Design of Durable, Repairable, and Maintainable Aircraft Composites

Advanced composites have found increasing application in commercial aircraft structures as a result of the strength, stiffness, fatigue, corrosion, and weight benefits afforded to improve performance.

Safety and functionality are high priorities for integrating composite components into commercial aircraft structures.

As a result, extensive analysis, laboratory testing, and certification flight testing to evaluate all aspects of service life are conducted by the Original Equipment Manufacturers (OEMs) and approved by the authorizing agencies.

As service experience with commercial aircraft composite structures has been gained, aircraft operators have identified a need for improvements in the durability and ease of repair and maintainability of these composite components.

The purpose of this document is to identify these needs and also to assist those involved to design and integrate composite commercial aircraft structures that exhibit improved durability and maintainability and that can be repaired effectively and rapidly at most locations, such as ramps, shops, depots, and overhaul stations. It is written particularly for the composite design engineer but should also prove invaluable to those in structural engineering, materials and processing, product support, advanced product development, systems engineering, technical services, and maintenance operations.

Contents: Design Considerations - Evaluating Damage Types of Construction Sources of Damage Durability Repairability Maintainability Database of Current Performance and Alternate Considerations - Design Pages Design Case Studies - Fan Cowl Door Lightning Strike Damage Radome Repairability Localized Heat Damage on Engine Fan Cowl Door Fan Duct Outlet Guide Vane Erosion Thrust Reverser Translating Sleeve Disbonding Wing-to-Fuselage Fairing Panel Disbond Spoiler Water Ingress Damage Composite Flight Control Surface Finish Cracking Successful Design Case Studies - Vertical Stabilizer Box.