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Instructor Notes
Introduction
A suggested schedule:
Class 1:
Pre-test 10 minutes
Presentation 40 minutes
Class 2:
Review 10 minutes
Activities 20 minutes
Post-test 20 minutes
Charles Goodyear added sulfur and heat to rubber to create a tough, durable form
that could be molded into shapes.
Rubber has become critical for the production of tires, seals and gaskets
Currently, many applications that used natural rubber have been replaced by
synthetic rubbers with high temperature, hardness or degradation resistance.
Rubber is an elastomer, meaning it can be made to stretch great lengths and return
to its original shape.
The Wright Brothers made their first controlled self-propelled flight on December
17th, 1903 at Kill Devil Hills near Kitty Hawk North Carolina.
Image Shown: The Wright Flyer at the National Smithsonian Museum of Flight.
The fabric was stretched over the spruce frame and coated with sealant.
This initial skin structure performed much like the sails of ships.
The Wright Brothers engine was a large part of their success in flight.
In 1903 most engines were constructed with cast iron which is roughly 3 times the
weight of aluminum per unit volume.
Many engines of the time were steam engines and did not have high horsepower
for their weight.
The Wright Brothers surveyed engine manufacturers of the time; none could make
an affordable, lightweight engine with enough power.
Plastics had been discovered prior to 1907, but Leo Hendrik Baekeland refined
plastic production to create a product called bakelite. This new plastic could be
molded into any shape and proved to be stronger and more durable than previous
types. Thus a new material type was available for control knobs, and electrically
insulating parts.
In 1915 Hugo Junkers built the first all metal airplane using a tubular structure
covered with corrugated sheet iron. This was a step away from the limitations of
using only natural wood materials with fixed properties.
Why stressed-skin?
The stressed skin concept combines the support structure and the aircrafts skin.
If the aircraft is built using a skeleton structure it would still require a skin for
aerodynamics, but if the skin is made stiff enough to resist tension and
compression, a skeleton structure is not required. If the correct design and
materials are chosen, a weight savings can be achieved.
Image Shown: Space frame construction fuselage that does not use stressed-skin.
In 1925 Henry Ford purchased the Stout Metal Airplane Company. The aircraft
designed and built were based on the previous work of Junkers.
In full monocoque construction, the skeletal ribs, spars and stiffeners would be
eliminated- only a structural skin would be used.
Note that the Ford Tri-motor used a corrugated skin to increase its stiffness. It
was later determined that this surface roughness created much drag.
Sheet metal skin, riveted lamination sheet metal ribs and formed stringers all
riveted together.
Starting with the initial flight of the Wright Brothers, aluminum saw
increased use as it was produced cheaper and with better properties.
In the early 1930s wood and wire construction was still competitive with early
aluminum construction.
Duralumin, an alloy of aluminum with copper added had been developed in 1903
by German metallurgist Alfred Wilm. The addition of copper allowed the
material to become stronger with age, but created corrosion problems especially
in salt water environments.
The United States Navy funded the development of Alclad- which consisted of
duralumin with pure aluminum coating to protect the alloy from corrosion.
In 1931 the Budd Company built the BB-1 Pioneer out of stainless steel sheet and
strip using newly developed spot welding technologies. The design was Italian in
origin and used sheet metal frame, sheet metal skinned fuselage and floats, and
fabric covers wings and control surfaces.
The Budd Company was the leader in building railcar which used large amounts
of stainless steel. The company viewed stainless steel aircraft as a way to expand
business and solve the corrosion issues associated with duralumin.
This aircraft was a flying boat configuration and performed as expected, logging
roughly 1000 flight hours.
Image Shown: The Budd BB-1 Pioneer on display outside the Franklin Institute
in Philadelphia.
Slide 15 Steel/ Stainless Steel vs. Aluminum
Stainless steel alloys generally have better corrosion resistance than aluminum
Aluminum is roughly 1/3 the weight of stainless steel
Stainless has been more costly
Thin stainless sheet is been susceptible to buckling failure than thicker aluminum
sheet of the same weight
For a simple beam structure under a bending load, the top surface of the beam in
loaded in compression, while the bottom surface is loaded in tension.
