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Structural Integrity of Hybrid Metal Composite Structures in a Fighter Aircraft

Structural Integrity of Hybrid Metal Composite Structures in a Fighter Aircraft. Presented at Flygteknik 2010 – Stockholm, October 18-19, 2010. NFFP – Structural Assessment of Hybrid Structures

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Structural Integrity of Hybrid Metal Composite Structures in a Fighter Aircraft

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  1. Structural Integrity of Hybrid Metal Composite Structures in a Fighter Aircraft Presented at Flygteknik 2010 – Stockholm, October 18-19, 2010

  2. NFFP – Structural Assessment of Hybrid Structures • Research programme aiming to develop the required methodology and data to certify complex metal/composite hybrid assemblages subjected • to in-flight coupled thermo-mechanical load spectra. • Focused on test verification techniques to cover the significant effects of: • Thermal induced stresses - dissimilar thermal expansion - heat transfer into structure - speed & altitude - surrounding temperature • Load sequences • - rare high peak loads • - frequent small load ranges

  3. Wing – Fuselage Attachment A/B/C/D - versions E/F - versions

  4. Full-scale fatigue test of complete airframe and sub assemblages

  5. sxTemp P high LT syFlight txyFlight P low LT syFlight syTemp txyFlight Coupled thermo-mechanical load cases

  6. Typical temperatures (MIL-STD-1530C) 100oC 85oC Gripen E/F – temperatures for static loads Sustained – through all structure: -40oC g +94oC

  7. Example – Super Sonic Fighter Sweep

  8. sxTemp P LT syFlight txyFlight Flight and temperature loads Stagnation Temperature To Heat transfer

  9. Detailed FE-analysis of complete wing

  10. 64 Aluminium 32 16 10 70 156 36 228 228 50 20 20 32 32 20 D= 8 D = 8 16 156 36 160 2 x composite 232 9,4 9,4 Fatigue testing of specimens exposed to heating

  11. Dissimilar failure mechanisms – metal / composite Load sequence effects – retardation / accelerations • Metal • predominating singel crack • Composites • matrix cracking • delamination • fiber breakage • interfacial debonding

  12. Fatigue test verification of metal and composite structure Truncation or extension of high loads composites (to verify life also for aircraft exposed to rare high loads) metals (to verify life also for aircraft not exposed to rare high loads) Load ranges Elimination of insignificant load cycles Mean maneuver load spectra for one service life e.g. 8,000 hrs. composites metals Log number of cycles

  13. Participants – NFFP project Zlatan Kapidzik Lars Djärv Martin Ekström Hans Ellström Jonas Wahlbäck Hans Ansell Joakim Schön Rolf Jarlås Anders Blom Börje Andersson

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