Composite Technology at Airbus Germany€¦ · 24.10.02 Breuer/ESWCG Composite Technology Germany 2 4 Outline Benefits of CFRP for Primary A/C Structures 4History of CFRP Introduction
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Breuer/ESWCG Composite Technology Germany 124.10.02
Composite Technology at Airbus GermanyComposite Technology at Airbus GermanyPast, Present, FuturePast, Present, Future
Ulf P. Ulf P. BreuerBreuerComposite Technology GermanyComposite Technology Germany
Airbus BremenAirbus Bremen
Breuer/ESWCG Composite Technology Germany 224.10.02
Q
OutlineOutline
Benefits of CFRP for Primary A/C Structures
Q History of CFRP Introduction to Airbus
Q CFRP Technology of A380
Q CFRP Technology of Next Generation A/C
Q Future Application of CFRP: Requirements and Recommendations
Q Conclusions
Breuer/ESWCG Composite Technology Germany 324.10.02
Benefits of CFRP for Primary A/C StructuresBenefits of CFRP for Primary A/C Structures(Selection of Main Design Drivers)(Selection of Main Design Drivers)
Q High Structural Performance to Mass Ratio
Q Utilization of Anisotropy for Tailored Design (Strength, Stiffness, Stability)
Q Single Load Path Design
Q Simple Shaping of Complex Structures
Q Excellent Fatigue Behaviour
Q Excellent Fire Worthiness
Q Excellent Crash Worthiness
Q Excellent Media/Corrosion Worthiness
Breuer/ESWCG Composite Technology Germany 424.10.02
History of CFRP Introduction to AirbusHistory of CFRP Introduction to Airbus(Selection of Major Milestones)(Selection of Major Milestones)
A320-200 (1987)SpoilerRudderElevatorFinMLG & NLG DoorsWing Shroud BoxWing T/E panelsFlap Track FairingsPylon FairingsNacelle CowlingsFloor PanelsAileronFlapsHorizontal Stabilizer
A340-500/-600 (2001)SpoilerRudderElevatorFinMLG & NLG DoorsWing Shroud BoxWing T/E panelsFlap Track FairingsPylon FairingsNacelle CowlingsFloor PanelsAileronFlapsHorizontal StabilizerRear Pressure BulkheadKeel Beam
A310-200 (1982)SpoilerRudderElevator
A310-300 (1985)SpoilerRudderElevatorFin
CFRP Technology of A380CFRP Technology of A380Floor Beamsfor Upper Deck
Rear Pressure Bulkhead
VerticalTail Plane
Outer Flaps
Center Wing Box
Section 19
Wing Ribs
J-Nose
HorizontalTail Plane
Belly Fairing
Section 19.1
Breuer/ESWCG Composite Technology Germany 524.10.02
Breuer/ESWCG Composite Technology Germany 624.10.02
CFRP Technology of Next Generation A/CCFRP Technology of Next Generation A/C
ANTA/ANSA (EIS 2012/2017)
CFRP Slat Structure (LuFo III)
CFRP High Lift Devices (LuFo/AWIATOR)CFRP Flap Supports (LuFo II/III)
CFRP Wing Box (V-Box, TANGO)CFRP Fuselage (TANGO/LuFo II/III)
Provided that composite solutions will be competitive, the amount of CFRP structure on the next generation Airbus A/C will increase significantly
Breuer/ESWCG Composite Technology Germany 724.10.02
CFRP TechnologyCFRP TechnologyRequirements and Recommendations: Major GoalsRequirements and Recommendations: Major Goals
Q Increase�
- cost/weight benefits applying CFRP to primary A/C structures- efficiency of the process chain from R&D to series production
Q Reduce�
- manufacturing and in-service effort
Q Maintain�
- highest quality demands
Q Meet�
- with future environmental demands
Breuer/ESWCG Composite Technology Germany 824.10.02
CFRP TechnologyCFRP TechnologyRequirements and Recommendations: Process ChainRequirements and Recommendations: Process Chain
Material Development
Design
Manufacturing
Assembly
Service
Breuer/ESWCG Composite Technology Germany 924.10.02
CFRP TechnologyCFRP TechnologyRequirements and Recommendations: Process ChainRequirements and Recommendations: Process Chain
-cheaper, lighter, stronger, stiffer, tougher (where necessary),reference: prepreg UD-tapeMaterial Development
-material adaptivity on demand-infinite shelf/shop life-processing/curing at room temperature-impact and moisture tolerant sandwich structuresDesign
Manufacturing
Assembly
Service
Breuer/ESWCG Composite Technology Germany 1024.10.02
CFRP TechnologyCFRP TechnologyRequirements and Recommendations: Process ChainRequirements and Recommendations: Process Chain
Material Development
-design to weight with 3-D-load path fibre orientationDesign
-reduction of notch factors (by elimination of rivets)
Manufacturing
Assembly
Service
Breuer/ESWCG Composite Technology Germany 1124.10.02
CFRP TechnologyCFRP TechnologyRequirements and Recommendations: Process ChainRequirements and Recommendations: Process Chain
Material Development
Design
- highly automated �net shape� processing of filaments to cured, complex shaped structuresManufacturing
- lightweight/flexible tooling- in process quality check
Assembly
Service
Breuer/ESWCG Composite Technology Germany 1224.10.02
CFRP TechnologyCFRP TechnologyRequirements and Recommendations: Process ChainRequirements and Recommendations: Process Chain
