outer wing casing: toughened carbon horizontal stabilizer leading edge ailerons:toughened carbon flags: carbon joint fairing between wing and fuselage: trail cone Kevlar Kevlar leading edge Kevlar trailing edge carbon/Nomex 0000000g motor hood: air intake duct: carbon radome Kevlar and toughened carbon Kevlar main landing gear hatch: front landing gear Kevlar hatch:Kevlar Figure 7.8 Composite Components in the Regional Transport Aircraft ATR 72 000 wing box Figure 7.9 Business Aircraft Falcon 10 Example:Business aircraft Falcon 10 (Figure 7.9).Aircrafts(AMD-BA)(FRA). The principal wing box(primary structure)is constructed in ribbed panels of carbon/epoxy;it has been flying experimentally since 1985. Mass of wing box:339 kg Reduction of mass in comparison with conventional metallic construction: 80kg(20%) ■ The connection between the wing and the fuselage and the attachment between the landing gears and the wing box are made using metallic pieces. 2003 by CRC Press LLC
Example: Business aircraft Falcon 10 (Figure 7.9). Aircrafts (AMD–BA) (FRA). The principal wing box (primary structure) is constructed in ribbed panels of carbon/epoxy; it has been flying experimentally since 1985. Mass of wing box: 339 kg Reduction of mass in comparison with conventional metallic construction: 80 kg (20%) The connection between the wing and the fuselage and the attachment between the landing gears and the wing box are made using metallic pieces. Figure 7.8 Composite Components in the Regional Transport Aircraft ATR 72 Figure 7.9 Business Aircraft Falcon 10 TX846_Frame_C07 Page 145 Monday, November 18, 2002 12:17 PM © 2003 by CRC Press LLC
front propeller classical solution greater cockpit aerodynamic back propeller propulsive propeller solution modified mass distribution Figure 7.10 Propulsive Propeller Configuration 7.1.7 Light Aircraft These are the aircrafts for tourism and for the gliders.The new generation of these aircrafts is characterized by A large utilization of composites A renewal in aerodynamic solutions Remarks:In addition to the problems to be resolved by the manufacturers (small manufacturers for the most part,comes the preparation of the dossiers of certification including composite primary structures. The useful reduction of masses,the range of flight,and the cruising speed, due to the utilization of composites,are amplified more clearly in these types of aircrafts. Example:Back propeller aircraft.The principle of this is illustrated in Figure 7.10,with the advantages and drawbacks.The modification of the mass distribution,due to the displacement of the motor,requires a propeller shaft (foreseen to be in carbon/epoxy)and a wing shifted to the back.One can propose the“all composite”solution as follows: The solution "long shaft."Sup'air airplane Centrair (FRA);Figure 7.11 The solution of shifted wing and additional duck wing:Beech Starship aircraft(USA);Figure 7.12: Eight to ten passengers:650 km/hr with low fuel consumption Structure in carbon/epoxy Mass of the wings:800 kg (reduction of 35%in comparison with a metallic solution) Mass of fuselage (structure):240 kg Mass of the composite:about 70%of the mass of the structure 2003 by CRC Press LLC
7.1.7 Light Aircraft These are the aircrafts for tourism and for the gliders. The new generation of these aircrafts is characterized by A large utilization of composites A renewal in aerodynamic solutions Remarks: In addition to the problems to be resolved by the manufacturers (small manufacturers for the most part), comes the preparation of the dossiers of certification including composite primary structures. The useful reduction of masses, the range of flight, and the cruising speed, due to the utilization of composites, are amplified more clearly in these types of aircrafts. Example: Back propeller aircraft. The principle of this is illustrated in Figure 7.10, with the advantages and drawbacks. The modification of the mass distribution, due to the displacement of the motor, requires a propeller shaft (foreseen to be in carbon/epoxy) and a wing shifted to the back. One can propose the “all composite” solution as follows: The solution “long shaft.” Sup’air airplane Centrair (FRA); Figure 7.11 The solution of shifted wing and additional duck wing: Beech Starship aircraft (USA); Figure 7.12: Eight to ten passengers: 650 km/hr with low fuel consumption Structure in carbon/epoxy Mass of the wings: 800 kg (reduction of 35% in comparison with a metallic solution) Mass of fuselage (structure): 240 kg Mass of the composite: about 70% of the mass of the structure Figure 7.10 Propulsive Propeller Configuration TX846_Frame_C07 Page 146 Monday, November 18, 2002 12:17 PM © 2003 by CRC Press LLC
construction: glass/epoxy Figure 7.11 An All-composite Airplane Figure 7.12 Beech Starship Aircraft Example:The modern glider planes.These are made entirely of composites. Figure 7.13 shows a plane made of glass/epoxy: Two-seater glider plane:Marianne Centrair (FRA): Mass:440 kg 2003 by CRC Press LLC
