ALBERT

Beschreibung: NASA and the Boeing Co. have been working together under the Environmentally Responsible Aviation Project to develop stitched unitized structure for reduced weight, reduced fuel burn and reduced pollutants in the next generation of commercial aircraft. The structural concept being evaluated is PRSEUS (Pultruded Rod Stitched Efficient Unitized Structure). In the PRSEUS concept, dry carbon fabric, pultruded carbon rods, and foam are stitched together into large preforms. Then these preforms are infused with an epoxy resin into large panels in an out-of-autoclave process. These panels have stiffeners in the length-wise and width-wise directions but contain no fasteners because all stiffeners are stitched to the panel skin. This document contains a description of the fabrication of panels for use in the 30-foot-long Multi-Bay Box test article to be evaluated at NASA LaRC. The document also describes a panel which explores new PRSEUS concepts for applications beyond the Multi-Bay Box.

Beschreibung: The Pultruded Rod Stitched Efficient Unitized Structure (PRSEUS) concept, developed by The Boeing Company, has been extensively studied as part of the National Aeronautics and Space Administration's (NASA s) Environmentally Responsible Aviation (ERA) Program. The PRSEUS concept provides a light-weight alternative to aluminum or traditional composite design concepts and is applicable to traditional-shaped fuselage barrels and wings, as well as advanced configurations such as a hybrid wing body or truss braced wings. Therefore, NASA, the Federal Aviation Administration (FAA) and The Boeing Company partnered in an effort to assess the performance and damage arrestments capabilities of a PRSEUS concept panel using a full-scale curved panel in the FAA Full-Scale Aircraft Structural Test Evaluation and Research (FASTER) facility. Testing was conducted in the FASTER facility by subjecting the panel to axial tension loads applied to the ends of the panel, internal pressure, and combined axial tension and internal pressure loadings. Additionally, reactive hoop loads were applied to the skin and frames of the panel along its edges. The panel successfully supported the required design loads in the pristine condition and with a severed stiffener. The panel also demonstrated that the PRSEUS concept could arrest the progression of damage including crack arrestment and crack turning. This paper presents the nonlinear post-test analysis and correlation with test results for the curved PRSEUS panel. It is shown that nonlinear analysis can accurately calculate the behavior of a PRSEUS panel under tension, pressure and combined loading conditions.

Beschreibung: Integrally stitched composite technology is an area that shows promise in enhancing the structural integrity of aircraft and aerospace structures. The most recent generation of this technology is the Pultruded Rod Stitched Efficient Unitized Structure (PRSEUS) concept. The goal of the PRSEUS concept relevant to this test is to provide damage containment capability for composite structures while reducing overall structural weight. The National Aeronautics and Space Administration (NASA), the Federal Aviation Administration (FAA), and The Boeing Company have partnered in an effort to assess the damage containment features of a full-scale curved PRSEUS panel using the FAA Full-Scale Aircraft Structural Test Evaluation and Research (FASTER) facility. A single PRSEUS test panel was subjected to axial tension, internal pressure, and combined axial tension and internal pressure loads. The test results showed excellent performance of the PRSEUS concept. No growth of Barely Visible Impact Damage (BVID) was observed after ultimate loads were applied. With a two-bay notch severing the central stringer, damage was contained within the two-bay region well above the required limit load conditions. Catastrophic failure was well above the ultimate load level. Information describing the test panel and procedure has been previously presented, so this paper focuses on the experimental procedure, test results, nondestructive inspection results, and preliminary test and analysis correlation.

Beschreibung: Stitched composite technology has the potential to substantially decrease structural weight through enhanced damage containment capabilities. The most recent generation of stitched composite technology, the Pultruded Rod Stitched Efficient Unitized Structure (PRSEUS) concept, has been shown to successfully arrest damage at the sub-component level through tension testing of a three stringer panel with damage in the form of a two-bay notch. In a joint effort undertaken by the National Aeronautics and Space Administration (NASA), the Federal Aviation Administration (FAA), and the Boeing Company, further studies are being conducted to characterize the damage containment features of the PRSEUS concept. A full-scale residual strength test will be performed on a fuselage panel to determine if the load capacity will meet strength, deformation, and damage tolerance requirements. A curved panel was designed, fabricated, and prepared for residual strength testing. A pre-test Finite Element Model (FEM) was developed using design allowables from previous test programs to predict test panel deformation characteristics and margins of safety. Three phases of testing with increasing damage severity include: (1) as manufactured; (2) barely visible impact damage (BVID) and visible impact damage (VID); and (3) discrete source damage (DSD) where the panel will be loaded to catastrophic failure. This paper presents the background information, test plan, and experimental procedure. This paper is the first of several future articles reporting the test preparations, results, and analysis conducted in the test program.

