materials and the aerospace industryenhancinginnovation.wustl.edu/sankaran.pdf · materials and the...

Materials and the Aerospace Industry

Krishnan K. Sankaran, Ph.D.Senior Technical Fellow Materials and Processes TechnologyBoeing Phantom Works

Enhancing Innovation and Competitiveness Through Investments in Fundamental Research

Westin Hotel, Arlington, VADecember 3-5, 2006

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Engineering, Operations & Technology | Phantom Works

Copyright © 2006 Boeing. All rights reserved.

AM&ST

Questions to Consider for Enhancing Innovation and Competitiveness

• Expanded federal investments in research and education and the impact

• Acceleration of ROI in basic research

• Collaboration models for research

• Specific areas of fundamental research

• Workforce challenges

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Boeing Products

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Materials Research to Meet 21st Century Defense NeedsDoD Sponsored, NRC/NMAB Study - 2003

• Revolutionary capabilities from R&D in

• Structural and multifunctional materials• Energy and power materials• Electronic and photonic materials• Functional organic and hybrid materials• Bio-derived and bio-inspired materials

• Five recommendations made

• Accelerate materials transition from concept to service• Computational modeling• Integrate research in various materials classes• Discover materials with substantially improved properties• Materials research from conception to service to retirement

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Strength and Corrosion Resistance ImprovementsRelative to 7075-T651 in New 7XXX-Series Alloys

YieldStrength(MPa)

600

550

1940 1950 1960 1970 1980 1990 2000

7075-T651

7075-T7351

7075-T76517050-T7451

7150-T651 7150-T7751

7055-T7751

Year First Used in Aircraft

Corrosion ResistanceLowMediumHigh

2005

7085-T7651

Thick Products 75 - 200 mm

Thin Products < 75 mm

500

650

700

450

400

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Composition (Wt. %) of 7XXX Series Alloys

7075 7050 7055 7085Zn 5.6 6.2 8.0 7.5Mg 2.5 2.3 2.0 1.5Cu 1.6 2.3 2.3 1.6

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Industry Perspective

• Technologies fuel growth• Products – 787 Dreamliner• Services – Expand the value of products to customers

• Technologies reduce the bottom line• Design – Enables more efficient structures• Manufacturing – Enables streamlined production

• Breakthrough Technologies - What will the future bring?

• Fundamental research• What are the gaps and what is needed to close them?

• Workforce challenges

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Growth: New Technologies Enable New Products and Services

• Large-scale composite components

• Advanced manufacturing processes

• System health monitoring

• Next-generation engines

• More-electric power systems

• Enabling interior architecture

• Integrated avionics

• Advanced flight controls

• Wireless IFE and other technologies improve the cabin

• Noise reduction technologies

• Advanced Recycling Technologies for Airplanes

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• Best introduction of a new Boeing Commercial Airplane ever

IntegratingBreakthroughTechnologies


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787-8

Composites Serve as 787 Primary Structural Material

CFRP 43%

Misc. 9%

• Lighter

• More durable

• Reduced corrosion and fatigue

• Reduced scheduled maintenance

• Opens new design possibilities

One Piece Fwd Fuselage One Piece Barrel Section Test Wing Box

Composites

Aluminum

Titanium

SteelOther

Composites

Aluminum

Titanium

SteelOther




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The Future of CompositesEnabling High Rate Production

CompositeSteelTitaniumAluminumMiscellaneous

Materials

Increased composites usage over time

1%747

3%757/767

11%777

50%

787Design &

manufacturing

technology

breakthrough



Materials

Increased composites usage over time

1%747

3%757/767

11%777

50%

787Design &

manufacturing

technology

breakthrough

Continued Development of Advanced Composites Will Be Required to Affordability Satisfy High Rate Production Needs

Continued Development of Advanced Composites Will Be Continued Development of Advanced Composites Will Be Required to Affordability Satisfy High Rate Production NeedsRequired to Affordability Satisfy High Rate Production Needs

45%

39%

5%11%

22%

3%

15%

60%

25,700airplanes

2.1 trilliondelivery dollars**In year 2004 dollars

Regional jetsSingle-aisleTwin-aisle747 and larger

2005-2024




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Titanium Usage in Aircraft Has Been Increasing

Composites are also Driving Growth in

Titanium

Composites

Titanium

Other

Steel

Aluminum

Composites

Titanium

Other

Steel

Aluminum

Year of Roll Out

707727 737 747

747 SP

767

757

777

787 (Projected)

02468

101214161820

1950 1960 1970 1980 1990 2000 2010 2020

Perc

ent T

i as

Func

tion

of O

EW

Year of Roll Out

707727 737 747

747 SP

767

757

777787 (Projected)

