Evaluation of a Lightweight Composite Bottom Plate for Air Cargo Containers

Air cargo containers are used to load luggage, freight, and mail on aircraft. They allow a large quantity of cargo to be bundled into a single unit. This study aims to investigate the replacement of the current 14,1kg aluminium floor with a 40% lighter composite in Nordisk containers. The result of these weight savings are yearly cost reductions or an increased turnover for airliners. I have performed analytical and finite element calculations and have conducted small and full scale tests based on the calculation results and requirements. The tests show that the composites do not have sufficient stiffness which caused excessive deflections in the full scale roller tests. Severe wear on the underside of the composite plates made operation impossible after 800 cycles compared to the aluminium 13000 cycles. Analytical calculations show that decreasing the requested weight savings to 30% might be necessary. For a sufficient stiffness, a composite weight of 9,6kg is achievable.