2012 january ththe 30 j-p domergue head of operations · eads innovation works … the spirit of...

EADS Innovation Works … the spirit of innovation, Advanced Concepts & Scenarios

2012 January the 30th

J-P Domergue

Head of Operations

© EADS 2012 EADS INNOVATION WORKS general presentation

EADS Management Structure EADS Innovation Works is part of the

Chief Technical Officer’s organization

Jussi Itävuori

Human Resources

Sean O’Keefe

EADS North America

Jean J. Botti

Chief Technical Officer

Marwan Lahoud

Strategy & Marketing

Hans-Peter Ring

Finance

Chairman of the Board Bodo Uebber

Louis Gallois Chief Executive Officer (CEO)

Eurocopter

Lutz Bertling (CEO)

Cassidian

Stefan Zoller (CEO)

Astrium

François Auque (CEO)

Coordination Cassidian Astrium

François Auque

Airbus

Fabrice

Brégier (COO)

Tom Enders (CEO)

Airbus Military Domingo

Ureña-Raso

EADS Innovation Works within the Corporate Technical Office

EADS

Innovation Works

R&T Enablers

Support Group

Chief Information

Officer

COO Innovation

CTO Deputy

Innovation Operations

and Networks

Chief of Staff

Quality & Business

improvement

Chief Technical Officer


A transnational organisation

Head of

Innovation Works CTO IW

Composites Technologies

CTO IW CT

Metallic Technologies & Surface Engineering

CTO IW MS

Structure Engineering Production

& Aeromechanics

CTO IW SP

Sensors, Electronics & Systems Integration

CTO IW SI

Engineering, Physics, IT, Security

Services & Simulation

CTO IW SE

Head of International Operations

CTO IW IO

Innovative Concepts &

Scenarios

CTO IW IC

Dean of College of Experts

Executive Experts

CTO IW CE

Energy

&

Propulsion

CTO IW EP

Innovation Works United Kingdom

CTO IW MU

Innovation Works Coordination in Germany CTO IW MG

Innovation Works Coordination in Spain

CTO IW MS

Innovation Works Coordination in France

CTO IW MF

Executive Advisor

CTO IW EA

Deputy to Head of IW

Head of Operations

CTO IW OP

Finance & Controlling

Human Resources

Technical Capabilities Centers


EADS Innovation Works : key figures (2010)

16 sites

9 countries

81 new patent applications

More than 700 Engineers

© EADS 2010


…Partnerships policy

A network based on talent & innovation

Optimize networking synergy to get innovations

CFK Valley

Stade


Competencies sharing (headcount 2010)


Composites

Technologies 13% Metallic

Technologies & Surface

Engineering 12%

Structure

Engineering, Production &

Aeromechanics 21%

Sensors,

Electronics & Systems

Integration 20%

Engineering,

Physics, IT, Security

Services & Simulation

20%

Energy &

Propulsion 7%

Innovative

Concepts & Scenarios

7%

Composites Technologies (TCC1)

Main activities:

Research in Composite Materials and Processes

with a multidisciplinary approach by means of

prediction, simulation, process testing and

mechanical testing.


A center dedicated to develop advanced light and robust

materials and processes applicable to new products

Metallic Technologies & Surface Engineering (TCC2)

A center dedicated to develop cost efficient, light, reliable and

environmental friendly surface treatments, metallic/hybrid

structures and associated intelligent production routes.

Main activities:

Integrated research on new materials,

surface treatments and structural concepts

with related robust manufacturing processes.

Testing and understanding of properties and

productivity. Failure analysis.


Structure Engineering, Production & Aeromechanics (TCC3)

A center dedicated to engineering of processes in the design and manufacture of advanced crossing mechanics, electronics and IT expertises.

Main activities:

Mechanical modelling and advanced testing of

composites and metallic materials & dynamic loads,

virtual structural testing methods & software,

acoustics, vibrations analysis & treatments.

Automated assembly & systems installations, digital

manufacturing, mediated workers, structural health

engineering (NDI & SHM). Active flow control

systems, advanced actuators technologies, control

algorithms & systems , morphing technologies.

Basic and upstream research to development of

prototypes, software & systems.


