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Design of a Cradle to Cradle Aircraft InfiniCraft

11/07/2013

By DSE group 05

“Aircraft Design Using Cradle to Cradle, Reality or Utopia?”

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Design Strategies

•  Eco-design: “be less bad”

• Cradle to Cradle: “be good”

• Never applied in aerospace

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Current Design Strategy

• Boom in the 70’s

•  Life span of 30 years

• => EOL plan under investigation in the 2000’s •  Projects

•  PAMELA •  AFRA

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Project Requirements

• General Requirements •  2 passengers •  Take-off length of 500 m •  Range of 1 000 km •  Cruise speed of 200 km/h @ 3 050 m •  Noise level < 62 dB •  Life span of 30 years / 20 000 flight hours / 12 000 flights •  500 units •  Ready in 2025 •  $ 150 000

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Project Requirements

• Cradle to Cradle® Requirements •  At least 90% recyclable •  Reintegration through technical cycle or biological cycle •  End-of-life disposal plan •  < 50 kg/h CO2 emissions •  Current solar income shall be used

• Additional Requirements •  In-flight emergency solution

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Content

•  Power & Propulsion

• Materials & Structures

•  Life Cycle Context

•  Lease Structure

• Conclusion

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Power & Propulsion

Power & Propulsion

Materials & Structures

Life Cycle Context

Lease Structure Conclusion

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Fuel Selection

• Biofuel vs. Hydrogen •  Lower initial system cost •  Lighter system •  Better availability

•  Ethanol •  Low price •  High availability •  Proven concept

•  Second generation biofuels •  Switchgrass •  Waste

Power & Propulsion

Materials & Structures

Life Cycle Context

Lease Structure Conclusion

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Fuel GWP

Power & Propulsion

Materials & Structures

Life Cycle Context

Lease Structure Conclusion

L. Luo, “Biomass Refining for Sustainable Development: Analysis and Directions”, Master's thesis, University of Leiden, The Netherlands, 2010.

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Fuel Land Use

• Different sources for ethanol are considered

•  Land use:

Source Land/aircraft/year

Stover (corn) 71 578 m2

Sugarcane 19 813 m2

Switchgrass 26 403 m2

Waste 0 m2

Power & Propulsion

Materials & Structures

Life Cycle Context

Lease Structure Conclusion

L. Luo, “Biomass Refining for Sustainable Development: Analysis and Directions”, Master's thesis, University of Leiden, The Netherlands, 2010.

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Example

• Kempen airport, located in Budel •  300 m3 of fuel per year •  Waste of 1 266 people needed •  Budel has 9 000 inhabitants

Power & Propulsion

Materials & Structures

Life Cycle Context

Lease Structure Conclusion

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Engine Selection

• Rotax 912 ULS • Can run on ethanol (with conversion kit) •  103 hp

• Noise •  3 bladed propeller to lower the noise •  60.4 dB at 610 m

Power & Propulsion

Materials & Structures

Life Cycle Context

Lease Structure Conclusion

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Aircraft Configuration

• Conventional design •  High wing •  Aluminium primary structure •  Allows for full C2C implementation •  Inspiration for aircraft manufacturers

• Cessna Skycatcher

Power & Propulsion

Materials & Structures

Life Cycle Context

Lease Structure Conclusion

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Emergency Solution

• Required by certification: •  Fire extinguishers •  Emergency locator transmitter •  Personal locator beacon

•  Parachute recovery system

Power & Propulsion

Materials & Structures

Life Cycle Context

Lease Structure Conclusion

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Materials & Structures

Power & Propulsion

Materials & Structures

Life Cycle Context

Lease Structure Conclusion

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Aluminium Analysis

• Automotive alloys: larger recycling market

•  Several possibilities: 6022 – 6016 – 6061 – 5086

Al-6022-T4 Al-7075-T6 Al-2024-T3

Ultimate tensile strength [MPa] 271 572 448

Young’s modulus [GPa] 68 71.7 73.1

Fracture toughness [MPa m] 40 33 38

Corrosion rate [mm/year] 0.11 0.16 0.15

Power & Propulsion

Materials & Structures

Life Cycle Context

Lease Structure Conclusion

asm.matweb.com

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128 MPa

Al-6022-T4 Al-7075-T6 Al-2024-T3

Fatigue Limit [MPa] 108 159 138

Power & Propulsion

Materials & Structures

Life Cycle Context

Lease Structure Conclusion

CES Edupack

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Load Cases

•  Loading Diagram •  Manoeuvre loads •  Gust loads

• Maximum Load cases •  + 4.4 g •  - 2.14 g

•  Safety factor of 1.5 •  + 6.6 g •  - 3.21 g

Power & Propulsion

Materials & Structures

Life Cycle Context

Lease Structure Conclusion

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• Wingbox •  Skin thickness: 2 mm •  125 MPa < 128 MPa

