critical area on the specimen for placement of the FBG before manufacturing and testing. In this research, FBG can successfully monitor and characterize delamination caused by both loading cases in structures that have mismatched stiffnesses. Also, FBG can predict the delamination growth quantitatively. A spectrum graph of the FBG results can be used to replace a conventional mechanical graph for use in structural health monitoring.

Thermal Activation of Asymetrical Composites for Vibration Control

The CBCM (Controlled Behaviour Composite Material) is a thermal active composite, which has been developed for morphing applications. The thermal activation is made by a source of heating generated within the composite structure. The coupling between the induced thermal field and the thermomechanical properties of the various components of the composite structure leads to the change of the structure shape. The heat source is generated by Joule effect, Carbon yarns inserted in the composite, are connected to a power supply. The application field of CBCM technology is the domain of shape modification and active assembly. The objective of this work is to illustrate the capabilities of CBCM in the domain of vibration control. We will study several reference plates with different constitution. The influences of these different constitutions, of the CBCM effect and the loss of stiffness for the matrix will be highlighted, for two boundary conditions, free/free and embedded/embedded.

Design and applications of morphing aircraft and their structures

Morphing aircraft can adaptively regulate their aerodynamic layout to meet the demands of varying flight conditions,improve their aerodynamic efficiency,and reduce their energy consumption.The design and fabrication of high-performance,lightweight,and intelligent morphing structures have become a hot topic in advanced aircraft design.This paper discusses morphing aircraft development history,structural characteristics,existing applications,and future prospects.First,some conventional mechanical morphing aircraft are examined with focus on their morphing modes,mechanisms,advantages,and disadvantages.Second,the novel applications of several technologies for morphing unmanned aerial vehicles,including additive manufacturing for fabricating complex morphing structures,lattice technology for reducing structural weight,and multi-mode morphing combined with flexible skins and foldable structures,are summarized and categorized.Moreover,in consideration of the further development of active morphing aircraft,the paper reviews morphing structures driven by smart material actuators,such as shape memory alloy and macro-fiber composites,and analyzes their advantages and limitations.Third,the paper discusses multiple challenges,including flexible structures,flexible skins,and control systems,in the design of future morphing aircraft.Lastly,the development and application of morphing structures in the aerospace field are discussed to provide a reference for future research and engineering applications.

Morphing wing flaps for large civil aircraft:Evolution of a smart technology across the Clean Sky program

Abstract Morphing wing structures are widely considered among the most promising technologies for the improvement of aerodynamic performances in large civil aircraft.The controlled adaptation of the wing shape to external operative conditions naturally enables the maximization of aircraft aerodynamic efficiency,with positive fallouts on the amount of fuel burned and pollutant emissions.The benefits brought by morphing wings at aircraft level are accompanied by the criticalities of the enabling technologies,mainly involving weight penalties,overconsumption of electrical power,and safety issues.The attempt to solve such criticalities passes through the development of novel design approaches,ensuring the consolidation of reliable structural solutions that are adequately mature for certification and in-flight operations.In this work,the development phases of a multimodal camber morphing wing flap,tailored for large civil aircraft applications,are outlined with specific reference to the activities addressed by the author in the framework of the Clean Sky program.The flap is morphed according to target shapes depending on aircraft flight conditions and defined to enhance high-lift performances during takeoff and landing,as well as wing aerodynamic efficiency during cruise.An innovative system based on finger-like robotic ribs driven by electromechanical actuators is proposed as morphing-enabling technology;the maturation process of the device is then traced from the proof of concept to the consolidation of a true-scale demonstrator for pre-flight ground validation tests.A step-by-step approach involving the design and testing of intermediate demonstrators is then carried out to show the compliance of the adaptive system with industrial standards and safety requirements.The technical issues encountered during the development of each intermediate demonstrator are critically analyzed,and justifications are provided for all the adopted engineering solutions.Finally,the layout of the true-scale demonstrator is presented,with emphasis on the architectural strengths,enabling the forthcoming validation in real operative conditions.

Smart structures with embedded flexible sensors fabricated by fused deposition modeling-based multimaterial 3D printing

Smart structures have the advantages of high system integrity and diverse sensing capabilities.However,the labor-intensive and timeconsuming fabrication process hinders the large-scale adoption of smart structures.Despite recent attempts to develop sensorembedded structures using 3D printing technologies,the reported smart structures generally suffer from the complex fabrication process,constrained part size,and limited sensing modality.Herein,we propose a workflow to design and fabricate novel smart structures via multi-material fused deposition modeling(FDM)-based 3D printing.More specifically,conductive filaments with tailorable mechanical and elec-trical properties,e.g.piezoresistive effects,were developed.Additionally,the printing process was optimized for processing soft filaments with Young’s modulus around 2 MPa,resolving the issue of filament buckling.Furthermore,the potential applications of the proposed workflow were showcased using three design cases,i.e.biaxial strain sensor,smart tire,and cable-driven soft finger with multiple sensing capabilities.This workflow provides a cost-effective and rapid solution for developing novel smart structures with soft materials.

