Continuous High Volume Part Production Technologies · Generic, NSR, A350-900, A350-1000 P4 - Prepreg Frame Technology Specific Part Specific ALCAS LCO7 V3 Door Surround Structure

© AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document.

Continuous High Volume Part Production Technologies

Innovation Day 31.05.2016

Alexander Gillessen

R&T Programme EngineerCluster Leader – Generic Technologies


May 2016

Agenda

Page 2

CTC

Continuous Profile Production – Part Portfolio

Continuous Profile Production – Technologies


May 2016

Composite Technology Centre Stade (CTC)

Page 3


May 2016

Composite Technology Centre Stade (CTC)

Page 4

TRL 2 TRL 4 TRL 6

-10 years -4 years Start of production

+ 20 years

End-userorientedresearch

Preparationfor serial

production

Serial production

End of life

Airc

raft

mat

urity

leve

l Product Life Cycle

Academic research

Recycling CompanyRecycling CompanyCFK NordCFK Nord OEMOEMCTC GmbHCTC GmbH


May 2016

Agenda

Page 5

CTC




May 2016

Continuous Profile Production – Part PortfolioGeneral Overview

Page 6

A320 A330 A340 A350 A380

StringerFrames

Fuselage VTP / HTP Wing

RibFloor Structure


May 2016

Continuous Profile Production – Part PortfolioCFRP Fuselage Frames

Typical Frame

potential rate: 13 a/c per month

high level of variants

~ 50.000 frames/year

A350 XWB NSR

Typical Frame

potential rate: 60 a/c per month

low level of variants

~ 150.000 frames/year

A350 XWB NSR


May 2016

Continuous Profile Production – Part PortfolioA320 VTP Stringer

Page 8

Assumptions

Rate: 60 ac/month from 2019

Stringer: 100m T-stringer per VTP centerbox

6.000m T stringer per month 70 km T stringer per year


May 2016

Continuous Profile Production – Part PortfolioNew Short Range WING Stringer

Page 9

Assumptions

Rate: 60 ac/month Part: 2 x wing upper cover + 2 x wing lower cover per ac 240 WUC+WLC /month

Stringer: 11 stringer per WUC + 10 stringer per WLC ~100 m stringer per WUC + ~ 80 m per WLC 21.600m stringer per month


May 2016

Continuous Profile Production – Part Portfolio GeometricalProfile Complexity

Page 10

Geometry (example fuselage frame)

R1 R2

R1≠ R2

variableweb high

local reinforcement(web and/or flanges(s))

global reinforcement(web and/or flanges(s))

0° plies web

twist

0° plies flange(s)

Fiber-Angle-Deviationdue to :Geometry- / Process- / Reproducing- Factors

Ondulation

Gaps / Overlaps

Thickness-Tolerance

Contour Tolerance

Reproducibility

Buy to Fly

€/kg

Key Characteristics


May 2016

Agenda

Page 11

CTC




May 2016

Continuous Profile Production – TechnologiesWhat profiles can we buy today and where we want to go

Page 12

Continuous/high volume

Discontinuous/Small volumes

Simple

Complex

com

plex

ity

manufacturing volume

UD Pultrusion profiles

Manual labour dominated, high production cost

*1) Image source: DPP (vDijk Pultrusion Products)

e.g. A350 fuselage frame

*2) Image source: Maschinenmarkt (Thomas Technik)

UD & multiaxial textile

Web height variation

Local patches

*1) *2)

Full automation for complex products

Fast and/or continuousimpregnation


May 2016

Continuous Profile Production – TechnologiesCTC – Portfolio

Page 13

2004 2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015 2016 2017 20182001 2002 2003 2019

3D Preforming (LOKOST)for complex, curved profiles -> Frames

PRTMfor complex profiles -> Stringer

NCFPrepreg

RTMAuto-RTM

RTMHP-RTM

Window Frame

A380 A350-900 A350-1000

Barrel Test-Part ManufacturingBarrel 1b, Barrel 1bR2

Manufacturing Feasibility Evaluation (NCF & Prepreg): Typical-Frame & Door Frame

Generic, NSR, A350-900, A350-1000

P4 - Prepreg Frame

Technology SpecificPart Specific

ALCAS LCO7 V3Door Surround Structure

KAPSDigital Factory

NSRDoor Frame

CoFuI²LCF Frame

A350Typical Frame

Airbus Supplier

Wing-Profiles


May 2016

Continuous Profile Production – TechnologiesCFRP Profile Production Line - Frames

