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3 generation of composite materials for airframe

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3 generation of composite materials for airframe

  1. 1. 3rd Generation of Composite Materials for Airframe June 2015 WMF - AIRBUS - 3rd Generation of Composites for Airframe Procurement Olivier Cauquil SVP Material and Parts Procurement World Materials Forum Workshop on Composites
  2. 2. © AIRBUS Operations S.L. All rights reserved. Confidential and proprietary document. Outline June 2015 WMF - AIRBUS - 3rd Generation of Composites for Airframe • Composite use evolution in Airbus • Current composite technologies Introduction • Cost reduction • Performance & Multifunctionality • Processability • Reuse & Recyclability Composite Airframe – Key development areas Conclusions
  3. 3. © AIRBUS Operations S.L. All rights reserved. Confidential and proprietary document. 0 10 20 30 40 50 1970 1980 1990 2000 2010 A400M Composite Structural Weight [%] A300 A310-200 A320 A340-300 A340-600 A380 A350 During the last 40 years, Airbus has continuously and progressively introduced composite technology in aircrafts, as a result of a successful and accumulated experience in this field Composite use in Airbus A/C: a sustained increase June 2015 WMF - AIRBUS - 3rd Generation of Composites for Airframe However, continuous R&D effort in composites is key to maintain their competition in Airframe field for future Airbus programs
  4. 4. © AIRBUS Operations S.L. All rights reserved. Confidential and proprietary document. June 2015 WMF - AIRBUS - 3rd Generation of Composites for Airframe Material use in Airbus Aircrafts
  5. 5. © AIRBUS Operations S.L. All rights reserved. Confidential and proprietary document. Overview of current composite technologies for Airframe June 2015 WMF - AIRBUS - 3rd Generation of Composites for Airframe Performance benchmark  Cost challenge!! Thermoset Prepreg (epoxy + CF, tape / fabric) Dry CF textile / Resin (epoxy) infusion Thermoplastics (PEEK/PEKK + CF prepreg / tape) High performance, low use  Cost & use increase challenges – Big parts!! Cost attractive  Performance challenge to reach prepreg!! Process: ATL / AFP lay-up + autoclave curing Process: dry textile lay-up + Liquid Resin Infusion + oven / tool curing Process: prepreg lay-up (+oven/autoclave) ; press forming, injection moulding… Primary structure, wide use Primary structure, still less used than prepreg Small parts, secondary structure
  6. 6. © AIRBUS Operations S.L. All rights reserved. Confidential and proprietary document. Key composite research areas June 2015 WMF - AIRBUS - 3rd Generation of Composites for Airframe NEOs – Incremental development Composite Materials development Performance & Multifunctionality  Damage tolerance  Conductivity  Damping… Reuse & Recyclability Processability  Thermoset: uncured or cured  Thermoplastic  Dry Fibers  Lay-up  Curing  NDI, quality control  … 3rd generation of COMPOSITE materials Cost Reduction  Fiber  Matrix  Prepreg  …
  7. 7. © AIRBUS Operations S.L. All rights reserved. Confidential and proprietary document. Performance – Thermoplastic materials development WMF - AIRBUS - 3rd Generation of Composites for Airframe Processing Tª Material Basic / technology development 1st generation Applications 2nd generation Application PEKK – CF (UD tape) as alternative to PEEK - CF (reference) • Material screening / characterization • Processability evaluation: • Lay-up processes, injection moulding, Over-moulding… • Welding (US, Induction, resistance) • Multifunctionality integration: electrical conductivity, acoustic attenuation… • Recyclability evaluation Secondary structure: Primary structure as fuselage / cabin, wing, … New Low melting polymer ADVANCED TP • Thermoplastic new formulation integrating multi functionalities • Advanced assembly concept • In-situ consolidation 400°C Towards long term 300°C Moveables/LE/TE/ HTP/VTP structure Pylon TBD Floor structure Towards long term TRL 3 June 2015
