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Metallic & Manufacturing
Light Materials for energy efficient structures •New light weight materials : Al, Mg, cellular...•Multifunctional/hybrid materials : FML, foams•Unitized structures concepts: co-extrusion
High performance material concepts•High specific properties light materials: Metal Matrix Composites•Nano-structured and nano-reinforced•High specific properties hard materials : Ti, steel•Extreme environment materials : metallics and ceramics
Eco efficient joining & assembly •Robust joining technologies (FSW, LBW)•Hybrid material fastening & machining
Near Net Shape Manufacturing•Additive layer manufacturing•Innovative forming technologies
© EADS 2012 EADS INNOVATION WORKS general presentatio n
Surface Engineering
Green surface technology: avoid direct environmental impact by toxic coating materials or auxiliary process materials
•Replacement of hazardous materials (Chromates, Cd, VOC…)•New corrosion inhibition concepts•Out-of-bath surface treatments: Dry (Plasma, laser) & Wet (spraying)
•One-coat layer concept
Sustainable functional surfaces : reduce environmental impact during operations (low weight, low drag, durability)
•Wear (erosion, abrasion, scratch) and fretting protection systems •Advanced Functional Coatings - Structures, Cabin and Systems•Aerodynamic surfaces•Metallic solution for CFRP lightning strike protection
SurTech enabling cost and/or lead time reduction•Cleaning and activation•Surfaces for moulds and tools
© EADS 2012 EADS INNOVATION WORKS general presentatio n
Failure, Material and Surface Analysis Skills
Materials and surface characterisation: •Physical & Chemical analysis (FTIR, Thermal, X-ray, XRF,…)•Microscopic material and surface characterization by electron microscopy (SEM-EDS) and surface analysis (XPS, SIMS)
•Tribological and corrosion testing, electrochemistry•Mechanical testing : static, fatigue and fracture mechanics•Destructive (hole-drilling) and non-destructive (X-ray) residual stress measurements
Operational durability: Understand and prevent failure and degradation of materials and coating ���� extend service life
•Correlation of processing parameter and in-service behaviour•Failure analysis and understanding of long term materials and coatings degradation behavior
•Failure prevention and enhancement of durability (residual stresses induction)
© EADS 2012 EADS INNOVATION WORKS general presentatio n
• Al-alloys : screening and characterization of weldable & improved AlCuLi, 7xxx and AlMgSc alloys, development of thermo-mechanical treatments, fundamental understanding of failure, corrosion and long therm behavior
• Mg-alloys: screening and characterisation of spec. high strength alloys with improved corrosion and flammability behavior, development of surface protection, development and simulation of cold and hot forming processes to produce
• Others: metal laminates, foams,…
Trolleys,Interior components
Raceways
Hatrack brackets, various other brackets
Fuel connectors
Seat structures
Door hingesElectronic bayaccess door
Shear-compr. Panel (Airbus, Aleris) Potential Mg applications
Light Materials for energy efficient structures
© EADS 2012 EADS INNOVATION WORKS general presentatio n
• Ti-alloys: challenge Ni-alloys with new near β titanium alloys. Taylor properties by improved heat treatments. Optimize castability and forming processes
• Nano structured and nano-re-inforced Al-, Mg- and Ti-alloys
• Steels: development of heat treatments to improve aging behavior of 15-5-PH
• Extreme environment metallics: low cost metallic high temperature alloy for satellite thrusters and missiles (Pt replacement). Cu based liner materials.
