HAW Hamburg

Hochschule fr Angewandte Wissenschaften Hamburg

Hamburg University of Applied Sciences

DEPARTMENT FAHRZEUGTECHNIK UND FLUGZEUGBAU

DEPARTMENT of AUTOMOTIVE and AERONAUTICAL ENGINEERING

Composite Pipes for Water/Waste Application

in Aircrafts
July, 5 2012
FACC technical colloquium
Salzburg, Austria

Prof. Dr.-
Dr.-Ing.
Ing. Ulrich Huber
Department of AUTOMOTIVE and AERONAUTICAL ENGINEERING
Prof. Dr.-
Dr.-Ing. Ulrich Huber
5.7.2012, Slide 1
Historic Design
Historic DesignIdeas
Ideas
HAW Hamburg

of course they knew that this

thing wouldnt fly.
But just the idea drew them
nuts

Source: Frankfurter Allgemeine Sonntagszeitung

Traxlers Galerie, ca. 2000

Department of AUTOMOTIVE and AERONAUTICAL ENGINEERING

Prof. Dr.-
Dr.-Ing. Ulrich Huber
5.7.2012, Slide 2
Energy Consumption of an Aircraft (Life Cycle)
HAW Hamburg

Total Energy consumption

of an aircraft (Lifecycle)
100 %

Manufacturing of Manufacturing of Operating the aircraft Recycling of

raw materials aircraft aircraft

0,30% 0,01% 99,65% 0,04%

raw materials parts flights reuse
semi finished assembly maintenance disposal
products transportation repairing transportation
standard parts

1 year 1,5 years 25 to 30 years 0,5 years

Saving weight is worth it!

Source: Airbus

Department of AUTOMOTIVE and AERONAUTICAL ENGINEERING

Prof. Dr.-
Dr.-Ing. Ulrich Huber
5.7.2012, Slide 3
Water/Waste System in Aircrafts
HAW Hamburg

Water supply of e.g. Kitchen and Toilets in

wide body passenger aircrafts

wastewater drains Fresh water pipe

Operating pressure pB: +0,672 bar Operating pressure pB: +3 bar
Inner Diameter: Di = 50,8 mm Inner Diameter: Di = 25,4 mm
Material: Titanium Material: Stainless Steel
Weight: ca. 500 g/m Weight: ca. 320 g/m
Cost: ca. 150 /m Cost: ca. 20 /m

Getting cheaper and reducing weight

using composites?

Department of AUTOMOTIVE and AERONAUTICAL ENGINEERING

Prof. Dr.-
Dr.-Ing. Ulrich Huber
5.7.2012, Slide 4
State of the Art
HAW Hamburg

Pipes: Titanium waste water pipes

Joining: Hydraflow

[Source: Midwest Performance Hardware (MPH)]/Airbus

Department of AUTOMOTIVE and AERONAUTICAL ENGINEERING

Prof. Dr.-
Dr.-Ing. Ulrich Huber
5.7.2012, Slide 5
Requirements for Composite Tubing
HAW Hamburg
Requirements
Requirements for the Pipes
1. Durable tightness having inner pressure and
2. Minimum weight

Requirements for the Coupling

1. Distance of the ends of pipes are allowed
2. Axial length tolerance
3. Angle tolerance
4. Tolerance against thermal expansion
5. Joining without tools
load bearing composite

liner (load bearing/not load bearing)

FRP-
FRP-Pipe 1 FRP-
FRP-Pipe 2

For all components the corresponding FAR

concerning mechanics and fire are mandatory!
Department of AUTOMOTIVE and AERONAUTICAL ENGINEERING
Prof. Dr.-
Dr.-Ing. Ulrich Huber
5.7.2012, Slide 6
Basic design of FRP Pipes
HAW Hamburg

1. A liner is mandatory due to leak tightness reasons which is not guaranteed by

the outer FRP wall.

