PROGRESS IN TECHNOLOGY SERIES

Ice Accretion and Icing Technology

Ice Accretion and Icing Technology

Flem

ming, R

obert J.

Robert J. FlemmingPT-163ISBN: 978-0-7680-8120-6

9 780768 081206

Ice Accretion and Icing TechnologyRobert J. Flemming

The e� ects of infl ight atmospheric icing can be devastating to aircraft.

Universities and industry have been hard at work to respond to the challenge of maintaining fl ight safety in all weather conditions. Proposed changes in the regulations for operation in icing conditions are sure to keep this type of research and development at its highest level. This is especially true for the e� ects of ice crystals in the atmosphere, and for the threat associated with supercooled large drop (SLD) icing.

This collection of ten SAE International technical papers brings together vital contributions to the subject.

Icing on aircraft surfaces would not be a problem if a material were discovered that prevented the freezing and accretion of supercooled drops. Many options that appeared to have promising icephobic properties have had serious shortfalls in durability. Yet, the search continues. One path has been to fi nd a material that at least reduces the ice adhesion so that lower values of force can remove the accreted ice. The other has been to understand the mechanics of drop adhesion to a substrate.

This collection addresses, among other topics, the measurement techniques and the drop physics that apply to icing, certifi cation for fl ight through ice crystal clouds and in supercooled large drops, improvements in predictive techniques, scaling methods, test facilities and techniques, and rotorcraft icing.

Robert J. FlemmingMr. Flemming completed a 45-year Sikorsky Aircraft career in June 2012. As a technical fellow prior to retirement, he served as an engineering mentor and advisor, while also serving as the chief of Sikorsky’s icing research, development, and certifi cation activities. With over thirty years of experience in the fi eld of icing, he is an internationally recognized aerodynamicist and aircraft

icing expert, and has authored or coauthored over 90 technical reports, conference publications, and other documents, many of which are publically-available icing reports, articles, and papers. He led the project that resulted in the icing certifi cation of the Sikorsky S-92A™ helicopter, assisted in the icing certifi cation of the Polish PZL Mielec M28 airplane, and recently compiled material for an FAA rotorcraft icing handbook. Mr. Flemming is a member of the American Helicopter Society, the American Institute of Aeronautics and Astronautics, and the SAE AC-9C Aircraft Icing Technology Committee. He has had leadership roles in several international icing conferences and is the co-chair for the SAE International Conference on Icing scheduled for Prague in June 2015. Mr. Flemming is an American Helicopter Society Technical Fellow (2009) and was honored with the Sikorsky Donald L. Ferris Lifetime Achievement Award (2005), the American Helicopter Society Howard Hughes Award (2006 and 2014), the Purdue University Outstanding Aerospace Engineer Award (2011), and the SAE Charles M. Manly Memorial Medal Award (2013). He was awarded two patents for aerodynamic designs, one patent for the S-92A dual-channel rotor ice protection system, and two icing patents for ice protection and icing instrument concepts.

SAE IN

TERNATIO

NA

L

AEROSPACE

v

Table of Contents

Introduction ............................................................................................................... vii

Effect of Stagnation Flow on an Impacting Water Droplet on a Superhydrophobic Surface (2013-01-2174) ............................................................... 1

Icing Process of Supercooled-Water Droplet Moving on a Surface by Using Luminescent Temperature-Imaging Technique (2013-01-2210) ............... 7

Considerations on the Use of Hydrophobic, Superhydrophobic or Icephobic Coatings as a Part of the Aircraft Ice Protection System (2013-01-2108) ............ 13

Evaluation of Icing Scaling on Swept NACA 0012 Airfoil Models (2011-38-0081) ............................................................................................................ 25

New SLD Icing Capabilities at DGA Aero-engine Testing (2011-38-0086) ............ 39

S-76D™ Tail Rotor Ice Impact Test (2011-38-0101) .................................................. 47

Numerical Correlation Between Meteorological Parameters and Aerodynamic Performance Degradation of Iced Airfoils (2013-01-2137) ............. 61

Calculation of Ice Shapes on Oscillating Airfoils (2011-38-0015) ......................... 75

Oscillating Airfoil Icing Tests in the NASA Glenn Research Center Icing Research Tunnel (2011-38-0016) ..................................................................... 85

In-Flight Icing of UAVs - The Influence of Reynolds Number on the Ice Accretion Process (2011-01-2572) ...................................................................... 95

About the Editor ...................................................................................................... 107

PROGRESS IN TECHNOLOGY SERIES

Design of Automotive Composites

Design of A

utomotive Com

posites

Lu, Pilla

Y. Charles Lu Srikanth Pilla

PT-164

Design of Automotive CompositesY. Charles Lu, Srikanth Pilla

Design of Automotive Composites reports case studies successfully

developed by the automotive industry in recent years.

