Composite Technology at Airbus Germany

Past, Present, Future

Ulf P. Breuer
Composite Technology Germany

Airbus Bremen

24.10.02 Breuer/ESWCG Composite Technology Germany 1

 Outline

4 Benefits of CFRP for Primary A/C Structures

4 History of CFRP Introduction to Airbus

4 CFRP Technology of A380

4 CFRP Technology of Next Generation A/C

4 Future Application of CFRP: Requirements and Recommendations

4 Conclusions

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 Benefits of CFRP for Primary A/C Structures
(Selection of Main Design Drivers)

4 High Structural Performance to Mass Ratio

4 Utilization of Anisotropy for Tailored Design

(Strength, Stiffness, Stability)

4 Single Load Path Design

4 Simple Shaping of Complex Structures

4 Excellent Fatigue Behaviour

4 Excellent Fire Worthiness

4 Excellent Crash Worthiness

4 Excellent Media/Corrosion Worthiness

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 History of CFRP Introduction to Airbus
(Selection of Major Milestones)

A340-500/-600 (2001)
Spoiler
Rudder
A320-200 (1987) Elevator
Spoiler Fin
Rudder MLG & NLG Doors
Elevator Wing Shroud Box
Fin Wing T/E panels
MLG & NLG Doors Flap Track Fairings
Wing Shroud Box Pylon Fairings
Wing T/E panels Nacelle Cowlings
Flap Track Fairings Floor Panels
A310-200 (1982) A310-300 (1985) Pylon Fairings Aileron
Spoiler Spoiler Nacelle Cowlings Flaps
Rudder Rudder Floor Panels Horizontal Stabilizer
Elevator Elevator Aileron Rear Pressure Bulkhead
Fin Flaps Keel Beam
Horizontal Stabilizer

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 CFRP Technology of A380
Floor Beams
for Upper Deck
Vertical
Belly Fairing Tail Plane

Outer Flaps Section 19.1

J-Nose

Horizontal
Tail Plane

Section 19
Rear Pressure
Center Wing Box Wing Ribs Bulkhead

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 CFRP Technology of Next Generation A/C
ANTA/ANSA (EIS 2012/2017)

CFRP Slat Structure (LuFo III)

CFRP Flap Supports (LuFo II/III)
CFRP High Lift Devices (LuFo/AWIATOR)
CFRP Wing Box (V-Box, TANGO)
CFRP Fuselage (TANGO/LuFo II/III)

Provided that composite solutions will be competitive, the amount of

CFRP structure on the next generation Airbus A/C will increase significantly

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 CFRP Technology
Requirements and Recommendations: Major Goals

4 Increase…

- cost/weight benefits applying CFRP to primary A/C structures

- efficiency of the process chain from R&D to series production

4 Reduce…

- manufacturing and in-service effort

4 Maintain…

- highest quality demands

4 Meet…

- with future environmental demands

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 CFRP Technology
Requirements and Recommendations: Process Chain

Material Development

Design

Manufacturing

Assembly

Service

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 CFRP Technology
Requirements and Recommendations: Process Chain

-cheaper, lighter, stronger, stiffer, tougher (where necessary),

Material Development reference: prepreg UD-tape
-material adaptivity on demand
-infinite shelf/shop life
-processing/curing at room temperature
Design -impact and moisture tolerant sandwich structures

Manufacturing

Assembly

Service

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 CFRP Technology
Requirements and Recommendations: Process Chain

Material Development

-design to weight with 3-D-load path fibre orientation

Design
-reduction of notch factors (by elimination of rivets)

Manufacturing

Assembly

Service

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 CFRP Technology
Requirements and Recommendations: Process Chain

Material Development

Design

- highly automated “net shape” processing

Manufacturing of filaments to cured, complex shaped structures
- lightweight/flexible tooling
- in process quality check
Assembly

Service

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 CFRP Technology
Requirements and Recommendations: Process Chain

Material Development

Design

Manufacturing

- improvement of joining technology (bonding and welding):

Assembly • dry, 1-step- surface preparation
• bonding and debonding “at the push of a button”
at room temperature
Service • on-line measurement of bonding loading capacity,
sealing, geometry
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 CFRP Technology
Requirements and Recommendations: Process Chain

Manufacturing

Assembly

- repair without rivets

Service
- easy inspection

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 CFRP Technology
Requirements and Recommendations: Manufacturing Technologies
Major CFRP Manufacturing/Assembly

(I) Prepreg Technology

Technologies

(II) Textile/Infusion Technology

(III) Thermoplastics

(IV) Bonding/Joining

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 CFRP Technology
Requirements and Recommendations: Manufacturing Technologies

(I) Prepreg Technology

4availability of high 4high material cost

4low cost high perfor-
performance materials mance R/T prepreg
4high processing effort
4large experience, 4efficient processing
broad application of tapes to integral
4high auxiliary
in primary A/C structures net shape parts
material cost

4autoclave processing 4efficient curing

4high amount technology
4automated tape laying of production waste

State of the Art Drawbacks Perspectives

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 CFRP Technology
Requirements and Recommendations: Manufacturing Technologies

(II) Textile/Infusion Technology

4poor performance 4low cost high perfor-

(mech. prop.) of textiles mance R/T resin systems
4standard 2-D-textiles compared to UD-prepreg
(fabric, NCF) 4high performance
4poor availability textiles (mech. prop.)
of net shape preform
4binder based technologies 4efficient processing
preforming (epoxy)
of rovings to integral
4poor handling of large
net shape preforms
4single component preforms
epoxy-resin 4efficient sandwich
4negative influence
of sewing/binding processing
on mech. prop.

State of the Art Drawbacks Perspectives

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 CFRP Technology
Requirements and Recommendations: Manufacturing Technologies
(III) Thermoplastics
4thermoplastic CFRP
established for
secondary structures,
fairings, ties, clips
4short cycle times
4infinite shop life
4formability,
free of autoclave
4weldability
State of the Art
24.10.02 Breuer/ESWCG Composite Technology Germany
4poor availability of semi
4low cost high per-
finished materials
formance materials
4high material costs 4enhanced degree
of freedom for part design
4limited wall thickness
4limited part size 4efficient processing of
TP tapes to complex
4limited processing shaped cured parts
technology
Drawbacks Perspectives
17
 CFRP Technology
Requirements and Recommendations: Manufacturing Technologies

(IV) Bonding/Joining

4notch factor, bolt collar 4high performance ad-

4domination of riveting
for highly loaded parts
4potential for further
automation of riveting
4world wide availability
of riveted repair techn.
4bonding of stiffeners
to shells by resin films
and rivets can cause hesives(R/T, H/W, Hm )
additional weight
41-step-surface
4high effort for bonding pre-treatment (repair!)
surface pre-treatment
4automated application
4poor perceptibility of adhesives
of imperfections 4autoclave (temperature,
in bonding interfaces pressure) free bonding,
“at the push of a button”
4poor availability
of bonded repair methods 4highly efficient NDT

State of the Art Drawbacks Perspectives

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 CFRP Technology
Conclusions

4 CFRP is recognized as a key technology to enhance A/C performance.

4 To be competitive, higher performance must not be paid by higher cost.

4 To increase the amount of CFRP structure,

the efficiency of the complete process chain (“design to fly”)
must be regarded and improved by new technologies.

4 The definition of clear technology targets is essential.

4 National and international technology programs must contribute directly

to “technology readiness”.

4 To be successful, Airbus must work very closely together

with all technology partners.

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 CFRP Technology
Upshot

“lets go upwards”

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