Composite Technology at Airbus Germany - DLR - DLR … · 2006-05-29 · 24.10.02 Breuer/ESWCG Composite Technology Germany 1 Composite Technology at Airbus Germany Past, Present,

Breuer/ESWCG Composite Technology Germany 124.10.02

Composite Technology at Airbus GermanyComposite Technology at Airbus GermanyPast, Present, FuturePast, Present, Future

Ulf P. Ulf P. BreuerBreuerComposite Technology GermanyComposite Technology Germany

Airbus BremenAirbus Bremen


Q

OutlineOutline

Benefits of CFRP for Primary A/C Structures

Q History of CFRP Introduction to Airbus

Q CFRP Technology of A380

Q CFRP Technology of Next Generation A/C

Q Future Application of CFRP: Requirements and Recommendations

Q Conclusions


Benefits of CFRP for Primary A/C StructuresBenefits of CFRP for Primary A/C Structures(Selection of Main Design Drivers)(Selection of Main Design Drivers)

Q High Structural Performance to Mass Ratio

Q Utilization of Anisotropy for Tailored Design (Strength, Stiffness, Stability)

Q Single Load Path Design

Q Simple Shaping of Complex Structures

Q Excellent Fatigue Behaviour

Q Excellent Fire Worthiness

Q Excellent Crash Worthiness

Q Excellent Media/Corrosion Worthiness


History of CFRP Introduction to AirbusHistory of CFRP Introduction to Airbus(Selection of Major Milestones)(Selection of Major Milestones)

A320-200 (1987)SpoilerRudderElevatorFinMLG & NLG DoorsWing Shroud BoxWing T/E panelsFlap Track FairingsPylon FairingsNacelle CowlingsFloor PanelsAileronFlapsHorizontal Stabilizer

A340-500/-600 (2001)SpoilerRudderElevatorFinMLG & NLG DoorsWing Shroud BoxWing T/E panelsFlap Track FairingsPylon FairingsNacelle CowlingsFloor PanelsAileronFlapsHorizontal StabilizerRear Pressure BulkheadKeel Beam

A310-200 (1982)SpoilerRudderElevator

A310-300 (1985)SpoilerRudderElevatorFin

CFRP Technology of A380CFRP Technology of A380Floor Beamsfor Upper Deck

Rear Pressure Bulkhead

VerticalTail Plane

Outer Flaps

Center Wing Box

Section 19

Wing Ribs

J-Nose

HorizontalTail Plane

Belly Fairing

Section 19.1



CFRP Technology of Next Generation A/CCFRP Technology of Next Generation A/C

ANTA/ANSA (EIS 2012/2017)

CFRP Slat Structure (LuFo III)

CFRP High Lift Devices (LuFo/AWIATOR)CFRP Flap Supports (LuFo II/III)

CFRP Wing Box (V-Box, TANGO)CFRP Fuselage (TANGO/LuFo II/III)

Provided that composite solutions will be competitive, the amount of CFRP structure on the next generation Airbus A/C will increase significantly


CFRP TechnologyCFRP TechnologyRequirements and Recommendations: Major GoalsRequirements and Recommendations: Major Goals

Q Increase�

- cost/weight benefits applying CFRP to primary A/C structures- efficiency of the process chain from R&D to series production

Q Reduce�

- manufacturing and in-service effort

Q Maintain�

- highest quality demands

Q Meet�

- with future environmental demands


CFRP TechnologyCFRP TechnologyRequirements and Recommendations: Process ChainRequirements and Recommendations: Process Chain

Material Development

Design

Manufacturing

Assembly

Service



-cheaper, lighter, stronger, stiffer, tougher (where necessary),reference: prepreg UD-tapeMaterial Development

-material adaptivity on demand-infinite shelf/shop life-processing/curing at room temperature-impact and moisture tolerant sandwich structuresDesign

Manufacturing

Assembly

Service




-design to weight with 3-D-load path fibre orientationDesign

-reduction of notch factors (by elimination of rivets)

