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8/12/2019 Boeing- Materials and the Aerospace Industry
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Materials and the Aerospace Industry
Krishnan K. Sankaran, Ph.D.
Senior Technical Fellow
Materials and Processes Technology
Boeing Phantom Works
Enhancing Innovation and Competitiveness Through
Investments in Fundamental Research
Westin Hotel, Arlington, VA
December 3-5, 2006
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Engineering, Operations & Technology | Phantom Works
Copyright © 2006 Boeing. All rights reserved.
AM&ST
Questions to Consider for Enhancing Innovation andCompetitiveness
• Expanded federal investments in research andeducation and the impact
• Acceleration of ROI in basic research
• Collaboration models for research
• Specific areas of fundamental research
• Workforce challenges
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Engineering, Operations & Technology | Phantom Works
Copyright © 2006 Boeing. All rights reserved.
AM&ST
Boeing Products
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Engineering, Operations & Technology | Phantom Works
Copyright © 2006 Boeing. All rights reserved.
AM&ST
Materials Research to Meet 21st Century Defense NeedsDoD Sponsored, NRC/NMAB Study - 2003
• Revolutionary capabil ities from R&D in
• Structural and multifunctional materials
• Energy and power materials
• Electronic and photonic materials
• Functional organic and hybrid materials
• Bio-derived and bio-inspired materials
• Five recommendations made
• Accelerate materials transition from concept to service
• Computational modeling• Integrate research in various materials classes
• Discover materials with substantially improved properties
• Materials research from conception to service to retirement
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Copyright © 2006 Boeing. All rights reserved.
AM&ST
Composition (Wt. %) of 7XXX Series Alloys
7075 7050 7055 7085
Zn 5.6 6.2 8.0 7.5Mg 2.5 2.3 2.0 1.5
Cu 1.6 2.3 2.3 1.6
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Engineering, Operations & Technology | Phantom Works
Copyright © 2006 Boeing. All rights reserved.
AM&ST
Industry Perspective
• Technologies fuel growth
• Products – 787 Dreamliner
• Services – Expand the value of products to customers
• Technologies reduce the bottom line
• Design – Enables more efficient structures
• Manufacturing – Enables streamlined production
• Breakthrough Technologies - What will the future bring?
• Fundamental research• What are the gaps and what is needed to close them?
• Workforce challenges
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AM&ST
• Best introduction of a new Boeing Commercial
Airplane ever
Integrating
Breakthrough
Technologies
Growth: New Technologies Enable New Products andServices
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Copyright © 2006 Boeing. All rights reserved.
AM&ST
787-8
Composites Serve as 787 Primary StructuralMaterial
CFRP
43%
Misc.
9%
• Lighter
• More durable
• Reduced corrosion andfatigue
• Reduced scheduled
maintenance
• Opens new design possibilities
One Piece Fwd Fuselage One Piece Barrel Section Test Wing Box
Composites
Aluminum
Titanium
Steel
Other
Composites
Aluminum
Titanium
Steel
Other
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AM&ST
The Future of CompositesEnabling High Rate Production
Composite
SteelTitanium
Aluminum
Miscellaneous
Materials
I n c r e a s e d
c o m p
o s i t e s
u s a g e
o v e r t
i m e
1%747
3%757/767
11%777
50%
787 D e s i g n &
m a n u f
a c t u r i n g
t e c h n o
l o g y
b r e a k t
h r o u g h
Composite
SteelTitanium
Aluminum
Miscellaneous
Composite
SteelTitanium
Aluminum
Miscellaneous
Materials
I n c r e a s e d
c o m p
o s i t e s
u s a g e
o v e r t
i m e
1%747
3%757/767
11%777
50%
787 D e s i g n &
m a n u f
a c t u r i n g
t e c h n o
l o g y
b r e a k t
h r o u g h
Continued Development of Advanced Composites Will Be
Required to Affordabili ty Satisfy High Rate Production Needs
Continued Development of Advanced Composites Will BeContinued Development of Advanced Composites Will Be
Required to Affordabil ity Satisfy High Rate Production NeedsRequired to Affordability Satisfy High Rate Production Needs
45%
39%
5%11%
22%
3%
15%
60%
25,700airplanes
2.1 trilliondelivery dollars*
*In year 2004 dollars
Regional jets
Single-aisle
Twin-aisle
747 and larger
2005-2024
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AM&ST
Titanium Usage in Aircraft Has Been Increasing
Composites are also
Driving Growth in
Titanium
Composites
Titanium
Other
Steel
Alumi num
Composites
Titanium
Other
Steel
Alumi num
Year of Roll Out
707727
737 747
747 SP
767
757
777
787 (Projected)
02
468
10
12
141618
20
1950 1960 1970 1980 1990 2000 2010 2020
P e r c e n t
T i a s F u n c t i o n
o
f O E W
Year of Roll Out
707727
737 747
747 SP
767
757
777
787 (Projected)
02
468
10
12
141618
20
1950 1960 1970 1980 1990 2000 2010 2020
P e r c e n t
T i a s F u n c t i o n
o
f O E W
Continued Development of Improved Alloys Are Needed to Improve
Performance, Manufacturability, and Affordability
Continued Development of Improved Alloys Are Needed to ImproveContinued Development of Improved Alloys Are Needed to Improve
Performance, Manufacturability, and AffordabilityPerformance, Manufacturability, and Affordability
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AM&ST
7 Characteristics of Future Products, Processes &Services
Extreme AffordabilityExtreme Affordability
“ Universally” Friendly“ Universally” Friendly
Super-Human IntelligenceSuper-Human Intelligence
Network CentricNetwork Centric
Platforms and systems with decision
making capabilities better than human
Multiple assets that collaborate on a
network to optimize the system
performance
Cost improvements of factors from 2-100
Minimal to no environmental impact of a
product throughout its full lifecycle
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Copyright © 2006 Boeing. All rights reserved.
