Technologies for Performance Efficiency and Environmental Compatibility

Technologies for Performance Efficiency and Environmental Compatibility Presented at Aeronautical Days 2006 Vienna, Austria 20 June 2006 Mark I. Goldhammer Chief Engineer Airplane Performance Product Development

Technologies for Performance Efficiency and Environmental Compatibility Introduction Aerodynamic Efficiency Weight Efficiency Propulsion System Efficiency Environmental Compatibility Multi-Disciplinary Optimization Boeing Product Applications Concluding Remarks

Many Factors Contribute to Saving Fuel and Avoiding Emissions Engine Aerodynamics Structures and materials Systems Air traffic management Engine/airframe integration

787 Aerodynamic Design Lessons learned from existing products CFD design, analysis, and optimization tools Extensive wind- tunnel test program

Complementary Use of CFD and Wind Tunnels for High-Lift Design Wind-Tunnel Testing 2-D Navier-Stokes CFD 3-D Navier-Stokes CFD

Global Wind Tunnels for Boeing Commercial Airplane Product Development Farnborough, UK Seattle, WA Mountain View, CA Minneapolis, MN Philadelphia, PA Hampton, VA Cologne, Germany Gifu, Japan Le Fauga, France Copyright 2005 The Boeing Company. All rights reserved.

Modern Computing and CFD Methods Speed Development and Lower Costs Supercomputing enables: Faster set-up & run times Increased capability Improved accuracy Result: More efficient aircraft Less wind tunnel and flight testing

CFD Has Significantly Improved the Wing Development Process Increased computational capability & accuracy CFD Tools Cartesian Grid Tech Boeing Tools A502 A488 TRANAIR TRANAIR Optimization TLNS3D-MB ZEUS CFL3D/ZEUS CFD++ Unstructured adaptive grid 3D-NS 1980 1985 1990 1995 2000 2005 Boeing Products 767 757 737-300 777 737NG 787 Wind Tunnel vs. CFD 1980 state of the art Modern close coupled nacelle installation, 77 0.02 Mach faster than 737-200 38 Wings Tested 21% thicker faster wing than 757, 767 technology 18 base Highly constrained wing design Faster wing than 737-300 11 4x Successful multipoint optimization design CFD runs Faster and more efficient than previous aircraft 11 60x CFD for Loads and Stability and Control COPYRIGHT COPYRIGHT 2005 THE BOEING 2006 THE COMPANY BOEING COMPANY Less testing, lower cost, better products

Weight Efficiency Trend of In-Production Aircraft Aircraft Weight 787 The 787 sets a new standard in aircraft weight efficiency Aircraft Capability

Composites Serve as Primary Structural Material 787-8 Carbon laminate Carbon sandwich Other composites Aluminum Titanium Titanium 15% Steel 10% Other 5% CFRP 43% Misc. 9% Composites 50% Aluminum 20%

Wing Progress Overview Lower Wing Skin Lay-up Ply 192 of 264 Lower Wing Skin Layup Mandrel MHI-Kobe Panel Stringer Fabrication FHI Utsunomiya Test Wing Box

Development Barrels Prove Concepts

Advanced Systems Technologies Contribute to Weight Reduction Common Core Open Systems Architecture More Electric Systems Architecture Advanced Flight Controls Integrated Health Management e-enabled Systems Wireless IFE COPYRIGHT 2006 2005 THE BOEING COMPANY

Propulsion Systems Feature Key Environmental Technologies GEnx Engine and nacelle features: Higher bypass ratio No-engine-bleed systems architecture Laminar flow nacelles Low-noise nacelles with chevrons Trent 1000 Low emission combustors

Opening a New Era in Fuel Efficiency 225 SEATS 275 SEATS 200 SEATS 250 SEATS 300 SEATS 350 SEATS 400 SEATS 450 SEATS Fuel consumption per seat 20% Better Current Twins Current Quads 500 SEATS 550 SEATS 787 Fuel consumption per trip

Environmental Compatibility Civil aviation is necessary for economic growth and prosperity but growth must be in line with the world s increasing environmental expectations