Sensors, Electronics & Systems Integration (TCC4)

Main activities:

Multidisciplinary system design (embedded

SW/HW, optronics, microwaves, radiation,

chemistry & biology, human machine interface)

and test in lab, field and flight


A center specialized in the development and integration of

sensor, communication and avionic systems to enable

functional and operational improvements in safety & security,

autonomy, availability and efficiency.

Simulation, Information Technologies & Systems Engineering (TCC5)

Main activities:

Advanced design, visualisation and simulation,

systems and software engineering, learning

systems development, signature and stealth

concepts, applied mathematics high performance

computing and computer security.

A center dedicated to improving the quality of chain of value

from initial design to after sales follow-up, by means of

simulation and virtual architecture enhanced by IT

technologies.


Energy & Propulsion (TCC6)

Main activities:

Energy & Power management architectures,

Electrical Power & Actuation, Propulsion

Systems, Power Generation, Fuel Systems,

Alternative Fuels


A center dedicated to identifying new sources of energy,

energy transformation, but also to optimizing the on board

energy with respect to environmental constrains.

Innovative Concepts & Scenarios (TCC7)

A center dedicated to identifying new technologies for future and

competitive products and defining the associated roadmaps with

each division by means of concept-demonstrators.

Main activities :

Maturing of technologies to enable their

application to the products of the different

Divisions, management and coordination

of transverse projects.


Innovative Concepts & Scenarios (TCC7)


Some snapshots on Structures & Materials activities of TCC1 and TCC2

Preform technologies

Thermoplastic technologies

Thermoset technologies

Bonding & Repair tehnologies

Chemistry

Multifunctional materials

Structures integration & assembly

Metallic & Manufacturing

Surface engineering

Failure, Material and Surface Analysis Skills

Light Materials for energy efficient structures

High performance material concepts

Eco-efficient joining and assembly

Near net shape manufacturing

Green surfaces technologies

Functional Surfaces for Sustainability


Dry fiber placement

• 2D Embroidery

• 7 axis dry fibres placement

• Fiber Patch Preforming

Preform assembly technologies

• Robot 3D Stitching with 3 stitching heads

• Automated pinning for thick preforms

Preform Technologies 1/2


Preform Technologies 2/2


Braiding technologies

– Robot assisted Braider with 144 bobbins

– Braided Frames prototype production line

One step thermoplastic part M&P

• 7 axis TP fibre placement

• LSP deposition

• New materials

Two steps part M&P

• Automated TP flat tape deposition

• 3D TP Multitows deposition with

Laser heating

• LSP deposition

Assembly of sub structure M&P

• 3D US Welding, co consolidation ,

Injection

Demonstrator

Ultrasounds

Head (20kHz)

Thermoplastic Technologies


process control and monitoring

• PC Controlled Flow and heating control

out of autoclave

• 2m *2m * 3m 400°C oven

tooling technologies

Thermoset Technologies


Bonding

• Robot assisted adhesive

application head

• Automated surface treatment

methods and monitoring

• Alternative curing techniques

• Fast bonding brackets

• Debonding on demand

Repair

• Guided milling machine / Robot

for complex surfaces

• Surface contamination detection

• On site structural repair

Bonding and repair technologies


Material Specification / QC

Selection / Modification

Optimization Cure Cycles

Resin flow / impregnation

FST Determination

Nano Composites

Chemistry


Composite material and electrical conductivity

Composite material for toughness

improvement

Fire smoke toxicity improvement

Self healing composite

Composite materials for high temperature and

durability

New fibre high performances

Epoxy IM7/977-2

y = -0,000010x - 0,231 R2 = 0,991

y = -0,000010x - 0,190 R2 = 0,992

y = -0,000013x - 0,167 R2 = 0,987

y = -0,000059x - 0,102 R2 = 0,993

y = -0,000059x - 0,129 R2 = 0,995

y = -0,000065x - 0,212 R2 = 0,995

y = -0,000140x - 0,824 R2 = 0,997

y = -0,000148x - 0,832 R2 = 0,997

y = -0,000160x - 0,984 R2 = 0,994

-16

-14

-12

-10

-8

-6

-4

-2

0

0 20 000 40 000 60 000 80 000

Time (Hours)

Weig

ht

loss (

%)

