Aircraft Manufacturing Industry Research Articles

Innovative Nanocomposite Coating for Aluminum Alloy in the Aircraft Manufacturing Industry with Increased Mechanical Strength, Flame Retardancy, and Corrosion Resistance

AbstractNanocomposites containing impermeable two‐dimensional materials are of significant interest for protecting metals against corrosion. Incorporating 4‐aminobutyltriethoxysilane (ABES) functionalized tantalum nitride (TaN) into a coating matrix enhances the barrier effect due to TaN's notable chemical and thermal stability. When integrated with graphitic carbon nitride (GCN) in polyurethane (PU), functionalized TaN significantly improves corrosion resistance and fire‐retardant capabilities. Electrochemical evaluations of aluminum coated with varying amounts of functionalized TaN/GCN in PU demonstrated substantial enhancements in protective behavior in chloride environments. The PU nanocomposite exhibited superior flame retardancy, with significant reductions in peak heat release rate (PHRR), total heat release (THR), and total smoke production (TSP) compared to pure PU. Flame retardancy tests demonstrated increased thermal stability, attributed to the synergistic effects between GCN and silanized TaN. Electrochemical impedance spectroscopy (EIS) measurements showed a high coating resistance of 8.89×1011 Ω cm2 for PU/functionalized TaN/GCN, even after 40 days of electrolyte exposure. Additionally, the PU/functionalized TaN/GCN coating demonstrated exceptional water repellency, indicated by a water contact angle (WCA) of 164°. Mechanical tests revealed that PU/functionalized TaN/GCN exhibited favorable adhesion strength and hardness, maintaining integrity even under prolonged immersion. These findings suggest that this nanocomposite is a promising coating component for aerospace applications. The integration of functionalized TaN/GCN within the PU matrix presents a novel approach to developing multifunctional coatings with enhanced performance across various metrics essential for aerospace materials.

Effects of using different riveting tools on the vibration exposure and muscle fatigue of riveters and buckers

Riveters and Buckers in the aircraft manufacturing industry are exposed to high vibration levels, often exceeding the Daily Exposure Limit Value (DELV) of 5 m/s2. Proper control of vibration exposure and muscle fatigue is crucial to minimize the risk of Work-related Musculoskeletal Disorders (WMSD). This study investigates the impact of different rivet guns, gun handle positions, and bucking bars on vibration exposure and muscle fatigue. Ten male participants, evenly divided between riveters and buckers, participated in the experiment. Throughout the investigation, various data, including acceleration, Electromyography (EMG), heart rate, grip strength, and perceived level of exertion, were collected simultaneously from the participants. The findings revealed that gun types 3 and 4 resulted in 43.27% lower vibration exposure than gun types 1 and 2, while combining a spring dampener and tungsten bucking bar yielded 24.46% less vibration than steel and tungsten. For both riveters and buckers, the horizontal gun handle position reduced vibration by 12.66% compared to the vertical handle position. Consequently, it is crucial to consider the type of gun, bucking bar, and handle position to mitigate vibration exposure and muscle fatigue among riveters and buckers in the aircraft manufacturing industry.

Stacking Effect of Carbon/Glass Fiber During Drilling Operation of Laminated Polymer Composite

Nowadays, fiber stacks are extensively used in the aircraft and structural component manufacturing industries. It is mainly due to their excellent mechanical and physiochemical performances. The different stacking sequences of fiber materials expand the structural properties due to high-strength carbon fiber and low-cost glass fiber. The fragile and anisotropic conduct of Carbon (Cf) and Glass (Gf) laminates generates different types of complex machining issues. This article focuses on the Drilling test of Carbon/glass fiber hybrid composites using different stacking sequences. The effect of varying stacking orders is explored in this study to identify a feasible composite. The control of varying constraints, namely, spindle speed (N), feed rate (f ), and stacking sequence (SS) of carbon (Cf) and glass fiber (Gf) reinforcement, is performed to achieve the optimal parametric condition. The finding reveals that sample A (C4G4) stacking sequence provides an acceptable value for thrust force 59.05 N and delamination 1.0001 for high drilling efficiency. The stacking technique of carbon/glass layers can be endorsed to the manufacturing sector for cost-effective composite development and a defect-free machining environment.