  8. 8. © AIRBUS Operations S.L. All rights reserved. Confidential and proprietary document. Multifunctional composites: key development Description / Objective: Integration of non-inherent composite properties to cover other functions (ex.: electrical conductivity) Benefit: they will mean an important step forward in terms of the main drivers of future aircraft parts, programs: weight and cost saving Functions and technologies: • Damage tolerance & high energy impact resistance: integrated shielding technologies • Electrical: conductive particles, nanotechnology • Acoustic & vibration attenuation: elastomeric material integration (embedded damping) • Erosion resistance: elastomeric surface film… • Anti / de - ice: hydrophobic / heatable coatings • Sensing: sensor integration inside CFRP Multifunctional Composites Today: “mono-skill” Composites with structural properties Electrical structural network Future: “multifunctional” Composites with structural and functional properties June 2015 WMF - AIRBUS - 3rd Generation of Composites for Airframe Fuselage acoustic solution LE Erosion protection Embedded damping CFRP coated with Cu Nanodoped RTM resin
  9. 9. © AIRBUS Operations S.L. All rights reserved. Confidential and proprietary document. Cost reduction June 2015 WMF - AIRBUS - 3rd Generation of Composites for Airframe TECHNOLOGY DEVELOPMENT Qualification New Approach Quality Control Approach New Precursor Technologies for Carbon Fiber High Tow Fibers New Resins Pre-Impregnated Architecture Towards low cost building blocks Towards less testing
  10. 10. © AIRBUS Operations S.L. All rights reserved. Confidential and proprietary document. Cost reduction: building blocks June 2015 WMF - AIRBUS - 3rd Generation of Composites for Airframe Fiber • Higher fiber tows  industrial fiber • Precursor  main focus Matrix • Low cost polymers  Epoxy alternative • Monomer  Substitution of “Fossil”- Monomers by “bio”-monomers (Source: vegetable oils  epoxy) Prepreg • New architecture • Interleaf system • Resin content tailoring • Higher areal weight K Cost Towards 50K Precursor fiber (PAN): high cost  Lower cost polymers  Biosources: lignin, Spinifex grass
  11. 11. © AIRBUS Operations S.L. All rights reserved. Confidential and proprietary document. Processability June 2015 WMF - AIRBUS - 3rd Generation of Composites for Airframe IMPROVE MANUFACTURING: HIGHER EFFICIENCY On line Process & NDI Concept Decrease of Process Control Specimens Low Cost Tooling Concept New curing approaches: COCURING, semicuring  PART INTEGRATION New Part Design: Design to Manufactu ring Reuse & Recycling More Efficient Process: QUICKER LAY-UP + CURING (RAPID CURING) Reduction / elimination of auxiliary materials
  12. 12. © AIRBUS Operations S.L. All rights reserved. Confidential and proprietary document. Reuse & Recycling June 2015 WMF - AIRBUS - 3rd Generation of Composites for Airframe Reduction of raw materials residue Recycling of composite raw materials Reuse of residue non cured material Composite Materials Must Get RECYCLABLE Scraps Cut Scraps After processing Carbon Fiber 0% Resins 1) Removal of resin by pyrolysis. 2) Electric Cogeneration 3) Getting fibers without sizing for TP injection moulding or matt prepregs
  13. 13. © AIRBUS Operations S.L. All rights reserved. Confidential and proprietary document.  Airbus has always bet on composite use as a way to improve A/C performance and, then, save weight, until reaching more than 50% of structural weight in composite for last generation aircraft: the A350 XWB  Current composite technologies: composites made of epoxy resin and carbon fibers are the predominant ones, while thermoplastic composite use in airframe is still low. 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 processes: cost reduction, performance, multifunctionality, processability & reuse / recycle are key development areas to maintain composite presence / use in commercial aeronautical field  Research community effort is key in these areas Conclusions June 2015 WMF - AIRBUS - 3rd Generation of Composites for Airframe
  14. 14. © AIRBUS Operations S.L. All rights reserved. Confidential and proprietary document. June 2015 WMF - AIRBUS - 3rd Generation of Composites for Airframe © 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 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 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 basis thereof. AIRBUS, its logo, A300, A310, A318, A319, A320, A321, A330, A340, A350, A380, A400M are registered trademarks. Presentation Prepared by: • Jose Sánchez Gómez – Composite Materials Senior Expert, ESCAA • Ivan Gayoso – Composites Procurement, PMCC • Tamara Blanco – R&T Composite Materials, ESCRNM Thank you for your attention

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