120°C no initial cracks150°C no initial cracks180°C no initial cracks120°C limited initial cracks150°C limited initial cracks180°C limited initial cracks120°C many initial cracks150°C many initial cracks180°C many initial cracksLinéaire (120°C no initial cracks)Linéaire (120°C limited initial cracks)Linéaire (120°C many initial cracks)Linéaire (150°C no initial cracks)Linéaire (150°C limited initial cracks)Linéaire (150°C many initial cracks)Linéaire (180°C no initial cracks)Linéaire (180°C limited initial cracks)Linéaire (180°C many initial cracks)

Merging condition on electrical conductivity

1,0E-09

1,0E-08

1,0E-07

1,0E-06

1,0E-05

1,0E-04

1,0E-03

1,0E-02

1,0E-01

1,0E+00

0,001 0,01 0,1 1

CNT content by weight (%)

co

nd

uc

tiv

ity

(S

/m)

50 rpm 500 rpm 2000 rpm

Hybrid particles Al2O3+NTC

Multi functional materials


Key objectives:

− highly integrated components

− reduced lead time / reduced cost

− Thermoset matrix, prepreg technology, RTM developments

− Double curvature reinforced panels, large cut-out, integrated stringers

+ beams, etc. One shot, no-fasteners philosophy

Structure integration & assembly


Metallic & Manufacturing

Light Materials for energy efficient structures •New light weight materials : Al, Mg, cellular...

•Multifunctional/hybrid materials : FML, foams

•Unitized structures concepts: co-extrusion

High performance material concepts •High specific properties light materials: Metal Matrix Composites

•Nano-structured and nano-reinforced

•High specific properties hard materials : Ti, steel

•Extreme environment materials : metallics and ceramics

Eco efficient joining & assembly •Robust joining technologies (FSW, LBW)

•Hybrid material fastening & machining

Near Net Shape Manufacturing •Additive layer manufacturing

•Innovative forming technologies


Surface Engineering

Green surface technology: avoid direct environmental impact by

toxic coating materials or auxiliary process materials

•Replacement of hazardous materials (Chromates, Cd, VOC…)

•New corrosion inhibition concepts

•Out-of-bath surface treatments: Dry (Plasma, laser) & Wet

(spraying)

•One-coat layer concept

Sustainable functional surfaces: reduce environmental impact

during operations (low weight, low drag, durability)

•Wear (erosion, abrasion, scratch) and fretting protection systems

•Advanced Functional Coatings - Structures, Cabin and Systems

•Aerodynamic surfaces

•Metallic solution for CFRP lightning strike protection

SurTech enabling cost and/or lead time reduction •Cleaning and activation

•Surfaces for moulds and tools


Failure, Material and Surface Analysis Skills

Materials and surface characterisation: •Physical & Chemical analysis (FTIR, Thermal, X-ray, XRF,…)

•Microscopic material and surface characterization by electron

microscopy (SEM-EDS) and surface analysis (XPS, SIMS)

•Tribological and corrosion testing, electrochemistry

•Mechanical testing : static, fatigue and fracture mechanics

•Destructive (hole-drilling) and non-destructive (X-ray) residual

stress measurements

Operational durability: Understand and prevent failure and

degradation of materials and coating extend service life

•Correlation of processing parameter and in-service behaviour

•Failure analysis and understanding of long term materials and

coatings degradation behavior

•Failure prevention and enhancement of durability (residual

stresses induction)


• Al-alloys: screening and characterization of weldable & improved AlCuLi, 7xxx and

AlMgSc alloys, development of thermo-mechanical treatments, fundamental

understanding of failure, corrosion and long therm behavior

• Mg-alloys: screening and characterisation of spec. high strength alloys with improved

corrosion and flammability behavior, development of surface protection, development

and simulation of cold and hot forming processes to produce

• Others: metal laminates, foams,…

Trolleys,

Interior components

Raceways

Hatrack brackets,

various other brackets

Fuel connectors

Seat structures

Door hingesElectronic bay

access door

Shear-compr. Panel (Airbus, Aleris) Potential Mg applications

Light Materials for energy efficient structures


• Ti-alloys: challenge Ni-alloys with new near titanium alloys. Taylor properties by

improved heat treatments. Optimize castability and forming processes

• Nano structured and nano-re-inforced Al-, Mg- and Ti-alloys

• Steels: development of heat treatments to improve aging behavior of 15-5-PH

• Extreme environment metallics: low cost metallic high temperature alloy for satellite

thrusters and missiles (Pt replacement). Cu based liner materials.

