Disbond resistant composite stiffener runout

Abstract

The disclosure herein provides for disbond resistant stringer runouts. Various aspects may be used independently or in combination to mitigate disbonding associated with the stiffener runout under operational loads. Aspects include a stiffener runout having rounded base flange corners. A recessed notch may be incorporated within the base flange to provide a flange termination point that is forward of the web termination point, allowing the web to terminate prior to the base flange. The web may be trimmed from a full height to a reduced height at the web termination point. The base flange may be co-bonded to the underlying composite structure via a scarf joint. Perimeter clamp radius fillers may be used to concentrate a clamping force around the perimeter of the base flange.

Claims

1. A method of controlling bondline separation between a composite stiffener and a composite structure, the method comprising: providing a composite stiffener comprising a web and a base flange, wherein the web terminates at a web termination point, wherein the base flange terminates at a flange termination point forward of the web termination point, and wherein the base flange comprises rounded corners; trimming the web from a full height at a location prior to a web termination point to a reduced height at the web termination point; providing a recessed notch within the base flange at the flange termination point such that the web termination point is positioned substantially at a center of the recessed notch; providing at least one perimeter clamp radius filler comprising a bottom surface configured to contact a top surface of the base flange around a portion of a perimeter of the top surface to create a contact area between the perimeter clamp radius filler and the portion of the perimeter of the top surface, and wherein the contact area defines a relief cavity between the perimeter clamp radius filler and the top surface; and bonding a bottom surface of the base flange to a top surface of the composite structure.

2. The method of claim 1, further comprising: securing the at least one perimeter clamp radius filler to the top surface of the base flange using a plurality of fasteners extending through a top surface of the perimeter clamp radius filler, through the relief cavity, through the base flange, and through the composite structure.

3. The method of claim 1, comprising forming the contact surface of the at least one perimeter clamp radius filler with a C-shape.

4. The method of claim 1, further comprising filling the relief cavity of the at least one perimeter clamp radius filler with a compliant filler material.

5. The method of claim 1, wherein the composite structure comprises a non-uniform thickness, and wherein the base flange comprises a non-uniform thickness corresponding to the non-uniform thickness of the composite structure such that bonding the bottom surface of the base flange to the top surface of the composite structure creates a scarf joint between the composite stiffener and the composite structure.

6. The method of claim 5, in which each of the base flange and the composite structure is formed of multiple plies of composite material, the method further comprising forming the non-uniform thickness of the base flange by reducing a number of plies of composite material in the base flange, and forming the non-uniform thickness of the composite structure by increasing a number of plies of composite material in the composite structure.

7. The method of claim 1, in which trimming the web from the full height to the reduced height comprises forming a leading edge of the web with a curved configuration.

8. A method of controlling bondline separation between a composite stiffener and a composite structure, the method comprising: providing a composite stiffener comprising a web and a base flange, wherein the web terminates at a web termination point, wherein the base flange terminates at a flange termination point forward of the web termination point, and wherein the base flange comprises rounded corners; trimming the web from a full height at a location prior to a web termination point to a reduced height at the web termination point; providing a recessed notch within the base flange at the flange termination point such that the web termination point is positioned substantially at a center of the recessed notch; and providing a fiberglass wedge, wherein bonding the bottom surface of the base flange to the top surface of the composite structure comprises bonding a bottom surface of the fiberglass wedge to the top surface of the composite structure and bonding a top surface of the fiberglass wedge to the bottom surface of the base flange, wherein the base flange comprises a non-uniform thickness corresponding to a configuration of the fiberglass wedge.

9. The method of claim 8, in which the base flange is formed of multiple plies of composite material, the method further comprising forming the non-uniform thickness of the base flange by reducing a number of plies of composite material in the base flange.

10. The method of claim 8, further comprising providing at least one perimeter clamp radius filler comprising a bottom surface configured to contact a top surface of the base flange around a portion of a perimeter of the top surface to create a contact area between the perimeter clamp radius filler and the portion of the perimeter of the top surface, and wherein the contact area defines a relief cavity between the perimeter clamp radius filler and the top surface.

11. The method of claim 10, further comprising securing the at least one perimeter clamp radius filler to the top surface of the base flange using a plurality of fasteners extending through a top surface of the perimeter clamp radius filler, through the relief cavity, through the base flange, and through the composite structure.

12. The method of claim 10, comprising forming the contact surface of the at least one perimeter clamp radius filler with a C-shape.

