Diego Garcia-Martin Airbus Operations S.L. Advanced Low Cost Aircraft Structures Aerodays Madrid 2011
CEC Work Programme European 6th Framework programme Thematic Priority 1.4 Aeronautics & Space Research Area 1 Strengthening Competitiveness Thematic ALCAS Priority 1.4 Aeronautics IP & Space Document Number: ALCAS- 01/02/05 Page 2
Industry Needs Industry Need Ensure that the next generation of products significantly reduce the direct operating costs of the operators Airframe Maintenance 6% Navigation & Landing Fees 9% Flight & Cabin Crew 13% Fuel 23% Engine Maintenance 5% Acquisition Cost 44% Improve Structural Efficiency to; Typical DOC s for Long Range Airliner reduce acquisition cost, through improved material utilisation, design and manufacturing processes reduce operator fuel costs through lower airframe weight, which also reduces environmental impact Document Number: ALCAS- 01/02/05 Page 3
ALCAS Partnership Netherlands Delft University of Technology, FAESP, NLR, Ned-Tech Sweden SAAB, Kungliga Tekniska högskolan, Novator Belgium Samtech, SONACA UK A-UK, ACG, Bombardier, GKN, INBIS, Messier-Dowty, TWI, Cranfield University, University of Plymouth, Swansea University, Sigmatex, CTS Ireland Irish Composites, CTL Germany A-D, DLR, EADS-D, TU Dresden France A-F, Dassault Aviation, CEAT, EADS CRC-F, Labinal, ENSAIT, Issoire-Aviation, Aeroforme, ECN, Ordimoule, SUPAERO Spain A-E, AICIA, EADS-CASA, Cad- Tech, INTA, Universidad Politecnica de Madrid Switzerland RUAG Aerospace Finland Patria, Helsinki University of Technology Russia TsAGI, Moscow Institute of Physics & Technology Ukraine National Aerospace University Latvia Riga Technical University Poland Military University of Technology Czech Republic VZLU Greece University of Patras Turkey TAI Italy Alenia, University of Pisa, University of Naples Israel IAI Document Number: ALCAS- Document Number: ALCAS/01/01005/1/WP5/PRS 01/02/05 Page 4 4
Platforms 1. Airliner Composite Wing Inner wing & centre box with landing gear & pylon integration 2. Airliner Composite Fuselage Panel tests to address key fuselage challenges 3. Business jet Composite Wing Lower cost by combining parts into an integrated structure 4. Business jet Composite Fuselage Rear fuselage with double shell concept & VTP/HTP & engine integration Document Number: ALCAS- 01/02/05 Page 5
Platform Objectives Airliner Wing 20% weight saving in the wing structure, with zero increase in recurring cost against the reference state-of-the-art metallic wing. Airliner Fuselage 20% weight saving of the fuselage structure, with zero increase in recurring cost, when integrating all current requirements for a composite fuselage, against the reference state-of-the-art metallic fuselage Business Jet Wing 20% reduction in recurring costs of the overall wing box structure, with a 10% weight saving against the reference state-of-the-art metallic wing Business Jet Fuselage 30% reduction in recurring costs of the overall fuselage metallic structure and a 10% weight saving against the reference state-of-the-art metallic fuselage Document Number: ALCAS- 01/02/05 Page 6
WP 1 Airliner Wing Objectives: To offer improved aircraft performance by proving the application of composite materials to a full composite lateral and centre wing box To realise the weight reduction potential of using the right composite materials and technologies for major components TARGET - 20% weight saving compared to metallic aircraft To improve the weight of a composite wing against a state of the art metallic structure To demonstrate lower manufacturing recurring costs through the use of low-cost technologies TARGET - ZERO increase in recurring costs To improve on the manufacturing costs of a composite wing box against the reference metallic baseline Also to reduce maintenance costs through the wider use of composite materials Page 7
WP 1 Airliner Wing Objective To produce a cost & weight effective composite Lateral Wing Box through : Design of the complex inner wing geometries Integration of high load inputs - Main Landing Gear & Pylon Attachments Exploitation of lower cost technologies for composite components & assembly This Work Package covers : - Lateral Wing Box Architecture, Configuration & Integration - Detail design & sizing - Component tooling, manufacture & sub assembly - Major Assembly Jig - Lateral Wing Box assembly - Assembly of the diffusion box to the Lateral Wing Box - Root Joint preparation to ease Final Assembly process - Lateral Wing Box delivery to the Final Assembly Line - Specimen structural test Page 8