Advanced nanocomposite coating for aluminium alloy with enhanced corrosion resistance, flame retardancy, and mechanical strength in aircraft manufacturing industries

Nanocomposites incorporating impermeable two-dimensional materials offer promising solutions for safeguarding metals against corrosion. Here, we explore the integration of [3-(2-aminoethylamino)butyl]triethoxysilane (ABES) functionalized tantalum nitride (Ta3N5) into a coating matrix, leveraging Ta3N5's exceptional chemical and thermal stability to enhance the barrier effect. When combined with graphitic carbon nitride (GCN) within polyurethane (PU), functionalized Ta3N5 contributes to enhanced corrosion resistance and fire-retardant capabilities. Evaluation of aluminium's protective behavior in chloride environments using electrochemical methods reveals significant improvements with varying amounts of functionalized Ta3N5/GCN in PU coatings. The resulting PU composite exhibits superior flame retardation, evidenced by substantial reductions in peak heat release rate (pHRR), total heat release (THR), and total smoke production (TSP) compared to pure PU. Electrochemical impedance spectroscopy (EIS) measurements demonstrate enhanced coating resistance (8.75×10¹¹ Ω.cm²) for PU/functionalized Ta3N5/GCN, even after 45 days of exposure to the electrolyte. Additionally, the newly formulated PU/functionalized Ta3N5/GCN coating exhibits exceptional water repellency, boasting a water contact angle (WCA) of 165°. Regarding mechanical properties, PU/functionalized Ta3N5/GCN displays favorable adhesion strength and hardness within the PU substrate, ensuring sustained integrity even under prolonged immersion. Consequently, this nanocomposite holds promise as a valuable coating component in aerospace applications. Therefore, the integration of functionalized Ta3N5/GCN within the PU matrix represents a novel approach to developing multifunctional coatings with improved performance across various metrics essential for aerospace materials. This work contributes significantly to advancing the field by offering novel solutions for corrosion protection and fire resistance, setting a new standard for the development of advanced coatings in aerospace and beyond.

Application of carbon fiber composite materials in aircraft

Carbon fiber composite is a material with excellent mechanical properties. Compared with other high-performance fiber materials, carbon fiber composites have the advantages of high strength and high modulus even at ultra-high temperatures. In addition, the carbon fiber composite material also has excellent electrical and thermal conductivity and electromagnetic shielding performance. Carbon fiber composites are widely used in the aircraft manufacturing industry due to their incomparable performance with other composite materials. In recent years, the amount of carbon fiber composite materials in newly developed aircraft products has reached more than 50%. This paper aims to explore the application of carbon fiber in aircraft, and to reflect the importance of carbon fiber composite materials by comparing models that use composite materials and models that do not use composite materials. The study explores the application of carbon fiber composite materials in aircraft through a comprehensive literature analysis and review. Key findings indicate significant advantages of these materials in enhancing aircraft performance, including reduced weight and increased strength. The paper also discusses the challenges in manufacturing and environmental impacts, offering insights into future research directions for sustainable aviation technologies.

Experimental Study and Analysis of Aerodynamic Characteristics of Gliders with Different Wing Geometries

At present, airplanes are widely used in people's daily lives, and research on this means of transportation is of great importance. Currently, academic research still lacks the influence of different aircraft wing shapes and areas on aircraft flight conditions. This article analyzes the basic principles of glider flight and explores the aerodynamic principles of gliders through paper plane simulation. Firstly, this paper introduces the development history of gliders. Secondly, the mechanical analysis of the aircraft is carried out. The factors that affect the flight performance of the aircraft are analyzed by paper airplane simulation experiments. The experimental results are analyzed, and the future development direction is forecasted. From the final research results, there is a close relationship between the aspect ratio and the glide angle of the plane. In the experiment, lower induced drag allows the aircraft to move further horizontally while descending resulting in a smaller glide angle. This study reveals the relationship between aspect ratio and glide angle, which provides intellectual support for the development of the aircraft manufacturing industry.

