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Development
Consulting
Education
Research
Bionic AircraftIncreasing resource efficiency of aviation
through implementation of ALM technology and
bionic design in all stages of an aircraft life cycle
Dr. Philipp Imgrund
Fraunhofer IAPT, Hamburg, Germany
The BionicAircraft project has received funding from the European Union’s
Horizon 2020 Research and Innovation Programme under Grant
Agreement No 690689
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Overall Ambition
Increasing efficiency of an aircraft by implementing Additive Manufacturing
and bionic design in all stages of an aircraft life cycle:
During manufacturing:due to resource efficient production by Additive
Manufacturing technology
During operation:by significant weight saving to advanced materials
and bionic lightweight design
In maintenance, overhaul and repair:due to innovative repair methods for AM
components
In recycling:by development of recycling methods for
AM powders and components
Resource Efficiency in Bionic Aircraft
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BionicAircraft at a Glance
Bionic Aircraft Project: “Increasing resource efficiency of aviation through implementation
of ALM technology and bionic design in all stages of an aircraft life cycle”
Societal Challenges / Call identifier: H2020-MG-1.2-2015
Grant Agreement No.: 690689
Consortium
9 international Partners
2 Research Centers
5 Industrial Partners
1 SME
1 Standardization Organization
Budget and Duration
Overall Budget 7.96 Mio. €
Running from 01.09.16 to 31.08.19
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Structure of BionicAircraft Project
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BionicAircraft Demonstrators
Demonstrator 1:
A330NEO Jack Actuator Bracket
Bionic design, Quality Assurance,
Repair and recycling concepts
Demonstrator 3:A350XWB T-Mount Fitting
Bionic design
Demonstrator 2:A340 Hydraulic Block
Quality Assurance, Repair and
recycling concepts
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Bionic Feature Catalogue: Selected Models
Honeycomb structures
for stiffening of surface areas
Grass stalk structure
for lightweight, bent-proof
design
Epidermal cells and butterfly
wing structures for material
savings in volume
Smooth transition between
planes by Mattheck tree curve
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Designing Support Structures with Bionic Features
Development goals
Reduce material usage
Minimize surface roughness
Increase ease of removability
Assure dimensional accuracy
Define tensile strength
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High-strength Aluminium Powder Development
Configurate ICP process for AlSi10Mg powder and
establish the material sheet
Manufacture Al-Si-Sc and Al-Li powders by gas
atomization
Al-Si-Sc powder
High sphericity
Average Ø: 29 µm
Al-Li powder
High sphericity
Average Ø: 35 µm
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ALM Process Development for Al-Si-Sc
© EOS GmbH
10x10x10 mm3 cube
with pyramid strut ρmax > 99.90% +20/-63 µm
d50: 29.09 µm
Commercial ALM-
machine at IAPT
Crack free
Density up to 99.92%
Building rate up to 26 cm3/h (provided, ρ > 99.7%)
Hardness: 165 HV10; UTS: 460 MPa; A 3.6 % as built
Good
processability
and initial mechanical
properties
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ALM process development for Al-Li alloys
Evaluation of AA2065+Cu and AA2065 powders in ALM process
Bu
ildin
gd
irectio
n
Similar performance of the two alloys in the ALM process
High affinity to hot cracks and narrow process parameter
window: crack free specimens can be manufactured with lower
laser power (200W) and extreme slow scan speed (50-100mm/s).
AA2065+Cu: 104 ± 4 HV2 and AA2065: 79 ± 1 HV2
10x10x10 mm3 cube
with pyramid strut
ρmax > 99.80% (Image analysis)
Test rig Aconity
LAB
Vickers
hardness
Etching
Good density, but low
building rates
(0.5 -1 cm³ / h) and initial
mechanical properties
Optimization in progress
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Test rig for ALM process optimization
■ AconityLAB as a ‘basis’ for the test-rig was chosen
■ Integration of own optical system (3D-scanner)
■ Integration of COHERENT 1 kW laser
■ Check and verification of laser and optical system (diagnostics:
beam caustic, beam profile, laser power)
■ Separate check of every component and system
■ Implementation of beam shaping element (M-Shaper)
Test rig operational since April 2018 for further
material development and beam shaping experiments
Test Rig development and installation
ALM test rig installed at IAPT
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Quality assurance aspects
AIRBUS
Fraunhofer IAPT
HTC and HexMet Tecnalia
In-process
integrity check
In-line
integrity checkIn-service
integrity check
Life time
prediction
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Samples for testing of sensing methods
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Repair of ALM parts by Laser Metal Deposition
Development of process settings for AlSi10Mg in LMD process
Process parameters were narrowed down for optimization w.r.t
density (up to 99.8%)
Substrate condition (foundry or ALM manufactured) has significant
influence on the quality of the deposits.
Foundry substrate.
Deposit porosity of
1%.
ALM manufactured
substrate.
Deposit porosity of
8.8%.
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Innovative ALM-based after-sales supply chain
On-the-go printing
Strategically located service
provider
Streaming print data direct to
customer
Logistic companies
Service provider with repair and advanced ALM
capabilities
Crowd sourcing Own central/local facilities
Shared ALM Hub
Internal Impact• Efficient production of small volumes
• Less inventory/ on-demand print
• Agile & digital supply chain
• Increase parts portfolio
• Cost savings
External Impact• New part performance
• Shorter lead-time
• Weight Savings
• Independency
• Cost savings
• Agility
- Outsourcing
- Insourcing
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Contact:
Dr.-Ing. Philipp Imgrund
+49 (0) 40 484010-740
www.bionic-aircraft.eu
www.twitter.com/bionicaircraft
Thank you for your attention!
