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Design, Analysis, and Test Development of Full-Scale Fuselage Test Panels to Assess Emerging Metallic Structures Technologies
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2024-11-01
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[PDF-25.35 MB]
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Abstract:The aircraft industry is striving to improve structural performance and reduce costs in fabrication, operation, and maintenance by introducing advanced designs/materials in conjunction with advanced manufacturing/assembly technologies. Collectively these technologies are referred to as Emerging Metallic Structures Technologies (EMST). Prior tests by Arconic on large scale flat panels have demonstrated the potential for durable and damage tolerant fuselage concepts utilizing EMST. However, full-scale fuselage curved panel testing was needed under representative pressure and bending loads to fully demonstrate the improved damage tolerance and residual strength at the aircraft structural level. A collaborative effort between Arconic, Embraer, NIAR and FAA was established to design, build, and test full-scale panels representing EMST concepts. Technologies being considered include advanced metallic skin alloys 2029 and 2060 Al-Li, Al-Li 2055 stringers and Al-Li 2099 integral frames, and Glass Reinforces Aluminum Laminates (GLARE) Fiber Metal Laminate (FML) strap reinforced fuselage skins. This report describes the sizing and loading methodologies used to design baseline Panel 1 for a generic single-aisle aircraft. Crown panels were built and tested for longitudinal and circumferential repeat inspection damage scenarios in the FAA’s Full-Scale Aircraft Structural Test and Evaluation (FASTER) facility, which was developed for full-scale testing of fuselage structures under simulated flight loading conditions. Panel 1 is representative of the current design and construction (2524-T3 skin with 7150-T77511 stringers and 7075-T62 shear tied frames) of transport category airplane structure. The panel was sized, and the FASTER test fixture loading was developed to represent fuselage structure located at the crown of the airplane, and forward of the wing where damage tolerance was determined to be the key sizing criterion in both the longitudinal and circumferential direction. Manufacturing differences in skin pocket thickness were accounted for by testing Panels 1 – 3 to the same stress intensity factors based on finite element (FE) analysis. A mesh convergence study was conducted. Final stress intensity solutions were provided for both the longitudinal and circumferential crack growth directions. The Panel 1 circumferential crack growth constant amplitude loading was developed using K-control Middle tension ((M(T)) testing by equating the spectrum K-control results to those of an “equivalent” constant amplitude K-control load.
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