Manufacturing

Assembly

Service




Design

- highly automated �net shape� processing of filaments to cured, complex shaped structuresManufacturing

- lightweight/flexible tooling- in process quality check

Assembly

Service




Design

Manufacturing

- improvement of joining technology (bonding and welding):Assembly � dry, 1-step- surface preparation

� bonding and debonding �at the push of a button�at room temperature

� on-line measurement of bonding loading capacity,sealing, geometry

Service



Manufacturing

Assembly

- repair without rivetsService - easy inspection


CFRP TechnologyCFRP TechnologyRequirements and Recommendations: Manufacturing TechnologiesRequirements and Recommendations: Manufacturing Technologies

Ma j

orC

FRP

Ma n

ufac

turin

g/A

s sem

bly

Tech

n olo

g ies

(I) Prepreg Technology

(II) Textile/Infusion Technology

(III) Thermoplastics

(IV) Bonding/Joining



(I) Prepreg Technology

Qavailability of high performance materials

Qhigh material cost

Qlarge experience, broad application in primary A/C structures

Qautoclave processing

Qhigh processing effort

Qhigh auxiliary material cost

Qhigh amount of production wasteQautomated tape laying

Qlow cost high perfor-mance R/T prepreg

Qefficient processingof tapes to integralnet shape parts

Qefficient curingtechnology

State of the Art Drawbacks Perspectives



(II) Textile/Infusion Technology

Qstandard 2-D-textiles(fabric, NCF)

Qbinder based preforming (epoxy)

Qsingle componentepoxy-resin

Qpoor performance(mech. prop.) of textilescompared to UD-prepreg

Qpoor availability of net shape preform technologies

Qpoor handling of large preforms

Qnegative influence of sewing/bindingon mech. prop.

Qlow cost high perfor-mance R/T resin systems

Qhigh performancetextiles (mech. prop.)

Qefficient processingof rovings to integralnet shape preforms

Qefficient sandwich processing




(III) Thermoplastics

Qthermoplastic CFRP established for secondary structures,fairings, ties, clips

Qinfinite shop life

Qpoor availability of semifinished materials

Qhigh material costs

Qlimited wall thickness

Qlimited processing technology

Qlow cost high per-formance materials

Qefficient processing ofTP tapes to complex shaped cured parts

Qenhanced degree of freedom for part design

Qformability,free of autoclave

Qweldability

Qshort cycle times

Qlimited part size




(IV) Bonding/Joining

Qdomination of rivetingfor highly loaded parts

Qpotential for further automation of riveting

Qnotch factor, bolt collarand rivets can causeadditional weight

Qhigh effort for bondingsurface pre-treatment

Qhigh performance ad-hesives(R/T, H/W, em )

Qworld wide availability of riveted repair techn.

Qbonding of stiffeners to shells by resin films

Qpoor perceptibilityof imperfectionsin bonding interfaces

Qpoor availability of bonded repair methods

Qautomated application of adhesives

Qautoclave (temperature,pressure) free bonding,�at the push of a button�

Q1-step-surfacepre-treatment (repair!)

Qhighly efficient NDT



CFRP TechnologyCFRP TechnologyConclusionsConclusions

Q CFRP is recognized as a key technology to enhance A/C performance.

Q To be competitive, higher performance must not be paid by higher cost.

Q To increase the amount of CFRP structure, the efficiency of the complete process chain (�design to fly�) must be regarded and improved by new technologies.

Q The definition of clear technology targets is essential.

Q National and international technology programs must contribute directlyto �technology readiness�.

Q To be successful, Airbus must work very closely together with all technology partners.


CFRP TechnologyCFRP TechnologyUpshotUpshot

�lets go upwards�

Documents

Composite Technology at Airbus Germany - DLR - DLR … · 2006-05-29 · 24.10.02 Breuer/ESWCG Composite Technology Germany 1 Composite Technology at Airbus Germany Past, Present,