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Airbus Costumer Benefit from Fiber Metal Laminates - ESAS - Ref. L53PR0605135 - Issue 1

May 2006

Airbus Customers Benefit from Fiber Metal Laminates

Application of smart structures in the aircraft industry

ILA 2006

Presented by

Jürgen PleitnerAirbus

May 2006Airbus Costumer Benefit from Fiber Metal Laminates - ESAS - Ref. L53PR0605135 - Issue 1 © A

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Investments of Airbus to Bring the Benefit to our Customers

Application of GLARE® Provides Substantial Improvements

There are Still Treasures to be Explored

1+1 = 3 ! Attractive Properties of Fiber Metal Laminates1+1 = 3 ! Attractive Properties of Fiber Metal Laminates



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Fiber Metal Laminates – A Proven Concept

Aluminium layer

Glass fiber/adhesive layer

Aluminium layer

Glass fiber/adhesive layer

Aluminium layer

Fiber Metal Laminates are thin metal sheets bonded together with prepregs

Bonding of Metals

Ø Well established in the aerospace industry since WWII.

Ø Bonded structures show improved fatigue properties over monolithic structures.

Fiber Metal Laminate

Ø Introduction of fibers into the bond film leads to further improvement of properties.

Ø Generation of the class of “Fiber Metal Laminates”.

GLARE® Is an Advanced Product of the FML class.


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Higher Crack Resistance

1

4

Pure AluminiumCrack grows completely through the material

Two Aluminium LayersCrack grows completely through first layer and continues along the bonded seal

Multiple Aluminium LayersCrack grows completely through first layer and can be stopped to continue through the bonded seal due to distributed force (only x 1.25 instead of x 2 with two layers)

Fiber Metal LaminationCrack grows completely through first layer and can be bridged by the strong fibermaterial


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GLARE® Design Features – “Giant” Tool Box

Splice in skin panel or doubler

Limitation of aluminum sheet width

Internal stress level in double curved panels

Additional glass fiber layers

embedded at frame locations

Inter-laminar doublers

spliced or go thru depending on length and orientation

Transition of GLARE® type

e.g. from GLARE® 4 to GLARE® 3

Additional layers

Aluminum sheet locally at frame station

Glass fiber layers locally between two aluminum sheets

Fiber Orientation and Lay-up

Adjust properties to loading condition


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Application of GLARE® Provides Substantial ImprovementsApplication of GLARE® Provides Substantial Improvements

1+1 = 3 ! Attractive Properties of Fiber Metal Laminates


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A380 – Weight Saving

Ø Superior F&DT properties of FML

Ø Splice concept allows elimination of longitudinal joints

Ø Additional fibers underneath stringer allow use of un-reinforced frames

Ø Static properties sufficient

⇒ FML (GLARE® ) in sections 13, 15 and18 allow about 800 kg weight reduction

Transition

®


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Fatigue Cycles

Hal

f Cra

ck L

engt

h

Glare 3

Glare 2

2024-T3

Crack Propagation is no Sizing Parameter

General differences of GLARE®

compared with Aluminium:

Ø Fatigue life is longer

Ø Crack initiation is earlier

Ø Contribution of crack propagation period on total fatigue life is larger

0 100000 200000 300000

2024T3

Glare 3-3/2-0.3

Cycles to failure

N (initiation)

N (crack growth)

N

2a

W

l

GLARE®


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A380 - Large Damage Capability (LDC)

accidental damage, growing

no demand to design outer frame flange against LDC

GLARE® 3 improved:

Additional Glass fibre layers in circumferential direction:

Ø Crack Turning

Ø Higher allowable circumferential stress levels

Ø Damage tolerant, light weight design

Ø Weight saving


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Improved Impact Resistance

2024-T3 baret=1.4mm

GLARE 3-3/2-0.3t=1.4mm

Carbon/PEEK quasi isotropic, t=2.1mm

Carbon/PEEKcross-ply, t=1.4mm

0

10

20

30

40

50

60

70

80

90

100M

inim

um

imp

acte

ner

gy

to in

itiat

efi

rst

crac

k(J)

Static

Low Velocity (m=575 g)

Low Velocity (m=2333 g)

High Velocity (m=23.3g)

18

5 49

63

12

21

37

95

63

13

>38

The impact energy threshold for first crack in GLARE® is found to be equal or better than for aluminium alloys and superior to composites.