Example: The modern glider planes. These are made entirely of composites. Figure 7.13 shows a plane made of glass/epoxy: Two-seater glider plane: Marianne Centrair (FRA): Mass: 440 kg Figure 7.11 An All-composite Airplane Figure 7.12 Beech Starship Aircraft TX846_Frame_C07 Page 147 Monday, November 18, 2002 12:17 PM © 2003 by CRC Press LLC
Figure 7.13 The Marianne Centrair Airplane Wings:2 parts bonded Fuselage:2 parts bonded 7.1.8 Fighter Aircraft For this type of aircraft,there is a progressive replacement of metallic elements by composite elements.Beyond specific characteristics already mentioned previ- ously for the large aircrafts,here the composite components have to assure the necessary rigidity for the wing box to conserve the ability of command in a domain of flight larger than for the case of large civil aircrafts. For the flight with electrical commands,the use of composites allows for an evolution of the aerodynamic design for better maneuverability. In the near future,25 to 40%of the structure of the fighter aircrafts will be made of composite materials. Example:European airplane Alphajet (Figure 7.14). Example:Airplane Mirage 2000 A.M.D.-B.A.(FRA;Figure 7.15).Mass of composite materials:65 kg (On this aircraft there are boron/epoxy composite components.) Characteristics of boron:The diameter of the fiber varies between 0.1 mm and 0.2 mm depending on the demand of the customer.The radius of curvature,in fact,cannot be less than 4 or 5 mm.One finds for the sheets:width is 1 m,80 filaments/cm,length:3.5 m. for the fabrics:patented process;"the warp direction consists of textile filaments,the fill direction consists of boron filaments. Example:Airplane F-18 Hornet,M.D.Douglas/Northrop (USA;Figure 7.16). Example:Airplane X-29 Grumman (USA;Figure 7.17). Example:Airplane Rafale A.M.D.-B.A.(FRA;Figure 7.18).Note that on this airplane there is a very large usage of high performance composites (carbon/ epoxy and Kevlar/epoxy).Mass of composite materials is 1,110 kg,leading to a 25%reduction in the mass of the structure.'Figure 7.18 shows the main compo- nents using composites. Patent Avions M.Dassault-Breguet Aviation/Brochier. 9 This is to compare with the number for Mirage 2000 airplane presented previously. 2003 by CRC Press LLC
Wings: 2 parts bonded Fuselage: 2 parts bonded 7.1.8 Fighter Aircraft For this type of aircraft, there is a progressive replacement of metallic elements by composite elements. Beyond specific characteristics already mentioned previously for the large aircrafts, here the composite components have to assure the necessary rigidity for the wing box to conserve the ability of command in a domain of flight larger than for the case of large civil aircrafts. For the flight with electrical commands, the use of composites allows for an evolution of the aerodynamic design for better maneuverability. In the near future, 25 to 40% of the structure of the fighter aircrafts will be made of composite materials. Example: European airplane Alphajet (Figure 7.14). Example: Airplane Mirage 2000 A.M.D.–B.A. (FRA; Figure 7.15). Mass of composite materials: 65 kg (On this aircraft there are boron/epoxy composite components.) Characteristics of boron: The diameter of the fiber varies between 0.1 mm and 0.2 mm depending on the demand of the customer. The radius of curvature, in fact, cannot be less than 4 or 5 mm. One finds for the sheets: width is 1 m, 80 filaments/cm, length: 3.5 m. for the fabrics: patented process; 8 the warp direction consists of textile filaments, the fill direction consists of boron filaments. Example: Airplane F-18 Hornet, M.D. Douglas/Northrop (USA; Figure 7.16). Example: Airplane X-29 Grumman (USA; Figure 7.17). Example: Airplane Rafale A.M.D.–B.A. (FRA; Figure 7.18). Note that on this airplane there is a very large usage of high performance composites (carbon/ epoxy and Kevlar/epoxy). Mass of composite materials is 1,110 kg, leading to a 25% reduction in the mass of the structure. 9 Figure 7.18 shows the main components using composites. Figure 7.13 The Marianne Centrair Airplane 8 Patent Avions M. Dassault-Bréguet Aviation/Brochier. 9 This is to compare with the number for Mirage 2000 airplane presented previously. TX846_Frame_C07 Page 148 Monday, November 18, 2002 12:17 PM © 2003 by CRC Press LLC
cylinder bearing carbon shell bolted on longerons ribs:light alloy vertical stabilizer fairing:glass rudder fairing:glass longeron:carbon/epoxy doors: glass rear caul:glass tips:glass karman: glass bearing fairing and wing arms:glass Figure 7.14 Alphajet Plane vertical stabilizer radio bay door box (carbon/boron carbon/boron radome: glass rudder carbon/boron landing gear hatch carbon/boron elevators carbon/boron fuselage doors Figure 7.15 Mirage Airplane 2003 by CRC Press LLC
Figure 7.14 Alphajet Plane Figure 7.15 Mirage Airplane TX846_Frame_C07 Page 149 Monday, November 18, 2002 12:17 PM © 2003 by CRC Press LLC