Z-Beam Composite Stiffened Panel Manufacturing Methods

Abstract

Stiffened panels are important primary structural elements of modern commercial aircraft. Composite materials such as carbon fiber reinforced plastic are being increasingly used in aircraft due to their desirable properties, namely their high strength to weight ratio. The methods to make stiffened panels using aluminum are well known, but less so for composites.

This research focuses on the possible manufacturing methods that can be used to create composite stiffened panels. A subset of possible systems was chosen, such that cocured, Z-beam, composite stiffened panels made of carbon fiber prepreg were investigated. Two unique manufacturing methods were designed, executed, and tested. One method used a vacuum bag approach, and the second used a 2-sided mold approach. The results of each method were compared primarily using a 3-Point Bending Test.

The methods were compared on the basis of production viability and part viability. The results conclude that the vacuum bag approach was certainly superior on the basis of Part Viability, and each method has its own benefits in terms of Production Viability.