2nd International Conference on Composites Testing and Model Identification

21 September 2004

Presented by

Rob Ferguson
Structures Analysis - Composites

Large Scale Composite Testing at Airbus Filton Site

Large Scale Composite Testing at Airbus Filton Site - ESACU - Ref ANS PR0405907

Outline

Background
Research Tests
4Butt

joint with bypass loading

AIRBUS UK LTD 2004. All rights reserved. Confidential and proprietary document.

4Simple

stiffened panel

4Shear

panel

4Large

stiffened panel

4Composite/metallic

joint panel

4Composite/metallic

joint

4Wingbox

tests

Aircraft Tests A340-500/600 J-nose

4Structural
4Leading

proof

edge impact

Large Scale Composite Testing at Airbus Filton Site - ESACU - Ref ANS PR0405907

21 September 2004

Page 2

The Airbus Family A Complete Range of Aircraft

Seats
600
A380

500
A340-600

400
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A340-500
A330-300

A340-300

300
A330-200

A300
A310

200

A321
A320
.

100

A319
A318

2750

16000

Range (km)

Airbus Fleet: More than 3300 aircraft

Large Scale Composite Testing at Airbus Filton Site - ESACU - Ref ANS PR0405907

21 September 2004

Page 3

Composite Materials in Airbus Aircraft

4 Composites

through the ages for Airbus aircraft

Progressive Introduction of Composite Materials

CFRP primary structures:
Fin, flaps, HTP

CFRP primary structures:

Fin, flaps, HTP as fuel tank,
rear pressure bulkhead, keel beam,
centre wing box, ribs, tail cone

CFRP primary structure:

Fin

CFRP primary structures:

Fin, flaps, HTP as fuel tank,
Rear pressure bulkhead,
keel beam

AIRBUS UK LTD 2004. All rights reserved. Confidential and proprietary document.

CFRP flight controls:

Spoilers, Airbrakes, Rudder
CFRP Spoilers:
In service trial

CFRP primary structures:

Fin, flaps,
HTP as fuel tank

GFRP fairings

1970 - 1979
A300

1972

1980 - 1989
A310-200 A310-300
A300-600

A320

1990 - 1999
A340 A330 A321 A319

2000 - 2006
A340-600

2006

A300-600R

Large Scale Composite Testing at Airbus Filton Site - ESACU - Ref ANS PR0405907

A380-800

21 September 2004

Page 4

 AIRBUS UK LTD 2004. All rights reserved. Confidential and proprietary document.

Composites on Airbus A320 Family

Large Scale Composite Testing at Airbus Filton Site - ESACU - Ref ANS PR0405907

21 September 2004

Page 5

Large Scale Testing

Large Scale =
4 Component
4 Sub-component
4 Detail

Purpose
structural analysis
4 Support certification
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4 Validate

Approach
4 Test

article design is specific to

a particular structure/aircraft
4 Consider multiple/complex load
cases
4 Environmental effects through
Load Enhancement Factors
Large Scale Composite Testing at Airbus Filton Site - ESACU - Ref ANS PR0405907

Pyramid of Test from MIL-HDBK-17

21 September 2004

Page 6

Research Tests

AIRBUS UK LTD 2004. All rights reserved. Confidential and proprietary document.

Large scale testing carried out under various projects:

4

TANGO (Technology Application to Near Term Business Goals

and Objectives)

CASCADE (Civil Aircraft Structural Composites Application

Development & Exploitation)

HLIE (High Load Input Element)

AMCAPS II (Affordable Manufacture of Composite Aircraft

Primary Structure)

Airbus internal test programmes

Objective:
4

Gather data to validate and enhance structural analysis methods

and tools

Large Scale Composite Testing at Airbus Filton Site - ESACU - Ref ANS PR0405907

21 September 2004

Page 7

Butt Joint With Bypass: Tensile Test

(TANGO Research Project)

Metallic panel

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Composite
bypass panel

Metallic
splice plate

Composite panel
Large Scale Composite Testing at Airbus Filton Site - ESACU - Ref ANS PR0405907

Test article in tensile load frame

21 September 2004

Page 8

Butt Joint With Bypass: Tensile Test

AIRBUS UK LTD 2004. All rights reserved. Confidential and proprietary document.