13. The method of claim 10, further comprising filling the relief cavity of the at least one perimeter clamp radius filler with a compliant filler material.

14. The method of claim 8, wherein the composite structure comprises a non-uniform thickness, and wherein the base flange comprises a non-uniform thickness corresponding to the non-uniform thickness of the composite structure such that bonding the bottom surface of the base flange to the top surface of the composite structure creates a scarf joint between the composite stiffener and the composite structure.

15. The method of claim 14, in which each of the base flange and the composite structure is formed of multiple plies of composite material, the method further comprising forming the non-uniform thickness of the base flange by reducing a number of plies of composite material in the base flange, and forming the non-uniform thickness of the composite structure by increasing a number of plies of composite material in the composite structure.

16. The method of claim 8, in which trimming the web from the full height to the reduced height comprises forming a leading edge of the web with a curved configuration.

17. A method of controlling bondline separation between a composite stiffener and a composite structure, the method comprising: providing a composite stiffener comprising a web and a base flange, wherein the web terminates at a web termination point and defines a web forward edge having a curved configuration, wherein the base flange terminates at a flange termination point forward of the web termination point, and wherein the base flange comprises rounded corners; trimming the web from a full height at a location prior to a web termination point to a reduced height at the web termination point; providing a recessed notch within the base flange at the flange termination point such that the web termination point is positioned substantially at a center of the recessed notch; providing at least one perimeter clamp radius filler comprising a bottom surface configured to contact a top surface of the base flange around a portion of a perimeter of the top surface to create a contact area between the perimeter clamp radius filler and the portion of the perimeter of the top surface, and wherein the contact area defines a relief cavity between the perimeter clamp radius filler and the top surface; and bonding a bottom surface of the base flange to a top surface of the composite structure.

18. The method of claim 17, further comprising: securing the at least one perimeter clamp radius filler to the top surface of the base flange using a plurality of fasteners extending through a top surface of the perimeter clamp radius filler, through the relief cavity, through the base flange, and through the composite structure.

19. The method of claim 17, further comprising providing a fiberglass wedge, wherein bonding the bottom surface of the base flange to the top surface of the composite structure comprises bonding a bottom surface of the fiberglass wedge to the top surface of the composite structure and bonding a top surface of the fiberglass wedge to the bottom surface of the base flange, wherein the base flange comprises a non-uniform thickness corresponding to a configuration of the fiberglass wedge.

20. The method of claim 17, comprising forming the contact surface of the at least one perimeter clamp radius filler with a C-shape.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 is a front view of a stiffener runout assembly illustrating aspects of a stiffener runout for controlling disbond according to various embodiments presented herein;

(2) FIG. 2 is a top view of a stiffener runout illustrating aspects of the stiffener runout for controlling disbond according to various embodiments presented herein;

(3) FIG. 3 is a side view of a stiffener runout assembly illustrating aspects of a stiffener runout for controlling disbond according to various embodiments presented herein;

(4) FIG. 4 is a side view of a stiffener runout assembly illustrating aspects of a stiffener runout and scarf joint for controlling disbond according to various embodiments presented herein;

(5) FIG. 5 is a side view of a stiffener runout assembly illustrating aspects of a stiffener runout and alternative scarf joint for controlling disbond according to various embodiments presented herein; and

(6) FIG. 6 is a flow diagram showing a method of controlling bondline separation between a composite stiffener and a composite structure according to various embodiments presented herein.

DETAILED DESCRIPTION

(7) The following detailed description is directed to controlling bondline separation between a composite stiffener and a composite structure. As discussed above, delamination or disbond may occur between stringers and co-bonded composite structures at stringer runout locations when subjected to operational loads. As composite materials are increasingly used in the construction of vehicles such as aircraft, controlling delamination and disbonding at the stringer runout locations is a primary concern. Solutions to the stringer disbonding issue should contemplate weight factors, as well as cost and complexity of manufacturing, particularly within the aircraft industry.

(8) Utilizing the concepts and technologies described herein, stringer runouts may incorporate various stringer runout aspects, alone or in combination, to prevent disbonding between composite stringers and co-bonded composite structures while minimizing weight and manufacturing complexity and cost. The various embodiments described below will be described within the context of a composite aircraft stringer co-bonded with composite aircraft skin. It should be appreciated that the various embodiments are not limited to these specific components, or to use within aircraft. Rather, the concepts described below may equally apply to any implementation in which a stringer or similar stiffening component is bonded to a composite structure.