The chapters, handpicked by Dr. Charles Lu and Dr. Srikanth Pilla, consist

of technical papers selected from the ‘Automotive Composites’ and other

relevant sessions, which the editors have been organizing for the SAE

International World Congress over the past five years.

They testify to the great potential of composites, still in early stages of

realization, despite their still-limited practical applications due to high cost

and lack of deeper design experience with unconventional materials.

The book is divided into four sections, including eleven technical papers

focusing on the use of composites in

• Body Structures

• Powertrain Components

• Suspension Components

• Electrical and Alternative Vehicle Components

The examples presented in Design of Automotive Composites come from

the major OEMs and top-tier suppliers, making them most relevant to those

addressing the new materials challenges of today.

Many of the innovative ideas described in the book have already been

implemented on existing or new model vehicles. Besides, a great deal of

innovation is still in the works.

Because composites can have a desirable combination of the best

properties of the constituent phases, they can be strong and ductile,

stiff and lightweight, greatly amplifying their capacity to be used in yet

undiscovered applications.

The benefits of composites go far beyond weight savings. Polymer matrix

composites have great potential for part integration, which will result in

lower manufacturing costs and faster time to market. The composite parts

can have much smaller tooling costs as compared to metal ones.

With these advantages in mind, there is little doubt

that composite materials can provide many tangible

benefits and will become, over time, the material of

choice for automakers.

Professor Y. Charles Lu, PhD, PE.Dr. Y. Charles Lu is an associate professor of mechanical engineering at the University of Kentucky and an associate editor of SAE International Journal of Materials and Manufacturing. His research interests include micro and nano-mechanics, polymers, and composites, finite-element analysis and computational materials science.

Dr. Lu has extensive experience both in the automotive industry, including senior positions at Dana Corporation and at Akron Rubber Development Laboratory.

He received his PhD in Engineering Sciences from the University of Western Ontario in 2000 and is a licensed professional engineer in the state of Kentucky.

Srikanth PillaDr. Pilla is an assistant professor in the Department of Automotive Engineering at Clemson University and holds an affiliated appointment in the Department of Materials Science and Engineering. He got his PhD from the University of Wisconsin-Milwaukee, with postdoctoral training at Stanford University. Dr. Pilla currently serves as an associate editor of the SAE International Journal of Materials

and Manufacturing. Dr. Pilla has edited two books and authored 70 scientific articles, including 40 journal papers.

His research focuses on the mechanics, processing, and characterization of polymers, biopolymers, multifunctional composites, nanocomposites, and microcellular foams and LCA modeling and analysis.

SAE IN

TERNATIO

NA

L

AUTOMOTIVE

v

Table of Contents

Introduction ............................................................................................................... vii

Body Structures .......................................................................................................... 1

System Level Design Simulation to Predict Passive Safety Performance for CFRP Automotive Structures (2013-01-0663)............................................................................3

Research of Multi-Axial Carbon Fiber Prepreg Material for Vehicle Body (2011-01-0216) ..............................................................................................................17

Glass-Reinforced Thermoplastic Composites for Front End Module Applications (2011-26-0053) ..............................................................................................................23

Powertrain Components ........................................................................................... 29

Structural Analysis of Steering System Components Considering the Anisotropic Material Properties of Carbon Fiber Reinforced Plastic (2013-01-0019) .......................31

Development of Intercooler Plastic Tank Material Instead of Aluminum Die-Cast (2013-01-1175) ..............................................................................................................37

2013 SRT Viper Carbon Fiber X-Brace (2013-01-1775)................................................45

Wear of Glass Fiber Reinforced Polyamide Worm Gear According to the Direction of the Glass Fiber (2010-01-0917) .................................................................53

Suspension Components ......................................................................................... 62

Design and Fatigue Life Comparison of Steel and Composite Leaf Spring (2012-01-0944) ..............................................................................................................65

Development of a Lightweight CFRP Coil Spring (2014-01-1057) ................................71

Electric and Alternative Vehicle Components ........................................................ 77

Development of Polymer Composite Battery Pack Case for an Electric Vehicle (2013-01-1177) ..............................................................................................................79

Composite Gas Cylinders for Automotive Vehicles— Current Status of Adoption of Technology and Way Forward (2013-26-0074) ..............87

About the Editors ...................................................................................................... 99

Biocomposites in Automotive Applications

Biocom

posites in Autom

otive Applications

Pilla, Lu

Srikanth Pilla Y. Charles Lu PT-165

ISBN: 978-0-7680-8148-0

9 780768 081480

Biocomposites in Automotive ApplicationsSrikanth Pilla, Y. Charles Lu

The automotive sector has taken a keen interest in lightweighting as new required performance standards for fuel economy come into place. This strategy includes parts consolidation, design optimization, and material substitution, with sustainable polymers playing a major role in reducing a vehicle’s weight.