• Extreme environment ceramics: ceramic matrix composites for appl. at >1700 °C

(combustion chambers, nozzles, ram-jets, TPS for re-entry, brake materials)

Milling time: 30 min

Milling time: 5 min

Milling time: 30 min

Milling time: 5 min

Manufacturing in textile

technique (braiding), TCC 1

High Performance Material Concepts


Eco-efficient joining and assembly

Friction Stir Welding: tooling concepts and robotized and self-reacting

FSW for final assembly lane and major component assembly

Metal / CFRP hybrid joints: optimization of one-shot drilling of hybrid

stacks, cold hole expansion of metal side of hybrid stacks, corrosion

prediction and protection, metal-CFRP rivetless assembly

(Hyperjoints, nanofoils)

Robotic FSW of A330 panel

CFRP

Metal

HORIZONTAL

TEE

REAR

VERTICAL TEE

FRONT

VERTICAL TEE

VEIL

CRUX

FS welded Rib 1

Cathode

Current density distribution (mA/mm2)

Cathode

Current density distribution (mA/mm2)


Additive Layer Manufacturing: cost savings for high value parts (improved buy/fly),

weight savings through topol. optimisation, improved carbon footprint (waste material

and weight savings), reduced lead-time and late design freeze

• powder bed for net shape complex parts (Ti, Al, Ni, steel..)

• large near-net parts by wire/powder feed (Ti,..)

Forming technologies: dieless and rapid forming of Ti-, Al- and steel sheets

through incremental sheet or laser forming.

Near-net shape Manufacturing

combined stretch

and incremental

forming


Green Surface Technologies

Compliance with environmental regulation REACH, anticipate supply chain disruption,

competitive advantage through 2nd generation protection concepts, lead time and

weight reduction reduction

• replacement of hazardous chemicals (Cr6, Cd, VOC, …) in anodizing and coversion

pre-treatments, 1s gen primers, Cd and hard-Cr replacement

• active corrosion inhibition through encapsulation, release on demand

• one-coat layer (SolGel, E-coat)

• dry (plasma, laser) and wet (SolGel) out-of-bath treatments

Corrosion inhibitors in

core of silica particles

Pre - treated Surface

Sol - Gel ONE - COAT


Sol - Gel ONE - COAT

ONE COAT CONCEPT


Sol - Gel One - COAT

Top Coat


Sol - Gel One - COAT

Top Coat


Anodising /conversion

Inhibited Primer

Top Coat





Inhibited Primer

Top Coat

STATE OF ART


33 Active & passive

surfaces

Rain/ Sand

Anti-Icing concept for

CFRP leading edge

Energy saving

Paints, foils

RibletsDrag reduction via

multifunctional surfaces

Anti-Icing coatings

Anti-Contamination

Structured surfaces

Erosion Protection

Active & passive

surfaces

Rain/ Sand


CFRP leading edge

Energy saving

Paints, foils



Anti-Icing coatings

Anti-Contamination

Structured surfaces

Erosion Protection

Rain/ Sand


CFRP leading edge

Energy saving

Paints, foils



Anti-Icing coatings

Anti-Contamination

Structured surfaces

Erosion Protection

• Aerodynamic Surfaces: Development of tailored surfaces/coatings for sand/rain erosion

protection of metallic and CFRP structures. Coatings enabling new anti-icing concepts.

Anti-contamination (e.g. photocatalytic coatings). Structured surfaces /paints/foils (e.g.

riblets). Development of cheap and reliable lab testing facilities.

• Wear and fretting protection: green and cost effective lifetime enhancement through

organic, inorganic, multilayer, self-lubricating coatings. Fast and meaningful test methods.

• Cabin application: Improved passenger comfort through easy-to-clean, scratch resistant,

anti-bacterial, anti-fingerprint coatings based on SolGel- and nanotechnology.

• Assembly, maintenance and repair: Development of processes and coatings for

local/assembly integrated application. Dry and wet pre-treatments for structural bonding

based on SolGel) and atm. plasma, laser, thermal spray technologies .

Functional Surfaces for Sustainability


2012 january ththe 30 j-p domergue head of operations · eads innovation works … the spirit of...

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