Room 102

March 6, 2017
1:00 pm - 4:00 pm

Workshop: Assembly & Joining

of Composite Materials

George “Nick” Bullen, FSME, CPIM, Technical Fellow, Northrop Aerospace Systems

PRESENTED BY
Assembly & Joining of Composite Materials Workshop

Monday, March 8, 2017

1:00 pm-4:00 pm
ROOM 102

By
George N Bullen
Nick
Housekeeping
Roster/Attendance
Introductions
Handouts/USB flash drives
Cell Phones
50 Minute Hour
Numbers Game
 What Can Expect Out of This Workshop?

Leave with a general knowledge for some of the various

processes for assembling parts made from composite
materials
Understand their primary applications and the corresponding
benefits and challenges of each process

Scaled Composites Northrop Grumman

Northrop Grumman Voyager Scaled Composites Bonded Wing Box Demonstration
Modification of X-47B Design SpaceShipTwo
 Overview
• The Basics for Assembling Composite Parts
• Adhesive Bonding
• Enabling Technology
• Fastening Composites
• Enabling Technology
• Assorted Assembly Enablers (Click Bonds and Z-pins)
• Unified Structure
• Advantages and Disadvantages
 Workshop Guidelines

• This Workshop is primarily focused on a “non-expert” audience

• Questions are encouraged…please interrupt

• Not intended as a “Death-by-Viewgraph” marathon
• There will be a breaks
• There will be team challenges, discussion, and videos
 Overview
Further Reading

Defining the The Future of the

Future State of Airplane Factory:
Airframe and Digitally
Automotive Optimized
Assembly Intelligent
Airplane
Assembly

SAE
International SAE International

Coming Soon
Overview
We Start Here
 Tacit Rainbow
• Composite Body – Aluminum Bulkheads
• Glued Together Using Automation
• Positioned with Determinant Assembly Features
 Tacit Rainbow
• Apply adhesive to the bulkhead grooves
• Insert bulkheads
• “Stuff” body
• Apply adhesive to top body cover and bulkhead grooves
• Position and seat the cover on bottom half (Determinant Assembly)
• Clamp, squeeze-out, and cure
• Glue on the nose
• All Automated
• Easy peazy!!!! Right?
Tacit Rainbow
A bridge too far
Program cancelled
Composite Material Parts Assembly
The Basics
 Trapping the Gap
Team Challenge One

The F35 (Center Section) has composite

skins fastened onto precision machined
bulkheads
Why is this challenging (for assembly)?
What can be done about it?
Adhesive Bonding
 Composite Bonding Definitions
• Co-curing: The act of curing a composite laminate and
simultaneously bonding it to some other uncured material,
or to a core material such as balsa, honeycomb, or foam
core.
• All resins & adhesives are cured during the same process.

• Co-bonding: The curing together of two or more elements,

of which at least one is fully cured and at least one is
uncured.
• Requires careful surface preparation of the previously- cured
substrate.
• Additional adhesive may be required at interface.
 Composite Bonding Definitions
• Secondary Bonding: The joining together, by the
process of adhesive bonding, two or more pre-cured
composite parts, where the only chemical or thermal
reaction occurring is the curing of the adhesive itself.

• Requires careful preparation of each previously cured substrate

at the bonding surfaces.
• Usually requires well designed fixtures to align & clamp parts
during processing.
• Re-heating previously cured substrates can be risky.
Problem:
Conventional design and assembly methods for composite
airframe structures severely limit meeting future DoD airframe
needs.
• Shorter build cycles
• Aggressive budgets
• Rate flexible for limited quantities to full production
• “Change-friendly” designs for multi-variant platforms

Action:
Use Rapid Airframe Production Integration Demonstration
(RAPID) to design and build a composite fuselage section
• Integrated complex contour inlet duct
• Integral fuel floors / testable wet bays
• High load introduction (e.g. Nose Landing Gear, Catapult &
Trap Hook)
• Fabricated/assembled with minimal tooling
• Used Out-of-Autoclave MTM®45-1 and Cycom®5320
Results:
• Details and bonded structure designs validated by analysis
• Bonded assembly reduced fasteners by 68%
• Mid course design change had minimal cost/schedule impact

RAPID Airframe Design and Assembly

 Fixed Floor pi preform Paste & co-bonded Co-bonded pi preform
co-bond shear clips skin caps

Duct co-bonded with pi Co-bonded lower Skin paste bond

preforms to upper substructure substructure
Assembly Operations
Bagging Lessons Learned
• Engineered bags simplified
bagging complex
configurations
• Need improved vacuum bag Pi cap co-bond for skin
leak detection capability, bag
consider IR Co-bonded corner clips
• Need to reassess the leak bag
check procedures for large Temporary Braces
structures (large size and sandwich
structure act as vacuum accumulator)
• Need improved methods for
strip bagging over surfaces
where peel ply has been
removed

Assembly Operations Final bagging lower substructure

Skin Bonding Lessons Learned
• MB7500 paste adhesive was easy to
process, had good squeeze out
• For larger structures, recommend
meter mix application equipment
Paste adhesive
• Hard pin location worked well for application
relocating the skin during the paste
bonding operations
• Recommend investigating
alternative clamping methods / Manual skin
tooling in lieu of dead weight for handling and
recurring production positioning
• Recommend developing skin
handling tools / slings for future use
• Optimize quantity of applied paste Dead weight
adhesive for future processes pressure
application

Assembly Operations
Paste bonded skin
Additional Lessons Learned
• Local co-bonding with small
heaters worked well for splice
• Corner clip paste bonding
process needs improvement
• Staggered pattern of small
holes minimized voids in the
bond line, but adds cost
Paste bonded fuel floors
• Magnets did not work for
clamping
• Cleco clamping problematic Heat reflective tent

• Recommend using co-bonded

corner clips where practical
• Need simpler fuel bay leak
check process
• Water difficult to completely
remove
• Requires drying structure prior
to next operation Fuel floor water leak check

Local co-bonded
Assembly Operations frame splice
 Savings: RAPID vs. Conventional Composite
• Assumes same weight and % of composite
fuselage structure
• Based on RAPID actual costs factored for
differences in production environment
• Non-recurring tooling: 59% savings
• Recurring Fabrication: 4% savings
• Recurring Assembly: 39% savings
• Combined Recurring Labor: 25% savings
• Recurring Material: (17%) increase (driven
by pi preform costs)
• Overall Combined Savings 38% @ T1

Up to 59% Reduction
Tooling Hours Total Savings = 53.5% in Tool $ Value

Tooling Material $ Savings = 72.2%

Total Savings = 59.1% Conventional
RAPID
Completed RAPID Fuselage Structure
 Metal Bonding
• Metal Bonding: The same as secondary bonding
except with metal substrates instead of cured
composite substrates.

