3rd Generation Of Composite Materials For Airframe
WMF - AIRBUS - 3rd Generation of Composites for AirframeJune 2015ProcurementOlivier CauquilSVP Material and Parts Procurement3rd Generation ofComposite Materialsfor AirframeWorld Materials ForumWorkshop on Composites
WMF - AIRBUS - 3rd Generation of Composites for AirframeOutlineIntroduction Composite use evolution in Airbus Current composite technologiesComposite Airframe – Key development areas Cost reduction Performance & Multifunctionality Processability Reuse & RecyclabilityConclusions AIRBUS Operations S.L. All rights reserved. Confidential and proprietary document.June 2015
WMF - AIRBUS - 3rd Generation of Composites for AirframeJune 2015Composite Structural Weight [%]Composite use in Airbus A/C: a sustained increase5040During the last 40 years, Airbus hascontinuously and progressivelyintroduced composite technology inaircrafts, as a result of a successful andaccumulated experience in this fieldA350A400M30However, continuous R&D effortin composites is key to maintaintheir competition in Airframefield for future Airbus 970 AIRBUS Operations S.L. All rights reserved. Confidential and proprietary document.1980199020002010
WMF - AIRBUS - 3rd Generation of Composites for AirframeMaterial use in Airbus Aircrafts AIRBUS Operations S.L. All rights reserved. Confidential and proprietary document.June 2015
WMF - AIRBUS - 3rd Generation of Composites for AirframeJune 2015Overview of current composite technologies for AirframePerformance benchmark Cost challenge!!ThermosetPrepreg(epoxy CF,tape / fabric)Process: ATL / AFP lay-up autoclave curingPrimary structure, wide useCost attractive Performance challenge to reach prepreg!!Dry CF textile /Resin (epoxy)infusionProcess: dry textile lay-up Liquid Resin Infusion oven /tool curingPrimary structure, still less used thanprepregHigh performance, low use Cost & use increase challenges – Big parts!!Thermoplastics(PEEK/PEKK CF prepreg /tape)Process: prepreg lay-up( oven/autoclave) ; pressforming, injectionmoulding AIRBUS Operations S.L. All rights reserved. Confidential and proprietary document.Small parts, secondary structure
WMF - AIRBUS - 3rd Generation of Composites for AirframeJune 2015Key composite research areasNEOs –Incrementaldevelopment3rd generation ofCOMPOSITE materials Damagetolerance Conductivity Damping Performance &Multifunctionality Thermoset:uncured orcured Thermoplastic Dry FibersCost ReductionComposite MaterialsdevelopmentReuse &Recyclability AIRBUS Operations S.L. All rights reserved. Confidential and proprietary document.FiberMatrixPrepreg Processability Lay-up Curing NDI, qualitycontrol
WMF - AIRBUS - 3rd Generation of Composites for AirframeJune 2015Performance – Thermoplastic materials developmentTowards long term300 C 400 CPEKK – CF (UDtape) as alternativeto PEEK - CF(reference)Basic / technologydevelopment NewLow meltingpolymer Thermoplasticnew formulationintegrating multifunctionalitiesAdvancedassembly conceptIn-situconsolidation AIRBUS Operations S.L. All rights reserved. Confidential and proprietary document.TRL3Material screening /characterizationProcessabilityevaluation: Lay-up processes,injection moulding,Over-moulding 1st /LE/TE/HTP/VTP structurePylon Welding (US,Induction, resistance)ADVANCED TPTBDTowards long termProcessing MaterialTª Multifunctionalityintegration: electricalconductivity,acousticattenuation RecyclabilityevaluationFloor structure2nd generationApplicationPrimarystructure asfuselage / cabin,wing,
WMF - AIRBUS - 3rd Generation of Composites for AirframeJune 2015Multifunctional composites: key developmentDescription / Objective: Integration of non-inherentcomposite properties to cover other functions (ex.:electrical conductivity)Today: “mono-skill”Composites with structural propertiesMultifunctional CompositesBenefit: they will mean an important step forward interms of the main drivers of future aircraft parts,programs: weight and cost savingElectricalFuselagestructural network acoustic solutionLE ErosionprotectionFunctions and technologies: Damage tolerance & high energy impactresistance: integrated shielding technologies Electrical: conductive particles, nanotechnology Acoustic & vibration attenuation: elastomericFuture: “multifunctional”Composites with structural andfunctional propertiesmaterial integration (embedded damping) Erosion resistance: elastomeric surface film Anti / de - ice: hydrophobic / heatable coatings Sensing: sensor integration inside CFRP AIRBUS Operations S.L. All rights reserved. Confidential and proprietary document.NanodopedRTM resinEmbeddeddampingCFRP coatedwith Cu
WMF - AIRBUS - 3rd Generation of Composites for AirframeJune 2015Cost reductionTECHNOLOGY DEVELOPMENTTowards lesstestingQualification New ApproachQuality Control ApproachNew Precursor Technologies forCarbon FiberHigh Tow FibersTowards low costbuilding blocksNew ResinsPre-Impregnated Architecture AIRBUS Operations S.L. All rights reserved. Confidential and proprietary document.