AM&ST
Growth: New Technologies Enable New Products andServices
Product Support – Maintenance, Mods, & Repairs
Develop advanced technologies which will improve the quality and
reduce the cost of Maintenance, Modifications and Repair
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AM&ST
Productivity Improvements: DesignTechnologies Enabling More Efficient Structures
Lower Cost & Lower Weight
Develop innovative structural concepts which will be lighter, easier
to build and maintain, and cost less to fabricate and support
Fewer partsFewer fastenersLess assembly
Lower weight
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AM&ST
Productivity Improvements: DesignTechnologies Enabling More Efficient Structures
Design & Analysis Tools
Develop the necessary analysis capabilities needed to support the
advanced concepts and integrate those into common design toolsand processes
Hat pl iesx direct ion
Noodle and sk inx direct ion
Hat p l iesx direct ionHat p l ies
x direct ion
Noodle and sk inx direct ion
Noodle and sk inx direct ion
Faster DesignsMore Iterations
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AM&ST
Productivity Improvements: DesignTechnologies Enabling More Efficient Structures
Materials by Design
Create high-performance materials and leverage with design
concepts to improve performance and/or lower costs
• Materials by Trial and Error • Lots of testing
• Architect the materials necessary toenable higher performance designs
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AM&ST
Modeling and Simulation
Develop, design, and build multiple iterations virtually to reduce costs
and speed development
Productivity Improvements: Design TechnologiesEnabling More Efficient Structures & Operations
Physical Virtual
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Copyright © 2006 Boeing. All rights reserved.
AM&ST
Goal: AnalysisSupported by
Experience,
Test & Demo
Time to Insertion Readiness
R I S
K
Time to Insertion Readiness Reduced by 55%
A A A A A A
R I S
K
A A A A A A
Traditional:
Test
Supported
by Analysis
Analytical Techniques Replace Empirical Testing
Develop methods to verify and certify new structural concepts and
material forms to speed those advancements product lines
Productivity Improvements: DesignTechnologies Enabling More Efficient Structures
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AM&ST
Network Enabled ManufacturingDevelop open architecture model for linking system-of-systems,e.g., Indoor GPS, RFID, SmartTools, Laser Projection all linked to
manufacturing work instructions and Quality Management System
NEM Converts today’s aerospace factories whereinformation collection and diagnostics are mostlymanual to state-of-the-art automated informationdatabase resource in real time. This methodology is
well adaptable to the future engineering work forcewho are familiar with intelligent computerized systems
NEM Converts today’s aerospace factories whereinformation collection and diagnostics are mostlymanual to state-of-the-art automated informationdatabase resource in real time. This methodology is
well adaptable to the future engineering work forcewho are familiar with intelligent computerized systems
Productivity Improvements: TechnologiesEnable Lower Cost Structures
NEM Converts today’s aerospace factories whereinformation collection and diagnostics are mostlymanual to state-of-the-art automated informationdatabase resource in real time. This methodology is
well adaptable to the future engineering work forcewho are familiar with intelligent computerized systems
NEM Converts today’s aerospace factories whereinformation collection and diagnostics are mostlymanual to state-of-the-art automated informationdatabase resource in real time. This methodology is
well adaptable to the future engineering work forcewho are familiar with intelligent computerized systems
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AM&ST
Aerospace Workplace Needs
• Educated Scientists and Engineers
• Globally sourced
• “Clearable” for Defense-relatd projects
• Mathematical and Analytical capability
– Probability and Statistics
• Communications across various disciplines
– Not just interdisciplinary studies, but interaction
Boeing invests significantly in employee trainingboth in-house and at universities
Boeing invests significantly in employee trainingBoeing invests significantly in employee trainingboth inboth in--house and at universitieshouse and at universities
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AM&ST
Fundamental Research Gaps and Needs
• Modeling and simulation
• Materials Informatics• Simulation of manufacturing processes
• Multi-functional materials
• Lower cost or affordable replacement for strategic materials
• Self assembled structures – “Grow the parts”
• In-service assessment of the health of materials• Diagnostics and prognostics
Materials are Key to Maintaining CompetitivenessMaterials are Key to Maintaining CompetitivenessMaterials are Key to Maintaining Competitiveness