Multi-layered plate finite element models with node-dependent kinematics for smart structures with piezoelectric components

This article presents a type of plate Finite Element(FE)models with adaptive mathematical refinement capabilities for modeling laminated smart structures with piezoelectric layers or distributed patches.The p-version shape functions are used in combination with the higher-order Layer-Wise(LW)kinematics adopting hierarchical Legendre polynomials.Node-Dependent Kinematics(NDK)is employed to implement local LW models in the regions with piezoelectric components and simulate the global substrate structure with the Equivalent Single-Layer(ESL)approach.Through the proposed NDK FE models,the electro-mechanical behavior of smart structures can be predicted with high fidelity and numerical efficiency,and various patch configurations can be conveniently modeled through one set of mesh grids.Moreover,the effectiveness and efficiency of the NDK FE approach are assessed through numerical examples and its application is demonstrated.

3D Printing of Continuous Fiber Reinforced Polymer Composites:Development,Application,and Prospective

Continuous fiber reinforced polymer composites(CFRPC)have been widely used in the field of automobile,air-craft,and space due to light weight,high specific strength and modulus in comparison with metal as well as alloys.Innovation on 3D printing of CFRPCs opened a new era for the design and fabrication of complicated composite structure with high performance and low cost.3D printing of CFRPCs provided an enabling technol-ogy to bridge the gaps between advanced materials and innovative structures.State-of-art has been reviewed according to the correlations of materials,structure,process,and performance as well as functions in 3D printing of CFRPCs.Typical applications and future perspective for 3D printing of CFRPCs were illustrated in order to grasp the opportunities and face the challenges,which need much more interdisciplinary researches covering the advanced materials,process and equipment,structural design,and final smart performance.

柔性变形翼结构设计、建模与分析研究进展

未来飞行器设计将面临空域、速域不断扩大、任务适应性要求不断提高的严峻挑战,变体飞行器可为提高飞行性能、扩大飞行包线提供新思路与新方法。采用柔性蒙皮配合相应的支撑结构成为克服传统变体飞行器缺点的主要解决方案。本文首先综述了柔性蒙皮、蜂窝支撑结构、新型智能材料在变体飞行器设计中的研究现状,然后对现有文献中柔性变形翼结构设计、建模与分析方法进行讨论。最后提出现有柔性变形翼结构设计、建模与分析方法存在的问题,以及未来可能的研究方向。

飞行器陶瓷基复合材料轻量化结构设计研究进展

高马赫数飞行带来的极端服役环境对新一代高速飞行器的材料、结构设计提出了更加严苛的要求,本文从“选、用、评”三方面对陶瓷基复合材料在飞行器结构设计中的应用进行综述,进而提出未来发展方向,为飞行器陶瓷基复合材料结构设计提供参考。全面综述了陶瓷基复合材料在不同应用场景下的选取准则及相应制备方法,系统介绍了陶瓷基复合材料在飞行器结构中的典型应用,分析了近服役工况下材料的评价准则及地面实验方法。为满足未来飞行器需求,提出需要结合计算机辅助优化技术和创新制备方法,提高陶瓷基复合材料的耐温和抗疲劳性能;发展高可靠、长寿命的连接技术和一体成型设计方案,充分发挥材料优势;开发多物理场耦合作用下的原位表征技术,以获得陶瓷基复合材料在实际使用中的性能演化行为,为飞行器轻量化结构设计提供可靠依据。

某型飞机复合材料结构损伤分布规律

针对飞机复合材料结构的损伤和修理问题,对某型固定翼飞机机翼、机身等部位的复合材料结构应用和损伤情况进行统计,复合材料在该型飞机的主要应用形式主要有实心整体壁板和夹芯层合板2种,建立随时间变化的结构损伤分布模型,利用统计方法对损伤分布进行拟合和检验。结果表明:结构损伤的数量比例分别为蒙皮分层占75%、长桁分层约占20%、长桁脱黏约占4%;对数正态分布、Weibull分布、Γ分布均可以拟合这3种类型损伤的几何参数分布,其中对数正态分布模型的拟合效果最好;单架飞机的损伤几何参数分布规律不随时间变化,同型号飞机之间的损伤几何参数分布规律也高度相似,可采用统一的函数形式描述。

Smart结构及其应用

本文介绍了Ｓｍａｒｔ结构的概念，对国外有关此领域的研究及应用作了简要评述。

复合材料夹芯结构低速冲击性能研究

复合材料夹芯结构为电子设备与外层蒙皮提供了一体化设计的思路,可以大幅降低飞行器的结构重量。通过低速冲击试验和ABAQUS仿真研究了5 J和10 J冲击能量下某飞行器复合材料机翼蒙皮典型夹芯区域在低速冲击下的性能。随着冲击能量的增加,复合材料泡沫夹芯结构的能量吸收率由5 J的72.0%提升至10 J的76.0%。由仿真结果可知,当冲击能量达到10 J时,出现了纤维损伤,且损伤沿表层铺层角度扩展,基体压缩损伤主要出现在冲击正面,基体拉伸损伤主要出现在冲击背面,损伤随冲击能量的增加而变大。当冲击能量达到10 J时,上面板与泡沫芯体粘接处也产生了较大的损伤。