Assessment of Emerging Metallic Structures Technologies Through Full-Scale Test and Analysis of Fuselage Panels

The aircraft industry is striving to improve performance and reduce costs in fabrication, operations, and maintenance by introducing advanced materials, construction methods, and production technologies. In response to the increased use of composite materials in aircraft such as the B787 and A350, the aluminum industry has made significant advancements in developing new aluminum alloy materials and product forms; improved structural concepts; and manufacturing processes that are lower cost compared to composites manufacturing. Collectively, these advances fall under the umbrella classification of Emerging Metallic Structures Technologies (EMST). Through a recent cooperative research and development agreement, Alcoa and the Federal Aviation Administration (FAA) have partnered in an effort to obtain full-scale fuselage panel test and analysis data to demonstrate whether and how fuselage concepts utilizing EMST improve the durability and damage tolerance compared to the current baseline aluminum fuselage structures. A single-aisle aircraft fuselage configuration will be used as the baseline structure. Fuselage panels will include 2029 and Al-Li 2060 skins; Al-Li 2055 and Al-Li 2099 stringers and frames; Friction Stir Weld skin panels; bonded stringers; lap joints simulating Multiple-Site Damage conditions; and local-bonded Fiber Metal Laminate strap reinforcement under frames and stringers. Testing will be conducted using the FAA’s Full-Scale Aircraft Structural Test Evaluation and Research facility. Data from this study will be used to verify improved weight and structural safety performance of the EMST and will also be used to assess the relevance of existing regulations and to inform whether additional safety standards and regulatory guidance should be developed to provide improved safety beyond that afforded by the existing airworthiness standards. This presentation will provide an overview of this multi-year collaborative program and previously generated test data by Alcoa used to select the various technologies included in this program.