Onto-SAGCN: Ontology modeling and spatial attention-based graph convolution networks for aircraft assembly quality prediction

Aircraft assembly is an essential stage in the aircraft manufacturing industry, and the increasing complexity of aircraft functionality has put higher requirements for assembly quality. Various deep learning methods based on image or structural data have been used to predict assembly quality. However, these methods focus more on the structural relationships and interactions between assembled products and are difficult to adapt to scenarios where products and equipment may change. This paper proposes a graph convolutional neural network based on ontology modeling and spatial attention mechanism (Onto-SAGCN) for assembly quality analysis and prediction. Specifically, formal representations of assembly equipment, products, and assembly processes are established using ontologies, enabling the unified modeling of spatial and temporal relationships between entities and resolving the issues of data representation inconsistency. Then, the ontologies are transformed into undirected graphs, where nodes represent entities, node attributes represent feature data, and edges represent relationships or constraints between nodes. Designed to process data from the assembly process, the Onto-SAGCN model is subsequently applied to the assembly of aircraft moving wings. It predicts the diameters of holes by gathering operational data from equipment during the assembly and benchmarks these predictions against other established methods. Experimental outcomes affirm the method's elevated accuracy and dependability in forecasting assembly quality.

The Role of the Government in the Development of the Aircraft Manufacturing Industry in Korea: Implications for Developing Countries

The Role of the Government in the Development of the Aircraft Manufacturing Industry in Korea: Implications for Developing Countries

Linking tactical planning and operational control to improve disruption management in global production networks in the aircraft manufacturing industry

Linking tactical planning and operational control to improve disruption management in global production networks in the aircraft manufacturing industry

Development of a HTS application for the Colombian aircraft manufacturing industry

Development of a HTS application for the Colombian aircraft manufacturing industry

Designing a User-Centered Inspection Device’s Handle for the Aircraft Manufacturing Industry

In aircraft manufacturing settings, workers are frequently exposed to biomechanical risk factors, mainly in the later stages of the production processes, including inspection tasks. To support the development of a novel inspection device appropriate for the end-users and their tasks, this study presents a user-centered approach for the device’s handle. Three different handles were proposed, and the current study aims to find out which handle can offer (1) the best ergonomic conditions and (2) the best stability in holding the device in hand during an inspection task. To this end, 23 volunteers participated in the experimental assessment, which comprised qualitative and quantitative data. A questionnaire was used for subjective comfort assessment. Partial times to execute the task studied, stability metrics of the device during its handling, and kinematic and electromyographic data of the upper limb recruited were measured and analyzed to compare the three handles. Outstanding results include the higher comfort perceived by the participants working with the selected handle for the final design, as well as the reduction in muscle effort. Globally, the results obtained demonstrated that the handle user-centered design potentiates good efficiency and usability of the novel device.

Value Analysis in Airframe Manufacturing Industry: A Value Network Approach

Research aim: To map the value network in the aircraft manufacturing industry ecosystem and to identify the fundamental values in the industry
 Design/Methode/Approach : A literature review was conducted on 26 research papers selected from 132 articles from Scopus and Google Scholar databases. In-depth interviews were conducted with several actors in the industry to validate the study result
 Research Finding: Quality, safety, and cost are the essential values in business competition, based on the industry’s long-term strategy and business objectives.
 Theoretical contribution/Originality: The using of network value analysis in the aircraft manufacturing industry
 Practitioner/Policy implication: The managerial implications of this study are in the form of strategic input for decision-makers in the industry, by understanding their roles and responsibilities in the industry value network.
 Research limitation: Since this study was conducted using a qualitative approach, the quantitative survey would be recommended for future study.
 he industry value network.

