Making automation pay - cost & throughput trade-offs in the manufacture of large composite components

The automation of complex manufacturing operations can provide significant savings over manual processes, and there remains much scope for increasing automation in the production of large scale structural composites. However the relationships between driving variables are complex, and the achievable throughput rate and corresponding cost for a given design are often not apparent. The deposition rate, number of machines required and unit production rates needed are interrelated and consequently the optimum unit cost is difficult to predict. A detailed study of the costs involved for a series of composite wing cover panels with different manufacturing requirements was undertaken. Panels were sized to account for manufacturing requirements and structural load requirements allowing both manual and automated lay-up procedures to influence design. It was discovered that the introduction of automated tape lay-up can significantly reduce material unit cost, and improve material utilisation, however higher production rates are needed to see this benefit

High Specification Offshore Blades Work Package: 1D: Blade Manufacturing

Blades are regarded as the only component unique to wind turbine blades. They represent only 10 – 15% of the total system cost so the perception is that a reduction in the cost of energy through blade cost improvements is constrained. However, the use of advanced manufacturing technologies is expected to directly reduce cost savings. The aim of this report is therefore to identify manufacturing technologies offering potential for facilitate the construction of very large offshore blades and their potential for (patentable) intellectual property exploitation. This report should be read in conjunction with Package 1C

Cost-efficient manufacturing of composite structures

The Advanced Composites Technology (ACT) program is seeking research breakthroughs that will allow structures made of graphite epoxy materials to replace metals in the wings and fuselages of future aircrafts. NASA's goals are to reduce acquisition cost by 20 to 25 percent, structural weight for a resized aircraft by 40 to 50 percent, and the number of parts by half compared to current production aluminum aircraft. The innovative structural concepts, materials, and fabrication techniques emerging from the ACT program are described, and the relationship between aerospace developments and industrial, commercial, and sporting goods applications are discussed

ARMD Workshop on Materials and Methods for Rapid Manufacturing for Commercial and Urban Aviation

This report documents the goals, organization and outcomes of the NASA Aeronautics Research Mission Directorates (ARMD) Materials and Methods for Rapid Manufacturing for Commercial and Urban Aviation Workshop. The workshop began with a series of plenary presentations by leaders in the field of structures and materials, followed by concurrent symposia focused on forecasting the future of various technologies related to rapid manufacturing of metallic materials and polymeric matrix composites, referred to herein as composites. Shortly after the workshop, questionnaires were sent to key workshop participants from the aerospace industry with requests to rank the importance of a series of potential investment areas identified during the workshop. Outcomes from the workshop and subsequent questionnaires are being used as guidance for NASA investments in this important technology area

A unified approach for composite cost reporting and prediction in the ACT program

The Structures Technology Program Office (STPO) at NASA Langley Research Center has held two workshops with representatives from the commercial airframe companies to establish a plan for development of a standard cost reporting format and a cost prediction tool for conceptual and preliminary designers. This paper reviews the findings of the workshop representatives with a plan for implementation of their recommendations. The recommendations of the cost tracking and reporting committee will be implemented by reinstituting the collection of composite part fabrication data in a format similar to the DoD/NASA Structural Composites Fabrication Guide. The process of data collection will be automated by taking advantage of current technology with user friendly computer interfaces and electronic data transmission. Development of a conceptual and preliminary designers' cost prediction model will be initiated. The model will provide a technically sound method for evaluating the relative cost of different composite structural designs, fabrication processes, and assembly methods that can be compared to equivalent metallic parts or assemblies. The feasibility of developing cost prediction software in a modular form for interfacing with state of the art preliminary design tools and computer aided design (CAD) programs is assessed

Advanced composites wing study program. Volume 1: Executive summary

The effort necessary to achieve a state of production readiness for the design and manufacturing of advanced composite wing structure is outlined. Technical assessment and program options are also reviewed for the wing study results

The 1981 current research on aviation weather (bibliography)

Current and ongoing research programs related to various areas of aviation meteorology are presented. Literature searches of major abstract publications, were conducted. Research project managers of various government agencies involved in aviation meteorology research provided a list of current research project titles and managers, supporting organizations, performing organizations, the principal investigators, and the objectives. These are tabulated under the headings of advanced meteorological instruments, forecasting, icing, lightning and atmospheric electricity; fog, visibility, and ceilings; low level wind shear, storm hazards/severe storms, turbulence, winds, and ozone and other meteorological parameters. This information was reviewed and assembled into a bibliography providing a current readily useable source of information in the area of aviation meteorology

Fabrication of the V-22 composite AFT fuselage using automated fiber placement

Boeing Helicopters and its subcontractors are working together under an Air Force Wright Research and Development Center (WRDC)-Manufacturing-Technology Large-Composite Primary Structure Fuselage program to develop and demonstrate new manufacturing techniques for producing composite fuselage skin and frame structures. Three sets of aft fuselage skins and frames have been fabricated and assembled, and substantial reductions in fabrication and assembly costs demonstrated

Full-scale performance assessment of aircraft secondary sandwich structure using thermoelastic stress analysis

The use of resin film infusion (RFI) has been proven to reduce the cost of production of aircraft secondary sandwich structure. In this paper thermoelastic stress analysis (TSA) is used to assess the performance of full scale aircraft sandwich structure panels produced using both the conventional autoclave process and RFI. Finite element (FE) models of both panel types are developed and TSA is used to validate the models