If the structure is changed to a tube, like a fuselage, the top skin is loaded in
compression and the bottom is in compression. If the skin is too thin, the top
surface in compression will buckle like an empty stepped on soda can.
Image Shown: A simple beam under loading, and a large sheet metal test sample
demonstrating buckling failure.
Sheets were made commercially available by 1936 and quickly adapted for
optical applications including aircraft windscreens and canopies.
The material is light, transparent, good impact resistance and is easily molded or
formed. It also weathers the environment well and will not yellow from UV
radiation.
Fiberglass was first produced by accident at Corning Glass by blowing air into
molten glass by researcher Dale Kleist. By the late 1930s fiberglass was being
spun to create cloth. In 1941 it was discovered that heat treating the fibers gave
increased flexibility which is key to use in composites.
Early in World War II, British agents stole the secrets to making polyester resin
which was given to American manufacturing firms to use as matrix material to
hold the fiberglass together. By 1942 Owens-Corning was producing aircraft
cockpit components from the fiberglass polyester composite materials.
Aircraft noses are often constructed from fiberglass to house the radar systems
and allow radio frequency transmission.
Before World War II iron based alloys were developed for high temperature
work. The war increased demand of performance materials for turbochargers and
jets.
A superalloy is defined as a metal that has high strength and creep resistance at
high temperatures, in addition to corrosion resistance.
Superalloys are now cobalt, nickel or nickel-iron based and some are grown as
single crystals. A typical application is jet engine turbine blades.
Superalloys are known with such names as: Hastelloy, Inconel, Waspaloy, Rene
alloys and others.
The National Lead Co. had been studying titanium for several years prior as a
replacement for stainless steel in some applications.
It was noted that the metal resisted corrosion, resisted acids and had high strength.
Titanium was identified as a strategic material for aircraft, 40% lighter than
stainless steel and a focal point for Cold War production.
Estimated weight savings per aircraft using titanium were 400 to 4,000 pounds
per engine depending on the size of the aircraft.
The Mach 3.2 capable A-12 and its replacement, the SR-71 were both largely
built from titanium to withstand the high temperatures generated at speed.
Image Shown: The A-12, the precursor to the SR-71.
Carbon fiber can be made to a tensile strength roughly 5 times that of steel.
It is typically used with epoxy resins or other plastic to form a matrix that keeps
the fibers together.
Rolls-Royce developed the RB211-06 engine for the Lockheed L-1011 airliner.
Rolls-Royce decided to use Hyfil, a newly developed carbon fiber from Royal
Aircraft Establishment at Farnborough for the fan stage.
Unfortunately the development costs for the new engine and materials in a
fiercely competitive market forced Rolls-Royce into bankruptcy and required a
government bailout.
Images Shown: The RB211 turbofan jet engine, and woven carbon fiber.
Boron fibers were discovered to have higher strength than carbon fibers.
The F-14 jet fighter was the first aircraft produced with boron composites
included in the initial design
The Space Shuttle uses thermal insulation made from 99.9% pure silica glass
fibers and 94% by volume air.
This light ceramic, with a density of 9 pounds per cubic foot allows the shuttle to
survive re-entry into the Earths atmosphere at Mach 25.
The material is called LI-900 and is manufactured by Lockheed into tiles which
are glued onto the Shuttle.
Lithium is the worlds lightest metal, and its addition to aluminum, decreases
weight, improves strength, toughness, corrosion resistance, and formability.
The Space Shuttle external fuel tank was changed to aluminum lithium alloy in
1998 bringing its weight from 66,000 lbs. to 58,800 to increase payload capacity.
The new Airbus A350 uses a considerable amount of aluminum-lithium for the
wings and fuselage, this amount is reported to be as high as 20%.
Image Shown: The Space Shuttle launching, the large center tank is the external
fuel tank.
This ends up being 35 tons per aircraft of carbon fiber and plastic composite of
which 23 tons is carbon fiber.
This widespread use of composites will make the 787 nearly 20% more efficient
than the earlier 767 of similar size and role.
