Sirris_am in aviation and aerospace_airbus

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Sirris Workshop - Additive manufacturing in aviation and aerospace 13/05/2014

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Sirris_am in aviation and aerospace_airbus

  1. 1. ThisdocumentanditscontentisthepropertyofAstrium[Ltd/SAS/GmbH]andisstrictlyconfidential.ItshallnotbecommunicatedtoanythirdpartywithoutthewrittenconsentofAstrium[Ltd/SAS/GmbH]. Christian Désagulier, Materials & Processes Expert An ALM Qualification Logic Proposal for Space Equipments SIRRIS, Liege Science Park, Rue Bois Saint Jean 12, 4102 Seraing 2014, May the 13th Current applications, trends and future developments of metal Additive Manufacturing / 3DPrinting for space and aviation
  2. 2. Confidential ThisdocumentanditscontentisthepropertyofAstrium[Ltd/SAS/GmbH]andisstrictlyconfidential.ItshallnotbecommunicatedtoanythirdpartywithoutthewrittenconsentofAstrium[Ltd/SAS/GmbH]. Introduction : 3 ALM school cases..  Copper foil gilded for DGR telecom reflector antenna  Integral Co-curing for ULR Ku sandwich (1 ply per skin, without adhesive, < 1 kg/m2)  Launchers CFRP composite Tanks  Ti64 brackets EBMed for ULR Ka antenna reflector
  3. 3. Confidential ThisdocumentanditscontentisthepropertyofAstrium[Ltd/SAS/GmbH]andisstrictlyconfidential.ItshallnotbecommunicatedtoanythirdpartywithoutthewrittenconsentofAstrium[Ltd/SAS/GmbH]. 1st ALM case : Copper foil gilded for DGR antenna
  4. 4. Confidential ThisdocumentanditscontentisthepropertyofAstrium[Ltd/SAS/GmbH]andisstrictlyconfidential.ItshallnotbecommunicatedtoanythirdpartywithoutthewrittenconsentofAstrium[Ltd/SAS/GmbH]. - 35 microns Copper foil annealed 1360 x 3500 mm - 0,5 micron gilded - NDI Gold thickness - Sample traveler for adhesion tests  more than 80’s flying since 1995 (i.e. 320 gilded copper foils)
  5. 5. Confidential ThisdocumentanditscontentisthepropertyofAstrium[Ltd/SAS/GmbH]andisstrictlyconfidential.ItshallnotbecommunicatedtoanythirdpartywithoutthewrittenconsentofAstrium[Ltd/SAS/GmbH]. 2d ALM case : Ultra-Light Reflector Ku antenna
  6. 6. Confidential ThisdocumentanditscontentisthepropertyofAstrium[Ltd/SAS/GmbH]andisstrictlyconfidential.ItshallnotbecommunicatedtoanythirdpartywithoutthewrittenconsentofAstrium[Ltd/SAS/GmbH]. - Integral Co-curing : 1 ply per skin, without adhesive, sandwich < 1 kg/m2 - NDI (thermography, US) + curing cycle checking - Mimic sample traveler (OOP/ Compression tests, micrographs)  100s customized antenna reflectors in flight since 2000..
  7. 7. Confidential ThisdocumentanditscontentisthepropertyofAstrium[Ltd/SAS/GmbH]andisstrictlyconfidential.ItshallnotbecommunicatedtoanythirdpartywithoutthewrittenconsentofAstrium[Ltd/SAS/GmbH]. 13 May 2014 7 The well known Additive Layer composite Manufacturing machines CFRP based  Filament winding Tow placement - Spherical tanks from Ø 0,3 m to 1 m - Cylindral tanks & structures from Ø 3m up to 5,5m, H up to 12 m 3d ALM case : CFRP Launchers Composite tanks & structures
  8. 8. Confidential ThisdocumentanditscontentisthepropertyofAstrium[Ltd/SAS/GmbH]andisstrictlyconfidential.ItshallnotbecommunicatedtoanythirdpartywithoutthewrittenconsentofAstrium[Ltd/SAS/GmbH]. 13 May 2014 8 100’s ALM tanks on civil and defence launchers, manufactured since 25 years..
