Upload
lamthuan
View
217
Download
0
Embed Size (px)
Citation preview
© AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.
Bonding of CFRP primary Aerospace structures Boundary conditions for certification
Presented by
Dipl. Ing. Thomas Kruse, M. Sc., Airframe Design - Research & Technology
June 2013 CFK-Vally Stade Convention 2013 - Thomas Kruse - Airframe Design R&T
© AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document.
Agenda
Background & motivation
CFRP bonding
Certification requirements
Damage scenarios & technology fields
Design- & technology approaches
Conclusion
June 2013 CFK-Vally Stade Convention 2013 - Thomas Kruse - Airframe Design R&T
© AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document.
Agenda
Background & motivation
CFRP bonding
Certification requirements
Damage scenarios & technology fields
Design- & technology approaches
Conclusion
June 2013 CFK-Vally Stade Convention 2013 - Thomas Kruse - Airframe Design R&T
© AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document.
mainly build from
Composite (53%)
Introducing Fuselage
stiffened skin out of CFRP
CFK-Vally Stade Convention 2013 - Thomas Kruse - Airframe Design R&T
Introduction
June 2013
Joining Technology is a
key-technology and enabler for
next generation aircraft concepts
© AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document.
Applied joining technologies:
CFK-Vally Stade Convention 2013 - Thomas Kruse - Airframe Design R&T
Introduction - Applied joining technologies
June 2013
Joining members Technology
Skin / Stringer Co-Bonding
Skin / Frame (Clip) Bolted Joints
Remark:
≈ 5km Stringer / Skin
Co-Bonded joints
applied per A350
© AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document.
flat Frame / Skin Interface
joined by PI-Joint technology
Skin
Web
PI - Preform
Adhesive
Joining Principle as enabler for new Architectures
Disruptive composite build concept:
The Lockheed-Martin ACCA „Carbon Comet“
June 2013 CFK-Vally Stade Convention 2013 - Thomas Kruse - Airframe Design R&T
© AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document.
Agenda
Background & motivation
CFRP bonding
Certification requirements
Damage scenarios & technology fields
Design- & technology approaches
Conclusion
June 2013 CFK-Vally Stade Convention 2013 - Thomas Kruse - Airframe Design R&T
© AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document.
CFK-Vally Stade Convention 2013 - Thomas Kruse - Airframe Design R&T
Main driver for joining of composite parts
June 2013
Cost & Lead time
System Integration
Structure
Mechanics
Weight
© AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document.
cured
un-cured
Classification of CFRP-bonding technologies
June 2013 CFK-Vally Stade Convention 2013 - Thomas Kruse - Airframe Design R&T
co-curing:
co-bonding:
secondary bonding:
un-cured
un-cured
cured
cured
adhesive
earl
y i
nte
gra
tio
n
late
in
teg
rati
on
adhesive
adhesive
© AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document.
Main technology fields for bonding for large civil aircraft
Material Qualification
Process safety
NDT / NDI
Design Concepts & Sizing Approach
June 2013 CFK-Vally Stade Convention 2013 - Thomas Kruse - Airframe Design R&T
© AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document.
Agenda
Background & motivation
CFRP bonding
Certification requirements
Damage scenarios & technology fields
Design- & technology approaches
Conclusion
June 2013 CFK-Vally Stade Convention 2013 - Thomas Kruse - Airframe Design R&T
© AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document.
Certification boundary conditions acc. AC 20-107B
I. Repeatable and reliable non-destructive inspection techniques
must be established that ensure the strength of each joint.
II. Full single part testing of bonded joints
III. Disbonds of each bonded joint greater than the maximum critical
disbonding must be prevented by design features
Need of advanced special design features
Changing or challenging of this rules is not an option! Airbus/EADS was involved to define the actual regulations based in AC 20-107B.
Bud: regulations are leaving degrees of freedom for improvement.
technology not available
effort not practical
e.g. chicken fasteners
June 2013 CFK-Vally Stade Convention 2013 - Thomas Kruse - Airframe Design R&T
© AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document.
Agenda
Background & motivation
CFRP bonding
Certification requirements
Damage scenarios & technology fields
Design- & technology approaches
Conclusion
June 2013 CFK-Vally Stade Convention 2013 - Thomas Kruse - Airframe Design R&T
© AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document.
Bondline failure-types
Failure within Bondline
(Disbond)
Weak bond
(not sufficient adhesion)
Manufacturing Process
Damage of Bondline
(Impact event)
Manufacturing Manufacturing Process
occurr
ence:
Detectable
by NDI/NDT (if > method-threshold)
Implementation of a
suitable Qualitycontrol System
In Service
Addressed by
Certification requirements
acc. AC 20-107B
Limitation of Disbond
occurr
ence:
occurr
ence:
June 2013 CFK-Vally Stade Convention 2013 - Thomas Kruse - Airframe Design R&T
© AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document.
