Lightweight structural component in particular for aircraft and method for its production

Abstract

Lightweight structural component including at least one panel and at least one stiffening element oriented one of lengthwise and crosswise. The at least one stiffening element includes two side pieces. Each of the two side pieces is at least partially connected to the panel in a material-locking manner. The two side pieces are connected to the panel at two separate joint zones. A method of producing the lightweight structural component includes milling the at least one panel to form at least one thickened region and joining the two side pieces to the at least one panel at the two separate joint zones. This Abstract is not intended to define the invention disclosed in the specification, nor intended to limit the scope of the invention in any way.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS[0001]The present application is a continuation application of parent U.S. patent application Ser. No. 10 / 757,419 filed on Jan. 15, 2004, the disclosure of which is expressly incorporated by reference herein in its entirety. The present application also claims priority under 35 U.S.C. §119 of German Patent Application No. 103 01 445.4, filed on Jan. 16, 2003, the disclosure of which is expressly incorporated by reference herein in its entirety.BACKGROUND OF THE INVENTION[0002]1. Field of the Invention[0003]The invention relates to the design and production of lightweight structural components. Objects in which its application is expedient and possible are all large-volume lightweight structures in which an essential part of the bearing pressure occurs as area load via skin sheets and which are provided with stiffening elements for load distribution, load diversion, reduction of deflection or prevention of denting or buckling. Typically such cas...

AI Technical Summary

Benefits of technology

[0027]The invention is directed to a new kind of lightweight structural component in particular for aircraft and a method for its effective and lower-cost production that is also suitable for complex stress types. It is applicable for both straight and curved stiffening elements, features an improved damage tolerance, direct tensile strength, transverse stress loading capacity and bending resistance, and can be used even with thicker stiffening elements. Moreover, it does not require expensive additional separate production steps.

[0028]The invention is also directed to a lightweight structural component that, despite integral embodiment, features a differential failure behavior, that leads to reduced load stresses and strains in the joint zone and its immediate vicinity and that can be produced simply with modern manufacturing methods.

Problems solved by technology

The stress on the panel / stiffening element structure is very complex due to the different load originations and the static and cyclical loads dependent on many parameters.

The fact that weight-saving potentials in terms of construction methods have been largely exhausted and that the production of this type of differential structure is too expensive because of the limited riveting speed and, in addition, can hardly be improved on in qualitative terms, have a negative impact on the design of the conventionally riveted structure.

Despite better static strength and higher rigidity compared with a riveted connection, the disadvantage of a connection produced in this way lies in its lower damage tolerance which is manifested by, e.g., a higher rate of crack growth of a circumferential crack after crossing the stringer and a lower residual strength.

The reason for this is that, on reaching a welded-on stiffening element, a crack spreads out into the latter.

The reason for this defect or disadvantage is that the known integral embodiments of the connection of the stiffening elements does not provide any adequate geometric, stress-related or microstructural possibilities for stopping a crack, a less damaging crack branching or an energy dissipation near the crack opening.

The crack can thus spread unhindered into the stiffening elements.

Another defect or disadvantage is that the direct tensile strength of a stringer / panel connection laser beam-welded from both sides simultaneously decreases with increasing weld seam depth, i.e., with increasing stringer thickness.

Together with solid state mechanical influences, both of these lead to a greater under-matching in the welding zone, a broader overaged region in the heat affected zone and to an increased risk of formation of micro-hot cracks.

The disadvantage of this solution is that this embodiment is only geared to the two bay crack type of stress, i.e., the bearing of a longitudinal or circumferential crack over two rib sections or stringer divisions.

The reason for the defect is that the two disadvantages of an integrally welded structure—the lack of an effective mechanism for delaying cracks and the locally increased crack growth rate in the weld seam—are combated only with disadvantageous consequences regarding loading capacity for other types of stress, or cannot be combated at all.

One defect of the arrangement is that it is not suitable for improving the prior art with regard to the two critical stress types “tension in the direction of the head of the stiffening element” and “bending in the direction crosswise to the stiffening element.” The danger of static failure as a result of the separation of the stiffening element from the panel, in particular during transverse stress in the side shells, therefore remains.

Moreover, it has a disadvantageous effect that the reinforcements of the stiffening elements do not reduce the local crack growth rate in the weld seam and its direct vicinity.

Another defect is that the reinforcing elements cannot be applied to or inserted in the stiffening elements in an economic manner.

The reason for this is that additional production steps, such as, e.g., riveting the doubler plates, adhering the doubler plates or drilling very long through bores are necessary to apply the reinforcements, which steps are in themselves very expensive or in part even more expensive than the riveting of the stiffening elements to the panel which is to be replaced.

Furthermore, the fact that the variant with inserted tension bands is not suitable for ribs has a disadvantageous effect.

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