Influential process nodes identification strategy for aircraft assembly system based on complex network and improved PageRank

In the manufacturing network, the fluctuation of process operation time can result in the delay of the total completion time, which brings a huge challenge to controlling entire production schedule. For aircraft manufacturing industries, the processes that have a significant impact on the completion time of the assembly line need to be identified and monitored in order to ensure the final assembly efficiency and reliability. However, due to the large number of process nodes and the complexity of resource constraints and relationship constraints, traditional node centrality algorithms cannot identify influential nodes accurately. Therefore, based on complex network theory, this paper studies the influential nodes identification problem in the context of assembly lines. Firstly, The Resource-Process Coupling Network for the assembly line is constructed based on the production background and network resource characteristics. Then, based on PageRank algorithm and the idea of resource iteration, Improved PageRank Algorithm (IPRA) is proposed to identify influential process nodes, which brings the resource and time parameters into the allocation rules. Finally, according to simulation results, a comparative analysis of IPRA and existing algorithms is conducted and concludes that our method can better identify influential nodes in actual complex production networks. Furthermore, this paper identifies influential process nodes of aircraft assembly line based on the case of the commercial aircraft manufactory.

Mechanical Properties of Al–Mg–Si Alloys (6xxx Series): A DFT-Based Study

Al–Mg–Si alloys are used in aircraft, train, and car manufacturing industries due to their advantages, which include non-corrosivity, low density, relatively low cost, high thermal and electrical conductivity, formability, and weldability. This study investigates the bulk mechanical properties of Al–Mg–Si alloys and the influence of the Si/Mg ratio on these properties. The Al cell was used as the starting structure, and then nine structures were modeled with varying percentages of aluminium, magnesium, and silicon. Elastic constant calculations were conducted using the stress–strain method as implemented in the quantum espresso code. This study found that the optimum properties obtained were a density of 2.762 g/cm3, a bulk modulus of 83.3 GPa, a shear modulus of 34.4 GPa, a Vickers hardness of 2.79 GPa, a Poisson’s ratio of 0.413, a Pugh’s ratio of 5.42, and a yield strength of 8.38 GPa. The optimum Si/Mg ratio was found to be 4.5 for most of the mechanical properties. The study successfully established that the Si/Mg ratio is a critical factor when dealing with the mechanical properties of the Al–Mg–Si alloys. The alloys with the optimum Si/Mg ratio can be used for industrial applications such as plane skins and mining equipment where these properties are required.

Separation and reconsolidation of thermoplastic glass fiber composites by power ultrasonics

Recycling of scrap aerospace composites generated during manufacturing process or after its end-of-use has been the current trend followed by aircraft manufacturing industries. These recycled composites shows a reduced mechanical performance as it was already used and further degraded by the recycling processes. Hence, a circular-material strategy is crucial, to recirculate these scrap composites in high-performance applications particularly where high raw material costs, raw material scarcity and energy demands are involved. This work investigates the circularity option for glass-fiber reinforced thermoplastic composite by the application of power ultrasonics. The glass-fiber layers along with the polypropylene matrix were separated in layers and then reconsolidated by power ultrasonics. This novel separation and reconsolidation approach by power ultrasonics, can retain approximately 75% of its original mechanical properties without any alteration in the fiber-bundle arrangement. Microscopic investigations at the reconsolidated interfaces provided a direct correlation with the mechanical performance and selected ultrasonic reconsolidation parameters.

Prediction and evaluation of projectile damage in composite plates using the neural network–cloud model

Composite plates are widely used in the aircraft manufacturing industry. The projectile damage of composite plates is affected by complex factors such as material, structure, impact velocity, and impact angle. A reliable method is needed for efficient structural health monitoring. In this paper, a composite plate damage prediction and evaluation model based on the cloud model and neural network is proposed; the five types of experimental characteristics are used as input parameters, and the depth and diameter of the damage area are used as output parameters to train the neural network–cloud model. This method transforms the quantitative data of impact damage of the composite plate into qualitative damage by introducing the cloud model, which makes the damage situation more intuitive. The results show that the accuracy of the prediction model is 97.23%, the accuracy of the evaluation model is 92.41%, and the comprehensive accuracy of the model is 89.85%. The composite damage prediction model has a good prediction performance.