(9) In the following detailed description, references are made to the accompanying drawings that form a part hereof, and which are shown by way of illustration, specific embodiments, or examples. Referring now to the drawings, in which like numerals represent like elements through the several figures, a disbond resistant stiffener runout and assembly, as well as methods form controlling disbond between a composite stiffener and a composite structure, will be described.

(10) FIG. 1 shows a front view of a stiffener runout assembly 100. According to this illustrative embodiment, the stiffener runout assembly 100 includes a stiffener runout 102 co-bonded onto a composite structure 104. The composite structure 104 may be any composite panel, sheet, or other component for which stiffening would be desirable, such as an aircraft skin. The stiffener runout 102 includes a web 106, a base flange 108 that includes a first flange portion 108A and a second flange portion 108B, and a cap 110. A noodle 114 is bonded within the region created between the web 106 and the first and second flange portions 108A and 108B.

(11) As shown in FIG. 1, the web may extend vertically in relation to the composite structure 104. The base flange 108 may be positioned at a bottom edge of the web 106, with the first flange portion 108A extending substantially horizontally from a front surface 120 of the web 106 and the second flange portion 108B extending substantially horizontally from a rear surface 122 of the web 106. The base flange 108 is bonded to the composite structure 104. According to various embodiments, the stiffener runout assembly 100 may include perimeter clamp radius fillers 112 positioned on the first and second flange portions 108A and 108B to assist with preventing disbond at the forward edges of the stiffener runout 102. The various features of the perimeter clamp radius fillers 112 will be described in greater detail below with respect to FIGS. 2 and 3. It should be appreciated that the stiffener runout 102 may include additional features and/or varying proportions or configurations as compared to the stiffener runout 102 shown in the figures without departing from the scope of this disclosure. The various figures may not be drawn to scale and are shown for illustrated purposes only.

(12) FIGS. 2 and 3 show top and side views, respectively, of a stiffener runout 102 according to one embodiment. As described above, the stiffener runout 102 may include a web 106 and a base flange 108. There are multiple features of the stiffener runout 102 that independently and collectively mitigate or eliminate any disbond between the stiffener runout 102 and the composite structure 104. One such feature includes the rounded corners 202 of the base flange 108. Conventional stiffeners include base flanges that have squared off corners. The square corners are easier to manufacture. Historically, delamination tends to occur at the corners of the base flange first, particularly when a partial shear loading exists. However, by trimming or otherwise creating the rounded corners 202 as shown in FIG. 2, the loads through the corners of the base flange 108 are more easily distributed, reducing the potential for delamination at those locations.

(13) Another feature disclosed herein to control disbonding includes the recessed notch 204 in base flange 108. According to various embodiments, the base flange 108 terminates at a flange termination point 206. The flange termination point 206 may be the most forward location of the stiffener runout 102. Similarly, the web 106 terminates at a web termination point 208. Conventional stiffeners include webs and base flanges that terminate at identical locations. The forward edge of a stringer runout is typically stiffer under the web 106 and noodle 114 as compared to the base flange 108. This stiffer central location of the typical stringer forward edge allows for disbonds to occur at this location before occurring at other locations of the base flange 108.

(14) However, as shown clearly in FIG. 2, the stiffener runout 102 of the various embodiments disclosed herein includes a flange termination point 206 that is forward of the web termination point 208. The web termination point 208 is located within a recessed notch 204, which may be on a semicircular or arcuate edge of the base flange 108 aft of the flange termination point 206. In doing so, any curvature between the termination end of the stiffener runout 102 and the composite structure 104 may be matched, which mitigates the disbonding under the web 106 and noodle 114.

(15) Similarly, as seen in FIG. 3, the web 106 may be trimmed from a full height 304 to a reduced height 306 at the web termination point 208. According to one embodiment, the reduced height 306 may be substantially flush with a top surface of the base flange 108. By tapering or reducing the height of the web 106, the loads within the stringer 102 are reduced at the flange termination point 206, which reduces the potential for disbond. Additionally, reducing the height of the web 106 reduces the stiffness of the stiffener runout 102 along the central axis of the stiffener, which similar to the benefits described above with respect to the recessed notch 204, mitigates the disbonding under the web 106 and noodle 114. According to one embodiment, a leading edge 302 of the web 106 is tapered according to a curved configuration as shown in FIG. 3.

