Structural Thermal Frictional (Brakes) Ablative/Nozzles ME ...vucoe.drbriansullivan.com/wp-content/uploads/Lecture-1-Introduction-Part-21.pdf · Structural Thermal Frictional (Brakes)

Structural

Thermal

Frictional (Brakes)

Ablative/Nozzles

1 ME 7502 Introduction - Dr. Brian J. Sullivan

Aerospace Space Marine Civil Engineering Automotive Recreational


Aerospace


Typical Aerospace Composite Applications

Cockpit components

Doors

Interiors: sidewall, ceiling and floor panels; storage and cargo bins; lavatories and galleys

Nose cones

Wheel brakes

Air conditioning ductwork

Engine components and cowlings

Pylon fairings

Leading edge slats

Ailerons

Flaps, spoilers and deflectors

Exteriors: Fuselage components

Access panels

Tail planes and elevators

Fin boxes and rudders


Airbus’ Innovative Use of Composites

Spoilers Center wing box

Horizontal tail

Vertical tail

Fuselage section


Commercial Aerospace


Military Fixed Wing

Cytec Engineered Materials Proprietary 7 ME 7502 Introduction - Dr. Brian J. Sullivan


Extensive use of Composites in Rotorcraft Applications


Business & Regional Jets

Cytec Engineered Materials Proprietary 10 ME 7502 Introduction - Dr. Brian J. Sullivan

Composites (plus skins)

F-22 Raptor 25% composite by weight

Composite usage on the F-22

Weight reduction - specific strength

Temperature performance

Stealth characteristics

Radar transparency

Lower cost 11 ME 7502 Introduction - Dr. Brian J. Sullivan

GlobalHawk UAV

UCAV X-45A


http://www.boeing.com/�

Marine Applications Rigid and flexible oil & gas

tubulars • Bulk chemical storage tanks • Racing sailboat hulls and

equipment.


Civil Engineering Applications

Repair, upgrading and retrofit of bridges, buildings and parking decks.

Selective use in composite bridge decks. Engineered lumber reinforcement


Commercial Automotive Applications

Light Truck Drive Shafts Air Bag Propellant Filters NGV Tanks Aftermarket (cosmetic parts,

brake pads) Race Car Body/Chassis,

Brakes and Clutches Motorcycle Drive Belts


Harley-Davidson



Automotive


Automotive


Recreational Applications

Tennis racquets and shoes Golf club shafts Fly fishing rods Bicycle frames and stems Snowboards Hockey sticks and skates Arrow shafts Baseball bats …...

Thornel T-300 carbon fibers have been used in a wide variety of recreational applications, including:


Bicycle and components


Recreational


http://www.goode.com/skipoles.html�

Ski Poles and Skis


http://www.goode.com/skipoles.html�

http://www.goode.com/snowskis.html�

http://www.goode.com/waterskis.html�

Wind Turbine Blades


Structural

Thermal

Frictional (Brakes)

Ablative


2X2X-- CuCu3X3X

4X4X5X5X

6X6X

1

10

100

1000

10000

0.01 0.1 1 10 100

Electrical Resistivity (µ-ohm-m)

Ther

mal

Con

duct

ivity

(W/m

K)

T-300

P-25

T-50

P-55

P-75

P-100P-120

K-1100

Vapor Grown, HTHOPG

Cu

AlMg

Ti

6xCu

3xCu

2X2X-- CuCu3X3X

4X4X5X5X

6X6X

1

10

100

1000

10000

0.01 0.1 1 10 100

Electrical Resistivity (µ-ohm-m)

Ther

mal

Con

duct

ivity

(W/m

K)

T-300

P-25

T-50

P-55

P-75

P-100P-120

K-1100

Vapor Grown, HTHOPG

Cu

AlMg

Ti

6xCu

3xCu

High Thermal Conductivity

Thermal Conductivity 2 to 3 times that of Copper

Comparison of Thermal and Electrical Behavior of Graphite 26 ME 7502 Introduction - Dr. Brian J. Sullivan

Space Applications - UHM Pitch Fibers

Lightweight satellite bus structures

Satellite antennae Solar array panels High modulus

stiffeners Avionics enclosures


Electronics Thermal Applications

Heat Dissipation Devices Clips & enclosures Heat sinks Heat pipes Thermal planes Circuit boards


Metal Matrix Cast Composites, Inc.

Discontinuous Graphite Reinforced Aluminum and Copper Example Products

Cu/Gr Power

Electronic Packaging

Al/Gr Electronic Assembly

Manufacturing Components

Al/Gr Structural Aerospace

Components

WWW.MMCCINC.COM 29 ME 7502 Introduction - Dr. Brian J. Sullivan

LMA TG 8000 TWTA Project

TWTA Units and Associated Electronics

High Gain Antenna Structure.


