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Speaker 4 Mr. Marcel Buckley UK Manufacturing Engineering Technology Manager – Composite Components Manufacturing Engineering AIRBUS [email protected] Analysing Composite Component Manufacturing – Challenges for Future Aerospace Programmes

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Page 1: UK Manufacturing Engineering Technology

Speaker 4

Mr. Marcel Buckley

UK Manufacturing Engineering Technology

Manager – Composite Components

Manufacturing Engineering

AIRBUS

[email protected]

Analysing Composite Component Manufacturing – Challenges for Future Aerospace Programmes

Page 2: UK Manufacturing Engineering Technology

Composite structural weight development

0

10

20

30

40

50

1970 1980 1990 2000 2010

Co

mp

osit

e S

tru

ctu

ral W

eig

ht

[%]

A300

A310-200

A320

A340-300A340-600

A400M

A380

A350-900 XWB

Evolution composite application at Airbus

During the past 30 years, AIRBUS has continuously and progressivelyintroduced composite technology as a consequence of successful experience

accumulated.

A310-300

+ Elevators

+ VTP box

A310-200

+ Rudder

+ Spoilers

+ Airbrakes

A310

+ Wet HTP box

+ Ailerons

A330-300A340-300

A330 / A340

A320-200

A320

+ Flaps

+ Dry HTP box

+ LG doors

+ Engine cowlings

A380

+ Center wing box

+ Wing ribs

+ Rear unpress. Fuselage

+ Cross beams

A380

+ Rear bulkhead

+ Keel beam

+ J-nose

A340-600/500

A340-600

A400M

A400M

+ Upper Wing

A300-B2

Fairings

Radome

A300

1970-1980 1980-1990 1990-2000 2000-2013

+ Main Wing

+ Fuselage

A350

A350

Page 3: UK Manufacturing Engineering Technology

A380-800

Rear pressure bulkhead

VTP & HTP

Flap Track Beam Sidewall Panels

Wing Ribs

Center Wing Box

Flaps, Spoilers & Ailerons

Un-pressurized Rear fuselage

Leading edge J-Nose

Pre-preg – Automated Tape Laying (ATL)

A340 HTP Skin

A380 Flap Skin

A380 Centre wing box Panel(Section 21)

Page 4: UK Manufacturing Engineering Technology

Pre-preg – Fibre Placement

Completed A380 Rear fuselage

(Section 19)

Fibre placement

• Large parts and complex shapes

• Optimum ply distribution

• First application on A380

Fibre placement machine

Resin Film Infusion with Non Crimp Fabric

Draping the Non Crimp Fabric material

Pressure Bulkhead with stiffeners

Completed A380 Pressure Bulkhead

Page 5: UK Manufacturing Engineering Technology

Resin Transfer Moulding (RTM)

A380 Rear Fuselage Frames

A380 Aileron Spar

A380 Fittings

A350 – Material Breakdown

A350-900 XWB

Material Breakdown (%)Including Landing Gear

Al/Al-Li

20%

Titanium

14%

Steel7%

Misc.

7%

Composite52%

A350 XWB puts the right material in the right place

Wing

Fuselage

Belly Fairing

EmpennageTi: Landing Gears,

Pylons, Attachments

Al/Al-Li: Some Frames, Ribs, Floor beams, Gear bays,..

Page 6: UK Manufacturing Engineering Technology

Recent Projects Supporting A350 XWB

CASCADE – gear rib

Automation

ALCAS design & analysis

A350 –

technology development

A350 – spar development

Box beam bending

FAITH –

5m kinked spar

480

760

Impact

Coupon & Element testing

A350 – stringer

development

Roll formed stringers

A350 – DB1

ALCAS – trial

inner spar

ObjectiveTo ensure that mature technologies are available to enable the design, development, validation, manufacture, equipping and testing of lightweight, aerodynamically efficient and low cost to produce wings which are optimised with the overall aircraft ensuring minimum environmental impact.

High Volume

Low Cost Wing

The development of technologies

necessary for wing manufacture

and assembly:-

• WP1 - Component Manufacture

Processes

• WP2 - Assembly Processes• WP3 - Manufacturing System

Development

• WP4 - Wing Concept Integration &

Demonstration

Integrated Equipped

Wing

The development of technologies

necessary for wing systems, their

installation, equipping and test:-

• WP1 - Systems Integration &

Installation

• WP2 - Systems Demonstrators• WP3 - Installation / Test

Equipment & Processes

• WP4 - Aircraft Integration

Multi-Disciplinary

Optimised Wing

The development of technologies

necessary for design,

development and validation:-

• WP1 - Integrate

• WP2 - Create

• WP3 - Develop• WP4 - Produce

Future Aircraft Programs – Next Generation Composite Wing

Page 7: UK Manufacturing Engineering Technology

Advanced 3D ATL Stringer 2D ATL Stringer Forming

Cover Bagging

Cover Machining

Skin Curing

Cover Painting

Stringer Integration

Ultrasonic NDT Sub Assembly

Cover Curing

Manufacturing Process Breakdown

2008 2009 2010 2011

TR

L 3

(C

OM

PO

NE

NT

DE

VE

LO

PM

EN

T)

TR

L 4

(IN

TE

GR

AT

ION

)

TR

L 1

-2

(BE

NC

HM

AR

KIN

G

& P

RO

VIN

G)

Technology

proving trial

using

element

based sizing

Feature

based trials

to prove

technology

Benchmarking

process with

detailed

technology

investigation

Small scaled

box

assembly

TECH

REPORTS /

DATA BASE

END OF BENCHMARKING

PHASE

END OF TECHNOLOGY DEVELOPMENT

PHASE

NOTES:

�TRL status has to be supported by Stress, Design, Manufacturing, Materials & Process.

�A30X to make down-selections at TRL reviews (Manufacturing TRL2 – February 2009).

�Technology delivered to TRL 4 (First integration and validation of technologies –stress methods, materials, parts, assembly methods, etc).

� Key next stage in follow on ‘demonstrator program’ to HIVOL (NGCW) will target TRL 6 (meaning to integrate and validate sub-systems (wing box to centre wing box).

PARTS TO ZONAL DEMONSTRATOR

END OF FEATURE DEMONSTRATOR

PHASE

Response to Cost Model Requirements

Page 8: UK Manufacturing Engineering Technology

Component Manufacturing Research & Development

in NGCW

�Improved & Smart tooling configurations

�High speed tool preparation

�Increased part integration

�Increased use of bonding

�Rapid material deposition systems

�Improved / Simplified processes

�Faster curing of components

�Minimise or improve the use of part finishing

technologies

�Increase in the use of automation across all

processes

Thank youfor your attention