Page 14

DLREvo

CTCAuto-RTM

Fully Automated Process Chain Variable Continuous 3D Preforming High-Pressure-Auto- RTM

Preforming Curing Net-Shape Part

- Profile

- Profile

- Profile

High-Pressure RTM

Auto-RTM

LoKost 2.0 plant

LoKost 1.0 plant

+


May 2016

Continuous Profile Production – TechnologiesCFRP Profile Production Line - Frames

Page 15

LoKost 1.0: Automated 3D Preforming LoKost 2.0: Automated complex 3D PreformingVariably curved Z- and LCF-profile preforms Variably curved omega-profile preforms

with interleaved patches and variation in the cross-section

…basic preforming system for continuous preforming…curved preforming

…variable curvature

...global patch integration

...local patch integration

...web height variation

...in-line quality check for single textile layer

...in-line cutting

...automated handling of preforms


May 2016

Continuous Profile Production – TechnologiesComparison of processing rates for complex profiles

Page 16

Preforming Infusion & curing

Trimming NDI

Productivity

High

Medium

Low Productivity bottleneck with current production systems

Continuous or high pressure impregnation

In-line NDT

In-line trimming


May 2016

Continuous Profile Production – TechnologiesHigh Pressure RTM Technology

TargetDevelopment and Enhancements of High-Pressure-RTM Technology (HP-RTM) for Aeronautical Application

technology feasibility validation for aerospace part production ( aerospace quality requirements)

process-time reduction for RTM-Part production from today ~3hrs to ~15 min

aerospace adapted fast curing 2K epoxy resin

innovative injection strategies and technologies

internal release agent application

isotherm process, no heating no cooling rates

mixing head mounted to tool, no cleaning of neat resin HP-RTM in aerospace industry

HP-RTM in automotive industry


May 2016

Continuous Profile Production – TechnologiesHigh Pressure RTM Technology

Page 18

Gefördert durch das Land Niedersachsen und die Hansestadt Bremen

CTC HD-RTM

• KraussMaffei RIM Star Thermo• 2 mixing heads, multipoint injection• 250to press • 2,5m x 1,5m press bolster• 15kW Heating- / Cooling system• Compression RTM capable• Qualified staff

Z-Frame Tool

• Straight Z-Frame, length 1200mm• Applicable for 4-pt-bending test-part production• Applicable for manufacturing feasibility demonstrator part

production

Coupon Tool

• Coupon t=2mm• Applicable for typical tests

(e.g. CAI, ILSS)• Applicable for generic analyses


May 2016

Continuous Profile Production – TechnologiesCFRP Profile Production Line - Stringer

Page 19

Fully Automated Process Chain Variable Continuous 2D & 3D Profile Manufacturing Preforms, Net-Shape Prepreg Profiles

and Fully Cured Parts

Curing - Line Cured Part

Net-Shape Prepreg Part

Preforming - Line

Net-Shape Prepreg - Line

Preform


May 2016


Page 20

Pultrusion + RTM


May 2016


Page 21

- significant part cost reduction through increase of manufacturing speed by a factor of 10 - manufacturing and material technology applicable to many part families (stringer, beams, struts)- no internal release agent, potential weight reduction (NCF instead of woven fabric)

Pultrusion + RTMFuture Potential:

Proven Feasibility:

Manufacturing Throughput per Line:

Jamco ADP prepreg stringer: up to 2m per hour*

PRTM textile stringer: more than 18m per hour

Summary:

*: Source: Patent DE 102007018052 A1

e.g. floor beam structures

T- / I-profiles


May 2016

Continuous Profile Production – TechnologiesCFRP Profile Production Line – Prepreg Frame

Page 22


May 2016

DryFibre Wing of the Future (WotF)

Page 23

Profile Production

Example: CFRP Profile Production Line

Profile Production

Example: CFRP Profile Production Line

Profile Production

Example: Prepreg Process Chain

Profile Integration

Example: AutoVac


May 2016

Marketplace and Facility Demonstration CTC

Page 24

PRTM

LoKost 1.0: Automated 3D Preforming LoKost 2.0: Automated complex 3D Preforming

HP-RTM


May 2016

© CTC GMBH. All rights reserved. Confidential and proprietary document.CTC GmbH is a100% subsidiary of AIRBUS Operations GmbH© CTC GMBH. All rights reserved. Confidential and proprietary document.CTC GmbH is a100% subsidiary of AIRBUS Operations GmbH

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Continuous High Volume Part Production Technologies · Generic, NSR, A350-900, A350-1000 P4 - Prepreg Frame Technology Specific Part Specific ALCAS LCO7 V3 Door Surround Structure