2. The liner must be secured against coming off from the load bearing liner
a) during vacuum even if short time vacuum
b) during temperature change due to different thermal expansion
coefficients

3. In order to reduce weight the use of carbon fibers will be inevitable.

4. The material choice for the matrix will be governed by costs and the FAR
requirements.

Department of AUTOMOTIVE and AERONAUTICAL ENGINEERING

Prof. Dr.-
Dr.-Ing. Ulrich Huber
5.7.2012, Slide 7
Predesign using Boiler Formula and Net Shape Theory
HAW Hamburg
pd
a , zul =
4 serf .
Waste Pipe
pd
t , zul =
2 serf .
Operating Pressure (MPa) 0,04
Burst Pressure (MPa) 0,36
Inner Diameter (mm) 50,8 mm (2 inch)
Strength of CFRP Laminate (MPa) 1500 MPa
Required Wall Thickness serf. =
pd
=
0,36 50,8
= 0,006 mm
Circumferential 2 t ,zul 3000
Required Wall Thickness serf. =
pd
=
0,36 50,8
= 0,003 mm
Axial 4 zul 6000
Total Required wall Thickness 0,009 mm

Design is governed by manufacturing!

Department of AUTOMOTIVE and AERONAUTICAL ENGINEERING
Prof. Dr.-
Dr.-Ing. Ulrich Huber
5.7.2012, Slide 8
Finite Element Analysis (Pipe)
HAW Hamburg

Load case: 120 C;

C; 1,8 bar inner pressure
Exemplary Results
CFRP-
CFRP-Wall Tsai-
Tsai-Wumax: 0,08
(Design limit: 0,5)
FE-
FE-Model

PPS-
PPS-Liner

1,max=1,87 MPa
(Design limit: 17 MPa)
MPa)

Department of AUTOMOTIVE and AERONAUTICAL ENGINEERING

Prof. Dr.-
Dr.-Ing. Ulrich Huber
5.7.2012, Slide 9
Stage of develpoment (Prototype)
HAW Hamburg

PPS-
PPS-Liner (wall thickness 2 mm)
leak tightness of pipes
chemical resistant against waste water and
cleaning agents
fire protection classification V0

GF woven fabric (wall thickness 0,4 mm)

optimizes adhesion of layers
E-glass fibers

CF-
CF-EP, 54
54
54 (wall thickness 0,4 mm)
mechanical resistance at
overpressure and vacuum Weights
toughness and robustness CFK layer: 107 g/m
adhesion layer GF-
GF-PPS: 139 g/m
liner: 447 g/m

total weight 695 g/m

Department of AUTOMOTIVE and AERONAUTICAL ENGINEERING

Prof. Dr.-
Dr.-Ing. Ulrich Huber
5.7.2012, Slide 10
Improvements of pipe
HAW Hamburg

Liner
- Extrusion pipe using toughened PPS
- Use of primer for improved adhesion
- reducing wall thickness to 1,5 mm
- actual weight: 333 g/m
- actual costs: 13,50 /m
/m

Filament wound layer

- CF-
CF-EP
Composite tube
- thickness 0,36 mm
- 54
54
54 winding angle weight 437 g/m
- actual weight: 104 g/m costs 63,50 /m
/m
- actual costs: 50 /m
/m

Department of AUTOMOTIVE and AERONAUTICAL ENGINEERING

Prof. Dr.-
Dr.-Ing. Ulrich Huber
5.7.2012, Slide 11
Concept for Joining
HAW Hamburg

Welding joints
tube fitting coupling ring

FRP-
FRP-layer
(filament winding)

liner

Department of AUTOMOTIVE and AERONAUTICAL ENGINEERING

Prof. Dr.-
Dr.-Ing. Ulrich Huber
5.7.2012, Slide 12
 Operation Mode of the Joining
HAW Hamburg

1 2 3

Slide the coupling ring Weld liner and Screwing coupling ring
on the pipe welding joint and pipe fitting

Department of AUTOMOTIVE and AERONAUTICAL ENGINEERING

Prof. Dr.-
Dr.-Ing. Ulrich Huber
5.7.2012, Slide 13
Design Areas
HAW Hamburg

3
4 5
Welded joint of liner and pipe
2 1 attachment
1
2 O-ring slot

Wall thickness of designed parts

3 and readiness for manufacturing

Clamping
4

5 Dimensioning of screw thread

Department of AUTOMOTIVE and AERONAUTICAL ENGINEERING

Prof. Dr.-
Dr.-Ing. Ulrich Huber
5.7.2012, Slide 14
 FE-
FE-Analyis (Joint)
HAW Hamburg

