the history (and future?) of composites in aviation
DESCRIPTION
Composites engineering Professor Richard Day discussed the role of composites in the history and future of aviation at Glyndŵr University's Catrin Finch Centre on 3 February 2011TRANSCRIPT
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the history (and future?) of composites in aviation
Richard Day
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"it should in no way be associated with that great body of factual
information relating to orthodox Zen Buddhist practice. It's not very factual
on motorcycles, either."
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outline
• introduction to composites
• development of aircraft
• today‟s issues
• conclusions
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an introduction to composites
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composite
A combination of materials designed to
result in a material with better overall
properties than the starting materials
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Composites may contain:
Monofilaments Whiskers/Staple Fibres Particulates
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fibres
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common textile structures
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prepreg
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development of aircraft
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Wright brothers glider 1900
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Wright brothers, Kitty Hawk, NC, 17th December 1903
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Wright brothers technology• Wood and cloth
• Wing warping for control (three axis control)
• Engine made in their bicycle shop
• Spruce frame –but wood is a composite containing cellulose fibres in a lignin and hemi cellulose matrix
• Muslin for surfaces- textile structure of cotton fibres
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control
http://www.aerospaceweb.org/question/dynamics/yaw/axes.jpg
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wood fibres (=paper)
http://en.wikipedia.org/wiki/File:PaperAutofluorescence.jpg
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Bristol Boxkite, British and Colonial Airplane Company 1910
Sir George White
First electric tram service in
Bristol, then London
Manufacture of buses 1908
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One (UK Edition) November 2010
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Boeing 247 (1932)
• metal, not wood
• monocoque construction
• cantilevered single wing
• variable pitch propeller
• reliable engine
• trim tabs
• autopilot
• de-icing
• retractable landing gear
• faster than the fighter in service at the
time! (Boeing P12 open cockpit biplane)
• comfortable for passengers
http://en.wikipedia.org/wiki/Boeing_247
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Antonov An-2 (Shijiazhuang Y-5) 1947-
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Boeing 707
• First flight
December 20,
1957
• Aluminium skin
2024-T3
• 2% glass fibre
composites
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aluminium alloys• Naming convention xxxx-yy
• xxxx is material type
• yy tells you about manufacture (which afters structure, hence properties)
• 1000 series- more or less pure aluminium
• 2000 series- copper (duralumin)
• 3000 series- manganese
• 4000 series- silicon
• 5000 series- magnesium
• 6000 series- magnesium and silicon
• 7000 series- zinc
• 8000 series- lithium
• 2,6,7000 series can be precipitation hardened- one metal in another to
improve the properties
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alloys and hardening
• Defects can make metals stronger
• Metals contain a number of defects which
include dislocations
• Precipitates (another material) within the
metal can hinder progress of defects- hence
the material is stronger than either alone.
• A composite??
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Boeing 737 - 1967
© Dylan Ashe
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A320- Feb 1987
composite empennages and control surfaces.
http://freeairlineindustry.blogspot.com/2010/12/airbus-a320-pictures.html
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Boeing 777
http://en.wikipedia.org/wiki/File:United_Airlines_B777-200_N780UA.jpg
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707
777ConcordeA300
A310
A320A340
A380
787A350
0
10
20
30
40
50
60
1940 1950 1960 1970 1980 1990 2000 2010 2020
composite weight /%
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Helicopter composite content
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today’s issues
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composite design
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Composite design
• Many designs are based on existing
designs for metallic structures.
• Hybrid „black metal‟ designs
• Need designs which make use of
composites fully
• Need to be able to rapidly manufacture
structures
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Honda jet - 2003
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driving forces for adoption of composites
aviation
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http://www.acare4europe.org/html/documentation.asp
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aviation- fuel consumption / CO2
• SR= specific range
• L=lift
• D=drag
• SFC=specific fuel consumption
• T=ambient temperature
• mg=weight
mg
T
T
SFCD
LMa
SR
0
0
Aerodynamics
Weight
Engines
To reduce CO2 emission by 50
% need to reduce fuel burn by
50 %. Engines expected to give
~20 %. Adoption of composites
gives lower weight, but also
could help aerodynamics
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Aviation-reducing CO2
• Aviation contributes 2 % of total CO2. There are many things that can be done to reduce CO2
– Air traffic management- choice of flight path (e.g. stay higher longer is more efficient). Single European Sky could lead to 12% reduction in fuel burn
– Eliminate unnecessary weight• electronic flight bag
• engine compressor washing-greater efficiency, this reduces fuel by 4 million gallons per year for American Airlines, other airlines (e.g. Virgin) do the same. Jet A £1.4/gallon->£5.6m saving
• aeroplane washing-a typical dirty plane carries >300 kg dirt
• American Airlines do not completely fill water tank as experience shows they do not need all the water- this saves £1.4m in fuel pa
• Review fuel load- dispatcher could change the forecast amount of fuel due to captain‟s preference, gut feeling, to avoid call from flight crew, doesn‟t believe the model used to predict fuel load…
– Maintenance can affect fuel burn, hence CO2 emissions – e.g. if APU needs to be left on it costs 1 gallon (£1.40) per minute to run
– 1 Tonne weight leads to 420 Tonnes CO2 per year-an extra 2l carton milk causes 0.8 Tonne of CO2 emission per year.