• Fuselage •  Skin thickness: 1 mm •  103 MPa < 108 MPa

Power & Propulsion

Materials & Structures

Life Cycle Context

Lease Structure Conclusion

Stress Analysis

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Secondary Structures

Fuel tanks

Thermoplastic composites

Interior

Customer based C2C-materials

Doors & window

Polycarbonate

Transparent

Control surfaces & wing tip

Thermoplastic composites

Maintenance: 3D-printing

Power & Propulsion

Materials & Structures

Life Cycle Context

Lease Structure Conclusion

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Secondary Structures

Production: compression moulding

Used for mass production

Cannot be done locally

Special & expensive tools

Maintenance: 3D-printing

Novel technique

Can be done locally

Time consuming nowadays

Power & Propulsion

Materials & Structures

Life Cycle Context

Lease Structure Conclusion

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•  Friction Stir Welding •  No additional material required •  Attachments to fuselage

• Rivets •  Same Al-6022 alloy as primary structure •  Skin to primary structure

• Bolts •  Easy detachment •  Wing tips & Control surfaces

Joining Methods

Power & Propulsion

Materials & Structures

Life Cycle Context

Lease Structure Conclusion

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• Basic six • Mobile devices as avionics systems

•  Up-to-date software •  Change layout to user preferences •  No heavy on-board computers •  Anti-theft

• Wiring •  Aluminium •  Insulation based on Noryl

(modified polyethylene)

Avionics

Power & Propulsion

Materials & Structures

Life Cycle Context

Lease Structure Conclusion

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Life Cycle Context

Power & Propulsion

Materials & Structures

Life Cycle Context

Lease Structure Conclusion

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InfiniCraft Life Cycle

Power & Propulsion

Materials & Structures

Life Cycle Context

Lease Structure Conclusion

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Manufacturing and Shipment

Power & Propulsion

Materials & Structures

Life Cycle Context

Lease Structure Conclusion

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Disassembly

Power & Propulsion

Materials & Structures

Life Cycle Context

Lease Structure Conclusion

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Disassembly

Power & Propulsion

Materials & Structures

Life Cycle Context

Lease Structure Conclusion

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Disassembly

Power & Propulsion

Materials & Structures

Life Cycle Context

Lease Structure Conclusion

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Disassembly

Power & Propulsion

Materials & Structures

Life Cycle Context

Lease Structure Conclusion

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Disassembly

Power & Propulsion

Materials & Structures

Life Cycle Context

Lease Structure Conclusion

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Disassembly

Power & Propulsion

Materials & Structures

Life Cycle Context

Lease Structure Conclusion

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Disassembly

Power & Propulsion

Materials & Structures

Life Cycle Context

Lease Structure Conclusion

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Disassembly

Power & Propulsion

Materials & Structures

Life Cycle Context

Lease Structure Conclusion

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Disassembly

Power & Propulsion

Materials & Structures

Life Cycle Context

Lease Structure Conclusion

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Disassembly

Power & Propulsion

Materials & Structures

Life Cycle Context

Lease Structure Conclusion

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Re-use of Parts

• Checking

• Recertified

Power & Propulsion

Materials & Structures

Life Cycle Context

Lease Structure Conclusion

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Recycle Rate of the InfiniCraft

Power & Propulsion

Materials & Structures

Life Cycle Context

Lease Structure Conclusion

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Lease Structure

Power & Propulsion

Materials & Structures

Life Cycle Context

Lease Structure Conclusion

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Total Operating Cost

• Dry lease price •  RDTE cost •  Acquisition cost

• Maintenance and overhaul •  Insurance •  Fuel •  Parking •  Landing fees

8 years 10 years 15 years

$ 152,- per hour $ 143,- per hour $ 130,- per hour

Power & Propulsion

Materials & Structures

Life Cycle Context

Lease Structure Conclusion

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Conclusion

Power & Propulsion

Materials & Structures

Life Cycle Context

Lease Structure Conclusion

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Comparison InfiniCraft and Skycatcher

Infincraft Cessna

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1 000 (+ 22.7 %)

500 (+ 44 %)

407 (+ 6.5 %)

729 (+ 21.7 %)

25.5 (+ 22.5 %)

179 530 (+ 19.7 %)

142.7 (- 4.5 %)

Parameter InfiniCraft Skycatcher

Range [km] 1 000 815

Payload [kg] 181 141

Unit price [$] 179 530 149 900

Total operating cost (10 year) [$/hour] 142.7 149.5

Cradle to Cradle® Yes No

Power & Propulsion

Materials & Structures

Life Cycle Context

Lease Structure Conclusion

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Conclusion

•  Inspire other manufacturers

• Reduce ecological impact

•  Economical benefits • Change in mindset

Power & Propulsion

Materials & Structures

Life Cycle Context

Lease Structure Conclusion

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Aircraft Design Using Cradle to Cradle:

Reality or Utopia?