Thermal Devices


Structural

Thermal

Frictional (Brakes)

Ablative


• Applications – Comm. Aircraft Brakes: 777, 767,

MD-11, MD-90, Fokker 100/70, Saab 340

– Military Aircraft Brakes: B-2, F-14, F-15, F-16, F-18, F-117, and C-17

– Automotive Brakes: – Formula 1, GT and high

performance production automobiles

Brake Applications


Carbon/Carbon Brakes


Aircraft Brakes

Qualified on Major Programs Commercial Aircraft - 767, 777, MD11,

MD-90, A-330, A-340, Fokker 100

Military - F14, F-15, F-16, F-18, F-117, B-2

Business aircraft- Saab 340, Astra SPX, Falcon 900, Challenger 604


Carbon/Carbon Brakes and Clutches

Aircraft brakes are based primarily on P-25 2K and 4K.

Formula 1 race car brakes and clutches based on other pitch fiber products.

Engineered preform technology advancing rapidly


Structural

Thermal

Frictional (Brakes)

Ablative/Nozzles 37 ME 7502 Introduction - Dr. Brian J. Sullivan

Launch Vehicles and Missiles

Qualified on Major Programs Rocket nozzles: Space Shuttle, Delta

II, III, & IV, Atlas, Pegasus, Castor (H2A), Titan

Missiles: Minuteman Refurbishment, Trident, Navy Standard, Patriot, Hawk, Hellfire


Carbon/Carbon Rocket Nozzel


Design Cycle for Composite Structures

40

The design cycle for composite structures introduces the requirement to design the material as well as the structure.

ME 7502 Introduction - Dr. Brian J. Sullivan

41

Structural Designer Has To Identify Material Geometry Attachments Fabrication Procedure CMC Designer Further Specifies Fibers, Matrix, And Other Constituents Fiber Architecture And Preforming Technique

Design of Ceramic Matrix Composites


42

Design Requirements Selection of Constituents

Preforming & Fiber Architecture

Micromechanics & Theoretical Database

Thermostructural Analysis

Material Characterization And Subcomponent Testing

Composite Design Procedure


43

OPERATING ENVIRONMENT Maximum Temperature Mechanical Loads Thermochemical Environment Lifetime DESIGN GOALS Minimum Cost Minimum Weight Maximum Performance Optimize Application

Design Requirements


44

Maximum Use Temperature

Fiber

Tem

pera

ture

, °C

0

500

1000

1500

2000

2500

3000

3500

4000

Nex

tel 7

20 (C

reep

)

Tyra

nno

LOX

M

Nic

alon

(CG

)

T300

Gra

phite

(n

onox

idiz

ing)

CONSTITUENTS Fibers Matrix Fillers Fiber/Matrix Interface Coatings SELECTION CRITERIA • Thermostructural Properties • Thermochemical Behavior • Cost, Availability • Size, Handleability

Selection of Constituents Thermochemical Stability


45

Approach

PREFORM FABRICATION Hand Lay Up Filament Winding & Fiber Placement 2D Weaving & Braiding Multidirectional Weaving & Braiding FIBER ARCHITECTURE Fiber Volume Fraction Fiber Orientation Fiber Proportions

Preform Fabrication And Fiber Architecture


46

Approach

Matrix Modulus, Msi

20 30 40 50

Com

posi

te M

odul

us, M

si

0

10

20

30

40

50

DirectionAirfoil Radialvf = 0.40Multi-D Braid

36.6 Msi

36.5 Msi

SCS6-Nicalon/ SiC

Matrix Modulus

Composite Modulus

EFFECTIVE MATRIX MODULUS

Models Based On Fundamental Elasticity • Hashin, J. Appl. Mech, Sept. 1979 • Jones, Mech of Composite Matls, 1975 • Rosen, ASTM, STP 617, 1977 • Pagano, Composite Sci. and Tech, 1988. Data Correlation • Theoretical Model Correlated With Available Data • Theory Exercised For Properties Vs. Fiber Architecture

Micromechanical Modeling


47

Effects of Fiber Architecture

Axial Tensile Strength

Braid Architecture

Axia

l Ten

sile

Stre

ngth

(ksi

)

0

10

20

30

40

50

60

70

80 Braided C/SiCvf = 40 percentT = 2000°F

45-7

5

45-5

0

45-2

5

80-2

5

80-5

0

80-7

5

60-2

5

60-5

0

60-7

5Hoop Tensile Strength

Braid Architecture

Hoo

p Te

nsile

Stre

ngth

(ksi

)

0

10

20

30

40

50

60

70Braided C/SiCvf = 40 percentT = 2000°F

45-7

5

45-5

0

45-2

5

80-2

5

80-5

0

80-7

5

60-2

5

60-5

0

60-7

5

a Braid designation identifies braid angle and proportion of braiding fibers, i.e., 45-75 implies 45° braid angle (0°=axial) and 75 percent braid fibers.