• Sometimes metals are bonded directly to composites

using one or more processes.
• Metals require very stringent surface preparation including
application of corrosion inhibiting primer prior to bonding to
obtain long term bond-durability at the metallic interface.
• Care must be taken when bonding metal to carbon as
galvanic corrosion can occur in the metal substrate
 Basic Bonding Requirements
Apply uniform clamping pressure
5-50 psi

Properly prepare Control the bond-line

substrate surfaces thickness

Correctly mix and/or

apply adhesive Properly cure the adhesive
Loads on Adhesive Bonded Joints

Tension Compression

Shear

Peel
Cleavage One or both parts are flexible
Both parts are rigid
 Common Joint Designs

Single Lap Tapered Single Lap

Single Strap Lap

 Common Joint Designs

Double Lap Double Tapered Strap Lap

Double Strap Lap

Common Joint Designs

Tapered Scarf Joint

 Failure Modes in Adhesive Bonds

• Adhesive Failure: Failure of a bonded joint between

the adhesive and the substrate.
• Primarily due to a lack of chemical bonding between the adhesive
and the bonding substrate.
• Can be indicative of poor surface preparation or contamination.
• Or, incorrect adhesive selection for the substrate materials.

Adhesive comes clean from one surface or both

Adhesive Failure
 Failure Modes in Adhesive Bonds

• Cohesive failure: Failure of an adhesive joint

occurring primarily in the adhesive layer.
• Optimum type of failure in an adhesive bonded joint when
failure occurs at predicted loads.
• Lower failure loads are indicative of poorly cured adhesive or moisture
or other contaminants present in the adhesive.

Cohesive Failure
1) Poor, Non-Uniform, and Uncured
Adhesive Bond-lines to OML Skin
 People Method Machine
Process Work
Instructions Surface prep
Cause
Composite Fabrication Working life of adhesive Time B/T OML cure & And
Cure times-adhesive adhesive application
Mfg. Engineering
Vacuum limits
Effect Diagram
Sand bags vs. vacuum
Material Supplier Vacuum gauges used
Mixing method
Quality Assurance Adhesive coverage Heaters
Cure time-VARTM resin
Adhesive Mixing Mixing equipment
Adhesive thickness
Time adhesive cure & IML Core cutting process` Adhesive bond failure
Training
Infusion Applicator between core and
precured VARTM skin
Nylon bag (Poorly cured Adhesive)
Shop cleanliness
Adhesive B/T skin & core Vacuum Levels
3M Super spray Glass Storage
Adhesive weight
Solvents used Temp & humidity
Glass beads Hardness check
Core Storage
Scrim Cloth/adhesive Production Acceptance
Adhesive Storage Checklist
VARTM resin
Booties used on shoes Dimensional control
Core
Fiberglass Material Environment Measurement System
 Click red lined boxes
MLAS Manufacturing Timeline Decision
made to
for more data
Fabricated using 3-step process use co-infusion Fabricated using Co-Infusion process.
process
Core was laid scrim side Aug 27th
up.
Discovery of Disbonds in Delivered Panels. Visual
Test Specimens Decision to OK Inspection, confirmed with Destruct Tests
scrim side down Aug 27th – Oct 1st
(36” X 36” quantity 4) June 11th

Fwd Fairing 3&4 (15.6’x 13’), Co-infusion Process Panel Test

Boost skirts 1&2 (9.3’ x 13’)
Plexus
Decision 3 Step Process Panel Test

Oct-Nov ‘07 April ‘08 May ‘08 June ‘08 July ‘08 Aug ‘08 Sept ‘08 Oct ‘08 Nov ‘08

Program
Directive
Decision
Boost Skirts 3&4 (9.3’ x 13’) Re-make of Boost skirt 3 Remakes using single co-
IPT Process Aug. 11-26th (9.3’ x 13’) infusion for Boost skirts 3&4
Decision (9.3’ x 13’) Aug.27th
Fwd Fairings 1&2 (16.5’ x 13’),
Coast Skirts 1-4 (5.3’x 13’).
Fabricated using co-Infusion
June 11th
process.

LEGEND
First MRB Second MRB Third MRB Fourth MRB Fifth MRB
Flight Hardware process process process process process execution.
execution. execution. execution. Execution Aug 27th
Test June 11th Aug 11th Aug 26th (Part Scrapped) (Co-infusion Decision)

MRB
 Low & Variable Core to
Continued on next slide
OML Skin Bond Strength

Click Colored boxes

MLAS Bond Strength
for Quad Chart

1.0
Low & Variable
Paste Adhesive
Material Strength
Fault Tree
Incorrect Paste
Bad or Incorrect Bad or Incorrect Incorrect Paste
1.1 1.2 Paste Adhesive Mix 1.3 Adhesive 1.4
Paste Adhesive Adhesive Cure
Application

Incorrect Paste Paste Adhesive Set

Incorrect Curative Adhesive Too Thick before Core is
1.1.1 Adhesive Selection 1.2.1 Selection or Ratio 1.3.1 1.4.1
or Too Thin Applied & Bagged
Decision

Expired Paste Insufficient Bag or

1.1.2 1.2.2 Expired Curative 1.4.2 Clamping Pressure
Adhesive

Inadequate time for

Incomplete Resin &
1.2.3 1.4.3 Adhesive to Set before
Curative Mixing VARTM Infusion

Adhesive not
1.5 Properly Stored
Legend Prior to Use

Potential Fault Potential

X.X Eliminated X.X Contributor X.X Root Cause
 MLAS Bond
Click Colored boxes
for Quad Chart
Low & Variable Core to
OML Skin Bond Strength Strength Fault
Tree
Low & Variable Incompatible
Core Tensile Process Control
2.0 3.0 VARTM Resin & 4.0
Strength Inadequate
Paste Adhesive
Bad or Resin Incompatible
Incompatible Quality Verification
2.1 3.1 with Cured Paste
4.1 Process
Core Batch Adhesive Inadequate
Bad or Resin Incompatible
2.1.1 Incompatible 3.2 with Partially Cured Manufacturing
Core Material Paste Adhesive 4.2 Process Control
Inadequate
Incompatible
2.1.2 Core Scrim
Adhesive

Contaminated
2.2 Core Surface

Legend
Potential Fault Potential
X.X Eliminated X.X Contributor X.X Root Cause
 The MLAS Team maximized
used advanced design,
development, Rapid Prototype,
and manufacturing tools
leveraging the digital tapestry
across the a wide geographic
landscape.