• Extreme environment ceramics: ceramic matrix composites for appl. at >1700 °C (combustion chambers, nozzles, ram-jets, TPS for re-entry, brake materials)
Milling time: 30 minMilling time: 30 min
Manufacturing in textile technique (braiding), TCC 1
High Performance Material Concepts
© EADS 2012 EADS INNOVATION WORKS general presentatio n
Eco-efficient joining and assembly
Friction Stir Welding : tooling concepts and robotized and self-reacting FSW for final assembly lane and major component assembly
Metal / CFRP hybrid joints : optimization of one-shot drilling of hybrid stacks, cold hole expansion of metal side of hybrid stacks, corrosion prediction and protection, metal-CFRP rivetless assembly(Hyperjoints, nanofoils)
Robotic FSW of A330 panel
CFRPMetal
FS welded Rib 1
© EADS 2012 EADS INNOVATION WORKS general presentatio n
Additive Layer Manufacturing: cost savings for high value parts (improved buy/fly ), weight savings through topol. optimisation, improved carbon footprint (waste material and weight savings), reduced lead-time and late design freeze
• powder bed for net shape complex parts (Ti, Al, Ni, steel..)
• large near-net parts by wire/powder feed (Ti,..)
Forming technologies: dieless and rapid forming of Ti-, Al- and steel sheets through incremental sheet or laser forming.
Page 7
Near-net shape Manufacturing
combined stretch and incremental
forming
© EADS 2012 EADS INNOVATION WORKS general presentatio n
Green Surface Technologies
Compliance with environmental regulation REACH , anticipate supply chain disruption, competitive advantage through 2nd generation protection concepts , lead time and weight reduction reduction
• replacement of hazardous chemicals (Cr6, Cd, VOC, …) in anodizing and coversionpre-treatments, 1s gen primers, Cd and hard-Cr replacement
• active corrosion inhibition through encapsulation , release on demand
• one-coat layer (SolGel, E-coat)
• dry (plasma, laser) and wet (SolGel) out-of-bath treatments
Corrosion inhibitors in core of silica particles
Pre-treated Surface
Sol-GelONE-COAT
Pre-treated Surface
Sol-GelONE-COAT
ONE COAT CONCEPT
Pre-treated Surface
Sol-GelOne-COAT
Top Coat
Pre-treated Surface
Sol-GelOne-COAT
Top Coat
Pre-treatedSurface Anodising/conversion
InhibitedPrimer
Top Coat
Pre-treatedSurface Anodising/conversion
Pre-treatedSurface Anodising/conversion
InhibitedPrimer
Top Coat
STATE OF ART
© EADS 2012 EADS INNOVATION WORKS general presentatio n
9� Active & passive
surfaces
� Rain/ Sand
� Anti-Icing concept for CFRP leading edge
� Energy saving
� Paints, foils � Riblets
Drag reduction via multifunctional surfaces
Anti-Icing coatings
Anti-Contamination
Structured surfaces
Erosion Protection
� Active & passive surfaces
� Rain/ Sand
� Anti-Icing concept for CFRP leading edge
� Energy saving
� Paints, foils � Riblets
Drag reduction via multifunctional surfaces
Anti-Icing coatings
Anti-Contamination
Structured surfaces
Erosion Protection
� Rain/ Sand
� Anti-Icing concept for CFRP leading edge
� Energy saving
� Paints, foils � Riblets
Drag reduction via multifunctional surfaces
Anti-Icing coatings
Anti-Contamination
Structured surfaces
Erosion Protection
• Aerodynamic Surfaces : Development of tailored surfaces/coatings for sand/rain erosionprotection of metallic and CFRP structures. Coatings enabling new anti-icing concepts. Anti-contamination (e.g. photocatalytic coatings). Structured surfaces /paints/foils (e.g. riblets). Development of cheap and reliable lab testing facilities.
• Wear and fretting protection: green and cost effective lifetime enhancement through organic, inorganic, multilayer, self-lubricating coatings. Fast and meaningful test methods.
• Cabin application: Improved passenger comfort through easy-to-clean, scratch resistant, anti-bacterial, anti-fingerprint coatings based on SolGel- and nanotechnology.
• Assembly, maintenance and repair: Development of processes and coatings for local/assembly integrated application. Dry and wet pre-treatments for structural bonding based on SolGel) and atm. plasma, laser, thermal spray technologies .
Functional Surfaces for Sustainability
© EADS 2012 EADS INNOVATION WORKS general presentatio n
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