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aviation- weight of materials
Material
Stainless steel 0.8
Titanium 1.1
Aluminium 1.5
Carbon fibre composite 3.6
Spruce 5.0
3
1
E
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‘Spruce goose’
2nd November 1947
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crude oil price
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“buy to fly ratio”
• The weight of metal bought compared to
the weight in the final component.
• Extreme values are
– 1.5:1 for fan blades
– 22:1 for structural parts
• Composites can be moulded to shape with
lower waste
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Fired engineer calls 787's plastic fuselage unsafe
A former senior aerospace engineer at Boeing's Phantom
Works research unit, fired last year under disputed
circumstances, is going public with concerns that the
new 787 Dreamliner is unsafe. Forty-six-year veteran
Vince Weldon contends that in a crash landing that
would be survivable in a metal airplane, the new jet's
innovative composite plastic materials will shatter too
easily and burn with toxic fumes.
Seattle Times 18th September 2007
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driving forces for adoption of composites
motor sport
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applications – motor sport
Jan Manuel Fangio 1911-??
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applications – motor sport
Jan Manuel Fangio 1911-95
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motor sport- F1 driver deaths in the past 30 years
Driver Year Where
Ayrton Senna 1994 Italian Grand Prix
Roland Ratzenburger 1994 Italian Grand Prix
Ricardo Paletti 1992 Canadian GP
Giles Villeneuve 1982 Belgian GP
Ronnie Peterson 1982 Italian GP
Tom Pryce 1977 South African GP
Mark Donahue 1975 Austrian GP
Helmuth Koinigg 1974 US GP
Francois Cevert 1974 US GP
Roger Williamson 1973 Dutch GP
Jochen Roindt 1970 Italian GP
Piers Courage 1970 Dutch GP
Gerhard Mitter 1969 German GP
Jo Schlesser 1968 French GP
Lorenzo Bandini 1967 Monaco GP
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motor sport - composites
• Step change in F1 technology with the
introduction of composites in 1981 by McLaren.
• The other teams followed- now all F1 cars are
largely carbon – epoxy
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Kovalainen has no memory of crash
"I have a slight headache and a stiff neck,
but apart from that I am feeling well and in
good spirits"
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Displacement
Lo
ad
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Manufacturing processes for aerospace composites
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autoclaving – the ‘gold standard’
• Complex processing & high capital
and operating costs
• Poor gas to solid heat transfer
• Limited temperature ramp rates
resulting in slow cure cycles
• Limited to Aerospace and high-
performance automotive industries
• Long delivery times for autoclaves
• But… low void content and good
properties!
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Demand
• Boeing 787, A350 currently being
designed and tested are twin aisle, long
distance planes for which demand is lower
than single aisle short range aircraft.
• Short range need builds at ~rate 40
• manufacturing techniques need to be
revolutionised
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How can we speed up manufacture of composite components?
• Improve heat transfer
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Deep fat frying of composites
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Quickstep Overview
Flexible Bladder
Heat Transfer Fluid
Flexible Bladder sealing mould to pressure chamber
Mould tool floating and supported in HTF
Pressure Chamber
Composite part to be moulded
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Microwaving of composites
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Uniform Microwave Heating ?
Simulated Electric Field in Microwave RTM Applicator
2 GHz 5 GHz
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microwave curing
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• Research into
composites
manufacture,
assembly and
evaluation
• M.Sc. Composites
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Official opening 7th October 2010
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Lancaster
LiverpoolManchester
Glyndŵr
Bolton
UNIVERSITY
CONSORTIUM
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“Glyndŵr University aims to
become indispensable as a
significant, relevant and expert
partner in regional and national
economic and social
development”.
vision statement
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themes
• Rapid manufacture, assembly and
recycling of composite structures
• Assessment of the fitness for purpose
of the structures
• Close coordination with industry and
its requirements
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To enable the manufacturing industry in
West Wales and the Valleys to grow by
adopting more advanced technologies, and
at the same time improve its sustainability
by reducing its environmental impact etc.
This will be achieved by a partnership of
Universities throughout Wales that will
harness the engineering expertise within
them for the benefit of the economic
prosperity of the Convergence Region.
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carbon fibre
• demand for carbon fibre will grow
– aircraft
– wind power
– industrial
– automotive
– other transport applications
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Map of the UK showing carbon fibre factories with products suitable for aviation
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Conclusions
• Most aircraft have had some form of
composite in the structure
• The amount of composite present is likely
to increase
• Beware tram/bicycle/car/bus makers –
they could be next years competition as
manufacturers and large scale users of
carbon fibre
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No CDs were harmed in making this presentation
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No CDs were harmed in making this presentation