Additive Manufacturing Of Aerospace Composite Structures

Additive Manufacturing of Aerospace Composite Structures: Fabrication and Reliability introduces the reader to the current state of technologies involved in processing and design of polymer-reinforced fiber composites using additive manufacturing's automated fiber placement methods, through ten seminal SAE International papers. Currently, the material layup strategy in terms of process selection and manufacturability is usually not prioritized in the design phase. Engineers do not have a good way to see how their design choices can affect the manufacturing process beyond their initial structural-level considerations. The result is typically a large amount of experimental testing necessary to qualify the materials and structures typified in the classical building-block approach. Such an environment makes mistakes difficult to solve and, should redesign be required, obtaining reliable information is hard to piece together. Additive Manufacturing of Aerospace Composite Structures: Fabrication and Reliability approaches the question of quality in these structures from a hands-on, solution-driven perspective.

This book covers advanced 3D printing processes and the latest developments in novel composite-based printing materials, thus enabling the reader to understand and benefit from the advantages of this groundbreaking technology. The rise in ecological anxieties has forced scientists and researchers from all over the world to find novel lightweight materials. Therefore, it is necessary to expand knowledge about the processing, applications, and challenges of 3D printing of composite materials to expanding the range of their application. This book presents an extensive survey on recent improvements in the research and development of additive manufacturing technologies that are used to make composite structures for various applications such as electronic, aerospace, construction, and biomedical applications. Advanced printing techniques including fused deposition modeling (FDM), selective laser sintering (SLS), selective laser melting (SLM), electron beam melting (EBM), inkjet 3D printing (3DP), stereolithography (SLA), and 3D plotting will be covered and discussed thoroughly in this book. This book also focuses the recent advances and challenges in polymer nanocomposite and introduces potential applications of these materials in various sectors.

Tooling for Composite Aerospace Structures: Manufacturing and Applications offers a comprehensive discussion on the design, analysis, manufacturing and operation of tooling that is used in the lamination of composite materials and assembly. Chapters cover general topics, the materials that are typically used for tooling, design aspects and recommendations on how to approach the design, and what engineers need to consider, including examples of designs and their pros and cons, how to perform these type of details, and the methods of inspection needed to ensure quality control. The book concludes with an outlook on the industry and the future. Covers the entire lifecycle of tool design, starting with a discussion on composite materials and ending with new concepts and material Introduces aspects of how to use modeling and simulation for tooling with detailed examples and validation data Offers a list of materials and where they should be used depending on the application

New edition updated with additional exercises and two new chapters. Design and Analysis of Composite Structures: With Applications to Aerospace Structures, 2nd Edition builds on the first edition and includes two new chapters on composite fittings and the design of a composite panel, as well additional exercises. The book enables graduate students and engineers to generate meaningful and robust designs of complex composite structures. A compilation of analysis and design methods for structural components made of advanced composites, it begins with simple parts such as skins and stiffeners and progresses through to applications such as entire components of fuselages and wings. It provides a link between theory and day-to-day design practice, using theory to derive solutions that are applicable to specific structures and structural details used in industry. Starting with the basic mathematical derivation followed by simplifications used in real-world design,Design and Analysis of Composite Structures: With Applications to Aerospace Structures, 2nd Edition presents the level of accuracy and range of applicability of each method along with design guidelines derived from experience combined with analysis. The author solves in detail examples taken from actual applications to show how the concepts can be applied, solving the same design problem with different methods based on different drivers (e.g. cost or weight) to show how the final configuration changes as the requirements and approach change. Each chapter is followed by exercises that represent specific design problems often encountered in the aerospace industry but which are also applicable in the in the automotive, marine, and construction industries. Updated to include additional exercises, that represent real design problems encountered in the aerospace industry, but which are also applicable in the in the automotive, marine, and construction industries. Includes two new chapters. One on composite fittings and another on application and the design of a composite panel. Provides a toolkit of analysis and design methods that enable engineers and graduate students to generate meaningful and robust designs of complex composite structures. Provides solutions that can be used in optimization schemes without having to run finite element models at each iteration; thus speeding up the design process and allowing the examination of many more alternatives than traditional approaches. Supported by a complete set of lecture slides and solutions to the exercises hosted on a companion website for instructors. An invaluable resource for Engineers and graduate students in aerospace engineering as well as Graduate students and engineers in mechanical, civil and marine engineering.

This book offers a comprehensive look at materials science topics in aerospace, air vehicle structures and manufacturing methods for aerospace products, examining recent trends and new technological developments. Coverage includes additive manufacturing, advanced material removal operations, novel wing systems, design of landing gear, eco-friendly aero-engines, and light alloys, advanced polymers, composite materials and smart materials for structural components. Case studies and coverage of practical applications demonstrate how these technologies are being successfully deployed. Materials, Structures & Manufacturing for Aircraft will appeal to a broad readership in the aviation community, including students, engineers, scientists, and researchers, as a reference source for material science and modern production techniques.

Composite Materials in Aerospace Design is one of six titles in a coherent and definitive series dedicated to advanced composite materials research, development and usage in the former Soviet Union. Much of the information presented has been classified until recently. Thus each volume provides a unique insight into hitherto unknown research and development data. This volume deals with the design philosophy and methodology used to produce primary and secondary load bearing composite structures with high life expectancies. The underlying theme is of extensive advanced composites research and development programs in aircraft and spacecraft applications, including the space orbital ship `BURAN'. The applicability of much of this work to other market sectors, such as automotive, shipbuilding and sporting goods is also examined in some detail. The text starts by describing typical structures for which composites may be used in this area and some of the basic requirements from the materials being used. Design of components with composite materials is then discussed, with specific reference to case studies. This is followed by discussion and results from evaluation of finished structures and components, methods of joining with conventional materials and finally, non-destructive testing methods and forecasting of the performance of the composite materials and the structures which they form. Composite Materials in Aerospace Design will be of interest to anyone researching or developing in composite materials science and technology, as well as design and aerospace engineers, both in industry and universities.

The results of an assessment of the state-of-the-art in the design and manufacturing of large composite structures are described. The focus of the assessment is on the use of polymeric matrix composite materials for large airframe structural components, such as those in commercial and military aircraft and space transportation vehicles. Applications of composite materials for large commercial transport aircraft, general aviation aircraft, rotorcraft, military aircraft, and unmanned rocket launch vehicles are reviewed. The results of the assessment of the state-of-the-art include a summary of lessons learned, examples of current practice, and an assessment of advanced technologies under development.

This book addresses the emerging needs of the aerospace industry by discussing recent developments and future trends of aeronautic materials. It is aimed at advancing existing materials and fostering the ability to develop novel materials with less weight, increased mechanical properties, more functionality, diverse manufacturing methods, and recyclability. The development of novel materials and multifunctional materials has helped to increase efficiency and safety, reduce costs, and decrease the environmental foot print of the aeronautical industry. In this book, integral metallic structures designed by disruptive concepts, including topology optimization and additive manufacturing, are highlighted.