R&T Strategy for Materials & Processes - European … · R&T Strategy for Materials & Processes ... Automated laser NDT for complex structures. ... Example - Composite Technology

R&T Strategy for Materials & ProcessesOur way forward to deliver best value for the programs and keep the lead in R&T

Presented byChristian Rückert

performance inspired

Centre of Competence Structure

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

Top-Down approach – translation into M&P specifics

Program R&T vision

Airframe Structure contributions

Materials & Process specifics

July 10th, 2012STOA Brussels

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Airframe contribution to major customers drivers

Passenger Appealing

AffordabilityProductivity

Environment Friendly

DOC: Direct Operating CostDMC: Direct Maintenance Cost

Low noise - Night operation.• Emissions: -50% while traffic growth

• Green Manufacturing• Recycling

Reduction of % DOC:- reduction of Fuel burn.- reduction of DMC.

Comfort.Additional Services Differentiation.

Aircraft availability 100%.Step-change in Turn Round Time.

Light & Green StructuresSimple & Flexible Cabin

Robust Structures & Proper Systems InstallationLightweight, Low Cost &

Maintenance Free Airframe

July 10th, 2012

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STOA Brussels


Product Policy & R&T Notional Products

Product Policy

R&T Notional Products

“2015”2013-2018

DerivativeProducts

“Continuous improvement and

constrained architecture”

“2020”2019-2022

“StepChanges

InFoundation

Technologies”

“2025”2023-2028

“Disruptivescenarios

withSpeculative

technologies”

“2030”2029+

Funct. Concepts“Energy,Green,

Growth”

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12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30

Game-changer SA

Next GenDerivatives improvements

SA foundations

A320NEO

-1000A350-900 -800

A380e

A30X

R&T Notional Products ensure programme Robustness



• Drivers & value• Economics, performance and weight improvements• Cost & lead time reduction enablers

• Product vision• Advanced metal wing & fuselage by applying new Al alloys• CFRP optimised structures• CFRP manufacturing cost reduction

Short term 2015-2020:Quick wins for A320Neo, A350-1000 and Derivatives

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Medium term 2020-2025:The A30X incremental changesProduct and architecture vision

Page 6Page 6

• Build up concepts for low cost, high volume CFRP solutions

• Integrated structure / system architecture• Challenge current system architecture & design rules• Fuselage / Cabin / System multidisciplinary trade-off• Multifunctional optimisation



Medium term 2020-2025:The A30X incremental changesTechnology enablers

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Painted ribletsOne shot CFRP Center wing box

Automated laser NDT for complex structures

Collaborative robot for frame one way assembly

• Deliver robust and mature technologies• Optimum material solution• One shot CFRP structures • One shot global NDT• New joining techniques• One way, hole to hole, shim free assembly• Aerodynamic efficient surfaces coatings• Materials and processes compliant with REACH* regulation

July 10th, 2012

*REACH: Registration Evaluation & Authorization of Chemicals

STOA Brussels

http://blog2b.hosting.dotgee.net/blog/wp-content/uploads/ecologie/ecologie_environnement.jpg


Medium term 2020-2025:The A30X incremental changesDesign capabilities

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DesignOptimisation

Design Validation

• Quick sizing for trade off

• Multi-disciplinary topological optimisation

• Multi scale simulation from overall A/C to structural detail

• Multipurpose large scale tests

• Virtual testing from A/C level to coupons

• Manufacturing processes simulation



Long term 2025-2030: The A30X disruptive conceptsMultifunctional approach

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• Unconventional A/C architecture• Wing Aero / Structures optimisation• Propeller Blade Release Structure proof• Acoustic efficient fuselage structures

• Enablers for smart & intelligent structures• Multifunctional materials• Multifunctional coatings• Nanotechnologies, Shape memory materials

• Integrated design process• Full virtual Aircraft Development• Full aircraft multidisciplinary Design

July 10th, 2012

Focus for M&P

STOA Brussels


“2020”2019-2022

“Step changes in Foundation Technologies”

“2015”2013-2018

Derivative Products“Continuous improvement

and constrained architecture ”

“2025”2023-2028

“Disruptive scenarioswith

Speculative Technos”

“2030”2029+

Functional Concepts “Energy,

Green, Growth”

STOA Brussels

Example - Composite Technology Roadmap (Dates Target EIS therefore TRL 6 = 2-3 years ahead)

New Thermoplastic and Thermoset resin systems

Sheet Moulding Compounds

Automated Bonding processes

July 10th, 2012

Page 10

Braiding process

Conductive, toughend Epoxy Systems (M2X)

More cost efficient Carbon reinforced composites/ High temp materials and ceramics

Improved functionalities of surface layers of laminates

Foam materials for structural sandwich parts out of infusion processes

Welding for Thermoplastic materials

New fibre types and eco-freindly resin systems

Autoclave curing without vacuum bagging

Alternative curing paths for lead time reduction

Robust Manufacturing through material property targeted simulation of process

New Repair and Bonding processes

Enabled recycling routes for composites

Complex 3-D preforms for load dependent material reinforcement


“2020”2019-2022

“Step changes in Foundation Technologies”

“2015”2013-2018

Derivative Products“Continuous improvement

and constrained architecture ”

“2025”2023-2028

“Disruptive scenarioswith

Speculative Technos”

“2030”2029+

Functional Concepts “Energy,

Green, Growth”

STOA Brussels

Example - Metallic Technology Roadmap (Dates Target EIS therefore TRL 6 = 2-3 years ahead)

Magnesium50nm50nm

Nanojoining

Lifecycle analysisTi - High Strength, Toughness, Temp and low cost

BulkAmorphous Metals

Ti MMC’s

Ti- Novel Net Shaping processes (forging, ALM, large casting)

Improved 15/5PH TMP

Novel Extrusions

Self Healing Metals

Laser Shock Peening

Al/Li or Al/Mg/Sc foil FML

Linked-up Process Simulation

Test Simulation

AlMgSc Alloys and processing

AlLi Alloys and processing

July 10th, 2012

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Example – how we measure technological maturity

0

1

2

3

4

51st Generation CFRPs

2st Generation CFRPs

Building block of resin formulation

Low cost material development

understand multifunctional materials principles

New qualification and certification

New chemistries

reduction of energy consumption

2nd MaterialsIn situ manufacturingSimulation technologies to reduce

manufacturing defects

Reliable surface treatment

bonding and repairs

New repairs materials

High temperature composites materials

Ceramic matrix materials

3 D preforms

Simulation technologies

Composite and Bonding Testing

TRL - Technology Readiness Level

July 10th, 2012

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STOA Brussels



© AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document. This document and all information contained herein is the sole property of AIRBUS Operations GmbH. No intellectual propertyrights are granted by the delivery of this document or the disclosure of its content. This document shall not be reproduced or disclosed to a third party without the express written consent of AIRBUS Operations GmbH. Thisdocument and its content shall not be used for any purpose other than that for which it is supplied. The statements made herein do not constitute an offer. They are based on the mentioned assumptions and are expressedin good faith. Where the supporting grounds for these statements are not shown, AIRBUS Operations GmbH will be pleased to explain the basis thereof.AIRBUS, its logo, A300, A310, A318, A319, A320, A321, A330, A340, A350, A380, A400M are registered trademarks.

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R&T Strategy for Materials & Processes - European … · R&T Strategy for Materials & Processes ... Automated laser NDT for complex structures. ... Example - Composite Technology