(TANGO Research Project)

In-plane strain (photoelastic) response of

composite face (left) and metallic face (right)
Large Scale Composite Testing at Airbus Filton Site - ESACU - Ref ANS PR0405907

After test - composite face (left);

side view (right)
21 September 2004

Page 9

Simple Stiffened Panel: Compression Test

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(Airbus Internal Research Project)

Test article showing anti-buckling guides

Large Scale Composite Testing at Airbus Filton Site - ESACU - Ref ANS PR0405907

21 September 2004

Page 10

Simple Stiffened Panel: Compression Test

AIRBUS UK LTD 2004. All rights reserved. Confidential and proprietary document.

(Airbus Internal Research Project)

Out-of plane displacement (Moir fringe) response of flat face showing

development of buckling modes
Large Scale Composite Testing at Airbus Filton Site - ESACU - Ref ANS PR0405907

21 September 2004

Page 11

Shear Panel: Cantilever Bend Shear Test

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(TANGO Research Project)

Shear panel in cantilever bend rig plain panel

(top left) and panel with access hole (left and
above)
Large Scale Composite Testing at Airbus Filton Site - ESACU - Ref ANS PR0405907

21 September 2004

Page 12

Shear Panel: Cantilever Bend Shear Test

(TANGO Research Project)

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In-plane strain (photoelastic)

response of plain shear panel

Out-of-plane displacement (Shape

Measurement System) response of
plain shear panel
Large Scale Composite Testing at Airbus Filton Site - ESACU - Ref ANS PR0405907

21 September 2004

Page 13

Shear Panel: Cantilever Bend Shear Test

(TANGO Research Project)

AIRBUS UK LTD 2004. All rights reserved. Confidential and proprietary document.

In-plane shear strain (Image Correlation)

response of panel with access hole

Out-of-plane displacement (Shape

Measurement System) response of
panel with access hole

Large Scale Composite Testing at Airbus Filton Site - ESACU - Ref ANS PR0405907

21 September 2004

Page 14

Large Stiffened Panel: Tensile Test

AIRBUS UK LTD 2004. All rights reserved. Confidential and proprietary document.

(CASCADE Research Project)

Large stiffened panel flat and

stiffened faces

Large Scale Composite Testing at Airbus Filton Site - ESACU - Ref ANS PR0405907

21 September 2004

Page 15

Large Stiffened Panel: Tensile Test

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(CASCADE Research Project)

Panel ready for proof test (above) and with

artificial damage and repairs (right)

Large Scale Composite Testing at Airbus Filton Site - ESACU - Ref ANS PR0405907

21 September 2004

Page 16

Composite / Metallic Panel Joint: Compression Test

AIRBUS UK LTD 2004. All rights reserved. Confidential and proprietary document.

(Airbus Internal Research Project)

Front and rear views of test article in compression load frame

Large Scale Composite Testing at Airbus Filton Site - ESACU - Ref ANS PR0405907

21 September 2004

Page 17

Composite / Metallic Panel Joint: Compression Test

AIRBUS UK LTD 2004. All rights reserved. Confidential and proprietary document.

(Airbus Internal Research Project)

In-plane strain (photoelastic) response of flat face (left) and stiffened face (right)
Large Scale Composite Testing at Airbus Filton Site - ESACU - Ref ANS PR0405907

21 September 2004

Page 18

Composite / Metallic Joint: Glyn Jones Shear Test

(TANGO Research Project)

Steel load transfer fitting

Alignment arm

AIRBUS UK LTD 2004. All rights reserved. Confidential and proprietary document.