(16) An additional feature used to control disbonding includes the use of the perimeter clamp radius fillers 112, as shown in FIGS. 2 and 3. As discussed above, traditional radius fillers are flat metallic components that may be secured to a base flange in order to provide pressure to the flange and corresponding bond between the flange and the underlying composite structure in an effort to mitigate disbonding. However, traditional radius fillers do not efficiently handle panel deformation. For example, when a composite structure 104 or panel deforms under load such that the panel under a portion of the traditional radius filler flexes downward, the traditional radius filler will tend to lift off of the surface, either over the portion of the panel that is deflecting downward, or as that portion of the radius filler deflects downward with the panel, an opposing edge of the traditional radius filler may lift off of the surface.

(17) The perimeter clamp radius fillers 112 described herein alleviate these deficiencies of traditional radius fillers by concentrating the clamping force around the perimeter of the base flange 108 where the disbonding is most likely to occur. Moreover, a relief cavity 212 within a central portion of the perimeter clamp radius filler 112 accommodates any deformation of the composite structure 104 and the corresponding base flange 108. The perimeter clamp radius fillers 112 may be metallic, or any other suitable material.

(18) According to one embodiment, each perimeter clamp radius filler 112 includes a bottom surface that projects downward from a portion of the perimeter of the radius filler to create a contact area 210 between the perimeter clamp radius filler 112 and a corresponding portion of the top surface around a perimeter of the base flange 108. The contact area 210 defines the boundaries of the relief cavity 212. Pressure is applied to the base flange 108 by the perimeter clamp radius filler 112 within the contact area 210 to prevent disbonding at the edges of the stiffener runout 102. Because pressure applied to the perimeter clamp radius filler 112 is distributed and concentrated around the perimeter of the base flange 108 while allowing for deformation within the relief cavity 212, the perimeter clamp radius fillers 112 provide a significant advantage over the less effective conventional radius fillers.

(19) According to various embodiments, the contact area 210 may be substantially C-shaped with an opening 216 that provides access to the relief cavity 212 from one edge of the base flange 108. The opening 216 may be positioned along the edge of the base flange 108 opposite the web 106 as shown in FIGS. 2 and 3 since that portion of the edge opposite the web 106 is not highly susceptible to disbonding. The opening 216 may alternatively be positioned at the most rearward edge or any other edge of the base flange 108, and may be configured according to any size and shape. According to one embodiment, the relief cavity 212 may be filled with a compliant filler, such as a sealant or other material appropriate to the particular application, that allows for deformation without applying pressure to the base flange 108. The opening 216 may provide a passage for excess compliant filler to escape from the relief cavity 212 during installation.

(20) Fasteners 214 may be threaded or otherwise placed through corresponding apertures in the perimeter clamp radius filler 112, base flange 108, and composite structure 104. Torque applied to the fasteners 214 transfers force from the perimeter clamp radius filler 112 to the perimeter of the base flange 108 via the contact area 210 to prevent disbonding. Although two fasteners 214 are shown for each perimeter clamp radius filler 112, any number of fasteners 214 may be used without departing from the scope of this disclosure.

(21) FIGS. 4 and 5 illustrate two alternative embodiments in which a type of scarf joint 402 is created between the stiffener runout 102 and the composite structure 104. For the purposes of this disclosure, the term scarf joint will be used to refer to a coupling between two or more components in which two of the components are manufactured or modified to have an angled surface that is engaged with a complementary angled surface of the other component. FIG. 4 shows a first embodiment in which the composite structure 104 has a uniform thickness, but is bonded to a fiberglass wedge 404. The fiberglass wedge 404 is hatched in the FIG. 4 to highlight the wedge for clarity purposes only. The fiberglass wedge 404 provides an angled wedge surface 406 that is co-cured onto an angled flange surface 408 of the base flange 108. The angled flange surface 408 may be created by reducing the plies of the composite material according to the desired angle and joint length. The fiberglass wedge 404 is highly compliant and is configured to shear load into the composite structure 104 over a longer length, thereby reducing the local moments that may cause disbonding. Although the fiberglass wedge 404 is described herein as being fiberglass, it should be appreciated that any suitable material that is more compliant (having less stiffness) than the material of the stiffener runout 102 and composite structure 104 may be used to create the wedge.