Load cases

Load case 1 2 3 4 5 6

Tightened
Tightened Tightened Tightened
coupling ring and
Tighten of coupling ring and coupling ring and Tighten of coupling ring and
-0,6 bar inner
load coupling ring +3,6 bar inner -0,6 bar inner coupling ring +3,6 bar inner
pressure
at 120 C pressure pressure at -55 C pressure
at -55 C
at 120C at 120C at -55 C

Department of AUTOMOTIVE and AERONAUTICAL ENGINEERING

Prof. Dr.-
Dr.-Ing. Ulrich Huber
5.7.2012, Slide 15
Finite Element Analysis (Examples)
HAW Hamburg
Load case: 120 C;
C; 3,6 bar inner pressure

[MPa] [MPa] [MPa]

[MPa] [MPa] [MPa]

[MPa]
[MPa] [MPa]

Department of AUTOMOTIVE and AERONAUTICAL ENGINEERING

Prof. Dr.-
Dr.-Ing. Ulrich Huber
5.7.2012, Slide 16
Stage of develpoment (Prototype)
HAW Hamburg

Material
PPS (Fortron
(Fortron 1140 L4)
having 40 % by weight glass fiber content

Manufacturing
Injection molding

costs (7.500 ppa)

ppa) weights
2 welding joints 0,96 2 welding joints 62 g
2 coupling rings 1,90 2 coupling rings 120 g
1 pipe fitting 1,40 1 pipe fitting 94 g

total cost: 4,26 total weight 276 g

Department of AUTOMOTIVE and AERONAUTICAL ENGINEERING

Prof. Dr.-
Dr.-Ing. Ulrich Huber
5.7.2012, Slide 17
Further work
HAW Hamburg

- test of adhesion PPS/CFRP

- investigation of damage behavior
- optimization of wall thickness of liner (stability issues)
- contamination behavior of PPS
- abrasion und wear in use and cleaning situations
- flow simulation of pipe joints
- validation of welding in joints
- development of curved pipes
- integration of pipe heating

Department of AUTOMOTIVE and AERONAUTICAL ENGINEERING

Prof. Dr.-
Dr.-Ing. Ulrich Huber
5.7.2012, Slide 18
 Conclusion
HAW Hamburg

The actual prototype has a weight of 695 g/m, this is significantly more than
titanium (500 g/m) . Optimizations promise a weight of 440 g/m.
g/m. The costs of
63,
63,50 /m
/m are competitive compared with titanium.
titanium.

The weight of the joint is about 276 g having 5 parts (2 x welding joints, 2 x
coupling ring and 1 x pipe fitting).
fitting). The manufacturing costs (injection
molding) are about 4,30 /pt
/pt.
/pt.

The finite element calculations show the load cases at -55 C

C and 120 C
C to be
covered by the design.
design. The high reserve factors result from manufacturing
requirements.
requirements.

Further investigations are required for use in practice.

practice.

Department of AUTOMOTIVE and AERONAUTICAL ENGINEERING

Prof. Dr.-
Dr.-Ing. Ulrich Huber
5.7.2012, Slide 19
Contact Details
HAW Hamburg

Prof. Dr.-
Dr.-Ing.
Ing. Ulrich Huber
Composite and Sandwich Technology

Address
University of applied science Hamburg
Dept. of Automotive and Aeronautical Engineering
Berliner Tor 9
20099 Hamburg
Germany

Mail: ulrich.huber@haw-
ulrich.huber@haw-hamburg.de
Net: www.haw-
www.haw-hamburg.de/f/

Phone: +49 (40) 42875 - 7988

Fax: +49 (40) 42875 - 7809

Department of AUTOMOTIVE and AERONAUTICAL ENGINEERING

Prof. Dr.-
Dr.-Ing. Ulrich Huber
5.7.2012, Slide 20