Engineering, Operations & Technology
BR&T
The Challenge of New Materials In the Aerospace Industry
Gerould Young Director Materials & Fabrication Technology Georgia Institute of Technology May 15th, 2013 BOEING is a trademark of Boeing Management Company. Copyright © 2011 Boeing. All rights reserved.
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Boeing Almost 100 Years of Innovation Engineering, Operations & Technology | BR&T
Copyright © 2011 Boeing. All rights reserved.
Year 1916 1928 1932 1935 1935 1938 1939 1941 1949 1956 1957 - 58 1958 1959 1961 1960's 1969 1969 1970 - 1980 1978 1981 1982 1982 - 1984 1986 1993 1995 1995 1998 2009
Model B&W - Model 1 Model 80 P26 Peashooter TBD Devastator B17 314 Clipper B29 P51 Mustang B47 KC-135 707 & DC-8 F4 Phanton X-15 CH47 Mercury & Gemni 747 Apollo & Lunar Landed F15 & F18 AV8 Space Shuttle B1B 757 - 767 V22 Osprey B2 C17 Globemaster 777 Space Station 787
Materials & Fabrication Technology Innovation Boeing's first airplane - spruce construction America's first airliner specifically for passenger comfort Fastest air cooled pursuit fighter in the world First all metal monoplane torpedo bomber Multi-engine long range bomber 3500 mile range - Transatlantic Flight Long range pressurized bomber First fighter to fly Britain to Berlin and back First swept wing multi-engine bomber Strategic Air Command aerial tanker Swept wing jet transport Jet fighter - 16 speed, altitude and time to climb records Rocket powered airplane - 354,000ft and 4,104mph Two rotor heavy lift Manned Spacecraft Largest airliner built Manned spaceflight to the moon Air superiority and multi-role fighter Fixed wing vertical take off aircraft Space access with return flight Swing wing supersonic bomber Narrow and Wide Body with nearly identical cockpits Tilt rotor aircraft All composite stealth long range bomber Heavy lift and short field capability Wide body with composite empennage - 100% digital definition International space station assembled in space First mostly composite airliner
Airframe Metallic Materials Evolution Materials & Fabrication Technology
Engineering, Operations & Technology | BR&T
AL ALLOY DEVELOPMENT (EIS for System Utilizing Alloy)
2017
2024
7075 7075
7178 7178
1910
1920
1930 DC -3 B-17 B-247
1940 B-29
2618 2618 2014 2014 7175 7175 2027 2027
6061
7475 7475 2219 2219
7050 7050 2124 2124
1950 1960 1970 B-707 B-727 B-747 L1011 DC-8 B-737 DC-10 COMET
AIRCRAFT SR 71
7150 8090 8090 7150 6056 2324 2324 6056 6013 2090 2224 6013 2224 2090
7349 7349 2195 2195 7055 7055 2524 2524 7449 7449 7039 7039
1980 1990 B-757 C-17 F18 B-767 SLWT CONCORDE A-319 A-340 A-330
F-15
4340 15-5PH 13-8PH TITANIUM AND STEEL ALLOYS Ti-6242 Ti-662 Ti-811 Ti-6242 Ti-64 Ti-13-11-3
2397 2397 2297 2297 7040 7040 7055 7055 6019 6019 2524 2524
7081, 2027 2050, 2022 2196, 6056 7081, 2023 2056, 6156 2139, 2013 7036 7056 7056 7140 2098 2098 7140 7055-T62 2198 2099, 2199 2099, 2199 2198 7085 7136 7136 7085
2000 B-777 EMB 170 F16 Retro F-22
747-8
Ti5553
C465
F18-E/F
Aermet 100 β-C
Ti-10-2-3 β21S
Increasing # Materials, Tailoring and Differentiation Copyright © 2011 Boeing. All rights reserved.