Beschreibung: Advanced aircraft configurations that have been developed to increase fuel efficiency require advanced, novel structural concepts capable of handling the unique load conditions that arise. One such concept is the Pultruded Rod Stitched Efficient Unitized Structure (PRSEUS) developed by the Boeing Company. The PRSEUS concept is being investigated by NASA s Environmentally Responsible Aviation (ERA) Program for use in a hybrid-wing body (HWB) aircraft. This paper summarizes the analysis and test of a PRSEUS panel subjected to internal pressure, the first such pressure test for this structural concept. The pressure panel used minimum gauge skin, with stringer and frame configurations consistent with previous PRSEUS tests. Analysis indicated that for the minimum gauge skin panel, the stringer locations exhibit fairly linear response, but the skin bays between the stringers exhibit nonlinear response. Excellent agreement was seen between nonlinear analysis and test results in the critical portion at the center of the panel. The pristine panel was capable of withstanding the required 18.4 psi pressure load condition without exhibiting any damage. The impacted panel was capable of withstanding a pressure load in excess of 28 psi before initial failure occurred at the center stringer, and the panel was capable of sustaining increased pressure load after the initial failure. This successful PRSEUS panel pressure panel test was a critical step in the building block approach for enabling the use of this advanced structural concept on future aircraft, such as the HWB.

Beschreibung: NASA has created the Environmentally Responsible Aviation Project to develop technologies which will reduce the impact of aviation on the environment. A critical aspect of this pursuit is the development of a lighter, more robust airframe that will enable the introduction of unconventional aircraft configurations. NASA and The Boeing Company are working together to develop a structural concept that is lightweight and an advancement beyond state-of-the-art composites. The Pultruded Rod Stitched Efficient Unitized Structure (PRSEUS) is an integrally stiffened panel design where elements are stitched together and designed to maintain residual load-carrying capabilities under a variety of damage scenarios. With the PRSEUS concept, through-the-thickness stitches are applied through dry fabric prior to resin infusion, and replace fasteners throughout each integral panel. Through-the-thickness reinforcement at discontinuities, such as along flange edges, has been shown to suppress delamination and turn cracks, which expands the design space and leads to lighter designs. The pultruded rod provides stiffening away from the more vulnerable skin surface and improves bending stiffness. A series of building blocks were evaluated to explore the fundamental assumptions related to the capability and advantages of PRSEUS panels. These building blocks addressed tension, compression, and pressure loading conditions. The emphasis of the development work has been to assess the loading capability, damage arrestment features, repairability, post-buckling behavior, and response of PRSEUS flat panels to out-of plane pressure loading. The results of this building-block program from coupons through an 80%-scale pressure box have demonstrated the viability of a PRSEUS center body for the Hybrid Wing Body (HWB) transport aircraft. This development program shows that the PRSEUS benefits are also applicable to traditional tube-andwing aircraft, those of advanced configurations, and other structures where weight and through-the-thickness strength are design considerations. An overview of the development of PRSEUS technology for commercial transport aircraft is the subject of this paper.

Beschreibung: NASA and the Boeing Company have been working together under the Environmentally Responsible Aviation Project to develop stitched unitized structure for reduced weight, reduced fuel burn and reduced pollutants in the next generation of commercial aircraft. The structural concept being evaluated is PRSEUS (Pultruded Rod Stitched Efficient Unitized Structure). In the PRSEUS concept, dry carbon fabric, pultruded carbon rods, and foam are stitched together into large preforms. Then these preforms are infused with an epoxy resin into large panels in an out-of-autoclave process. These panels have stiffeners in the length-wise and width-wise directions but contain no fasteners because all stiffeners are stitched to the panel skin. This document contains a description of the fabrication of panels for use in the 30-foot-long Multi-Bay Box test article to be evaluated at NASA LaRC.

Beschreibung: This report describes the development of a novel structural concept, Pultruded Rod Stitched Efficient Unitized Structure (PRSEUS), that addresses the demanding fuselage loading requirements for the Hybrid Wing or Blended Wing Body (BWB) airplane configuration. In addition to the analytical studies, a three specimen test program was also completed to assess the concept under axial tension loading, axial compression loading, and internal pressure loading.

Beschreibung: A series of single-frame and single-stringer compression tests were conducted at NASA Langley Research Center on specimens harvested from a large panel built using the Pultruded Rod Stitched Efficient Unitized Structure (PRSEUS) concept. Different frame and stringer designs were used in fabrication of the PRSEUS panel. In this paper, the details of the experimental testing of single-frame and single-stringer compression specimens are presented, as well as discussions on the performance of the various structural configurations included in the panel. Nonlinear finite element models were developed to further understand the failure processes observed during the experimental campaign.

Beschreibung: This report summarizes work performed by The Boeing Company, through its Boeing Research & Technology organization located in Huntington Beach, California, under the Environmentally Responsible Aviation (ERA) project. The report documents work performed to structurally analyze and assemble a large-scale Multi-bay Box (MBB) Test Article capable of withstanding bending and internal pressure loadings representative of a Hybrid Wing Body (HWB) aircraft. The work included fabrication of tooling elements for use in the fabrication and assembly of the test article.