(22) FIG. 5 shows the second embodiment in which the scarf joint 402 is created by reducing the plies of the composite material according to the desired angle of the angled flange surface 408 and length of the scarf joint 402. Similarly, a corresponding angled structure surface 502 may be created by increasing plies of the composite material according to the desired angle of the angled structure surface 502 and length of the scarf joint 402. The result is a non-uniform thickness of the base flange 108 that complements a non-uniform thickness of the composite structure 104 within the scarf joint 402. According to an example embodiment, the run to rise ratio associated with the angled structure surface 502 and angled flange surface 408 of the scarf joint 402 is approximately 20:1. According to various embodiments, the ratio may be between 20:1-30:1. Similar to the effect of a scarf joint 402 created with the fiberglass wedge 404 discussed above with respect to FIG. 4, the effect of the scarf joint 402 created by altering the plies of the base flange 108 and composite structure 104 as shown in FIG. 5 is to shear the loads from the stiffener into the composite structure 104 over a relatively long distance. Doing so minimizes the detrimental local moments by reducing the offset in the load line that may initiate disbonding.

(23) Turning now to FIG. 6, an illustrative routine 600 for controlling bondline separation between a stiffener runout 102 and a composite structure 104 will now be described in detail. It should be appreciated that more or fewer operations may be performed than shown in the FIG. 6 and described herein. Moreover, these operations may also be performed in a different order than those described herein. The routine 600 begins at operation 602, where the stiffener runout 102 having a web 106 and a base flange 108 of composite materials is created. It should be appreciated that other features of a stiffener that are not germane to this disclosure may additionally be created during this or any other operation of the routine 600. For example, creation of the stiffener may commonly include bonding the cap 110 to the top edge of the web 106, as well as bonding the noodle 114 in the appropriate position between the bottom edge of the web 106 and the first and second flange portions 108A and 108B.

(24) From operation 602, the routine 600 continues to operation 604, where the rounded corners 202 of the base flange 108 are created. This operation may be performed by trimming conventional square corners after curing of the base flange 108, or may be a part of the composite molding process. At operation 606, the recessed notch 204 is created in the base flange 108. The recessed notch 204 may be created via trimming material from the base flange 108 or may be created during the material composite molding process. The size and depth of the recessed notch 204 may depend on the particular implementation and the desired distance between the flange termination point 206 and the web termination point 208. The routine 600 continues from operation 606 to operation 608, where the height of the web 106 is trimmed from the full height 304 to the reduced height 306 at the web termination point 208. The leading edge 302 of the web 106 may be trimmed according to a curved configuration or linearly tapered to the reduced height 306.

(25) From operation 608, the routine 600 continues to operation 610, where the scarf joint 402 is created between the stiffener runout 102 and the composite structure 104. As discussed above with respect to FIG. 4, a first method for creating the scarf joint 402 involves utilizing a fiberglass wedge 404 bonded to a top surface of the composite structure 104, providing an angled wedge surface 406 that is co-cured into an angled flange surface 408 of the base flange 108. The angled flange surface 408 of the base flange 108 may be created by dropping plies to create the desired 20:1-30:1 or other ratio at the scarf joint 402. Also as discussed above with respect to FIG. 5, a second method for creating the scarf joint 402 includes dropping plies in the base flange 108 to create the angled flange surface 408 and increasing plies in the composite structure 104 to create the angled structure surface 502. The angled flange surface 408 and the angled structure surface 502 are then co-cured to create the scarf joint 402.

(26) The routine 600 continues from operation 610 to operation 612, where the perimeter clamp radius fillers 112 are secured to the base flange 108 with fasteners 214. Torque is applied to the fasteners 214 to concentrate a clamping force within the contact area 210 against the perimeter of the base flange 108 to mitigate disbonding in these areas. At operation 614, the relief cavity 212 is filled with a compliant sealant or other material and the routine 600 ends.

(27) During use, loads from the stiffener runout 102 may be sheared into the composite structure 104 at the scarf joint 402 over a relatively long distance to reduce the offset in the load line that could initiate a disbond between the stiffener runout 102 and the composite structure 104. These loads may include a first loading condition in which static loads are experienced, such as during a steady straight and level aircraft flight operation. The loads may shift to a second loading condition in which dynamic loads are experienced, such as during a climb, turn, or velocity change. During this load shift, the scarf joint 402 and other features of the stiffener runout 102 described above serve to distribute the loads to the composite structure 104 in a manner that prevents or delays the disbonding that may be present with conventional stringer runouts.

(28) It should be clear from discussion above that the concepts described herein may be used independently or in combination to mitigate disbonding at the stiffener runout 102 under operational loads. The subject matter described above is provided by way of illustration only and should not be construed as limiting. Various modifications and changes may be made to the subject matter described herein without following the example embodiments and applications illustrated and described, and without departing from the true spirit and scope of the present disclosure, which is set forth in the following claims.