Applying a Stiffened Stitched Concept to Shear-Loaded Structure

NASA and The Boeing Company have worked to develop new low-cost, lightweight composite structures for aircraft. A stitched carbon-epoxy material system was developed to reduce the weight and cost of transport aircraft structure, first in the NASA Advanced Composites Technology (ACT) Program in the 1990's and now in the Environmentally Responsible Aviation (ERA) Project. By stitching through the thickness of a dry carbon fiber material prior to cure, the need for mechanical fasteners is almost eliminated. Stitching also provides the benefit of reducing or eliminating delaminations, including those between stiffener flanges and skin. The stitched panel concept used in the ACT program used simple blade-stiffeners as stringers, caps, and clips. Today, the Pultruded Rod Stitched Efficient Unitized Structure (PRSEUS) concept is being developed for application to advanced vehicle configurations. PRSEUS provides additional weight savings through the use of a stiffener with a thin web and a unidirectional carbon rod at the top of the web which provides structurally efficient stiffening. Comparisons between stitched and unstitched structure and between blade-stiffened and rod-stiffened structure are presented focusing on a panel loaded in shear. Shear loading is representative of spar loading in wing structures.