Abstract. This work presents some of the most recent advances in the technologies which could enable accurate assessment of useful life for composite aircraft fatigue-critical, flight-critical components and structure. Such technology advances include: (1) nondestructive subsurface measurement shift from just detection of defects to three-dimensional measurement of defect location and size; (2) material characterization methods ability to generate 3D material allowables at minimum time and cost; and (3) fatigue structural analysis techniques ability to capture multiple damage modes and their interaction. The authors summarize their recent results in all three subjects.
BackgroundCurrently, composite designs adopt metal design philosophy and use the same factor of safety of 1.5 to determine the ultimate design load from the limit load even though composite parts are inherently more susceptible to variations in manufacturing processes than metal parts. In addition to material variation in the resin content, bulk factor, and fiber alignment, part fabrication process variations such as operator skill, tooling setup, humidity fluctuation, equipment control, etc. are common causes that contribute to variation in part quality. Consequently, the increased sensitivity of composite part quality to material and process variations lowers production yields. In order to increase production yields, heavy burden is placed on composite manufacturing communities to understand and control their processes. Production yields of greater than 90% remain a "hit-and-miss" target.The effects of manufacturing process parameters on structural strength, durability and damage tolerance are not well understood. In particular, the effects of inadequate design method and manufacturing process used to produce carbon/epoxy and glass/epoxy composite aircraft fatigue-critical, flight-critical components manifest themselves as defects such as wrinkles and porosity/voids, and such defects impact the performance and the service life of these components.Manufacturing defects can severely deteriorate the matrix-dominated properties resulting in degraded strength and fatigue structural performance of composites. * Oral presentation.