• Design through launch = less

than one year
• OoA cure of autoclave
materials
• Determinant assembly (No
fixtures)
Time to Cure Global Hawk
First certified military
aircraft constructed using an
all bonded primary
structure.
 Failure Modes in Adhesive Bonds
• Substrate failure: Inter-laminar fracture in
composite structures, usually between the first and
second plies adjacent to the bond-line; can be
common in composite laminates especially those
with brittle epoxies.

Substrate Failure
 Adhesive Bonding

• A wide variety of materials are available when

adhesives are used to bond materials together.
• The choice of which adhesive is best is usually
dictated by the type of composite to be bonded, the
application of the bonded composite, the service
environment, and cost.
• The most common polymers in the structural
adhesives class are: epoxies, polyurethanes, acrylics,
cyanoacrylates, silicones, and phenolics.
 Selection of a proper adhesive

• Thermal Conductivity of adhesive.

• Chemical Compatibility.
• Viscosity.
• Temperature resistance.
• Mechanical strength of adhesive.
 Aerospace Structural Adhesives

• Epoxies
• Wide range of high-strength adhesives available with a variety of curing
& service temperatures
• Bismaleimide (BMI)
• High temperature cure/service (up to 600°F)
• Cyanate Ester
• Good dielectric properties
• Low Coefficient of Thermal expansion (C.T.E.)
• Hybrids
 Marine Adhesives
• Polyester
• Polyester is less expensive than epoxy and is widely used in
marine and other industrial applications.
• Putty joints and fillets are used in many marine designs.
• Polyester is a chemically weak adhesive Vs. epoxy.
• High degree of shrink inherent to polyester resin.
• Vinyl Ester
• Higher strength, modulus, and elongation than polyesters.
• Both polyesters & vinyl esters are co-polymerized with
polystyrene and release high levels of volatile
organic compounds (VOC’s).
 Liquids, Pastes, & Film Adhesives
• Liquids
• Viscosities typically range between 100-6000 cps.
• Generally works best in thinner bond-lines and provide for
a higher degree of direct load transfer than pastes.
• Effective thickness range: .002-.010 inch.
• Can run out of thicker bond-lines with too low of a viscosity.
• Liquids tend to be more brittle and less resistant to peel
and cleavage loads than pastes or films.
• Often “liquid” adhesives are categorized as “pastes”
without distinction by the various adhesive manufacturers.

* Water at 70 degrees F = 1 - 3 centipoise (CPS)

 Liquids, Pastes, & Film Adhesives
• Pastes
• Paste adhesive viscosities typically are > 8000 cps
• Generally works better in slightly thicker bondlines
• Effective thickness range: .005-.020 inch
• Thicker shim or gap filling applications are not necessarily
considered structural – sometimes used with fasteners
• Different fillers offer a wide range of properties
• Minerals, rubbers, thermoplastics, & metals are common
• Pastes usually do not wet-out as well on the substrate as liquids due to
the influence of the added filler
 Liquids, Pastes, & Film Adhesives
• Film Adhesives
• High-performance structural pre-preg film
adhesives
• Stored frozen & thawed to room temperature before use
• Requires an elevated temperature cure cycle
• Different carriers for maintaining bond-line
thickness control
• Woven scrim cloth
• Knit carrier
• Non-woven (mat)
• Typically carriers are made of treated Polyester or
Nylon fibers
 Reticulation
A pattern or arrangement of interlacing lines resembling a net.

• Reticulating film adhesives

• Bonding to honeycomb core
• Heating an unsupported or knit supported film
adhesive, causing the adhesive to flow and fillet
the core cell ends
• Reticulating perforated skins in acoustic panels
• Heating an unsupported film adhesive, causing
the adhesive to flow away from the small holes in
the acoustic skin prior to bonding it to a
honeycomb or other open cell core material
 Surface Preparation of Composites
• Goal
• Raise the surface-free energy of the composite substrate to
enhance wetting of the surface and to facilitate molecular
cross-linking.
• Raise surface energy without damaging fibers in the
laminate
• Ref: Armstrong & Allen; Surface Tension/Surface Energy
• Methods
• Scotch Brite or sandpaper abrasion
• Grit-blast with alumina, silica, or other abrasive media
• High risk method - somewhat operator dependent
 Surface Free-Energy Exchange
If the surface tension value of the liquid is greater than the
surface-free energy value of the substrate the liquid
molecules stay bound together.

Poor wetting means a poor bond!

 Surface Free-Energy Exchange

When the surface free energy value of the

substrate is higher than that of the liquid it allows
the liquid to uniformly wet the surface
This is important to achieving a good bond