Micromechanical Modeling


48

Modeling Issues

ANSYS 5.5.3 JUN 21 200011:51:18 ELEMENTS

1 2

X

Y

Z

XV =-.819735 YV =.300779 ZV =.487408

*DIST=7.145 *XF =2.502 *YF =5.481 *ZF =-3.347 A-ZS=-11.918 PRECISE HIDDEN

XY

Z

WIND=2 XV =-.82 YV =.3 ZV =.5

*DIST=1.666 *XF =-.973536 *YF =3.887 *ZF =-6.31 A-ZS=-2.033 PRECISE HIDDEN

• Include Effects of Anisotropy • Couple Transient Heat Transfer & Stress Analysis • Compute Stresses At Times Of: - Maximum Thermal Gradient - Maximum Mechanical Load - Maximum Temperature - Critical Events • Define Design Stress - Matrix Cracking (SiC-Based) - Creep Stress (Oxide/Oxide) • Maximum Stress Failure Criterion



49

Optimized Fiber Architecture

80-75 Braid Margins of Safety

Mar

gin

of S

afet

y

0

1

2

3

4

Axi

al

Hoo

p

Thru

-Thi

ckne

ss

Inte

rlam

inar

She

ar80-50 Braid Margins of Safety

Mar

gin

of S

afet

y

0

1

2

3

4

Axi

al

Hoo

p

Thru

-Thi

ckne

ss

Inte

rlam

inar

She

ar

80-25 Braid Margins of Safety

Mar

gin

of S

afet

y

0

1

2

3

4

Axi

al

Hoo

p

Thru

-Thi

ckne

ss

Inte

rlam

inar

She

ar

Margins of Safety = Strength/Stress - 1 Select Fiber Architecture For Balanced Margins of Safety



50

Test Critical Properties

• Thermostructural Analysis Defines Critical Properties And Temperatures • Property Tests Must Address Anisotropy, Specimen Size, Fiber Architecture • Correlate Micromechanical Model • Use Model To Compute Consistent Orthotropic, Temperature Dependent Properties

Material Characterization


51

Test Critical Design Features

Subcomponent Testing

• Confirm Design With Subcomponent Tests - Critical Loads And Design Features, e.g. attachment regions • Analyze Subcomponent Test To Insure Test Matches Operation • Predict Behavior Prior To Test • Perform Post-Test Data Correlation

Test run on May 13, 2004 in DFRC Flight Loads Lab.

Photo taken at 2400° F. Orange glow is test article emitting visible light. Sensors can be seen as shadows

on test article. ME 7502 Introduction - Dr. Brian J. Sullivan

52

MATRIX ALGEBRA

{ }

[ ]

[ ] kl

ij

k

I

aaaaaaaaaa

a

xxxx

x

δ;100010001

;

;

333231

232221

131211

3

2

1

=

=

=Column matrix:

Square matrix:

Unit matrix:

Diagonal matrix: [ ]

[ ]

=

=

000000000

0

000000

33

22

11

dd

dd

Null matrix:

TYPES:


53

MATRIX OPERATIONS

[ ] [ ] [ ] [ ]

[ ][ ] [ ][ ]

[ ] [ ] [ ]( ) [ ][ ] [ ][ ] [ ][ ] [ ][ ][ ] [ ][ ] [ ] [ ]{ } { } ilil

jkjkij

dxacolcolsqaIaaIcbasqsqsqbcacbac

abbabababababababababababa

ba

abbabababa

ba

====

==+=+

≠

++++++++

=

+=

++++

=+

321

322322221221312321221121

321322121211311321121111

22222121

12121111

.........

...

...

.........

...

...

[ ][ ] [ ] ,cba = [ ] [ ] [ ] [ ] [ ][ ] 11 , −− == bcacab

Addition (subtraction):

Multiplication:

If then

Transpose [ ] jiTij

T aaaaaaaaaaa

a =

=

332313

322212

312111


54

Matrix Inverse

Cofactor

Determinant

Inverse

[ ]

( )[ ]

[ ] ( )[ ]

[ ] [ ] [ ][ ] [ ] { } { }

{ }

{ } [ ]{ } { }{ }

{ }{ }

[ ] [ ][ ] [ ]

{ }{ }

{ } [ ]{ } [ ]{ } { } [ ]{ } [ ]{ }βαδβαγ

βα

δγ

δγ

δδδγγγ

βα

βββααα

dcba

dcba

feg

fdcba

dc

dcbaaabaaabbbaaa

e

aaCofa

subaasubaasubaasubaa

aCof

aaaaaaaaaaaaaaaaaDet

T

+=+=

=

=

==

=

=

=

=

=

=

−+−+−==

−

;

;

321321

;

..........................................

......

......

.........

...

...

)()()(

3

2

1

3

2

1

3333

1111

33333231

23232221

131211131211

1

22222121

12121111

312232211333213123123223332211

Partitioning


55

Best bet:

USE MATHCAD


Structural Thermal Frictional (Brakes) Ablative/Nozzles ME ...vucoe.drbriansullivan.com/wp-content/uploads/Lecture-1-Introduction-Part-21.pdf · Structural Thermal Frictional (Brakes)

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