Test and Analysis of Fuselage Structure to Assess Emerging Metallic Structures Technologies

In partnership with Arconic and Embraer, the Federal Aviation Administration (FAA) is assessing emerging metallic structures technologies (EMST) using the FAA’s Full-Scale Aircraft Structural Test Evaluation and Research (FASTER) facility. In this collaborative effort, full-scale fuselage panel test data will be obtained to assess the effect of EMST fuselage concepts on damage tolerance performance as compared to the current baseline aluminum fuselage structures located on the crown of a typical single isle aircraft forward of the wing. Several technologies will be considered including advanced aluminum-lithium (Al-Li) alloys and selective reinforcement using fiber metal laminates. 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.

Initial efforts focused on the first baseline panel consisting of 2524-T3 skin and conventional 7000-series aluminum substructure assembled through riveting. Results from baseline panel 1 test was presented in AeroMat 2019, and will be compared to future tests on advanced panels containing varying EMST. Panel 2 and 3 consisting of 2060-T8 Al-Li and 2029-T8 clad aluminum skins, respectively. Both of these panels were stiffened with integrals frame made of 2099-T83 Al-Li and stringers made of 2055-T84 Al-Li. A predominant challenge throughout the testing program was to develop an approach to account for small differences in final panel-to-panel chem-milled skin thickness which met manufacturing tolerances but resulted in significant skin stress intensity differences for these thin skin gage panels.

An update will be provided to the AeroMat audience summarizing experimental and analytical procedures, recent fuselage panel results demonstrating improvements in damage tolerance performance using advanced alloys, the challenges encountered, and lessons learned.