Sustainable polymers are largely biodegradable, biocompatible, and sourced from renewable plant and agricultural stocks. A facile way to enhance their properties, so they can indeed replace the ones made from fossil fuels, is by reinforcing them with fi bers to make composites.

Natural fi bers are gaining more acceptance in the industry due to their renewable nature, low cost, low density, low energy consumption, high specifi c strength and sti� ness, CO2 sequestration potential, biodegradability, and less wear imposed on machinery.

Biocomposites then become a very feasible way to help address the fuel consumption challenge ahead of us.

Biocomposites in Automotive Applications, edited by known experts in the fi eld, is segmented into three sections and includes eleven hand-picked SAE International technical papers covering:

• Processing and characterization of biocomposites

• Automotive applications of biocomposites

• A perspective on automotive sustainability

It is a must read for those interested in the growing importance of composites used in automotive applications and their impact on sustainable mobility.

Professor Srikanth PillaDr. Pilla is an assistant professor in the Department of Automotive Engineering at Clemson University and holds an a� liated appointment in the Department of Materials Science and Engineering. He got his PhD from the University of Wisconsin-Milwaukee, with postdoctoral training at Stanford University. Dr. Pilla currently serves as an associate editor of the SAE International Journal of Materials

and Manufacturing. Dr. Pilla has edited two books and authored 70 scientifi c articles, including 40 journal papers.

His research focuses on the mechanics, processing, and characterization of polymers, biopolymers, multifunctional composites, nanocomposites, and microcellular foams and LCA modeling and analysis.

Professor Y. Charles Lu, PhD, PE.Dr. Y. Charles Lu is H.E. Katterjohn Professor of mechanical engineering at the University of Kentucky and an associate editor of SAE International Journal of Materials and Manufacturing. His research interests include micro and nano-mechanics, polymers, and composites, fi nite-element analysis and computational materials science.

Dr. Lu has extensive experience both in the automotive industry, including senior positions at Dana Corporation and at Akron Rubber Development Laboratory.

He received his PhD in Engineering Sciences from the University of Western Ontario in 2000 and is a licensed professional engineer in the state of Kentucky.

SAE IN

TERNATIO

NA

L

AUTOMOTIVE

v

Table of Contents

Introduction ................................................................................................................. 1

Processing and Characterization of Biocomposites ............................................... 5

Processing and Characterization of Solid and Microcellular PHBV/Coir 2 Fiber Composites (2010-01-0422) ...................................................................................7

Effects of Natural Fiber Surface Treatments and Matrix Modification on Mechanical Properties of Their Composites (2010-01-0426) ........................................27

A Study on Impact Perforation Resistance of Jute-Polyester Composite Laminates (2014-01-1055) ..............................................................................................................37

A Comparative Study on the Axial Impact Performance of Jute and Glass Fiber-Based Composite Tubes (2013-01-1178) .............................................................45

Utilization of Agricultural By-products as Fillers and Reinforcements in ABS (2010-01-0424) ..............................................................................................................53

Analysis of the Microstructure and Mechanical Resistance of Laminated Polyester Composites Reinforced with Curauá Fibers (2013-36-0376) ........................................63

Automotive Applications of Biocomposites ........................................................... 71

Agro-Waste Based Friction Material for Automotive Application (2014-01-0945) ..........73

Friction Performance of Eco-Friendly Cu-Free Brake Materials with Geopolymer Matrixes (2013-01-2026) ...........................................................................81

Natural Oil Polyol (NOP) Based Polyurethane Slabstock Foam for Automotive Interior Foam-Fabric/Vinyl Laminate Construction (2011-01-0459) ...............................91

Development of Flax Fiber/Soy-Based Polyurethane Composites for Mass Transit Flooring Application (2010-01-0428) ..................................................................99

A Perspective on Automotive Sustainability ........................................................ 107

SAE’s Green Technology Systems Group: Focus on Environmental Sustainability for the Automotive Industry (2011-01-1258) ................................................................109

About the Editors .....................................................................................................131