Sikorsky August 21 2017 This document does not contain export controlled technical data This work was sponsored by the Office of Naval Research ONR under contract number N0001415C0119 the views and conclusions contained herein are those of the authors and should not be interpreted as nec ID: 693903
Download Presentation The PPT/PDF document "Advanced Integrated Composite Repair" is the property of its rightful owner. Permission is granted to download and print the materials on this web site for personal, non-commercial use only, and to display it on your personal computer provided you do not modify the materials and that you retain all copyright notices contained in the materials. By downloading content from our website, you accept the terms of this agreement.
Slide1
Advanced Integrated Composite RepairSikorskyAugust 21, 2017
This document does not contain export controlled technical data.
This work was sponsored by the Office of Naval Research, ONR, under contract number N00014-15-C-0119; the views and conclusions contained herein are those of the authors and should not be interpreted as necessarily representing the official policies or endorsements, either expressed or implied, of the Office of Naval Research, the U.S. Navy or the U.S. government.Distribution Statement A. Approved for public release; distribution unlimited
Copyright 2017 Lockheed Martin CorporationSlide2
2Modeling and Structural AnalysisAdditive Manufacturing & PrototypesBehavior Modeling and SimulationStructural Testing
Design and Analysis
Acknowledgements
George Bauer
Mark Gurvich
Jim Lua
Kevin Dyer
Errick Robles
Matt Gaspin
Structural AnalysisSlide3
3Advanced Integrated Composite RepairSikorsky / Jonathan Garhart
Approach
Identify optimal materials, manufacturing and analytical technologies to enable the development of a lean composite repair cell based on 3D scanning,
a
dditive tooling and advanced laminate analysis.
Conduct coupon testing to develop laminate and bond properties for use in patch modeling and analysis.
Execute manufacturing trials to validate process in a sub-element scale representative setting.
Conduct
element
testing to demonstrate feasibility and structural integrity of patch fabrication and application methods.Slide4
4Advanced Integrated Composite RepairSikorsky / Jonathan GarhartHigh performance composites enable an expansion of the range of field repairs over current wet layup and fastened approaches.Integrated field repair system expands shipboard maintenance options leading to increased aircraft availability.Automated system reduces labor content and quality variability while improving process efficiency.
Benefits
Elements of Novelty
Curing laminate off repair site allows for higher temperature cure of high performance material.
RT storage prepreg eliminates wet lay up without requiring freezer storage.
Latest scanning and 3D printing technology yield rapid and accurate tooling.Slide5
System Specification5Slide6
6MaterialPatz IM7/PMT-F31 Plain WeaveRoom temp storage Benzoxazine ScanningCreaform: HandySCAN 3D™ High resolution hand held laser scannerAdditive Tooling FabricationStratasys Fortus 400 MC14” x 16”x 16” envelop FDM printerAdditive Tooling Materials
UltemTM 1010
215 C capable thermoplasticBond Surface PreparationSurfx AtomFloTM 500 Plasma etching
for bond surface prep
System components selected and interactivity validated
Surfx Atomflo
TM
500
HandySCAN 3D™
Image courtesy of Stratasys
Fortus 400 MC
System Specification Slide7
Repair Design & Analysis7Slide8
8Damage Site Scan Surface DataParametric Repair ModelTooling Design3D Printed Tool
3D Print Data
Local Structural Criteria CAD/FE Model
Micromechanics
Model
-
Analytic Methods
Optimized Repair Design
Laminate Configuration
Laminate Configuration
Ply Data
Fabricate
Repair Laminate
Data
Action / Product
Abaqus
Ansys
Repair Bonding
Surface Prep
Space Claim
Model Generation
Repair Process FlowSlide9
ObjectiveVerify fidelity of fracture mechanics modeling predictions through the comparison analytical and empirical results.ApproachEstablish a specimen configuration that incorporates the features of a typical repair and which can be loaded to induce desire failure modes. Conduct a series of analytical evaluations of various repair and material configurations to determine the relationship between performance and specific attributes. Conduct physical testing of specific configurations to compare response and failure modes to predictions.9
Model Validation
Analytic model validated through coupon testingSlide10
10Specimen Configuration3.0”20.0”
4 Point Bend Test Setup Induces Tension in Repair Patch/Sandwich Skin Interface
2.25”
Up To 9.25” Patch Region
Representative repair and standardized test methodSlide11
Manufacturing Demonstration11Slide12
ObjectiveValidate all phases of the integrated repair process and interoperability of individual systems through the execution of a full scale repair trail.ApproachComplete a skin laminate and core repair on a demonstration trial article with a structural configuration similar to a typical rotorcraft airframe component. The execution of the repair will utilize all aspects of the integrated system in a manner fully consistent with proposed deployed configuration.12Demonstration PlanDemonstration validates process methodsSlide13
Section of Airfoil componentCarbon skins over aluminum honeycomb core13Demonstration ArticleRepresentative composite structure provided by NavAirSlide14
14
Repair Preparation
Core Septum Installed to Seal Off Core
Damaged Skin and Core Removed
Core Filled and Faired Registration Holes Added
Remove Primer & Prepare Site
Standard methods and tools used to prepare repair siteSlide15
15
Article
ScanningHandySCAN 3D™ System
Scan Process
Surface Data
Surface data acquisition and processing optimized
3
R
esolution levels evaluated
Surface characteristics effect data capture
Data
post processed in Space
Claim
Engineered surface output as basis for tool designSlide16
Tool and Repair Fabrication16
Tool Modeling
3D Print Tool
Cure Patch
Etch Surface
Bond Repair
Manufacturing Trial verifies process capability
Tool design process established
Tooling construction optimized
Minimize build time & density
Maintain structural integrity
Laminate OoA processes methods establishedSlide17
Full Scale Test17Slide18
18Full Scale Repair Test PlanValidate manufacturing repair and process technologies.Establish baseline panel pristine static & fatigue strength Exercise system-wide repair process:Induce specific damage, optimize repair, design patch construction.Execute repair and test: establish static and fatigue repair strength capabilities.Program focus: aircraft sandwich skin structure.Susceptible to damage, relatively large surface/exposure area.Primarily carrying aircraft shear loading.Engineer full scale test to:Test repaired sandwich skin shear load capabilities.Limit test fixture influence and unexpected failure modes.Slide19
19Repair Test PlanTestStatic/FatigueType1StaticPristine2FatiguePristine3StaticRepaired
4FatigueRepaired
5StaticRepaired w/Defect6Fatigue
Repaired w/Defect
Static/Fatigue Test Approach:
First test static article to determine ultimate failure load.
Measure panel shear strains. Scan article as needed.
Cycle fatigue test article at load of 2/3 ultimate strength.
If no failure or detectable growth is noticed, increase cyclic load by 10%
P = ~60,000
lbf
PSlide20
System elements selected and integratedAutomated repair modeling approach establishedFracture mechanics model completed / validation proceedingManufacturing trial processes validatedFull scale tool completeMaterial characterization testing in processFull Scale test plan approved by NavAir20Summary - Conclusions