747-LCF A380 787
Ti62222
Composite Materials Have Enabled Next Generation of Military and Commercial Aircraft Materials & Fabrication Technology
Engineering, Operations & Technology | BR&T High Strength Fibers Brittle Epoxies
Fiber
Matrix
Fabrication
Structures
Platform EIS
Intermediate Stiffness Fibers Toughened Epoxies
Fiberglass Boron Carbon T-300, AS4
Polyester
IM6, AS4D Kevlar
Hand layup, woven cloth
Fairings, radomes Marine
CTLM Prepreg tape Bolted assembly
Sports Equip Military aircraft
F-15, F-14
1970’s Copyright © 2011 Boeing. All rights reserved.
Form3
T-800 IM7
GLARE TiGR
T-Epoxy 8552 8551-7 3900 977-3
Epoxy Epoxy 934, 3501-6 R6376
737, 757, 767 AV-8B, F/A-18A-D
1980’s
RTM / VARTM Co-cured Stringers Determinate assembly Press formed T-plastics
Spacecraft Commercial tails
B-2 737 tail(5)
IM8, IM10, Other IM++
HM
PPS, PEI Tailored PEEK, IBMS8-399 T-Epoxy T-plastic TP polymers PEKK 5320-1 BMI / PMI T-plastic T-Epoxy Nanos Next Gen Ceramics 5215 Epoxies 5250-4 Benzoxazine
Co-bonded stringers Hot draping Thermoplastic Welding
Commercial Ctrl. Surfaces
Intermediate Stiffness Plus Fibers Toughened Plus Epoxies
F-22 F/A-18E/F
A340 tail 777 tail
1990’s
CCM OOA Multihead Robotics Tow placement
Braiding Stitching
Automotive?
Commercial Aircraft
A380
V-22
787
A350 F-35 Next Gen Military & Commercial Aircraft
2000’s
2010’s
Commercial Transport Performance Improvement Materials Contribution Materials & Fabrication Technology
Baseline
30%
Block Fuel* – 3,000 nmi
Total A/C Structural Weight Reduction (%)
Engineering, Operations & Technology | BR&T
Composite Structure Improvement 707-320B
747-200B DC-10-30
747-400 767-300ER
Metallic Structure Improvement 777-200ER
Total Airframe 787-9 Structure
Systems
Engines
Total Fuel Burn Savings (%)
Materials
Aerodynamics
1960
1970
1980
1990
2000
2010
Entry into Service (EIS)
Materials Improvements Pace Airplane Performance Improvements *Block Fuel = gals/seat over 3,000 miles E Kaduce, 2012, The Boeing Company, based on publically-available data Copyright © 2011 Boeing. All rights reserved.
2020
A Conclusion Materials Are A Critical Enabler Engineering, Operations & Technology | BR&T
Materials & Fabrication Technology
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
Copyright © 2011 Boeing. All rights reserved.
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Development Trends in Different Industries Engineering, Operations & Technology | BR&T
Materials & Fabrication Technology
Development Time Is Increasing At Unsustainable Rate Copyright © 2011 Boeing. All rights reserved.
2013_BLM.ppt
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Airplane Development vs. Material Development Materials & Fabrication Technology
Engineering, Operations & Technology | BR&T
5-7 Years Market Airplane Dev
Airplane Study
Launch
Firm Config.
Build
EIS
Production Materials Orders
2-3 Years (ideal) 8-10 Years (reality) Materials Dev
Materials Need ID’d
R&D
ScaleUp
Design Allowables
Prod. Ready
Previous Dev Efforts Time (Years) Copyright © 2011 Boeing. All rights reserved.
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Materials Data Required for Airframe Design Engineering, Operations & Technology | Boeing Research & Technology
Physical Properties
Static Mech. Properties
Durability and Damage Tolerance Properties
Environmental Effects
Tensile Strength
Temperature Humidity Fatigue Strength
Heat Capacity Thermal Conductivity Poisson’s Ratio Tensile, Compression, Shear and Bulk Modulus
Certification
Castability
Density Thermal Expansion
Producibility
Compressive Strength Shear Strength Bearing Strength
Copyright © 2012 Boeing. All rights reserved.
