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Engineering, Operations & Technology BR&T

BOEING is a trademark of Boeing Management Company. Copyright © 2011 Boeing. All rights reserved.

The Challenge of New Materials In the Aerospace Industry

Author, 8/6/2013, Filename.ppt | 1

Gerould Young Director Materials & Fabrication Technology Georgia Institute of Technology May 15th, 2013

Engineering, Operations & Technology | BR&T

Copyright © 2011 Boeing. All rights reserved.

Materials & Fabrication Technology

Boeing Almost 100 Years of Innovation

Year Model Innovation 1916 B&W - Model 1 Boeing's first airplane - spruce construction 1928 Model 80 America's first airliner specifically for passenger comfort 1932 P26 Peashooter Fastest air cooled pursuit fighter in the world 1935 TBD Devastator First all metal monoplane torpedo bomber 1935 B17 Multi-engine long range bomber 1938 314 Clipper 3500 mile range - Transatlantic Flight 1939 B29 Long range pressurized bomber 1941 P51 Mustang First fighter to fly Britain to Berlin and back 1949 B47 First swept wing multi-engine bomber 1956 KC-135 Strategic Air Command aerial tanker 1957 - 58 707 & DC-8 Swept wing jet transport 1958 F4 Phanton Jet fighter - 16 speed, altitude and time to climb records 1959 X-15 Rocket powered airplane - 354,000ft and 4,104mph 1961 CH47 Two rotor heavy lift 1960's Mercury & Gemni Manned Spacecraft 1969 747 Largest airliner built 1969 Apollo & Lunar Landed Manned spaceflight to the moon 1970 - 1980 F15 & F18 Air superiority and multi-role fighter 1978 AV8 Fixed wing vertical take off aircraft 1981 Space Shuttle Space access with return flight 1982 B1B Swing wing supersonic bomber 1982 - 1984 757 - 767 Narrow and Wide Body with nearly identical cockpits 1986 V22 Osprey Tilt rotor aircraft 1993 B2 All composite stealth long range bomber 1995 C17 Globemaster Heavy lift and short field capability 1995 777 Wide body with composite empennage - 100% digital definition 1998 Space Station International space station assembled in space 2009 787 First mostly composite airliner




Airframe Metallic Materials Evolution

AL ALLOY DEVELOPMENT (EIS for System Utilizing Alloy)7081, 20272050, 2022

7349 2397 2196, 6056 7081, 20232017 2024 2195 2297 2056, 6156 2139, 2013

7075 2618 6061 7055 7040 7036 70562014 7475 7150 8090 2524 7055 2098 7140 7055-T627175 2219 7050 2324 6056 7449 6019 2099, 2199 2198

7178 2027 2124 2224 6013 2090 7039 2524 7136 7085

DC -3 B-29 B-707 B-727 B-747 L1011 B-757 C-17 F18 B-777 EMB 170 747-LCF 747-8B-17 DC-8 B-737 DC-10 B-767 SLWT F16 Retro F-22 A380B-247 COMET CONCORDE A-319 787

A-340A-330

AIRCRAFT

TITANIUM AND STEEL ALLOYSTi-10-2-3 Ti62222 Ti5553 C465β21S

1990 20001940 1950 1960 19701910 1920 1930 1980

Increasing # Materials, Tailoring and Differentiation

Ti-13-11-3

SR 71 F-15

Ti-64

F18-E/F

Aermet 100

Ti-662 Ti-6242

4340

Ti-6242

15-5PH 13-8PH

β-C Ti-811

7075

7178

2618 201471752027

7475 2219 7050

2124

7150 2324 2224 6013

8090 6056 2090

7349 2195 7055 2524 7449 7039

2397 2297 7040 7055 6019 2524

2098 2099, 2199 7136

7056 7140 2198 7085




Composite Materials Have Enabled Next Generation of Military and Commercial Aircraft

