gif2008 workshop composites hellard

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Composites in Airbus @ Global Investor Forum by Dr Roland Thévenin _V51PR0800355_v1

Presented byGuy Hellard

Composites in AirbusA Long Story of Innovations and Experiences

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Composites in Airbus @ Global Investor Forum by Dr Roland Thévenin _V51PR0800355_v1 2

Composites in Airbus

1. Market Situation and Industrial Composite Applications

3. Conclusions

Table of Content

2. A350 Structures

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Table of Content



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1980 1990 2000 2010

Composites Introduction

A step by step gain of composite experience

• Within primary structures

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1980 1990 2000 2010

Composites Introduction


• Within primary structures

Unique experience with more than 70

million FH cumulated

A330/A340 + HTP as fuel tank

A310-300 Fin, Rudder, Elevators

A320 + HTP, Flaps, Ailerons,

Spoilers

A340-600 + Rear Pressure Bulkhead,

Keel Beam

A380+ Rear Fuselage, Center Wing Box,

Wing RibsATR72

+ Outer wing

A350XWB + Outer wing,

FuselageV10F

+ Outer wing

A400M + Cargo door,

Outer wing

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Composite structure / Structure weight (%)

A310-300

A320 A330 A340-600

A380-800

A350XWB60

40

20

10

0

19851985 19881988 19931993 20022002 20072007 20132013

… step by step approach…

A400 M

53%53%

25%25%

5%5%


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Technology introduction

Improve performances

Lower production costQuality robustnessReduce lead time

Reduce Lifecycle cost(maintenance cost)

ManufacturingDesign

Use

Why Composites?

Achieved by trade-off

Need to design for CFRP

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CFRP: Supply vs. Demand

• Main growth drivers: civil aviation & wind power industries

• Suppliers increase investment budgets

• EADS demand to increase substantially beyond 2010

0

10.000

20.000

2005 2010 2015 2020

EADS Carbon Fiber Demand

0

10.000

20.000

2005 2010 2015 2020

EADS Carbon Fiber Demandtons

• Close cooperation with current and potential suppliers to ensure smooth ramp up

• Outlook: supplier production capacities to double by 2010

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• Single Part Production 1Typical Manufacturing Process

5) Curing 6) Non destructive testing 7) Milling 8) Painting

How composites are manufactured?

Wing Panel : CFRP Prepreg1) Preparation of mould 2) Automatic tape laying 3) Stringer integration 4) Vacuum bagging

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Industrialisation

Optimisation and assurance of processes

3D-Tape layer

Trimming machine

Paint robot Riveting robot

Multi-channel NDT

Ni-alloy jig• From repair intensive CFRP tool to Nickel-Alloy jig

• From manual tape laying to automated processes

• From manual 1-channel Non-Destructive Testing (NDT) to automated multi-channel testing methods (192 channels)

• From manual drilling to automated processes on multi flexible tooling.

• From manual painting to automated process

• From manual riveting to half/fully automated riveting machines

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EurocopterNH90, Tiger:• fuselageEC135:

Primary structuresMain rotorTailboom

Squirrel and Dolphin Rotor hub

Astrium• Satellites antenna

Astrium (cont’d)• Arianne 5

Upper partsSegments

• Launchers and MissilesUpper parts and fairingsCriogenic tanks

MTAD• CN 235/C295

Elevators, Fairings• A400M• HTP, VTP, Wing covers• Elevator

MAS• EF-2000

wingfuselagefairingsstabilizers

• BARRACUDA (UAV)

wingfuselagefairingsstabilizers

CFRP

Composites applications @ EADS

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Composites applications @ EADS

Bottom Shell NH90

CFRP structure examples

Antenna deflector ASTRA

NH90 ST

Wing panel EF2000

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A380 Composites applications

Major applications

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A400M Composites applications

New major applications

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Table of Content

2. A350 Structures



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Fuselage:• Skin• Frame• Keel Beam • Rear Fuselage

Centre Wing Box:•Covers / Stringers / Spars

Outer Wing Box:• Covers / Stringers / Spars

CFRP

Al & Al-Li

Titanium

Steel

Empennage (VTP, HTP)

Technologies selected to improve performance and lower maintenance tasks

Misc.A350-900 XWBMaterial Breakdown (%)Including Landing Gear

Al/Al-Li: Ribs, Floor beams, Gear bays,..

Titanium: Landing Gears, Pylons, Attachments

Intelligent airframe

A350 Structures

Al/Al-Li19%

Titanium14%

Steel6%

Misc.8%

Composite 53%

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• Use of CFRP panels, stringers, frame, Keel Beam • Panel as long as possible to reduce the amount of circumferential joints• Optimisation of each panel for its design caseSO

LUTI

ON

Fuselage Innovations : CFRP

A350 Structures

• Improve passenger comfort by higher cabin pressure• Weight reduction : Fuel-burn savings• Cost reduction and environmental impact reduction• Fatigue- and corrosion-free: Reduce maintenance costs

BEN

EFIT

• Reduce operational cost• Reduce global environmental impact

RA

TIO

NA

LE

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A350 Structures

Status of developments

Fuselage Innovations : CFRP - 4 Panels

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A350 Structures

RTM FramesStatus of developments

Full barrel technology for Rear fuselage

Fuselage Innovations : CFRP - Barrel

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• Use of CFRP spars, skins and stringers

• Fuel-burn savings through weight reduction: cost and environmental improvement

• Fatigue- and corrosion-free composites save maintenance costs

BEN

EFIT

SOLU

TIO

N

• Aeroelastic tailoring as a passive adaptive structure

• Reduce operational cost• Reduce global environmental impactR

ATI

ON

ALE

Wing Innovations : CFRP

CFRP outer wing box

CFRP center wing box

A350 Structures

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Robustness will override the other sizing criteria within the areas prone to accidental damage.

A350 Structures

Maintainability / Reparability

Robustness

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A350 Structures

Repairs

Standard bolted repair concept for structural damages

– Existing tools and skills– Similar repair times

Bonded repairs for minor cosmetic damage

Maintainability / Reparability

Most of the former principles still apply

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Table of Content

2. A350 Structures

3. Conclusions



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• Long term and unique experience in composite technologies• Comprehensive experience of primary composite parts:

design, certification and maintenance• Multi function approach (e.g. electrical & structural) to improve

performance and associated lightning strike protection• Good long term behavior of carbon composites (corrosion,

fatigue) decreases maintenance cost• Use of multi panel concept to allow best design optimization

and large repair capability• A350 XWB composite fuselage optimal compromise

between longitudinal & circumferential integration:- long panel concept in the main fuselage area - full barrel concept in the non-pressurised area

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Conclusions

1/2

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• Better structure weight efficiency• Capital intensive production investments determine ramp up

flexibility• Extremely high quality requirements of CFRP parts • 4-Panels CFRP Fuselage structure is a risk averse manufacturing

solution:• Avoids fitting issues encountered in final assembly line• More flexibility during assembly process• Easier part handling for large diameter• Less complex and lighter tooling• Higher manufacturing speed

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Conclusions

2/2

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© AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.

This document and all information contained herein is the sole property of AIRBUS S.A.S.. 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 S.A.S. 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 S.A.S. 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.

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