Material Development
Design
Manufacturing
- improvement of joining technology (bonding and welding):Assembly � dry, 1-step- surface preparation
� bonding and debonding �at the push of a button�at room temperature
� on-line measurement of bonding loading capacity,sealing, geometry
Service
Breuer/ESWCG Composite Technology Germany 1324.10.02
CFRP TechnologyCFRP TechnologyRequirements and Recommendations: Process ChainRequirements and Recommendations: Process Chain
Manufacturing
Assembly
- repair without rivetsService - easy inspection
Breuer/ESWCG Composite Technology Germany 1424.10.02
CFRP TechnologyCFRP TechnologyRequirements and Recommendations: Manufacturing TechnologiesRequirements and Recommendations: Manufacturing Technologies
Ma j
orC
FRP
Ma n
ufac
turin
g/A
s sem
bly
Tech
n olo
g ies
(I) Prepreg Technology
(II) Textile/Infusion Technology
(III) Thermoplastics
(IV) Bonding/Joining
Breuer/ESWCG Composite Technology Germany 1524.10.02
CFRP TechnologyCFRP TechnologyRequirements and Recommendations: Manufacturing TechnologiesRequirements and Recommendations: Manufacturing Technologies
(I) Prepreg Technology
Qavailability of high performance materials
Qhigh material cost
Qlarge experience, broad application in primary A/C structures
Qautoclave processing
Qhigh processing effort
Qhigh auxiliary material cost
Qhigh amount of production wasteQautomated tape laying
Qlow cost high perfor-mance R/T prepreg
Qefficient processingof tapes to integralnet shape parts
Qefficient curingtechnology
State of the Art Drawbacks Perspectives
Breuer/ESWCG Composite Technology Germany 1624.10.02
CFRP TechnologyCFRP TechnologyRequirements and Recommendations: Manufacturing TechnologiesRequirements and Recommendations: Manufacturing Technologies
(II) Textile/Infusion Technology
Qstandard 2-D-textiles(fabric, NCF)
Qbinder based preforming (epoxy)
Qsingle componentepoxy-resin
Qpoor performance(mech. prop.) of textilescompared to UD-prepreg
Qpoor availability of net shape preform technologies
Qpoor handling of large preforms
Qnegative influence of sewing/bindingon mech. prop.
Qlow cost high perfor-mance R/T resin systems
Qhigh performancetextiles (mech. prop.)
Qefficient processingof rovings to integralnet shape preforms
Qefficient sandwich processing
State of the Art Drawbacks Perspectives
Breuer/ESWCG Composite Technology Germany 1724.10.02
CFRP TechnologyCFRP TechnologyRequirements and Recommendations: Manufacturing TechnologiesRequirements and Recommendations: Manufacturing Technologies
(III) Thermoplastics
Qthermoplastic CFRP established for secondary structures,fairings, ties, clips
Qinfinite shop life
Qpoor availability of semifinished materials
Qhigh material costs
Qlimited wall thickness
Qlimited processing technology
Qlow cost high per-formance materials
Qefficient processing ofTP tapes to complex shaped cured parts
Qenhanced degree of freedom for part design
Qformability,free of autoclave
Qweldability
Qshort cycle times
Qlimited part size
State of the Art Drawbacks Perspectives
Breuer/ESWCG Composite Technology Germany 1824.10.02
CFRP TechnologyCFRP TechnologyRequirements and Recommendations: Manufacturing TechnologiesRequirements and Recommendations: Manufacturing Technologies
(IV) Bonding/Joining
Qdomination of rivetingfor highly loaded parts
Qpotential for further automation of riveting
Qnotch factor, bolt collarand rivets can causeadditional weight
Qhigh effort for bondingsurface pre-treatment
Qhigh performance ad-hesives(R/T, H/W, em )
Qworld wide availability of riveted repair techn.
Qbonding of stiffeners to shells by resin films
Qpoor perceptibilityof imperfectionsin bonding interfaces
Qpoor availability of bonded repair methods
Qautomated application of adhesives
Qautoclave (temperature,pressure) free bonding,�at the push of a button�
Q1-step-surfacepre-treatment (repair!)
Qhighly efficient NDT
State of the Art Drawbacks Perspectives
Breuer/ESWCG Composite Technology Germany 1924.10.02
CFRP TechnologyCFRP TechnologyConclusionsConclusions
Q CFRP is recognized as a key technology to enhance A/C performance.
Q To be competitive, higher performance must not be paid by higher cost.
Q To increase the amount of CFRP structure, the efficiency of the complete process chain (�design to fly�) must be regarded and improved by new technologies.
Q The definition of clear technology targets is essential.
Q National and international technology programs must contribute directlyto �technology readiness�.
Q To be successful, Airbus must work very closely together with all technology partners.
Breuer/ESWCG Composite Technology Germany 2024.10.02
CFRP TechnologyCFRP TechnologyUpshotUpshot
�lets go upwards�
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