  9. 9. Confidential ThisdocumentanditscontentisthepropertyofAstrium[Ltd/SAS/GmbH]andisstrictlyconfidential.ItshallnotbecommunicatedtoanythirdpartywithoutthewrittenconsentofAstrium[Ltd/SAS/GmbH]. 3d ALM case : Satellite Bi-axial Sun Sensor
  10. 10. Confidential ThisdocumentanditscontentisthepropertyofAstrium[Ltd/SAS/GmbH]andisstrictlyconfidential.ItshallnotbecommunicatedtoanythirdpartywithoutthewrittenconsentofAstrium[Ltd/SAS/GmbH]. 3d ALM case : Satellite Bi-axial Sun Sensor
  11. 11. Confidential ThisdocumentanditscontentisthepropertyofAstrium[Ltd/SAS/GmbH]andisstrictlyconfidential.ItshallnotbecommunicatedtoanythirdpartywithoutthewrittenconsentofAstrium[Ltd/SAS/GmbH]. Sirris, 2014, May the 13h Telemetry Support (TMTC) + Bi-Axial Sun Sensor (BASS) Ti64 node support - Conventional design for back up need - Quality audit of the manufacturer subcontractor and registration of the qualified EBM process - Manufacturing according to registered process - NDT & traveler samples checking - Mast to CFRP tubes integration with bonding of the knot - Mast to Satellite integration  ATLANTIC BIRD 7, first ALM commercial application in GEO, launched on Tuesday the 27th of September 2011, delivered to the customer on the 23th of October.. 3d ALM case : Satellite Bi-axial Sun Sensor
  12. 12. Confidential ThisdocumentanditscontentisthepropertyofAstrium[Ltd/SAS/GmbH]andisstrictlyconfidential.ItshallnotbecommunicatedtoanythirdpartywithoutthewrittenconsentofAstrium[Ltd/SAS/GmbH]. ALM - One Technology But Several Processes Powder Bed Wire feed Ti64 Inconel Stainless steelsScalmalloy® Maraging Electron Beam LASER CMT Ti64 Stainless steels INVAR ? CrCo alloys and High T° alloys Al-Si-Mg Alloys HP-Al Alloys (2xxx, 7xxx)
  13. 13. Confidential ThisdocumentanditscontentisthepropertyofAstrium[Ltd/SAS/GmbH]andisstrictlyconfidential.ItshallnotbecommunicatedtoanythirdpartywithoutthewrittenconsentofAstrium[Ltd/SAS/GmbH]. General technical status@EADS General technical status@AIRBUS AIRBUS
  14. 14. Confidential ThisdocumentanditscontentisthepropertyofAstrium[Ltd/SAS/GmbH]andisstrictlyconfidential.ItshallnotbecommunicatedtoanythirdpartywithoutthewrittenconsentofAstrium[Ltd/SAS/GmbH]. ASTRIUM Qualification logic Two possible approaches  Proof load test on each new built part, or on one part per batch  Validation of samples produced with the parts  Traceability  NDI qualification  High level Incoming inspection “Conventional” The long-term target “Composite” Interim approach during ALM maturity development  the choice depend on the maturity of processes and considering volume of parts..  Development of a specific qualification logic, in particular on inspection and verification methods, contributing to increase of technical maturity  Impact and sensitivity of process parameters  NDI qualification  Raw material (powder) supply chain qualification
  15. 15. Confidential ThisdocumentanditscontentisthepropertyofAstrium[Ltd/SAS/GmbH]andisstrictlyconfidential.ItshallnotbecommunicatedtoanythirdpartywithoutthewrittenconsentofAstrium[Ltd/SAS/GmbH].

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