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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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Composites in Airbus @ Global Investor Forum by Dr Roland Thévenin _V51PR0800355_v1 3
Table of Content
Composites in Airbus
1. Market Situation and Industrial Composite Applications
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Composites in Airbus @ Global Investor Forum by Dr Roland Thévenin _V51PR0800355_v1 4
1980 1990 2000 2010
Composites Introduction
A step by step gain of composite experience
• Within primary structures
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Composites in Airbus @ Global Investor Forum by Dr Roland Thévenin _V51PR0800355_v1 5
1980 1990 2000 2010
Composites Introduction
A step by step gain of composite experience
• 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
6 1
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Composites in Airbus @ Global Investor Forum by Dr Roland Thévenin _V51PR0800355_v1 6
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%
A step by step gain of composite experience
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Composites in Airbus @ Global Investor Forum by Dr Roland Thévenin _V51PR0800355_v1 7
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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Composites in Airbus @ Global Investor Forum by Dr Roland Thévenin _V51PR0800355_v1 8
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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Composites in Airbus @ Global Investor Forum by Dr Roland Thévenin _V51PR0800355_v1 9
• 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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Composites in Airbus @ Global Investor Forum by Dr Roland Thévenin _V51PR0800355_v1 10
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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Composites in Airbus @ Global Investor Forum by Dr Roland Thévenin _V51PR0800355_v1 11
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 in Airbus @ Global Investor Forum by Dr Roland Thévenin _V51PR0800355_v1 12
Composites applications @ EADS
Bottom Shell NH90
CFRP structure examples
Antenna deflector ASTRA
NH90 ST
Wing panel EF2000
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Composites in Airbus @ Global Investor Forum by Dr Roland Thévenin _V51PR0800355_v1 13
A380 Composites applications
Major applications
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Composites in Airbus @ Global Investor Forum by Dr Roland Thévenin _V51PR0800355_v1 14
A400M Composites applications
New major applications
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Composites in Airbus @ Global Investor Forum by Dr Roland Thévenin _V51PR0800355_v1 15
Table of Content
2. A350 Structures
Composites in Airbus
1. Market Situation and Industrial Composite Applications
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Composites in Airbus @ Global Investor Forum by Dr Roland Thévenin _V51PR0800355_v1 16
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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Composites in Airbus @ Global Investor Forum by Dr Roland Thévenin _V51PR0800355_v1 17
• 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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Composites in Airbus @ Global Investor Forum by Dr Roland Thévenin _V51PR0800355_v1 18
A350 Structures
Status of developments
Fuselage Innovations : CFRP - 4 Panels
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Composites in Airbus @ Global Investor Forum by Dr Roland Thévenin _V51PR0800355_v1 19
A350 Structures
RTM FramesStatus of developments
Full barrel technology for Rear fuselage
Fuselage Innovations : CFRP - Barrel
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Composites in Airbus @ Global Investor Forum by Dr Roland Thévenin _V51PR0800355_v1 20
• 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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Composites in Airbus @ Global Investor Forum by Dr Roland Thévenin _V51PR0800355_v1 21
Robustness will override the other sizing criteria within the areas prone to accidental damage.
A350 Structures
Maintainability / Reparability
Robustness
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Composites in Airbus @ Global Investor Forum by Dr Roland Thévenin _V51PR0800355_v1 22
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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Composites in Airbus @ Global Investor Forum by Dr Roland Thévenin _V51PR0800355_v1 23
Table of Content
2. A350 Structures
3. Conclusions
Composites in Airbus
1. Market Situation and Industrial Composite Applications
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Composites in Airbus @ Global Investor Forum by Dr Roland Thévenin _V51PR0800355_v1 24
• 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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Composites in Airbus @ Global Investor Forum by Dr Roland Thévenin _V51PR0800355_v1 25
• 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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Composites in Airbus @ Global Investor Forum by Dr Roland Thévenin _V51PR0800355_v1 26
© 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.
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AIRBUS, its logo, A300, A310, A318, A319, A320, A321, A330, A340, A350, A380, A400M are registered trademarks.