Platform EIS

Matrix

Fiber

1970’s 1980’s 1990’s 2000’s 2010’s

Structures

Fiberglass IM6, AS4D

Form3 Carbon

T-300, AS4 Boron

Polyester Epoxy 934, 3501-6

T-Epoxy 8552 3900 977-3

BMI / PMI

Tailored polymers

Benzoxazine Ceramics

Fabrication Hand layup, woven cloth

CTLM Prepreg tape

Bolted assembly

Co-bonded stringers Hot draping

Thermoplastic Welding

Co-cured Stringers Determinate assembly

Press formed T-plastics

CCM OOA

Multihead Robotics

Tow placement

Braiding Stitching

Fairings, radomes Marine

Commercial Ctrl. Surfaces

Spacecraft Commercial tails

Sports Equip Military aircraft Commercial

Aircraft

777 tail

787 A350 F-15, F-14 B-2

737 tail(5) AV-8B,

F/A-18A-D

F-22

Automotive?

Nanos

737, 757, 767

T-800

PPS, PEI T-plastic

IM8, IM10, Other IM++

HM

A340 tail

PEEK, PEKK

T-plastic

A380

GLARE TiGR

F-35

Kevlar

V-22

IM7

Epoxy R6376 8551-7

T-Epoxy 5215

5250-4

T-Epoxy 5320-1

RTM / VARTM

F/A-18E/F

Next Gen Epoxies

Next Gen Military & Commercial

Aircraft

IBMS8-399 TP

High Strength Fibers Brittle Epoxies

Intermediate Stiffness Fibers Toughened Epoxies

Intermediate Stiffness Plus Fibers Toughened Plus Epoxies




Entry into Service (EIS)

Materials Improvements Pace Airplane Performance Improvements

Commercial Transport Performance Improvement Materials Contribution

1960 1970 1980 1990 2000 2010 2020

Tota

l A/C

Stru

ctur

al

Wei

ght R

educ

tion

(%)

Systems

Materials

Aerodynamics

Engines

Composite Structure Improvement

Total Airframe Structure

Metallic Structure Improvement

Baseline

30%

747-200B DC-10-30 747-400

777-200ER

787-9

767-300ER

Total Fuel Burn Savings (%)

Bloc

k Fu

el* –

3,0

00 n

mi

*Block Fuel = gals/seat over 3,000 miles E Kaduce, 2012, The Boeing Company, based on publically-available data

707-320B




6

A Conclusion Materials Are A Critical Enabler

History Says……….. Demand for improved aircraft performance will continue Properties of existing materials will improve New materials will be discovered Optimization capability will improve More materials will be used

But ………. Development costs climb Development schedules increase




Development Trends in Different Industries

2013_BLM.ppt | 7

Development Time Is Increasing At Unsustainable Rate




Airplane Development vs. Material Development

8

Airplane Dev

Materials Dev

Airplane Study

Time (Years)

Market Firm Config. Build EIS

Materials Need ID’d R&D Scale-

Up Design

Allowables

5-7 Years

8-10 Years (reality)

Prod. Ready

Launch

Production Materials Orders

Previous Dev Efforts

2-3 Years (ideal)