02468

101214161820

1950 1960 1970 1980 1990 2000 2010 2020

Perc

ent T

i as

Func

tion

of O

EW

Continued Development of Improved Alloys Are Needed to Improve Performance, Manufacturability, and Affordability

Continued Development of Improved Alloys Are Needed to Improve Continued Development of Improved Alloys Are Needed to Improve Performance, Manufacturability, and AffordabilityPerformance, Manufacturability, and Affordability




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7 Characteristics of Future Products, Processes & Services

Extreme AffordabilityExtreme Affordability

“Universally” Friendly“Universally” Friendly

Super-Human IntelligenceSuper-Human Intelligence

Network CentricNetwork Centric

Platforms and systems with decision making capabilities better than human

Multiple assets that collaborate on a network to optimize the system performance

Cost improvements of factors from 2-100

Minimal to no environmental impact of a product throughout its full lifecycle




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Integration of many functions into a single component

2 to 100-fold performance improvements

Easy to upgrade with the latest technological advancements

Highly IntegratedHighly Integrated

Breakthrough PerformanceBreakthrough Performance

Adaptability to ChangeAdaptability to Change

7 Characteristics of Future Products, Processes & Services




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Product Support – Integrated Vehicle Health ManagementDevelop diagnostic/prognostic technologies that will allow us tomonitor the performance of our products in the field to ensure optimum performance and maximum availability to our customers

Monitor Detect Analyze Plan Manage




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Product Support – Maintenance, Mods, & RepairsDevelop advanced technologies which will improve the quality andreduce the cost of Maintenance, Modifications and Repair




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Productivity Improvements: Design Technologies Enabling More Efficient Structures

Lower Cost & Lower WeightDevelop innovative structural concepts which will be lighter, easier to build and maintain, and cost less to fabricate and support

Fewer partsFewer fastenersLess assemblyLower weight




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Design & Analysis Tools Develop the necessary analysis capabilities needed to support the advanced concepts and integrate those into common design tools and processes

H at p lies x d irection

N oodle and sk in x d irection

H at p lies x d irectionH at p lies

x d irection



Faster DesignsMore Iterations




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Materials by Design Create high-performance materials and leverage with design concepts to improve performance and/or lower costs

• Materials by Trial and Error• Lots of testing

• Architect the materials necessary to enable higher performance designs




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Modeling and Simulation Develop, design, and build multiple iterations virtually to reduce costs and speed development

Productivity Improvements: Design Technologies Enabling More Efficient Structures & Operations

Physical Virtual




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Goal: AnalysisSupported by Experience, Test & Demo

Time to Insertion Readiness

RIS

K

Time to Insertion Readiness Reduced by 55%

AAAAAA

RIS

K

AAAAAA

Traditional: Test Supported by Analysis

Analytical Techniques Replace Empirical Testing Develop methods to verify and certify new structural concepts and material forms to speed those advancements product lines





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Network Enabled ManufacturingDevelop open architecture model for linking system-of-systems, e.g., Indoor GPS, RFID, SmartTools, Laser Projection all linked to manufacturing work instructions and Quality Management System

NEM Converts today’s aerospace factories where information collection and diagnostics are mostly manual to state-of-the-art automated information database resource in real time. This methodology is well adaptable to the future engineering work force who are familiar with intelligent computerized systems


Productivity Improvements: Technologies Enable Lower Cost Structures






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Aerospace Direction

• Increased global sourcing of subcomponents and materials

• Global sourcing of assembly

• Airbus to assemble planes in China (2006)

• Networked manufacturing

• “Materials by Design”

• Lean manufacturing

• “Green” materials and processes

• Networked aircraft, satellites, etc.




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Aerospace Workplace Needs

• Educated Scientists and Engineers

• Globally sourced

• “Clearable” for Defense-relatd projects

• Mathematical and Analytical capability

– Probability and Statistics

• Communications across various disciplines

– Not just interdisciplinary studies, but interaction

Boeing invests significantly in employee trainingboth in-house and at universities

Boeing invests significantly in employee trainingBoeing invests significantly in employee trainingboth inboth in--house and at universitieshouse and at universities




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Fundamental Research Gaps and Needs

• Modeling and simulation

• Materials Informatics• Simulation of manufacturing processes

• Multi-functional materials

• Lower cost or affordable replacement for strategic materials

• Self assembled structures – “Grow the parts”

• In-service assessment of the health of materials• Diagnostics and prognostics

Materials are Key to Maintaining CompetitivenessMaterials are Key to Maintaining CompetitivenessMaterials are Key to Maintaining Competitiveness

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