®


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Investments of Airbus to Bring the Benefit to our CustomersInvestments of Airbus to Bring the Benefit to our Customers



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Mature and Effective Manufacturing Process

2. Chemical treatment line2. Chemical treatment line 3. Robot spraying3. Robot spraying

4. Prepreg cutting4. Prepreg cutting 5. Inspections5. Inspections

1. De-coiling from roll1. De-coiling from roll

6. First aluminium layers6. First aluminium layers

7. Prepreg layer 0°7. Prepreg layer 0° 8. Prepreg layer 90°8. Prepreg layer 90° 9. Top aluminium layers9. Top aluminium layers


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Mature and Effective Manufacturing Process

12. C-Scan12. C-Scan

13. Machining13. Machining 14. 2nd bonding for doublers and/or stringers14. 2nd bonding for doublers and/or stringers

11. Cured Glare skin11. Cured Glare skin10. Autoclave10. Autoclave


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Structure design- Extended Enterprise- Automation & Standardization - Support & Training- Robust processes- Handbooks

Structure Design + Analysis

Engineers Systematically Support the Aircraft Development Cycle

Manufacturing- Acceptable Damage Limits- Handling of Concessions- Manufacturing Defects

Maintenance- Allowable Damages- Standardization and Simplification

of Repair Design Principles, Analysis Methods and Tools

- Bonded Repair

Pre Design- Feasibility Studies- Rapid Sizing- Rapid What If Analysis Capability- Robust design optimization- Selection of Material and Design

Principles

Research- New Materials- New Design Principles- New Technologies- Improved Methods- Virtual Testing- Robust Failure Analysis

- MoC; Top Level Requirements- Test/Analysis Pyramid Optimization- Audits and Technical Reviews- A/L Integration

- Static Test Working Group- DCS Network- ES Analysis Group- Validation Testing

Certification & Safety/ Technical Authority

Pre Design Manufacturing

MaintenanceResearch

Test Pyramid

Full Scale TestComponentsSub ComponentsElementsDetailsCoupons

Structure Engineering


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There are Still Treasures to be ExploredThere are Still Treasures to be Explored



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There are still treasures to be explored

Continuous improvement and wider application range:4FML stringers4New aluminum alloys: 7475, Al-Li4New prepregs4Application in other areas of aircraft4Support future development of A380 family, e.g. A380 freighter

Transfer knowledge and benefits of FMLs to new Airbus aircraft

GLARE Demonstrator Panel

AIRBUS A380

They will show their good properties in-service (A310 demo panel flying since 1999 without problems).

Fiber Metal Laminates have been successfully introduced into the Airbus A380.


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Investments of Airbus to Bring the Benefit to our CustomersInvestments of Airbus to Bring the Benefit to our Customers

Applications of GLARE® Provides Substantial ImprovementsApplications of GLARE® Provides Substantial Improvements

There are Still Treasures to be Explored for Applications in Future Airbus AircraftsThere are Still Treasures to be Explored for Applications in Future Airbus Aircrafts

1+1 = 3 ! Attractive Properties of Fiber Metal Laminates1+1 = 3 ! Attractive Properties of Fiber Metal Laminates

Thank you very much for your attention!


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© AIRBUS DEUTSCHLAND GMBH. All rights reserved. Confidential and proprietary document.

This document and all information contained herein is the sole property of AIRBUS DEUTSCHLAND GMBH. 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 DEUTSCHLAND GMBH. 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 DEUTSCHLAND GMBH 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.

This presentation has been made possible by contribution from:

T. Beumler, F. Pellenkoft, A. Tillich, W. Wohlers, C. Smart, Airbus,

Fokker Aerospace

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