46 Introduction Power &

Propulsion Structures &

Materials Operations &

Logistics Conclusion

Reality!

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Questions?

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Initial Sizing

• Requirements as input:

•  From customers

•  From regulations (CS-23)

•  Sizing parameters as output:

•  Wing surface 10.4 m2

•  Lift coefficient 1.1 in clean configuration

•  Airfoil NACA-2412

•  Flaps Plain flaps

•  Power 103 hp

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Weight Estimation

Empty weight of 407 kg

Take-off weight of 729 kg

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Weight-Range diagram

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Noise Analysis

•  60.4 dB at 610 m

•  610 m needs to be achieved after 6500m

• Can be achieved with the climb rate

•  3 bladed propeller to lower the noise

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Coatings

•  Electro-chemical reaction of the aluminium structure with the environment (atmospheric corrosion)

⇒ Corrosion protection required • Two possibilities: anodising and reactive coating • Anodising: reduces the material’s fatigue resistance ⇒ Reactive coating will be used

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Reactive Anti-Corrosion Coating

•  Insulates the aluminium to suppress electro-chemical reactions • Today’s used inhibitors: Chromates • Green alternative: Si/Zr/Ce

• Can be implemented within the aircraft’s paint

C.-C. Changa, C.-C. Wang, C.-W. Wuc, S.-C. Liuc, and F.-D. Maid, “Using ToF-SIMS and EIS to Evaluate Green Pretreatment Reagent: Corrosion Protection of Aluminum Alloy by Silica/Zirconium/Cerium Hybrid Coating”, Applied Surface Science, vol. 255, pp. 1531-1533, 2008.

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Primary Structures 3 design options -  Monocoque: Low weight, good aerodynamic shape

Difficult replacability of components -  Truss structure: Easy manufacturing, maintenance and recycling Heavy, aerodynamically inefficient structure -  Semi-monocoque: Low weight, better aerodynamic shape

More complex and less robust Mostly used in today’s aircraft

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Wiring

• Comparison of copper and aluminium •  Lighter, cheaper alumiunium core wires •  Insulation based on Noryl (modified polyethylene)

•  Fully recyclable •  No halogens nor pigments (meets WEEE* requirements)

*Waste Electrical and Electronic Equipment

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Processing of the Materials

Material Recycle Rate [%] Processing

Aluminium 100 Shredding / melting

Steel 100 Shredding / melting

TPC 100 Grinding / melting

Polycarbonate 95 Grinding / melting

Rubber 80 Grinding

Wood 100 Biodegradable

Engine fluids 95 Filtered

Engine block 87 Breakdown in components

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Processing of the Materials

Material Recycle Rate [%] Processing

Electronics 87 Breakdown in components

Instruments 90 Breakdown in components

Lights 95 Breakdown in components

Wiring 100 Stripped

Interior 100 Cradle to Cradle materials

Coatings 0 Chemically removed

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Fuel Price Determination

E100 [€/L] Avgas [€/L]

Base: €0.53 Base: €1.64

Excise tax: €0.75 Excise tax: €0.75

Consumer tax: €0.27 Consumer tax: €0.50

Pump price: €1.55 Pump price: €2.89

Exemption: €0.75 Exemption: €0.00

Fuel cost: €0.80 Fuel cost: €2.89

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Verification & Validation Design Requirements

ü  2 passengers

?  $ 150 000

ü 500 units

ü Ready in 2025

?  Life span of 30 years / 20 000 flight hours / 12 000 flights

Mission Requirements

ü Range of 1 000 km

ü Cruise speed of 200 km/h @ 3 050 m

ü Take-off length of 500 m

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Verification & Validation

Cradle to Cradle® Requirements

ü At least 90% recyclable

ü Reintegration through technical cycle or biological cycle

ü End-of-life disposal plan

ü < 50 kg/h CO2 emissions

ü Current solar energy shall be used

Additional Requirements

ü Noise level < 62 dB

ü In-flight emergency solution