Safety Provision for Composite Structures in Aviation: Today and Tomorrow

• Published in: Journal of machinery manufacture and reliability 2020-12, Vol.49 (11), p.920-931
• Main Authors: Dubinskii, S. V., Zichenkov, M. Ch, Zharenov, I. A.
• Format: Article
• Language: English
• Subjects: Aircraft safety; Composite structures; Damage tolerance; Engineering; Experimentation; Fatigue tests; Machines; Manufacturing; Model testing; Probabilistic models; Processes; Reliability; Safety margins; Strength; Wear Resistance of Machines and Structures
• ISSN: 1052-6188; 1934-9394
• DOI: 10.3103/S1052618820110023

The present study analyzes the current and prospective approaches to structural-safety provision of composite aircraft. The modern approach to material design values selection is based on the “worst-case scenarios,” wherein all safety-reducing factors occur simultaneously. The prospective method involves a probabilistic model based on operating experience enabling the reduction of excessive safety margins. The fundamental principle of damage tolerance provision accepted nowadays in industry is search for internal defects and inspecting 100% of structures in production and operation. The prospective approach should be focused on real-time composite-material-state monitoring incorporating next-generation smart technologies like embedded nanosensors and multiscale mathematical model. Full-scale fatigue testing is the most expensive and time-consuming stage of certification, therefore, most efforts in this field are being focused on limiting experimentation and replacing it with virtual testing. The corresponding prospects are analyzed, major risks are examined and measures to implement digital twin of a full-scale article are proposed.