Composite

Load

Metal

Large Scale Composite Testing at Airbus Filton Site - ESACU - Ref ANS PR0405907

Load
Joint zone
(butt joint with
single splice plate)

21 September 2004

Page 19

Composite / Metallic Joint: Glyn Jones Shear Test

AIRBUS UK LTD 2004. All rights reserved. Confidential and proprietary document.

(TANGO Research Project)

Test article in loading rig

Large Scale Composite Testing at Airbus Filton Site - ESACU - Ref ANS PR0405907

21 September 2004

Page 20

Composite / Metallic Joint: Glyn Jones Shear Test

(TANGO Research Project)

AIRBUS UK LTD 2004. All rights reserved. Confidential and proprietary document.

Composite
panel
Metallic
panel

In-plane strain (photoelastic) response of butt joint (left)

and splice plate (right)
Large Scale Composite Testing at Airbus Filton Site - ESACU - Ref ANS PR0405907

21 September 2004

Page 21

Composite / Metallic Joint: 3 & 4 Point Bend Tests

AIRBUS UK LTD 2004. All rights reserved. Confidential and proprietary document.

(TANGO Research Project)

Front and back views of test article

Large Scale Composite Testing at Airbus Filton Site - ESACU - Ref ANS PR0405907

21 September 2004

Page 22

Composite / Metallic Joint: 3 & 4 Point Bend Tests

AIRBUS UK LTD 2004. All rights reserved. Confidential and proprietary document.

(TANGO Research Project)

Test article in three point bending rig

Large Scale Composite Testing at Airbus Filton Site - ESACU - Ref ANS PR0405907

21 September 2004

Page 23

Composite / Metallic Joint: 3 & 4 Point Bend Tests

(TANGO Research Project)

AIRBUS UK LTD 2004. All rights reserved. Confidential and proprietary document.

Composite component

Metallic component

In-plane strain (photoelastic) response of splice plate three point bend loading
Large Scale Composite Testing at Airbus Filton Site - ESACU - Ref ANS PR0405907

21 September 2004

Page 24

Composite / Metallic Joint: 3 & 4 Point Bend Tests

(TANGO Research Project)

AIRBUS UK LTD 2004. All rights reserved. Confidential and proprietary document.

Composite component

Metallic component

In-plane strain (photoelastic) response of splice plate four point bend loading
Large Scale Composite Testing at Airbus Filton Site - ESACU - Ref ANS PR0405907

21 September 2004

Page 25

Partial Wingbox: Structural Test

(High Load Input Element Research Project)

AIRBUS UK LTD 2004. All rights reserved. Confidential and proprietary document.

Load frame and test article design

Partial wingbox under construction

Large Scale Composite Testing at Airbus Filton Site - ESACU - Ref ANS PR0405907

21 September 2004

Page 26

Partial Wingbox: Structural Test

AIRBUS UK LTD 2004. All rights reserved. Confidential and proprietary document.

(High Load Input Element Research Project)

Partial wingbox in loading jig

Large Scale Composite Testing at Airbus Filton Site - ESACU - Ref ANS PR0405907

21 September 2004

Page 27

Partial Wingbox: Structural Test

AIRBUS UK LTD 2004. All rights reserved. Confidential and proprietary document.

(High Load Input Element Research Project)

In-plane strain (photoelastic) response of

selected areas of upper skin (left) and
lower skin (above)
Large Scale Composite Testing at Airbus Filton Site - ESACU - Ref ANS PR0405907

21 September 2004

Page 28

Outer Wingbox: Structural Test

(TANGO Research Project)

Metallic diffusion structure and

support rig design

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Schematic of outer wingbox with

upper cover removed

Detail of joint between outer wingbox

and metallic diffusion structure
Large Scale Composite Testing at Airbus Filton Site - ESACU - Ref ANS PR0405907

21 September 2004

Page 29

Outer Wingbox: Structural Test

AIRBUS UK LTD 2004. All rights reserved. Confidential and proprietary document.