WMF - AIRBUS - 3rd Generation of Composites for AirframeJune 2015Cost reduction: building blocksFiber Matrix Low costalternativeHigher fiber tows industrial fiberKCostTowards50K Lower costpolymers Biosources:lignin, SpinifexgrassPrepreg New architecture Interleaf system Resin content tailoring Higher areal weight AIRBUS Operations S.L. All rights reserved. Confidential and proprietary document. Epoxy Monomer Substitution of “Fossil”Monomersby“bio”-monomers(Source: vegetable oils epoxy)Precursor main focusPrecursor fiber(PAN): high costpolymers
WMF - AIRBUS - 3rd Generation of Composites for AirframeJune 2015ProcessabilityMore EfficientProcess:QUICKER LAY-UP CURING(RAPID CURING)New curingapproaches:COCURING,semicuring PARTINTEGRATIONIMPROVEOn lineProcess &NDIConceptMANUFACTURING:Reuse &RecyclingLow CostToolingConceptHIGHER EFFICIENCYDecrease ofProcessControlSpecimens AIRBUS Operations S.L. All rights reserved. Confidential and proprietary document.New PartDesign:Design toManufacturingReduction /elimination ofauxiliarymaterials
WMF - AIRBUS - 3rd Generation of Composites for AirframeJune 2015Reuse & RecyclingCompositeMaterials Must GetRECYCLABLEReduction of raw materials residueRecycling ofcompositeraw materialsScrapsCut Scraps1)Removal of resin bypyrolysis.2)Electric Cogeneration3)Getting fibers withoutsizing for TP injectionmoulding or matt prepregsAfterprocessingCarbon Fiber0% ResinsReuse of residue non cured material AIRBUS Operations S.L. All rights reserved. Confidential and proprietary document.
WMF - AIRBUS - 3rd Generation of Composites for AirframeJune 2015Conclusions Airbus has always bet on composite use as a way to improve A/Cperformance and, then, save weight, until reaching more than 50% of structuralweight in composite for last generation aircraft: the A350 XWB Current composite technologies: composites made of epoxy resin andcarbon fibers are the predominant ones, while thermoplastic composite use inairframe is still low. In terms of composite processing: prepreg is the most usedtechnology, followed by liquid resin infusion Composite materials need to compete again with metallic materials forairframe applications that are made of composite in last generation A/C(example: fuselage) A continuous R&D effort is needed to develop innovative compositematerials and processes: cost reduction, performance, multifunctionality,processability & reuse / recycle are key development areas to maintaincomposite presence / use in commercial aeronautical field Researchcommunity effort is key in these areas AIRBUS Operations S.L. All rights reserved. Confidential and proprietary document.
WMF - AIRBUS - 3rd Generation of Composites for AirframeJune 2015 AIRBUS Operations S.L. All rights reserved. Confidential and proprietary document. This document and all information contained herein is the sole property of AIRBUS Operations S.L. No intellectual property rights are granted by the delivery of this document orthe disclosure of its content. This document shall not be reproduced or disclosed to a third party without the express written consent of AIRBUS Operations S.L. 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 S.L will be pleased to explain the basisthereof. AIRBUS, its logo, A300, A310, A318, A319, A320, A321, A330, A340, A350, A380, A400M are registered trademarks.Thank youfor your attention AIRBUS Operations S.L. All rights reserved. Confidential and proprietary document.Presentation Prepared by: Jose Sánchez Gómez – Composite Materials SeniorExpert, ESCAA Ivan Gayoso – Composites Procurement, PMCC Tamara Blanco – R&T Composite Materials, ESCRNM
In terms of composite processing: prepreg is the most used technology, followed by liquid resin infusion Composite materials need to compete again with metallic materials for airframe applications that are made of composite in last generation A/C (example: fuselage) A continuous R&D effort is needed to develop innovative composite materials and .
Types of composite: A) Based on curing mechanism: 1- Chemically activated composite 2- Light activated composite B) Based on size of filler particles: 1 - Conventional composite 2- Small particles composite 3-Micro filled composite 4- Hybrid composite 1- Chemically activated, composite resins: This is two - paste system:
78 composite materials Composite materials resources. Composite Materials Resources scouting literature Chemistry, Engineering, Inventing, Model Design and Building, Robotics, and Space Exploration merit badge pamphlets Books Marshall, Andrew C. Composite Basics, 7th ed. Marshall Consulting Publishing, 2005. Rutan, Burt. Moldless Composite
Federal Aviation Administration CE F, General Composite Structure Guidance Background –With the evolving/advancing composite technology and expanding composite applications, AC 20-107 “Composite Aircraft Structure” will require revision Deliverables –Revision to AC 20-107, “Composite Aircraft Structure,” to
Daily Math Practice D Math Buzz 093 Circle prime or composite. 13 prime composite 15 prime composite 22 prime composite 17 prime composite 23 prime composite Multiply. 6 x 728 _ 4 times as many as 397. _ 559 x 9 —–——
Connecting the HDMI to Composite / S-Video Scaler 1. Connect the included HDMI cable from the Hi-Def source to the HDMI connector of the HDMI to Composite / S-Video Scaler. 2. Connect a Composite cable (RCA-type) between the HDMI to Composite / S-Video Scaler and the Composite input on the display or A/V receiver. Optionally connect an
Composite 3 19 57 37. Prime 38. Prime 39. Neither 40. Neither 41. Composite 11 11 121 42. Composite 3 23 69 43. Prime 44. Prime 45. Composite 3 13 39 46. Composite 7 7 49 47. There are two whole numbers that are neither prime nor composite, 0 and 1. 48. False; the square of a
(P 0.05). The packable composite -with or without fluid composite- showed lower microleakage, whereas microhybrid and fiber-reinforced composites without fluid composite, showed higher mi-croleakage. Discussion: The fluid composite significantly decreased the microleakage at gingival margins of Class II composite restorations.
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