This is important to achieving a good bond

Clean the Freshly Energized Composite Surface
Objective: Remove dust and debris from bonding surface
without inducing contamination.
• Solvent wipe with clean cheesecloth or approved wipes
• Double wipe method often specified: Use a solvent saturated wipe
followed with a clean dry wipe to pick-up residual contaminants
• High risk of inducing moisture or other contaminants onto freshly
energized/slightly porous composite surface
• What effect does wiping with solvent have on the surface-free
energy of the freshly prepared composite surface?
• Alternative: Dry wipe with clean cheesecloth or approved
wipes
• Multiple wipes may be required to remove dust sufficiently
• Low risk of inducing moisture or other contaminants
 What About Peel-Ply Surfaces?
• Non-coated Nylon or polyester fabrics
• Leaves no trace contaminates on part surface
• Does not always peel off easy
• Release treated Nylon or polyester fabrics
• Can transfer release agent to part surface
• P.T.F.E. Coated Glass Fabrics
• Easy to remove from part surface with low risk of
damage to part
• Produces a fairly low-energy surface on the composite
 Adhesive Application Issues
• Applying Film Adhesives
• Simple to apply along the faying surface of one or both
substrates that are to be joined
• Heat may be required to form some films to complex
shapes
• Applying Liquid & Paste Adhesives
• Goal: to apply slightly more adhesive than required and
close the joint in a timely fashion
• Provide enough adhesive along the joint to do the job
• *Refer to application template design sketch
• Excess adhesive = excess weight
 Open Time is the Enemy
• A freshly energized surface will try to stabilize over
time and subsequently lose the desired effect
• The surface takes on H2O and other contaminants when
left exposed to the normal shop/clean-room environment
• Adhesive left open on the surface for extended time
may also be affected by the environment (H2O &
CO2)
• Amine Carbonate formation can inhibit most room
temperature curing epoxy adhesive systems
• *Refer to Hysol EA 9394 Open Time Considerations
 Bond-line Thickness Control
• Consistent bond-line thickness of the adhesive
layer is critical, without uniform thickness the
joint strength is only as good as its
weakest point
• Options for thickness control media:
• Micro-Beads (mixed in the adhesive)
• Scrim Cloth
• Knit Carriers
• Non-Woven Carriers (Mat)
 Uniform Clamping Pressure
• Uniform clamping pressure is required to achieve
good wet-out and optimum bond strength
• Added force contributes to free-energy
exchange
• Typical bonding pressures range from 5-50psi
• Mechanical clamping requires sturdy fixturing
• Vacuum bagging can provide uniform pressure
• Vacuum bagging can also cause micro-
porosity in the joint due to frothing of the
adhesive under vacuum
 Curing the Adhesive
• To achieve maximum performance and ultimate structural &
thermal properties, the adhesive must be properly cured
and/or post-cured
• Room temperature curing systems usually take several
days to achieve good structural properties
• The standard definition of room temperature is 77°
F (25°C)
• Elevated temperatures lower the adhesive viscosity and
enhancing the wet-out (energy exchange) characteristics
• High performance adhesives usually require an elevated
temperature cure and/or post-cure for best
performance
 Lap Shear Coupons
• Single lap coupon
• ASTM D1002: Standard Test Method for Lap Shear
Adhesion for metallic Bonding
• ASTM D5868-01: Standard Test Method for Lap Shear
Adhesion for Fiber Reinforced Plastic (FRP) Bonding
• Somewhat useful for quality assurance testing of
adhesives and surface preparation methodology
• The varying stiffness of different substrate materials
influence the apparent adhesive shear strength in the
lap shear test*

*Ref. L.J. Hart-Smith, The Bonded Lap Shear Coupon-Useful for Quality Assurance But
Dangerously Misleading for Design Data
 Single Lap Shear Coupon
• Not useful for generating actual design data*
• Example: 1 inch wide x ½ inch overlap coupon
fails at 3000 lbs breaking loads.
• Multiply the breaking strength x 2 = 6000 psi.
• However - with a 1 inch wide by 1 inch overlap
the breaking number is significantly less than
6000 lbs.
• The joint strength is not doubled with the
overlap length

*Ref. L.J. Hart-Smith, The Bonded Lap Shear Coupon-Useful for Quality Assurance
But Dangerously Misleading for Design Data
 Effect of Different Fiber Forms at the
Faying Surfaces in a Bonded Joint
• Uni-directional Tape
• Should run directly across the joint for best results
• Normally not recommended as faying layer in joint design
• Bi-directional woven fabrics
• Plain & Twill weaves
• Generally good surface materials for faying layer in joint design
• Harness-satin weaves
• Warp/fill face orientation dominance must be considered
• Multi-axial stitched fabrics
• Functions like a unidirectional tape dependent on faying layer
orientation
• Non-woven mats
• Diminished load transfer through mat surface layer
 Summary
• To achieve an optimum bond with metals
• Clean surfaces free of oils & dirt if applicable
• Refresh oxide layer with suitable process
• Chemically etch or couple to fresh oxide layer
• Apply corrosion inhibiting primer (Aluminum)
• Use appropriate adhesive for the application
• Provide uniform bond-line thickness
• Provide constant clamping pressure along B/L
• Cure adhesive to achieve structural properties
 Summary
• To achieve an optimum bond with composites
• Abrade or energize the surfaces to be bonded
• Clean surfaces free from dust or debris
• Use appropriate adhesive for the application
• Provide uniform bond-line thickness
• Provide constant clamping pressure along bond-line
• Cure adhesive to achieve structural properties
Example
 Bonded Structure

Suggested Reading

• DARPA’s Transition Reliable Unitized STructure (TRUST) project.

• Gardiner G. Certification of bonded composite primary structures.

Composites World. March 4, 2013.
http://www.mmsonline.com/articles/certification-of-bonded-composite-
primary-structures

• Samuel B. Fraunhofer I. Cracking Stopping in the Bondline of

Adhesively Bonded Composite Adherents by Means of a Mechanical
Fastener: Numerical and Experimental Investigation. 2015-01-2611
Published 09/15/2015, Copyright © 2015 SAE International,
doi:10.4271/2015-01-2611, saematman.saejournals.org
 When will fasteners go away?
AT THIS CONFERENCE
Enabling Technology
Technical Sessions
Tuesday – 11:30 AM
Laser Bond-line Inspection
David Lahrman, VP
Business Development
LSP Technologies, Inc.
Questions?
Fastening Composites
 Why don’t we just “glue’ stuff
together and get rid of fasteners?

Even if we could……..
The current “batch” and many emerging airplane
types use and will continue to use fasteners to hold
all the pieces of the airplane together.
Continues to be labor intensive
Why address fastening
Safety

• 250,000 to 7 Million Holes

ZIPPER EFFECT

With Fasteners
90
 Why is this important
On April 28, 1988, an Aloha Airlines 737's fuselage blew open
at 24,000 feet, killing a flight attendant and injuring eight
people.

91
 Black Metal

Joining Metal Pieces Together

Drilling Metal to Metal

 Black Metal to Black Gold

Drilling through composites - challenging

Every hole is different

Drilling through composites - challenging

Every outcome is different

 Drilling Effects

Push Down
Peel up

(a) radiography (b) ultrasonic C-Scan (c) computerized tomography

 Limitations of touch probes
• Current gauges meant for metal
Measure length of bore Turn 90°
Measure length of bore

Gauge Gauge

IN OUT

96
 Limitations of touch probes
Current gauges meant for metal

Regions of uncertainty

97
 Current gauges
designed/meant for metals

In composites – the impact is large

Complexity of drill and fill

• Drill and Countersink

• De-stack, Inspect, deburr, repair, clean, re-stack

• EYES ON Human operation
• 100% of holes Composites

• Re-stack and Install fasteners

99
Drilling through stacks of dissimilar materials

Composite
Liquid Shim
Metal
Composite/Composite Stacks
Automated Drilling/Countersink Dissimilar Material Stacks “One Shot”
Pressure
Encoder Foot ON
ASSEMBLY
Spindle
Compression Cylinder

Composite
/Titanium
Stack
Controller

Terms:
• Tracking
• Engagement
• Detection
Preset distances
• Compression
• Drill & Drill/Peck
• Countersink
Drilling/Countersink Dissimilar Material Stacks “One Shot”

Encoder
Spindle
Compression Cylinder

Tracking: Composite
Distance from the /Titanium
surface of the
Stack
Controller workpiece to the
surface of the
pressure foot when
moving from hole to
hole.
Drilling/Countersink Dissimilar Material Stacks “One Shot”
Engagement & Detection
1. Pressure foot touches workpiece
2. Pressure foot presses shaft against encoder
3. Encoder sends signal to controller
4. Controller activates drill/countersink routine

Encoder Composite
/Titanium
Spindle Stack
Compression Cylinder

Controller
Drilling/Countersink Dissimilar Material Stacks “One Shot”
Compression
1. As drill approaches workpiece the pressure foot
presses against the compression valve.
2. The compression pushes against the workpiece to
hold the stack together.