Imbedded sensors:
Stress/Strain
Impact/Damage
Heat
Slide 28 Summary-
Student Activities:
Group Activity:
Break into groups of three, and each group choose a specific material used
to manufacture aircraft. Create a five minute presentation addressing the
following points:
How is this material processed from raw materials?
How much of this material is used each year for aircraft?
What is the future trend for this material in aircraft manufacturing
What kind of aircraft components is this material used for?
What are the material properties?
What kind of equipment is needed to produce parts from this material?
Individual Activities:
1. Write a one page paper that explains in detail why one material
used for aircraft was replaced by another material.
Pre/Post Test:
1. What kind of composite materials were used for the first aircraft?
a. Carbon fiber
b. Aluminum
c. Natural composites
d. Titanium
3. What material was deemed a strategic resource for aircraft during the
Cold War?
a. Copper
b. Aluminum
c. Steel
d. Titanium
5. Carbon fiber has a strength that is roughly _______ that of the same size piece
of steel.
a. Twice
b. Half
c. Same
d. Five times
6. Boron fiber composites are very high strength, but what is one reason they
have not seen widespread use?
a. Lexan
b. Aluminum
c. Carbon fiber
d. Plexiglas
8. The Space Shuttle external fuel tank structure was originally made from
aluminum, what material was it redesigned for to increase the Shuttles
payload capacity?
9. Name two emerging technologies that will see increased use for future
aircraft.
10. What component of composites was accidentally discovered in the 1930s and
saw expanded use in a minor role during World War II?
11. List three reasons for the development of newer materials for aircraft.
12. What was the problem encountered with the use of early aluminum alloys?
13. Why didnt the use of stainless steel for aircraft structures gain widespread use
as shown by the Budd Company?
14. What material is tapped from trees in its raw form to make fluid seals?
15. The Boeing 787 airliner uses a majority of _________ to create a new level of
fuel efficiency.
a. Aluminum
b. Carbon fiber
c. GLARE
d. Boron composite
References:
Aluminum construction
http://www.centennialofflight.gov/essay/Aerospace/Junkers/Aero55.htm
http://en.wikipedia.org/wiki/Aluminum
http://en.wikipedia.org/wiki/Duralumin
Aluminum Lithium
http://aluminumlithium.com/
http://www.wired.com/wiredscience/2007/11/my-what-a-big-o/
Boron composites
http://www.anft.net/f-14/f14-history-f14a-interavia.htm
http://en.wikipedia.org/wiki/F14_Tomcat
Composites
http://authors.library.caltech.edu/5456/1/hrst.mit.edu/hrs/materials/public/
composites/Composites_Overview.htm
Ceramics
http://en.wikipedia.org/wiki/Space_Shuttle
http://en.wikipedia.org/wiki/LI-900
Fiberglass
http://en.allexperts.com/e/h/hi/history_of_fiberglass.htm
Glare
http://en.wikipedia.org/wiki/Glare_(material)
http://en.wikipedia.org/wiki/Airbus_A380
Intelligent materials
http://www.morpheus.umd.edu/research/systems/BATS.html
Plastics
http://www.mindfully.org/Plastic/Plastics-History.htm
http://inventors.about.com/od/pstartinventions/a/plastics.htm
http://www.statemaster.com/encyclopedia/Bakelite
http://en.wikipedia.org/wiki/Poly(methyl_methacrylate)
http://www.centennialofflight.gov/essay/Evolution_of_Technology/metal_
plane/Tech15.htm
http://en.wikipedia.org/wiki/Fuselage
http://www.tpub.com/content/aviation/14014/css/14014_78.htm\
Superalloys
http://www.tms.org/Meetings/Specialty/Superalloys2000/SuperalloysHisto
ry.html
http://en.wikipedia.org/wiki/Superalloy
http://www.eramet.fr/us/Site/Template/T1.aspx?SELECTID=122&ID=109
Titanium
http://www.fundinguniverse.com/company-histories/Titanium-Metals-
Corporation-Company-History.html
http://www.californiasciencecenter.org/Exhibits/AirAndSpace/AirAndAirc
raft/A12/A12.php
http://www.sr-71.org/blackbird/a-12/
Wright Brothers
http://en.wikipedia.org/wiki/Wright_brothers