(TANGO Research Project)

Assembly of outer wingbox

Large Scale Composite Testing at Airbus Filton Site - ESACU - Ref ANS PR0405907

21 September 2004

Page 30

Outer Wingbox: Structural Test

AIRBUS UK LTD 2004. All rights reserved. Confidential and proprietary document.

(TANGO Research Project)

Outer wingbox in loading frame (above)

and with loading jacks attached (right)
Large Scale Composite Testing at Airbus Filton Site - ESACU - Ref ANS PR0405907

21 September 2004

Page 31

Aircraft Tests

Testing carried out to support A340-500/600 J-nose

design :
4

Glass fibre / thermoplastic resin leading edge structure

AIRBUS UK LTD 2004. All rights reserved. Confidential and proprietary document.

Objective:
4

Demonstrate satisfactory structural static strength

Demonstrate satisfactory impact response

Large Scale Composite Testing at Airbus Filton Site - ESACU - Ref ANS PR0405907

21 September 2004

Page 32

Composite J-Nose Tests

AIRBUS UK LTD 2004. All rights reserved. Confidential and proprietary document.

(A340-500/600)

J-nose is fixed leading

edge structure

J-nose structure for A340-600

Large Scale Composite Testing at Airbus Filton Site - ESACU - Ref ANS PR0405907

21 September 2004

Page 33

Composite J-Nose: Structural Test

AIRBUS UK LTD 2004. All rights reserved. Confidential and proprietary document.

(A340-500/600)

J-nose structural test

Large Scale Composite Testing at Airbus Filton Site - ESACU - Ref ANS PR0405907

21 September 2004

Page 34

Composite J-Nose: Impact Test

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(A340-500/600)

First upper panel test

Large Scale Composite Testing at Airbus Filton Site - ESACU - Ref ANS PR0405907

Second upper panel test

21 September 2004

Page 35

Conclusions

A selection of large scale composite tests carried out at

Airbus Filton site have been presented, including
Research tests from TANGO, CASCADE, HLIE and AMCAPS II
4 A340-500/600 leading edge structure
4

AIRBUS UK LTD 2004. All rights reserved. Confidential and proprietary document.

Structural tests are carried out to the highest possible

standards using state of the art instrumentation and data
acquisition techniques

Research and certification testing is on track to support

aircraft projects

Future work includes

Further testing on the TANGO wingbox including fatigue, repair etc.
4 ALCAS main landing gear support structure, pylon and supporting
tests
4

Large Scale Composite Testing at Airbus Filton Site - ESACU - Ref ANS PR0405907

21 September 2004

Page 36

Acknowledgements

TANGO is funded by the participants and the European

Union under the GROWTH RTD programme

AMCAPS II, CASCADE and HLIE were funded by the

AIRBUS UK LTD 2004. All rights reserved. Confidential and proprietary document.

participants and the UK Department of Trade and Industry

under CARAD (Civil Aircraft Research And Demonstration)

Large Scale Composite Testing at Airbus Filton Site - ESACU - Ref ANS PR0405907

21 September 2004

Page 37

 AIRBUS UK LTD 2004. All rights reserved. Confidential and proprietary document.

This document and all information contained herein is the sole

property of AIRBUS UK LTD. No intellectual property rights
are granted by the delivery of this document or the disclosure
of its content. This document shall not be reproduced or
disclosed to a third party without the express written consent
of AIRBUS UK LTD. This document and its content shall not
be used for any purpose other than that for which it is
supplied.
The statements made herein do not constitute an offer. They
are based on the mentioned assumptions and are expressed
in good faith. Where the supporting grounds for these
statements are not shown, AIRBUS UK LTD will be pleased to
explain the basis thereof.

Large Scale Composite Testing at Airbus Filton Site - ESACU - Ref ANS PR0405907

21 September 2004

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