Encoder Composite
/Titanium
Spindle Stack
Compression Cylinder

Controller
Drilling/Countersink Dissimilar Material Stacks “One Shot”
Drill
1. Drill high RPM and high IPM through composites
2. Reduce speed before engaging titanium to low
RPM and Low IPM

Encoder Composite
/Titanium
Spindle Stack
Compression Cylinder

Controller
Drilling/Countersink Dissimilar Material Stacks “One Shot”
Drill
1. Drill into titanium just past drill point Encoder
2. Rapid retract to clear chip
3. Rapid return to previous drill stop
less .050” to account for workpiece 1. Spindle
spring-back
4. Continue drilling with same peck Compression Cylinder
routine until titanium is drilled
(Approx. .100” each peck) Encoder
This is called peck 2. Spindle
drilling
Compression Cylinder

Encoder

3. Spindle
Compression Cylinder
Drilling/Countersink Dissimilar Material Stacks “One Shot”
Countersink
1. Engage countersink RPM and IPM
Encoder
2. Countersink workpiece
1. Dwell at bottom of countersink 1. Spindle
.5 seconds
3. Full retract Compression Cylinder

Encoder
2. Spindle
Compression Cylinder

Encoder

3. Spindle
Compression Cylinder
Drilling/Countersink Dissimilar Material Stacks “One Shot”

Encoder
Return to
tracking Spindle
distance Compression Cylinder

Tracking: Composite
Distance from the /Titanium
surface of the
Stack
Controller workpiece to the
surface of the
pressure foot when
moving from hole to
hole.
 On-assembly Drill Head Examples

ADS F35 Fuselage

Northrop Grumman

JGADS F35 Wing

Lockheed

Aeroscan probe inside

pressure foot (Cut away)
Impact from drilling
composites (Boeing)
 Steps in de-stacking
• De-stack, inspect, deburr, repair, clean, re-stack
• Eyes on Human operation
4 5

Chips

1 2 3
111
 On-assembly automated drilling
Tooling for vibration/deflection mitigation
Tooling/Fixture

Exaggerated compressive drilling operation forces against the workpiece

Some Effects of De-Stacking
• Gapped Fasteners
• Drill misaligned to normal
• De-stack

Photo Courtesy of TRULOCK Precision

Measuring Instruments

113
Complexity of inspection
• Inspection – eyes on
• Each hole size (range) = one gauge
• Each Countersink size (range) = one gauge
• Measure grip length = one gauge
• Visual Inspection (de-stack observation)
NOTE: Each airplane can have a thousand gauges

114
Complexity of inspection
• Example F/A18 Vertical Stabilizer (composite)
• One skin
• 634 holes
• 34 fastener sizes (diameter)
• 34 grip lengths
• = 25 gauges
• = 1150 independent
measurements

115
Why Automate
Automating the Process

Automated Assembly Cell

Northrop Grumman
F35 Integrated Assembly Line (IAL)
Palmdale, California
Why is this important
• Automation
• Improves throughput
• Fewer defects & rework
• Decrease accidents &
repetitive motion disabilities

Before complete
Transition to Automation
Two processes separated by humans

Humans impact throughput

119
 Drill, Inspect, Fill (DIF)
Three separate operations
Automating the gauging process
Automation
• Enables automated one shot drill & fill
• One gauge & operation
• No de-stack
• 7% assembly cost savings
• Eliminates eyes-on
• Provides complete hole diagnostics Also helps when
(required for composite parts assembly)
hands drill product
Handheld
• One gauge & operation
• No de-stack
• 5% assembly cost savings
• Objective inspection
• Provides complete hole diagnostics
(required for composite parts assembly)
121
 Enabling Technology
Non-Contact Ring Laser Technology
• Countersinks

• Countersinks are simultaneously

scanned using the same probe
• No hardware modification is
needed
• Determines countersink depth

Composite
Aluminum
• Destack
• Aeroscan proactively can identify gaps, burrs, and debris as
part of the inspection and diagnostic process reducing or
eliminating the need for Destacking or post-drill process
evaluations.* Substructure
Liquid Shim
Damage and Voids
Composites

HOLE De-stack 

* Potential

Burrs and Debris

Sample Application

Same nose piece

and locking
mechanism
Operation transferred to an automated gauge
One gauge – one measurement cycle
Vertical Stabilizer Double Sided Automated Drilling System
VADS

In Operation since - 2002

Aeroscan Retrofit -2016
Applied Drilling Systems (ADS)

In Operation since - 2010

Aeroscan Retrofit -2016
Future Applications
 Advantages and Disadvantages
Advantages include:
• Automating the entire process DIF
• Improved composite assessment
• In-process tool monitoring
• Eliminate de-stack
• Data analytics
• Independent actionable machine decisions

Disadvantages include:
• No multi step checks and balances
Scary Stuff!!!
• Glass (Questionable Robustness)
• Pricy$$$$
 Consequence
Specific Risks

1. Technical 5

2. Cost
4

Rigid testing 3. Integrator Involvement

Likelihood
can mitigate risk 3
4. Migration (TTP)

5. Workforce Development 2

6. Program
1
7. Facility Requirements

8. Reduce Uncertainties 1 2 3 4 5
ALTERNATIVES
Conoscopic Holography

The first sensor takes several reference points while the second sensor
attached to a periscope is able to get into holes and measure both the
depth and side walls. By using a periscope’s co-linearity technology the
gage can scan inside deep holes to get depth, diameter, and sharp
angles such as countersinks.
Non-contact Capacitive Hole Diameter Sensor Probes

Non-contact capacitive hole

diameter probes are made by
installing two, three, four or more
non-contact capacitive
displacement sensors around a
circular metal probe.
 Air Probes