Prediction of Machining Distortion of Long Beam Monolithic Components Based on the Energy Principle

The aircraft manufacturing industry faces a severe problem of machining distortion. Machining distortion is caused primarily by residual stresses. The energy conversion during the machining process is the essence of residual stress leading to machining distortion. This paper uses the energy principle to analyze the mechanism of machining distortion of long beam parts, pointing out that during stress redistribution, part of the strain energy is released to do work, and the result of stress redistribution is consistent with the principle of minimum potential energy. The energy concept is used to develop a theoretical model of stress redistribution. A theoretical model of stress redistribution based on the energy principle is proposed. A model is proposed for predicting machining distortion during the machining of long beam-like parts, and the model’s accuracy is demonstrated using a case study.

Significance of gyrotactic microorganism and bioconvection analysis for radiative Williamson fluid flow with ferromagnetic nanoparticles

Research on nanotechnology took interest of scientists as well as researchers because of its vast range of applications like curing cancer, medicines, aircraft manufacturing industry, use of nano-robot technology, bio-nano, heat exchanger instruments, used as coolants in engines of vehicles, microelectronics, water distillation, pharmaceutical procedures and rubber materials. Major purpose of this inspection is to examine the usefulness of radiation phenomena with magnetic effects micro-polar nanofluid by use of impermeable surface. The concept of microorganism’s notion is used to make suspended nano-particles stable by using effect of bioconvection influenced by synchronizing deliberation of suitable magnetic field. Since bioconvection is also an appealing research field for bioengineering and biotechnology, in recent year’s variety of bio-convection models are studied for production of microorganisms. The determination of current exploration is to compute the 2-dimensional flow of Williamson ferrofluid under the influence of magnetic dipole. Characteristics of Brownian motion parameter and thermophoresis diffusion for Williamson ferrofluid model apprehending the properties of convective boundary conditions, thermal motile as well as thermal gradients are considered. The system of nonlinear PDEs is transformed in form of ODEs with the help of apt transformations; additionally obtained ODEs are then solved with the help of bvp4c numerical scheme. Impacts of some important physical parameters are expressed pictorially. Results perceived that fluids temperature increases by increasing thermal radiation as well as thermophoresis parameter moreover shows declining behavior in case of Prandtl number. Moment of motile microorganism rises for larger δ1 and Pe whereas microorganism have opposite trend againstLb.

Predictive maintenance analytics and implementation for aircraft: Challenges and opportunities

AbstractThe increase in available data from sensors embedded in industrial equipment has led to a recent rise in the use of industrial predictive maintenance. In the aircraft industry, predictive maintenance has become an essential tool for optimizing maintenance schedules, reducing aircraft downtime, and identifying unexpected faults. Despite this, there is currently no comprehensive survey of predictive maintenance applications and techniques solely devoted to the aircraft manufacturing industry. This article is an in‐depth state‐of‐the‐art systematic literature review of the different data types, applications, projects, and opportunities for predictive maintenance in this industry. The goal of this review is to identify, and highlight the challenges and opportunities for future research in this field. This review found that the current focus of research is too biased towards aircraft engines due to a lack of publicly available data sets, and that greater automation is an important step to optimize aircraft maintenance to its full potential.

Error Management Climate and Job Stress in Project-Based Organizations: An Empirical Evidence from Pakistani Aircraft Manufacturing Industry

Drawing on the JD-R model, this study examines the influence of error management climate (EMC) on the job stress of frontline aeronautical employees. It also analyzes the moderating role of psychological capital (PsyCap) dimensions (i.e., hope, optimism, self-efficacy, and resilience) for the relationship between error management climate and job stress. The data was collected from 208 individuals through a questionnaire survey and was analyzed using a partial least squares structural equation modeling (PLS-SEM) approach. The results revealed that employees’ perceptions of error management climate have a significant negative impact on job stress. PsyCap optimism and PsyCap self-efficacy were found to have a negative moderating influence on the relationship between EMC and job stress. The other two dimensions of hope and resilience were found to have a moderating influence in the same direction as expected, but not at statistically significant levels. The findings of this study provide a unique perspective in realizing the part national and organizational cultures could play in either enhancing or attenuating the influence of an individual’s psychological resources such as psychological capital.