In this study structural design, analysis and composite manufacturing applications for a tactical UAV, which was designed and manufactured in Aerospace Engineering Department of Middle East Technical University (METU), is introduced. In order to make an accurate structural analysis, the material and loading is modeled properly. Computational fluid dynamics (CFD) was used to determine the 3D pressure distribution around the wing and then the nodal forces were exported into the finite element program by means of interpolation from CFD mesh to finite element mesh. Composite materials which are mainly used in METU TUAV are woven fabrics which are wetted with epoxy resin during manufacturing. In order to find the elastic constants of the woven fabric composites, a FORTRAN code is written which utilizes point-wise lamination theory. After the aerodynamic load calculation and material characterization steps, linear static and dynamic analysis of the METU TUAV&rsquo / s wing is performed and approximate torsional divergence speed is calculated based on a simplified approach. Lastly, co-cured composite manufacturing of a multi-cell box structure is explained and a co-cured multi-cell box beam is manufactured.

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This investigation explored the feasibility of recently developed toughened cyanate ester networks as candidate materials for high performance composite matrix applications. The resin investigated was a Bisphenol-A cyanate ester toughened with hydroxy functionalized phenolphthalein based amorphous poly(arylene ether sulfone). The thermoplastic modified toughened networks exhibited improvement in the fracture toughness over the base cyanate ester networks without significant reductions in mechanical properties or glass transition temperature. Void free, unidirectional carbon fiber prepreg was successfully manufactured with the toughened cyanate resin using a solventless hot-melt technique. The resin mass fraction of the prepregs was between 31 and 35%. The carbon fiber, toughened cyanate ester prepreg was fabricated into composite panels for mechanical and physical testing. The cure cycle used to manufacture the composite laminates was developed with the aid of a process simulation model developed by Loos and Springer. In order to accurately simulate the resin curing and flow processes, the cure reaction kinetics and melt viscosity was characterized as a function of temperature and degree of cure and input into the simulation model. The model generated cure cycle was used in the manufacture 8-ply unidirectional and 16-ply quasi-isotropic composite laminates. The manufactured laminates were well consolidated to the specified fiber volume fraction between 59 and 60%. Photomicrographs showed that the laminates are void free, the fiber and resin distribution is uniform and fiber wet-out is very good. Mechanical tests were performed to measure the impact damage resistance and shear properties of the toughened cyanate ester resin composites. The results show improvements in impact damage resistance compared with the commonly used hot-melt epoxy resin composites. The influence of processing on performance was observed from the results of shear tests. Carbon fabric composite panels were manufactured by liquid molding processes (resin transfer molding and resin film infusion), with a series of four toughened cyanate ester resins generated by varying the concentration and the molecular weight of the toughener. The panels were subjected to physical, damage tolerance, and fracture toughness tests. The results of physical testing indicate consistently uniform quality, and the void content was found to be less than 2%. The toughened cyanate ester composites exhibited significantly improved impact damage resistance and tolerance compared with hot-melt epoxy systems. Marked increase in the mode II fracture toughness were observed with an increase in the concentration and the molecular weight of the toughener. / Ph. D.