The air probe (also referred to as an air

plug gage, air spindle or mandrel) consists
of a precision ground hardened steel body
incorporating two or more air gage nozzles.
Air is passed through the probe body to the
nozzles where a back pressure is
produced by the surface of the workpiece.
An air gage readout (air comparator)
senses the resulting back pressure and
displays the size of the workpiece.
 Laser Profilometer
Electroimpact
Automated countersink measurement
methods which require contact with the
workpiece are susceptible to a loss of
accuracy due to cutting debris and lube build-
up. A non-contact method for countersink
diameter measurement on CFRP eliminates
the need for periodic cleaning. Holes are
scanned in process using a laser
profilometer. Coordinates for points along the
countersink edge are processed with a
filtering algorithm providing a highly
repeatable estimate for major and minor
diameter.
 Ring Laser Non-Contact Probe
Current Peacekeeper and small ICBM guidance systems require
measurement tolerances of 5 microinches (five millionths of an inch) on
bores used in critical bearings in the SFIR (Specific Force Integrating
Receiver) and TGG (Third Generation Gyro). Quest Integrated, Inc.,
conducted a Phase I program to investigate the feasibility of developing a
noncontact measurement system based on the principle of optical
triangulation for characterizing the diameter and cylindricity of these
bores. The study showed that the fundamental limitations to the
measurement technique are in the sub-microinch range. A first prototype
probe was constructed and used to demonstrate the measurement of
internal diameters to the resolution limit of the AID converters employed (8
microinches).

The probe has been further developed and allows easy measurement of
the internal dimensions of cylindrical shapes. This tool has wide
applications as a generic precision measuring tool.
 Ring Laser Non-Contact Probe
The substrates used for the probe body were abrasive-waterjet
(AWJ) machined and drilled at Quest from ULE™ coefficient
glass. This high titanium glass supplied by Corning Glass has a
thermal expansion coefficient of approximately 30 ppb per degree
Fahrenheit at room temperature.
 Ring Laser Non-Contact Probe

The substrates were Abrasive Water Jet (AWJ) cut to 0.130-

inch square blocks 0.875-inch long. They were then AWJ
drilled. With a few days of experimentation, the two one-
hole substrates were drilled without damage to a hole
diameter of 0.098 inch with less than 0.001 inch of taper
over the entire length of the hole. Coincidentally, this hole
diameter is ideally suited for mounting standard 0.5-mm-
diameter (0.019685”) GRIN lenses.
FURTHER READING:
Bullen G.N. Automated Assembly on the Moon. Aerospace and Defense Advanced Manufacturing,
Annual Journal, SME. 2014.
Malcomb Joseph R. Laser Profilometry For Non-Contact Automated Countersink Diameter
Measurement. 2014-01-2255. 09/16/2014 SAE International doi:10.4271/2014-01-2255
saeaero.saejournals.org

AT THIS CONFERENCE:
Integrated Assembly II/S-1
Wednesday February 10
From 2-4 PM
Non-Contact Holistic Measurement of Aerospace Fastener Holes with Ring Laser Adaptive Optics Dr.
Harris Bergman, VP, Engineering Innovation, United Sciences
Integrated Assembly I/S-1
From 10:30 – 10:55 AM
Automation for Families of Parts George Bullen
 NOTE
Automation need not be complex or expensive
QUESTIONS
 ADVANCED ANALYTICS

What is advanced analytics?

ADVANCED ANALYTICS

Advanced Analytics are analytical techniques applied

to as-manufactured data, which go beyond simply
describing the data –

Includes a Digital Imagery Plan to document as built

configurations that are reconciled back to the
original engineering.
ADVANCED ANALYTICS

instead they explore the hidden relationships and

patterns within the data.

They allow us to infer things that are happening that

cannot be seen with simpler cross-tab analysis.
 ADVANCED ANALYTICS
The idea is to get to red
ADVANCED ANALYTICS

Automated exploration of as-manufactured data.

Reduces time to decision.

As A General Rule of Thumb:

As Much As 75% Of On-Part Dimensional
float Are Due To Variations Beyond Machine
Performance!
ADVANCED ANALYTICS

For
automated assembly
begins with enterprise operations intelligence
software

that enables event-driven analytics and process

improvements
 ADVANCED ANALYTICS

• The engineers thought the digital tapestry was a

beautiful thing
ADVANCED ANALYTICS

• At the assembly (on the shop floor) it looked like

this

Mechanics view of the digital thread

Automation for Families of Parts
10:30 AM – 10:55 AM
Wednesday
QUESTIONS
Assorted Assembly Enablers
(Click Bonds™ and Z-pins)
Click Bond™
 Nut-plates
Three for One

• Applied for many reasons

• Remove and Replace (R&R) parts
 Nut-plates
Three for One
• Primary holes are drilled
• Secondary nut-plate attach holes are drilled
• Specialized nut-plate pneumatic drill motor
• By hand (standard d pneumatic drill motor)

Option A

Option B
 Nut-plates
Three for One

• Blind fasteners are installed and “pulled”

OR
• Rivets are installed and squeezed
 Nut-plates
Three for One

Nut plate process

Drill Primary Drill Nut- Install Nut-

Hole plate Holes plate

One Hole Two Holes Three Holes

One Two Three

Fastener Fasteners Fasteners
 Click Bond™
Replaces holes and fasteners with adhesive
Click Bond™
 Click Bond™

Used on the F/A18 E/F

and many other airplanes

NASA qualified for

space vehicles
 Click Bond™
One for One
Click Bond™ process

Drill Primary Install Nut-

Hole plate

One Hole

One
Fastener
 CAUTIONS
One Example

Boeing Alert Service Bulletin 777– 78A0065, Revision 2,

dated May 6, 2010, describes procedures for reviewing
the airplane maintenance records to determine whether
sealant was added; repetitive detailed inspections of all
thrust reverser (T/R) inner wall insulation blanket edges,
grommet holes, penetrations, and seams for sealant
that is cracked, has gaps, is loose, or is missing;
repetitive general visual inspections of click
bond studs,
QUESTIONS?
Z-pins™
 Z-pins™
What are Z-pins?
• Z-pinning is a technique to insert reinforcing fibers (also called Z-pins
or Z-fibers) along the Z-direction of continuous fiber-reinforced
plastics.
• Z-pins can be made of metal or pre-cured unidirectional composite
fibers. It is designed for use within pre-preg technology
• There is extensive experimental evidence that Z-pinning
dramatically improves the resistance of the composite
structure to delamination.
 Z-pins™
• Several ways of inserting Z-pins have been developed to date.
• One method involves the use of an ultrasonic hammer that forces the
Z-pins through the uncured preform while inducing high frequency
vibrations to them.
• The vibrating chamfered tip of the Z-pins locally heats up and softens
the resin allowing the Z-fiber to penetrate the preform with minimal
disruption of the long fibers.
Z-pins™
 Z-pins™
Case Example