Engineering, Operations & Technology | Boeing Research & Technology

Materials Data Required for Airframe Design

EOT_RT_Template.ppt | 9

Physical Properties

Static Mech. Properties

Durability and Damage Tolerance Properties

Environmental Effects Producibility Certification

Density

Thermal Expansion

Heat Capacity

Thermal

Conductivity

Poisson’s Ratio

Tensile,

Compression,Shear and

Bulk Modulus

Tensile Strength

Compressive

Strength

Shear Strength

Bearing Strength

Fatigue Strength

Notch Sensitivity

Crack Growth

Toughness

Special Design Factors

Temperature Humidity

Chemical

Resistance

Wear

Corrosion Resistance

Oxidation

Resistance

Castability

Formability

Deformation Characteristics

Weldability

Machinability

Assembly

Chemical

Processing

Inspection Methods

Material Specs

Process Specs

Approved

Supplier List

Repair Methods

Safety

MSDS




Building Block Approach

First Part Qual Pre-

Production Verification

Pre-Production MfgTrials & Scale

Up Demonstration

Sub-Scale Demonstration &

Robustness Tests

Effect of Defects & Sensitivity Testing

Process & Equipment Development, Stable Materials & Processes

Process & Equipment Screening & Selection

Structures Certification Building Blocks

Manufacturing Qualification Building Blocks

Full

Scale Tests

Component Tests

Sub-Component Tests

Structural Element Tests

Allowables Development

Materials & Process Specification Development

Material and Process Screening and Selection





Future: Material Performance to Certification

Constituent Design

Material Configurations

Element Design

Sub-Component Designs

Component Designs

• Material Development • Process Development

Computational Materials

Material Models

Computational Allowables

Failure Modeling

Virtual Testing & Sim

Computational Design Values

• Producibility • Accept/Reject • Assembly • NDT Standards

• Mechanical Props • Knock-downs • Environmental • Effects of Defects

• Structural Performance • Damage Tolerance • Static & Fatigue • Analysis Validation • Design Values

• DaDT • Analysis Validation

Full Scale

• Static • GVT • Fatigue • Flight

Vehicle

Materials, Structures, and Manufacturing defined and certified in digital form to meet platform requirements




Future: Material Performance to Qualification

Constituent Design

Material System & Forms

Vehicle

• Material Development • Process Development

Computational Materials

Material Models

Process and Manufacturing Simulation for Quality

Aspects of Full Size Parts

Tolerances & Assembly Simulation

• Manufacturing Scale up • Full size fabricated elements • Effects of Defects • Expanded Mfg Limits

• Mat’l & Process Capability

• Initial Accept & Reject Criteria

• Producibility • Inspection Standards • Quality & Effects of

Defects • Process Tolerances

•Production System

Processing and Quality Simulation

Process Development

Scale Up

Assembly

Materials, Structures, and Manufacturing defined and qualified in digital form to meet platform requirements





Aerospace Composites- Rate and Volume Trend

Platform Percent Composites

Total Wt (lbs) Approx Composite

Wt (lbs)

Approx Delivery Rate

Wt (lbs/Month)

# Delivered Total Wt Composites

Delivered (lbs)

C-17

8% 277,000 22,714 1.5 218 4,951,652

B-2 High 20

F-18 c/d 10% 24,700 2,470 1,450 3,581,500

777 10% 300,000 30,000 7 210,000 1066 31,980,000

F-22 20% 31,700 6,340 6 339 2,149,260

F-18 e/f 18% 30,500 5,490 4 21,960 500 2,745,000

V-22 43% 33,140 14,250 1 14,250 160 2,280,000

787 50% 250,000 125,000 5 625,000 130 16,250,000

Total 871,210 63,934,360

Boeing Has Fielded More than 63 Million Pounds of Composite Structure Boeing Will Field Nearly 10 Million Additional Pounds Every Year




0

5

10

15

20

25

0

200,000

400,000

600,000

800,000

1,000,000

1,200,000

1985 1990 1995 2000 2005 2010 2015 2020

lbs/mo 787

lbs/mo 777

lbs/mo V-22

lbs/mo F-22

lbs/mo F-18

lbs/mo C-17

Rate/mo 787


Detail Component Size

Lbs of Material D

elivered

Prod

uctio

n R

ate

lbs/

mo

Production Volume & Rate

Industrialization of Aerospace Grade Composites

Structural Integration Coupled with Production Volume and Rate Increases Will Drive a Tipping Point in Manufacturing Cost




Parting Thoughts


Optimization will continue to increase number of materials

Materials improvements are vital to aircraft performance improvements

Discovery is only a small part of materials development

Computational materials & manufacturing tools will speed decision making

New material development must have:

Reduced qualification and certification costs & schedule

Concurrent scale-up and quality in manufacturing

the challenge of new materials in the aerospace industryctlm bolted assembly . co-bonded stringers...

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