The Boeing Company

Brian P Justusson

Joseph D Schaefer

Bryan W Lilley

Philipp Andreas Boettcher

Troy Winfree

Derek R Tuck

Haozhong Gu

Brian Scott Kasperson

Matthew Jeffrey Molitor

Brittan A Farmer

Yadan Wu

Jordan A Severson

Louisa Michael

David R Barbee

A tension load fixture for applying tension or loading forces to a specimen comprises a pair of tension arms and an imaging device. The pair of tension arms are configured to releasably couple to opposite end regions of a specimen and to apply tension or loading forces to the specimen. The specimen is configured to be positioned between the pair of tension arms and defines a notch between the opposite end regions of the specimen. The notch extends from a side of the specimen to a middle region of the specimen. The imaging device is configured to capture one or more images of the middle region of the specimen and is configured to rotate about a central axis of the tension load fixture that is proximate to the middle region of the specimen to facilitate generation of a three-dimensional image of the middle region of the specimen as the specimen is subjected to tension or loading forces.

Tension load fixture and method for evaluating fracture behavior of a composite material

A computer-based method for evaluating progressive damage in a metal test component includes providing Computed Tomography (CT) image data of the component to a processor and processing the CT image data via the processor, including detecting observable defects in the component. The method also includes characterizing the observable defects into corresponding defect categories, generating a data table of the observable defects and the corresponding defect categories, and embedding a collective set of data from the data table into a finite element model (FEM) of the component to thereby construct a modified FEM of the metal test component. Additionally, the method includes analyzing the modified FEM through an isotropic and/or anisotropic structural model, via the processor, to thereby generate a set of test results. A quality control action is then executed with respect to the metal test component based on the test results.

Progressive damage and failure analysis of metal parts using computed tomography

A method for modeling a new design for electromagnetic effects includes identifying, with a model based system engineering tool, an area of interest in the new design where a lightning strike may occur. The new design includes structural features and electromagnetic features. The method further includes generating, with an electromagnetic effects solver tool and a structural solver tool, a design model for the area of interest in the new design, extracting design parameters from the design model, and generating a reduced order model by processing the design parameters, test results, and simulation results with a modeling tool. The reduced order model couples the structural features with the electromagnetic features. The test results are determined by tests of known designs. The simulation results are determined by simulations of known models. The method further includes storing the reduced order model in a storage medium that is readable by a statistical modeling tool.

Modeling new designs for electromagnetic effects

A computer is configured to generate a computer model predicting the progressive creation, density, and spacing of a plurality of cracks in a filler material, such as a 'noodle,' for example, disposed at a connection interface between a load-bearing composite structural component, such as a stringer or a spar, for example, and the structural framework of a vehicle on which those structural components are utilized.

Method for determining noodle and interface residual stresses and properties under hygrothermal-mechanical loadings

An example method includes determining, by a computing system, a dry thickness of a fabric preform. The method also includes determining, by the computing system, a debulked thickness of the fabric preform using the dry thickness of the fabric preform. In addition, the method includes determining, by the computing system, a stitch tension using the dry thickness of the fabric preform and the debulked thickness of the fabric preform. And the method includes causing, by the computing system, a stitching machine to apply a through-the-thickness stitch having the stitch tension to the fabric preform.

Manufacturing processes for improved mechanical performance of stitched composites

A method, apparatus, and system for managing a composite structure. A set of component models is created for a set of components in the composite structure. A set of embedded reinforcement element models is placed within the set of component models for the set of components in the composite structure to form a composite structure model for the composite structure. The set of embedded reinforcement element models is for a set of embedded reinforcements embedded within the set of components in the composite structure. A structural analysis of the composite structure is performed using the composite structure model formed by the set of component models and the set of embedded reinforcement element models, wherein the set of embedded reinforcement element models enables modeling at least one of a deformation or a failure of embedded reinforcements.

Reinforced composite structure analysis system

A method includes obtaining failure initiation characteristics of a bonding layer of one or more bonded structures and determining, based on the failure initiation characteristics, a first characteristic dimension for each analysis element of a first portion of a finite element analysis model. The method includes obtaining failure propagation characteristics of the bonding layer and determining, based on the failure propagation characteristics, a second characteristic dimension for each analysis element of a second portion of the model. The method includes assigning a first set of material parameters to analysis elements of the first portion of the model and assigning a second set of material parameters to analysis elements of the second portion of the model. The method includes evaluating failure modes of the one or more bonded structures based on a solution to the model, the first set of material parameters, and the second set of material parameters.

System and method for predicting failure initiation and propagation in bonded structures

A compression test fixture including a first specimen engagement member having a first channel, the first channel having a first depth; a second specimen engagement member having a second channel having a second depth that is different than the first depth; and at least one coupling member engaged to both the first specimen engagement member and the second specimen engagement member such that a gap is defined between the first specimen engagement member and the second specimen engagement member, where the first channel and the second channel support the test specimen within the gap such that at least one opposing major surface of the test specimen is visible within the gap.

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St. Louis, MO, United States of America

Brian P Justusson