Application of Z-Pins to F/A – 18 E/F

Mechanical Fastener Attachment Advanced Attachment with “Z-Pins”
Requires: Requires:
• Pre-Curing of Multiple Details • Integration of Composite Lay-ups
• Drilling/Countersinking of Fastener Holes • Installation of Z-pins Prior to Cure
• Application of Liquid Shim • Backside OML Sealing
• Wet Installation of Fasteners

Pre-Cured Composite Co-Cured Composite

Radius Block Hat Stiffener

Pre-Cured Co-Cured
Composite Skin Composite Skin

.011” Dia. GR/BMI Z-Pins

Demonstrated Benefits (420 pins/in2)

 Reduced Touch Labor

 Reduced Weight
 Reduced Part Count
 Reduced Defect Count
 Increased Interlaminar Capability
 Improved Damage Tolerance
 Co-cured Hats With Z-Pins
Inlet Duct Skins
4,800 Fewer Fasteners

Mechanically Fastened Hat Configuration Current Z-Pin Hat Configuration

FE42 Installation FF42 Installation
Part Number Breakdown
Cocured Hats With Z-Pins
74A342709 (2/2) 74A342725 (4/4)
74A328511 (3/3)

74A328509 (8/8) Z-Pin Cocured Hat Stiffened Part (TOW Placed)

74A325620 (7/7)
Z-Pin Cocured Hat Stiffened Part (Hand Lay-Up)

74A341701 (1/1) 74A326703 (2/2)

74A348701 (6/12)
74A341701 (5/9)

74A328326 (7/7)

74A328615 (2/2)
74A325604 (9/9)
74A326729 (2/2)

74A328854 (14/14)
74A326753 (2/2)
74A328851 (15/21)
74A328646 (3/3)
74A328853 (7/11)
74A345602 (5/7) & (6/8)
74A328855 (20/20) 74A345662 (13/15)

74A328852 (10/11)

Inlet Duct Skins

 Structural Certification
• Joint Design Must Meet Conventional Acceptance Criteria Plus:
• 30% Increase on Fatigue Spectrum Design Loads As a Robustness
Factor
• Cannot Change Load Paths/Failure Mechanisms
• Demonstrate Acceptable B-basis Allowables With Z-fiber
• Load Induced Delaminations Are Allowed… Provided:
• Delams Do Not Extend Over .75” Into the Joint
• Any Delams Must Not Grow for 3 Lifetimes After Initiation
• Delams Must Not Compromise Joint Static Capability After Fatigue
Limits Are Met
Z-Pin Insertion
Zone

Allowable
Defect Zone
Z-Fiber Reinforcement Density Manufacturing Certification
Must Allow Standard NDE Inspection

• Developed New Manufacturing

Process for Co-cured Hats
Thinning Under Hat Must • Verified Through Inspection/Dissection of 8 Full
Meet Navy Specifications Scale Articles, 4 Part Numbers
• Created Appropriate Control Documents ie..PCD,
MMS, PS
• Developed Production Insertion Plan
to Smooth Implementation
• Produced 100% Acceptable DD63
Tear Down Articles for All Part #’S
 Benefits To F/A-18 E/F

 Reduced Cost by $85K Per Ship-Set

 Composite Part Touch Labor Reduction
 Weight Reduction of 34 Lbs Per Ship-Set
 Elimination of More Than 4,800 Fasteners Per Ship-Set
 Eliminates Nylon Channels Covering Fuel Tank Fasteners
 Reduced Engine FOD Potential
 Eliminates 4,800 Fasteners Per Ship-Set in Inlet Duct
 Reduced Assembly
 Improved Quality And Part Fit-up
 Reduced O&S Costs
 Typical Fixed N-UCAS Skin Panel
• Fixed skins baseline:
- Skins IM7 composite, some titanium
- Pre-cured composite hat stiffeners bolted on
Some clipped to sub-structure (highly loaded) Otherwise panel breakers

Air Data Ports

View A
 • Hat Stiffeners
-Total Quantity: ~ 400
-Total Linear Feet: ~520 ft

Composite Hat
Bolted on

Fiberglass Barrier Ply

OML Pre-cured Skin

Typical N-UCAS Fixed Skin Panel, Detail View

Leveraging the Technology Forward
Technology Revolution for Broader Usage of Composites:
Design Criteria Evolution
Damage Tolerant Structure
Allows Load Induced Delams
F/A-18 Application Demonstrated: Enables Integrated Structures

Cost savings
Weight Savings
Reduced Part Count
Improved Quality Enabling Additional Applications:
 UCAV-N Integrated Structure
 Fastener-less Inlet Designs
Expanding Applications  Integrated Thermal Protection for B-2 and Space
Applications

Z-pinsTM Provided Significant Benefits to the F/A-18E/F Program.

Will be Considered in Applications That Solve Existing Technical Problems.
 Z-pins™
Automating the Process

• Several attempts to automate the Z-pinning process

• Example: Limited success using load cells to replicate the hand
“touchy-feely” sensitivity needed
• Research continues
Questions? Comments?
Unified Structure
 Large Scale Composite Space Structures
• Altair Lunar Lander
• Ascent Module
• Descent Module
• Ares V Heavy Lifter
• Payload Shroud
• EDS
• Core Stage
• Avionics Skirt Lunar
• Lunar Surface Systems Surface Systems
• Habitats
• Rovers

Altair Ares V
 Unitization
• Reduces Mass
• Eliminates Longitudinal Joints
• Integrates Assembly and
Separation Joints
• Reduces Minimum Gauge Penalty
• Reduces Cost
• Reduces Part Counts
• Reduces Supply Chain
• Reduces Assembly Operations

Unitization Reduces Mass And Cost

Ares V Composite Structures
Unitization Candidates
ERGO Man
For Size
Comparison
Altair BAA Configuration Composite Structures
 Unitized Structure
1500 Pounds Weight Reduction
Altair TAC0 Structural Arrangement Altair Configuration Studies

AM Crew Cabin Habitat Airlock

Min Surface Area Refuel after LOI Fit in 5m Fairing

Strut & Truss Propellant Depot

DM LOX Node Studies Studies
DM LH2 Tank
Tank EDSA 100%
LOX Payload Tank Fill at Launch Capacity
for 2.4m Diameter Tank by Launch Vehicle

90%

80%

70%

60%

Fill Percent
50%

EDS Configuration Air-launched Crew 40%

30%

20%

10%

Studies Transport System 0%

Launch Vehicle

Patent Pending End Ftg Tank Size vs Launch Opt

MLAS Crew Escape
System
Improved Metal Tank Studies

Common Tooling Core &

Upper Stage LOX & LH2
Common Bulkhead Potential Tanks More Unitized Orthogrid vs Optimized Skin Stringer
187 As of 10/04/09
Win Strategy: Low Cost Wins

Composites
Cost and Drivers
Autoclaves
Floor Space
Rigid Sequential Manufacturing
Material Distribution (Layup) Rates
189
 Grandpa…tell usthat
scary story about the
AUTOCLAVESagain.