Commitment to a Better Future Analytical studies Wind-tunnel tests Static engine tests 2001 QTD 1 Quiet Technology Demonstrator Boeing Rolls-Royce American Airlines 2005 QTD 2 Quiet Technology Demonstrator Boeing General Electric Goodrich NASA All Nippon Airlines 747-8 The shape of the future 787 Dreamliner Sustained Technology Programs Deliver Efficient Quiet Designs RESEARCH & DEVELOPMENT

Reducing noise for communities and passengers with new innovations Fan and core chevrons Joint-less inlet Acoustic lip liner COPYRIGHT COPYRIGHT 2005 THE BOEING 2006 THE COMPANY BOEING COMPANY Low-noise landing gear fairing

Quiet for Airport Communities 85 db Noise Contours at O Hare 767-300ER 787-8 Feet 0 10000 Source MS Mappoint, (c) Microsoft, Inc. Meters 0 3000 4001051704

Continuous Descent Approach: Reduces Noise, Saves Fuel 767 Flights Demonstrate Quiet Operational Procedures and Reduced Fuel Consumption at Louisville, KY Partners: Boeing Commercial Airplanes, Boeing Air Traffic Management, United Parcel Service, NASA, FAA, MIT, Regional Airport Authority 3-6 db Reduction in Approach Noise 767 Standard Approach 767 Continuous Descent Approach

Designed for the Environment Environmental considerations are integral to the DESIGN design of the 787 LIFE CYCLE APPROACH 31/2 6 1/2 THEN NOW Primer VOC s (grams/liter) MANUFACTURE OPERATIONS RECYCLE

Multi-Disciplinary Optimization Flight Controls Systems Materials Noise Traditional MDO Aerodynamics MDO Structures Propulsion Recurring Cost R&M Mfg Life Cycle Cost

Shortened Product Development Cycle Time Number of Configurations Variations Today Conceptual Design Preliminary Design Wind Tunnel Validation Preliminary Design Wind Tunnel Confirmation Flight Test Conceptual Design Target Prelim. Design Wind Tunnel Confirmation Flight Test Flow Time

Boeing Commercial Airplane Product Family Complete market coverage with operational commonality Long range, fast, quiet Reliable, efficient, low operating cost Passenger experience e-enabled Standardization

Point-to-Point Provides Value for Airlines, Passengers and Communities Hub and Spoke Point to Point Frankfurt Vienna 25% less fuel Flight time reduced by 1.3 hours Trip time reduced by 2.8 hours Block Fuel Per Passenger Flight Time 12.6 Hours Flight Time 11.3 Hours Less Local Community Noise Less Local Emissions Tokyo Narita Frankfurt Frankfurt - Vienna Narita - Vienna 787-8 Non-Stop

787 Design Features Patented raked tip Multi-disciplinary wing optimization Composite primary structure Simplified High lift System Variable camber trail edge Advanced engines & nacelle chevrons Mission Requirements Extremely long range Unprecedented efficiency Very low community & cabin noise Very low emissions Copyright 2005 The Boeing Company. All rights reserved. More-electric systems architecture

787 is Proceeding On Schedule Airplane Announcement Authority to Offer Program Launch Firm Configuration Start of Major Assembly 787-8 First Flight 787-8 Enters Service 787-3 Enters Service 787-9 Enters Service 2002 2003 2004 2005 2006 2007 2008 2009 2010

747-8 Design for Environment Design Features Improved Wing Aerodynamics Enhanced Flight Deck 787 Technology High Bypass Engines Advanced Nacelles and Chevron Nozzles Fly Quieter - Use Less Fuel - Lower Emissions

Significantly Quieter for Communities Community Noise targets: ICAO Chapter 4 QC 2 Departure QC 1 Arrival 747-8 747-400 Noise area reduced by more than 30% over the 747-400

Longer Range 777-300 Extended wing box and new wing tip (additional 76 inch per side) Overhead space utilization provisions Supplemental electronic tail skid Strengthened 777-300 wing Strengthened fuselage Revised flight controls software ad avionics GE90-115B engines Increased wing fuel capacity

Design for Performance and Environment Weight improvements Materials Load alleviation Aerodynamic design optimization based on Evolution from previous Boeing products Extensive advanced CFD Focused wind-tunnel testing, including flight Reynolds number simulation Engine performance improvements Higher bypass ratio No-bleed architecture Low aerodynamic interference installation Improved environmental performance Community noise Cabin noise Emissions Materials impact on the environment