WP 1 Airliner Wing Ribs Alenia Assytem/Lola Airbus IAI PATRIA Eire Comp. Pylon GKN Upper Cover Bombardier/Airbus Rear Spar Airbus Gear Rib NLR Other partners include, SAAB, Uni. Patras Side Stay Fitting EADS IW Front Spar GKN Lower Cover Airbus Page 9
WP 1 Airliner Wing WP 1.2.3 Lower Cover Prepreg material in combination with ATL technology Integrated composite reinforcements for high-loaded areas. Stringers fully optimized in weight. Design for manufacturing. Page 10
WP 1 Airliner Wing Use Tab 'Insert - Header & Footer' for Presentation Title - Siglum - Reference Month 200X Page 11
WP1 Airliner wing Final assembly of wing and centre box Page 12
WP1 Airliner wing Page 13
WP1 Airliner wing Page 14
Objectives Advanced Low Cost Aircraft Structures WP2 Airliner fuselage 20% weight saving of the fuselage structure, with zero increase in recurring cost, when integrating all current requirements for a composite fuselage, against the reference state-of-the-art metallic fuselage To address key fuselage challenges and complex design features by panel testing. This includes, Large cut-outs in curved panels Load introduction longitudinal and circumferential Damage capabilities impact, large damage, post-buckling, crash Systems integration Document Number: ALCAS- 01/02/05 Page 15
WP2 Airliner fuselage Large cut out test panel Integral door frame Section through door frame/ intercostal connection Spiral Preforms ALCAS Final Review, Toulouse (V3)
WP2 Airliner fuselage Panel Tests Omega stringers specimen T stringers specimen ALCAS Final Review, Toulouse (V3)
WP3 Business jet wing Develop and assess new composite technologies for Business Jet wing or stabilizer structures Objective 20% reduction in recurring costs of the overall wing box structure, with a 10% weight saving against the reference state-of-the-art metallic wing This includes assessment of the following key areas, High structural integration : less drilling, wet fasteners, assembly process, Innovative processes : Liquid resin Infusion, Z-pinning Novel materials : Out of Autoclave Page 18
Sub-scale wing boxes feasibility Advanced Low Cost Aircraft Structures WP3 Business jet wing Dassault (Fr) Fokker (Nl) Saab (Sweden) Alenia (It) Removable cover VZLU (Czh) ACG (UK) Sigmatex (UK) EADS-CRC-F NLR (Nl) ACG (UK) Univ of Pisa (It) Sup Aero (Fr) Nedtech (Nl) Sonaca (B) Sonaca (B) Ordimoule (Fr) ATS (Nl) Alenia (It) HTP design and manufacture RUAG (CH) EADS-CASA-MTA (Sp) Test centre RUAG (CH) Page 19
WP3 Business jet wing Page 20
WP3 Business jet wing Test results Team 1 and 3, no failure at 2 LL Team 2 and 4 failure at 1.65 LL Page 21
WP3 Business jet wing Development of a composite horizontal tail plane Objectives To Demonstrate real applicability of integrated composite technology to a large structural component To evaluate technologies implemented against existing metallic or other composite solutions. Integrated box: - Design and manufacture DAV, ALENIA, RUAG - Tooling ACG Ribs: ACG 2 ALENIA 5 (+ metallic parts) DAV 2 (1metallic 1composite) Section leading edge: SONACA Page 22 Rear spar with integrated fittings: FAESP, Ned-Tech, NLR, AS-Kleizen Central joint: RUAG Lower cover: EADS-CASA
WP3 Business jet wing Assembly of the validation article at Biarritz Page 23
WP3 Business jet wing Test rig ready for HTP installation Start of the test scheduled end of February Page 24
WP4 Business jet fuselage Develop unitised highly integrated composite rear fuselage, allowing dramatic reduction of the number of components to assemble Objective: 30% reduction in recurring costs of the overall fuselage metallic structure and a 10% weight saving against the reference state-of-the-art metallic fuselage Key aspects include: High load introduction into sandwich shell Curing into a female mould to obtain a "ready to paint" surface System installation philosophy and concepts (no frames to attach equipment) Page 25
WP4 Business Jet fuselage Dassault (Fr) Loading device VZLU (Czh) ACG (UK) Sigmatex (UK) Alenia Univ of Naples (It) carbon inserts EADS CRC Suresnes Ordimoule (Fr) Dassault (Fr) Fuselage shell EADS-CASA-MTA (Sp) Test centre VZLU (Czh) Page 26
Shell curing (EADS-CASA) : Advanced Low Cost Aircraft Structures WP4 Business Jet fuselage Page 27
WP4 Business Jet fuselage Test preparation Page 28
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