Notch Sensitivity
Chemical Resistance
Crack Growth
Wear
Toughness
Corrosion Resistance
Special Design Factors Oxidation Resistance
Formability Deformation Characteristics Weldability Machinability
Material Specs Process Specs Approved Supplier List
Assembly
Repair Methods
Chemical Processing
Safety
Inspection Methods
MSDS
EOT_RT_Template.ppt | 9
Building Block Approach Engineering, Operations & Technology | BR&T
Manufacturing Qualification Building Blocks First Part Qual PreProduction Verification Pre-Production MfgTrials & Scale Up Demonstration Sub-Scale Demonstration & Robustness Tests
Materials & Fabrication Technology
Structures Certification Building Blocks Full Scale Tests Component Tests Sub-Component Tests Structural Element Tests
Effect of Defects & Sensitivity Testing
Allowables Development
Process & Equipment Development, Stable Materials & Processes
Materials & Process Specification Development
Process & Equipment Screening & Selection
Material and Process Screening and Selection
Copyright © 2011 Boeing. All rights reserved.
Future: Material Performance to Certification Materials & Fabrication Technology
Engineering, Operations & Technology | BR&T
Materials, Structures, and Manufacturing defined and certified in digital form to meet platform requirements
Vehicle Full Scale
SubComponent Designs
Component Designs
Element Design
Virtual Testing & Sim
Computational Design Values
Material Configurations Failure Modeling Constituent Design
Computational Allowables Material Models
Computational Materials • Material Development • Process Development
Copyright © 2011 Boeing. All rights reserved.
• Producibility • Accept/Reject • Assembly • NDT Standards
• Mechanical Props • Knock-downs • Environmental • Effects of Defects
• Design Values • DaDT • Analysis Validation
• Structural Performance • Damage Tolerance • Static & Fatigue • Analysis Validation
• Static • GVT • Fatigue • Flight
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Future: Material Performance to Qualification Materials & Fabrication Technology
Engineering, Operations & Technology | BR&T
Materials, Structures, and Manufacturing defined and qualified in digital form to meet platform requirements
Vehicle Assembly Scale Up
Process Development
Constituent Design
Material System & Forms
Tolerances & Assembly Simulation
Processing and Quality Simulation Material Models Computational Materials • Material Development • Process Development
• Mat’l & Process Capability • Initial Accept & Reject Criteria
Copyright © 2011 Boeing. All rights reserved.
• Producibility • Inspection Standards • Quality & Effects of Defects • Process Tolerances
Process and Manufacturing Simulation for Quality Aspects of Full Size Parts • Manufacturing Scale up • Full size fabricated elements • Effects of Defects • Expanded Mfg Limits
•Production System
Aerospace Composites- Rate and Volume Trend Materials & Fabrication Technology
Engineering, Operations & Technology | BR&T Platform
C-17
Percent Composites
Total Wt (lbs)
Approx Composite Wt (lbs)
Approx Delivery Rate
8%
277,000
22,714
1.5
B-2
High
F-18 c/d
10%
24,700
2,470
777
10%
300,000
30,000
7
F-22
20%
31,700
6,340
6
F-18 e/f
18%
30,500
5,490
4
V-22
43%
33,140
14,250
787
50%
250,000
125,000
Total
Wt (lbs/Month)
# Delivered
Total Wt Composites Delivered (lbs)
218
4,951,652
20 1,450
3,581,500
1066
31,980,000
339
2,149,260
21,960
500
2,745,000
1
14,250
160
2,280,000
5
625,000
130
16,250,000
210,000
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 Copyright © 2011 Boeing. All rights reserved.
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Industrialization of Aerospace Grade Composites Materials & Fabrication Technology
Engineering, Operations & Technology | BR&T
Detail Component Size
1,200,000
Production Volume &25 Rate
1,000,000
800,000 15
600,000
10 400,000
Lbs of Material Delivered
Production Rate lbs/mo
20
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
5 200,000
0
0 1985
1990
1995
2000
2005
2010
2015
2020
Structural Integration Coupled with Production Volume and Rate Increases Will Drive a Tipping Point in Manufacturing Cost Copyright © 2011 Boeing. All rights reserved.
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Parting Thoughts Engineering, Operations & Technology | BR&T
Materials & Fabrication Technology
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
Copyright © 2011 Boeing. All rights reserved.
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