Technology fields & damage tolerance
Material Qualification
Process safety
NDT / NDI
Design & Sizing
Capability to handle / avoid (in future): Weak Bonds In Service
Damages
( )
June 2013 CFK-Vally Stade Convention 2013 - Thomas Kruse - Airframe Design R&T
© AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document.
Agenda
Background & motivation
CFRP bonding
Certification requirements
Damage scenarios & technology fields
Design- & technology approaches
Conclusion
June 2013 CFK-Vally Stade Convention 2013 - Thomas Kruse - Airframe Design R&T
© AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document.
Design & Technology - approaches
June 2013 CFK-Vally Stade Convention 2013 - Thomas Kruse - Airframe Design R&T
Certification of Bonding
Limitation of Disbond
Increase Process Safety
Avoid adhesion as joining
mechanism
Direct contribution
to enable certification
© AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document.
Design & Technology-approach:
Limit Disbond Z-Pinning
Modified Z-Pinning
June 2013 CFK-Vally Stade Convention 2013 - Thomas Kruse - Airframe Design R&T
© AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document.
Additional technology approaches:
June 2013 CFK-Vally Stade Convention 2013 - Thomas Kruse - Airframe Design R&T
Under investigation e.g. within EU Project
Design & Technology-approach:
Limit Disbond
Surface interfering Features Surface and Geometry
Modification
Mechanical through-thickness
features
Adhesive bondline
architecturing
Identified technology streams:
© AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document.
June 2013 CFK-Vally Stade Convention 2013 - Thomas Kruse - Airframe Design R&T
Basic M&P
Design & Stress
Surface
Preparation
Automation Skills
Technology-approach:
Increase Process Safety
© AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document.
June 2013 CFK-Vally Stade Convention 2013 - Thomas Kruse - Airframe Design R&T
Design & Technology-approach:
Increase Process Safety
Skin
Web
PI - Preform
Adhesive
Modular Joints (developed e.g. in EU Projects MoJo & CERFAC)
• Joining of two cured
components
• Local Co-Bonding
by uncured (textile)
Joining element
• Different shapes
(e.g. PI / H) investigated
© AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document.
June 2013 CFK-Vally Stade Convention 2013 - Thomas Kruse - Airframe Design R&T
Welding Process Thermoplast - Layer
(Co-cured)
Thermoset Part
Thermoset Part
Activities ongoing - Airbus & EADS-IW with CRC-ACS (Australia) & DLR
No Structural application today
Design & Technology-approach:
Avoid adhesion as joining mechanism
© AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document.
June 2013 CFK-Vally Stade Convention 2013 - Thomas Kruse - Airframe Design R&T
Design & Technology-approach:
Avoid adhesion as joining mechanism
Partially un-cured zones – joined by co-curing
Partially cured parts – joined by co-curing
© AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document.
Agenda
Background & motivation
CFRP bonding
Certification requirements
Damage scenarios & technology fields
Design- & technology approaches
Conclusion
June 2013 CFK-Vally Stade Convention 2013 - Thomas Kruse - Airframe Design R&T
© AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document.
Roadmap to certification
June 2013 CFK-Vally Stade Convention 2013 - Thomas Kruse - Airframe Design R&T
Certification process safety
NDT capabilities
enabling technologies
design concepts
sizing approach
© AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document.
June 2013 CFK-Vally Stade Convention 2013 - Thomas Kruse - Airframe Design R&T
Today certification of bonded joints w/o additional fasteners is not possible
Further research and technology development needed and addressed at Airbus
New novel ideas & technologies can act as future enabler for secured certification
Process Safety
• Significant Progress
• Still not sufficient for certification w/o fasteners
Limitation of Disbond
• Derived from Certification Requirements
• Investigated in EU-Project BOPACS
Alternative joining
mechanism
• Target: Utilize alternative mechanism to adhesion
• Promising technologies under investigation
Conclusion
© AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document.
Thank you for the attention….
Questions?
June 2013 CFK-Vally Stade Convention 2013 - Thomas Kruse - Airframe Design R&T
Dipl. Ing. Thomas KRUSE, M.Sc.
Airframe Design - Research & Technology
Phone: +49 40 743 83469
© AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document.
June 2013 CFK-Vally Stade Convention 2013 - Thomas Kruse - Airframe Design R&T
© AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document. This document and all information contained herein is the sole property of AIRBUS Operations GmbH. No intellectual property
rights are granted by the delivery of this document or the disclosure of its content. This document shall not be reproduced or disclosed to a third party without the express written consent of AIRBUS Operations GmbH. This
document and its content shall not be used for any purpose other than that for which it is supplied. The statements made herein do not constitute an offer. They are based on the mentioned assumptions and are expressed
in good faith. Where the supporting grounds for these statements are not shown, AIRBUS Operations GmbH will be pleased to explain the basis thereof.
AIRBUS, its logo, A300, A310, A318, A319, A320, A321, A330, A340, A350, A380, A400M are registered trademarks.