A Long Story of Innovations and Experiences

Transcription

Presented by
Guy Hellard
Composites in Airbus
A Long Story of Innovations and Experiences
Composites in Airbus @ Global Investor Forum by Dr Roland Thévenin _V51PR0800355_v1
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Table of Content
1. Market Situation and Industrial Composite Applications
2. A350
Structures
© AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.
3. Conclusions
2
2
Table of Content
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3
A step by step gain of composite experience
Composites Introduction
• Within primary structures
1980
1990
2000
2010
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4
Composites Introduction
A350XWB
+ Outer wing,
Fuselage
• Within primary structures
V10F
+ Outer wing
ATR72
+ Outer wing
A330/A340
+ HTP as fuel tank
A320
+ HTP, Flaps, Ailerons,
Spoilers
A310-300
Fin, Rudder, Elevators
1980
A380
+ Rear Fuselage, Center Wing Box,
Wing Ribs
A340-600
+ Rear Pressure Bulkhead,
Keel Beam
Unique experience
with more than 70
million FH cumulated
1990
A400M
+ Cargo door,
Outer wing
2000
2010
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5
Composite structure / Structure weight (%)
… step by step
approach…
60
A350XWB
53%
40
A400 M
25%
20
A320
10
5%
A330
A380-800
A340-600
A310-300
0
1985 1988
1993
2002
2007
2013
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1
Why Composites?
Technology introduction
Design
Manufacturing
Use
Improve performances
Lower production cost
Quality robustness
Reduce lead time
Reduce Lifecycle cost
(maintenance cost)
Achieved by trade-off
Need to design for CFRP
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CFRP: Supply vs. Demand
• Main growth drivers: civil
aviation & wind power
industries
• Suppliers increase
investment budgets
• EADS demand to increase
substantially beyond 2010
tons
EADS Carbon Fiber Demand
20.000
10.000
0
2005
2010
2015
2020
• Close cooperation with current and potential suppliers to
ensure smooth ramp up
• Outlook: supplier production capacities to double by 2010
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How composites are manufactured?
•Typical
Single Part
Production 1
Manufacturing
Process
Wing Panel : CFRP Prepreg
1) Preparation of mould
5) Curing
2) Automatic tape laying
6) Non destructive testing
3) Stringer integration
7) Milling
4) Vacuum bagging
8) Painting
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9
Industrialisation
Optimisation and assurance of processes
• From repair intensive CFRP
•
•
•
•
•
Ni-alloy jig
tool to Nickel-Alloy jig
From manual tape laying to
automated processes
From manual 1-channel NonDestructive Testing (NDT) to
automated multi-channel
testing methods (192 channels)
From manual drilling to
automated processes on multi
flexible tooling.
From manual painting to
automated process
From manual riveting to
half/fully automated riveting
machines
3D-Tape layer
Multi-channel NDT
Trimming machine
Paint robot
Riveting robot
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10
Composites applications @ EADS
CFRP
Eurocopter
NH90, Tiger:
• fuselage
Upper
parts
Segments
EC135:
Primary
Main
structures
rotor
Tailboom
Squirrel and Dolphin
Rotor
Astrium (cont’d)
• Arianne 5
hub
Astrium
• Satellites antenna
• Launchers and Missiles
Upper
parts and
fairings
Criogenic tanks
• EF-2000
wing
fuselage
fairings
stabilizers
• BARRACUDA
(UAV)
MTAD
• CN 235/C295
Elevators,
MAS
wing
Fairings
• A400M
• HTP, VTP, Wing covers
• Elevator
fuselage
fairings
stabilizers
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Composites applications @ EADS
CFRP structure examples
Bottom Shell NH90
NH90
Antenna deflector ASTRA
ST
Wing panel EF2000
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12
A380 Composites applications
Major applications
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A400M Composites applications
New major applications
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Table of Content
2. A350
Structures
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A350
Structures
Intelligent airframe
Fuselage:
Empennage (VTP, HTP)
• Skin
• Frame
• Keel Beam
• Rear Fuselage
CFRP
Al/Al-Li:
Al & Al-Li
Ribs,
Floor beams,
Gear bays,..
Titanium:
Landing Gears,
Pylons,
Attachments
Titanium
Steel
A350-900 XWB
Misc.
Material Breakdown (%)
Including Landing Gear
Misc.
8%
Al/Al-Li
19%
6% Steel
Outer Wing Box:
• Covers / Stringers / Spars
Centre Wing Box:
Composite
53%
14%
•Covers / Stringers / Spars
Titanium
Technologies selected to improve
performance and lower maintenance tasks
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A350
Structures
RATIONALE
• Reduce operational cost
• Reduce global environmental impact
SOLUTION
• Use of CFRP panels, stringers, frame, Keel Beam
• Panel as long as possible to reduce the amount of circumferential joints
• Optimisation of each panel for its design case
BENEFIT
Fuselage Innovations : CFRP
• Improve passenger comfort by higher cabin pressure
• Weight reduction : Fuel-burn savings
• Cost reduction and environmental impact reduction
• Fatigue- and corrosion-free: Reduce maintenance costs
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A350
Structures
Fuselage Innovations : CFRP - 4 Panels
Status of developments
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A350
Structures
Fuselage Innovations : CFRP - Barrel
Status of developments
RTM Frames
Full barrel technology for Rear fuselage
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A350
Structures
• Aeroelastic tailoring as a passive
adaptive structure
• Reduce operational cost
• Reduce global environmental impact
• Use of CFRP spars, skins
CFRP outer wing box
CFRP center wing box
and stringers
• Fuel-burn savings through weight
BENEFIT
SOLUTION
RATIONALE
Wing Innovations : CFRP
reduction: cost and environmental
improvement
• Fatigue- and corrosion-free
composites save maintenance costs
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A350
Structures
Maintainability / Reparability
Robustness
Robustness will override the other sizing criteria
within the areas prone to accidental damage.
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A350
Structures
Maintainability / Reparability
Repairs
Standard
bolted repair concept for
structural damages
– Existing tools and skills
– Similar repair times
Bonded
repairs for minor cosmetic damage
Most of the former principles still apply
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Table of Content
2. A350
Structures
3. Conclusions
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Conclusions
1/2
• Long term and unique experience in composite technologies
• Comprehensive experience of primary composite parts:
design, certification and maintenance
• Multi function approach (e.g. electrical & structural) to improve
performance and associated lightning strike protection
• Good long term behavior of carbon composites (corrosion,
fatigue) decreases maintenance cost
• Use of multi panel concept to allow best design optimization
and large repair capability
• A350 XWB composite fuselage optimal compromise
between longitudinal & circumferential integration:
- long panel concept in the main fuselage area
- full barrel concept in the non-pressurised area
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Conclusions
2/2
• Better structure weight efficiency
• Capital intensive production investments determine ramp up
flexibility
• Extremely high quality requirements of CFRP parts
• 4-Panels CFRP Fuselage structure is a risk averse manufacturing
solution:
• Avoids fitting issues encountered in final assembly line
• More flexibility during assembly process
• Easier part handling for large diameter
• Less complex and lighter tooling
• Higher manufacturing speed
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© AIRBUS S.A.S. All rights reserved. Confidential and
proprietary document.
This document and all information contained herein is the sole
property of AIRBUS S.A.S.. 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 S.A.S. 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 S.A.S. 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.
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A Long Story of Innovations and Experiences

Transcription

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