“…here I opened wide the door … darkness there and nothing more.
Deep into that darkness peering, long I stood there, wondering, fearing, doubting,
dreaming dreams no mortal ever dared to dream before;”
Edgar Allan Poe “The Raven”

Approved for Public Release: Northrop Grumman Aerospace Systems Case 13-0319, 03-08-2013
First…Some Useful Definitions
Out of autoclave composite manufacturing is an alternative to the traditional high
pressure/elevated temperature autoclave curing process commonly used by the
aerospace industry for manufacturing composite material. Out of autoclave (OOA) is a
process that achieves the same quality as an autoclave.

Autoclave is a high pressure (100+ psi) and elevated

temperature (750°F +) vessel used for consolidating and
curing prepreg composite laminates
OOA is any composite fabrication that is not
performed with an autoclave
1. Wet Lay-up
2. VARTM
3. Compression Molding
4. RTM
5. SQRTM
6. VBO prepreg

Approved for public release; NG15-0599, 4/14/15

Part designs not limited to autoclave size
Autoclave costs increase exponentially with increasing
diameter
Reduced risk for vacuum bags leaks/failure at high pressure
Lower potential for core migration and skin dimpling
Lower recurring operating costs
Oven configurations are more flexible & less expensive
 Options to consider portable/pop-up ovens
 Simplify handling/transport of large/heavy tools in/out of autoclave
Larger industry base due to lower asset requirements
Increased ability for large structural integration

Approved for public release; NG15-0599, 4/14/15

 Built by
Scaled Composites
for Virgin Galactic

• One of the largest aircraft built and

flown to date and fabricated primarily
with out-of-autoclave cure materials
• Wingspan: 141 ft

Approved for public release; NG15-0599, 4/14/15

 Burt Rutan-Voyager Scaled Composites-SpaceShipOne
1st around the world nonstop, non-refueled flight First manned private spaceflight

Northrop Grumman-X-47B (Modified Demo) Northrop Grumman

Complex bonded composite CRAD Bonded Wing Box Demonstration Article

Approved for public release; NG15-0599, 4/14/15

Disadvantages
Complex Tooling
Stringer Holding Expansion Membranes
Fixture

Geometry
Adjustment
System

Mandrel Shaft
Expandable
Cylinder

Radial Stiffeners

Tape Laying Surface

196
 Northrop Grumman Private

Stringer Holding Section IML Surface

Fixture

Geometry Adjustment
Expansion Membranes System
The travel is longer than the
different in thickness
 Laminated Skin 0,2 to 0,4% elongation

Maximum pressure:
29 psi (2 Kg/cm2)
199
Win Strategy: Low Cost Wins

In Situ Manufacturing System (IsMS)

200
 Basic Manufacturing Flow
Example: Ares V Interstage: 10 Meter Ø, 14.6 Meter Long
• Traditional Manufacturing Flow:
• 6 Manufacturing Stations
• 6 Moves
1 2 3 4 5 6

•Layup •Cure •Extraction •Inspection •Machining •Inspection •Secondary

Processing

• IsMS Manufacturing Flow:

• 1 Manufacturing Station
• 1 Move
1

•Layup •Secondary
•Cure Processing
•Inspection
•Machining
•Inspection
•Extraction

The IsMS Reduces Facility Requirements By Consolidating

Processes Into A Single Station And Eliminating Required Moves
201
 What Is The In-situ Manufacturing System?
• Multiple Variants:

Unitized Composite Segmented Composite Metallic Friction

Structure Fabrication Structure Assembly Stir Welding
Structure Assembly

IsMS Is a Flexible Manufacturing Technology For Large Space

Structures Reducing Cost and a Northrop Grumman Discriminator
Unitized Composite Structure Fabrication
• Single footprint system with multiple processing heads
• Automated Tape Placement head
• Drill head
• Non-Destructive Inspection head
• Cures components via Out-of-Autoclave technologies

Automated Lay-up Non-Autoclave Drill, NDI &

Cure Extraction
Segmented Composite Structure Assembly

Major Assembly
and NDI

Segmented Panel
Assembly Component
Extraction
Metallic Friction Stir Welding Structure Assembly

Friction Stir Welding

and Drilling

Segmented Panel
Assembly Component
Extraction
IsMS Handling & Assembly Fixture
• Indexes mandrels and assembly fixtures onto IsMS
• Extracts components from mandrel/fixture and
locks component’s geometry
• Rotates components for Secondary Operations
• Indexes to additional Handling Fixtures for
component splice operations

Index for Group A Outfitting Align for Component Mate

 Would Mitigate Current Composite Cost
and
Complexity to Bring It On Par With
Aluminum

AM Air Lock

Habitat Crew Module

The IsMS8 Is Scaleable To Ares V Class Structures

207
 Summary
• Lower Mass
• Reduce or Eliminate Dome Parasitic Mass from Natural Path Lamination
• Unitize Barrels, Domes and Cones Eliminate Longitudinal Joints
• Integrate Assembly and Separation Joints
• Lower Cost
• Not Slave to Large Fixed Asset (Autoclave)
• Reduce Facility Requirements (Single Footprint)
• Reduce Supply Chain, Processes and Parts
• Demonstrated Capabilities
• 8 Foot Diameter Pathfinder In-situ Manufacturing System
• Scaleable to Constellation Class Structures
• Workforce Development
• Hands on Growth Opportunities for Young Engineers
• Hands on Opportunities for Interns
 Conclusion
• Composites Enables Unified Structure
• Size Constraints
• The Joining of Composites Is Complex
• Fasteners
• Adhesives
• Automation
• Future Composite Material Advances
• Will Challenge Manufacturing Technology
Questions?
 Thank you!

George N Bullen
Nick

Contact Information
[email protected]