You are on page 1of 15

Engineering, Operations & Technology

BR&T

The Challenge of New Materials


In the Aerospace Industry

Gerould Young
Director Materials & Fabrication Technology
Georgia Institute of Technology
May 15th, 2013
BOEING is a trademark of Boeing Management Company.
Copyright © 2011 Boeing. All rights reserved. Author, 8/6/2013, Filename.ppt |1
Boeing Almost 100 Years of Innovation
Engineering, Operations & Technology | BR&T Materials & Fabrication Technology
Year Model Innovation
1916 B&W - Model 1 Boeing's first airplane - spruce construction
1928 Model 80 America's first airliner specifically for passenger comfort
1932 P26 Peashooter Fastest air cooled pursuit fighter in the world
1935 TBD Devastator First all metal monoplane torpedo bomber
1935 B17 Multi-engine long range bomber
1938 314 Clipper 3500 mile range - Transatlantic Flight
1939 B29 Long range pressurized bomber
1941 P51 Mustang First fighter to fly Britain to Berlin and back
1949 B47 First swept wing multi-engine bomber
1956 KC-135 Strategic Air Command aerial tanker
1957 - 58 707 & DC-8 Swept wing jet transport
1958 F4 Phanton Jet fighter - 16 speed, altitude and time to climb records
1959 X-15 Rocket powered airplane - 354,000ft and 4,104mph
1961 CH47 Two rotor heavy lift
1960's Mercury & Gemni Manned Spacecraft
1969 747 Largest airliner built
1969 Apollo & Lunar Landed Manned spaceflight to the moon
1970 - 1980 F15 & F18 Air superiority and multi-role fighter
1978 AV8 Fixed wing vertical take off aircraft
1981 Space Shuttle Space access with return flight
1982 B1B Swing wing supersonic bomber
1982 - 1984 757 - 767 Narrow and Wide Body with nearly identical cockpits
1986 V22 Osprey Tilt rotor aircraft
1993 B2 All composite stealth long range bomber
1995 C17 Globemaster Heavy lift and short field capability
1995 777 Wide body with composite empennage - 100% digital definition
1998 Space Station International space station assembled in space
Copyright © 2011 Boeing. All rights reserved. 2009 787 First mostly composite airliner
Airframe Metallic Materials Evolution
Engineering, Operations & Technology | BR&T Materials & Fabrication Technology

AL ALLOY DEVELOPMENT (EIS for System Utilizing Alloy)


7081, 2027
2050, 2022
7349 2397 2196, 6056 7081, 2023
7349 2397
2017 2024 2195
2195 2297 2056, 6156 2139, 2013
2297
7075
7075 2618
2618 6061 7055
7055 7040
7040 7036 7056
7056
2014
2014 7475
7475 7150
7150 8090
8090 2524
2524 7055
7055 2098
2098 7140
7140 7055-T62
7175
7175 2219
2219 7050
7050 2324
2324 6056
6056 7449
7449 6019
6019 2099, 2199 2198
2099, 2199 2198
7178 2027 7136 7085
7178 2027 2124
2124 2224
2224 6013 2090
6013 2090 7039
7039 2524
2524 7136 7085

1910 1920 1930 1940 1950 1960 1970 1980 1990 2000
DC -3 B-29 B-707 B-727 B-747 L1011 B-757 C-17 F18 B-777 EMB 170 747-LCF 747-8
B-17 DC-8 B-737 DC-10 B-767 SLWT F16 Retro F-22 A380
B-247 COMET CONCORDE A-319 787
A-340
A-330
AIRCRAFT
SR 71 F-15 F18-E/F

4340 15-5PH 13-8PH Aermet 100


TITANIUM AND STEEL ALLOYS
Ti-662 Ti-6242 Ti-10-2-3 Ti62222 Ti5553 C465
Ti-811 Ti-6242 β-C
Ti-64 Ti-13-11-3 β21S

Increasing # Materials, Tailoring and Differentiation

Copyright © 2011 Boeing. All rights reserved.


Composite Materials Have Enabled Next
Generation of Military and Commercial Aircraft
Engineering, Operations & Technology | BR&T Materials & Fabrication Technology
High Strength Fibers Intermediate Stiffness Fibers Intermediate Stiffness Plus Fibers
Brittle Epoxies Toughened Epoxies Toughened Plus Epoxies
Fiber Fiberglass Form3
Boron Carbon IM6, AS4D T-800
T-300, AS4 Kevlar IM7 GLARE
HM IM8, IM10,
TiGR
Other IM++

Polyester Epoxy T-Epoxy PPS, PEI PEEK, IBMS8-399 Tailored


Matrix 934, 3501-6
Epoxy
8551-7 8552 T-plastic PEKK TP
T-Epoxy
polymers
R6376 3900 BMI / PMI T-plastic T-Epoxy 5320-1
Next Gen Nanos
977-3 Ceramics 5215
Epoxies
5250-4 Benzoxazine

Hand layup, CTLM Co-bonded stringers RTM / VARTM


Fabrication woven cloth Prepreg tape Hot draping Co-cured Stringers Braiding
CCM
Thermoplastic OOA
Bolted assembly Determinate assembly Stitching
Welding Multihead
Press formed T-plastics
Robotics
Tow placement

Fairings, radomes
Structures Marine Sports Equip Commercial Spacecraft Automotive?
Military aircraft Ctrl. Surfaces Commercial tails Commercial
Aircraft

Platform F-15, F-14 737, 757, 767 B-2 F-22 A380 787 A350
AV-8B,
EIS F/A-18A-D 737 tail(5)
A340 tail F/A-18E/F F-35
777 tail V-22 Next Gen Military
& Commercial
Aircraft

1970’s 1980’s 1990’s 2000’s 2010’s


Copyright © 2011 Boeing. All rights reserved.
Commercial Transport Performance Improvement
Materials Contribution
Engineering, Operations & Technology | BR&T Materials & Fabrication Technology

Composite Structure
Weight Reduction (%)

Block Fuel* – 3,000 nmi


Total A/C Structural

Baseline Improvement
707-320B
747-200B
DC-10-30 Metallic Structure
747-400 Improvement
767-300ER
777-200ER
30% Total Airframe
Systems
787-9 Structure

Engines Total Fuel Burn


Materials Savings (%)

Aerodynamics

1960 1970 1980 1990 2000 2010 2020


Entry into Service (EIS)

Materials Improvements Pace Airplane Performance Improvements


*Block Fuel = gals/seat over 3,000 miles
E Kaduce, 2012, The Boeing Company, based on publically-available data
Copyright © 2011 Boeing. All rights reserved.
A Conclusion
Materials Are A Critical Enabler
Engineering, Operations & Technology | BR&T Materials & Fabrication Technology

History Says………..
 Demand for improved aircraft performance will continue
 Properties of existing materials will improve
 New materials will be discovered
 Optimization capability will improve
 More materials will be used

 But ……….
 Development costs climb
 Development schedules increase

Copyright © 2011 Boeing. All rights reserved. 6


Development Trends in Different Industries
Engineering, Operations & Technology | BR&T Materials & Fabrication Technology

Development Time Is Increasing At Unsustainable Rate


Copyright © 2011 Boeing. All rights reserved. 2013_BLM.ppt |7
Airplane Development vs. Material Development
Engineering, Operations & Technology | BR&T Materials & Fabrication Technology

5-7 Years

Market Airplane Firm


Airplane Launch Build EIS
Study Config.
Dev Production
Materials Orders

2-3 Years (ideal)

8-10 Years (reality)

Materials Materials Scale- Design Prod.


Dev R&D
Need ID’d Up Allowables Ready

Previous Dev Efforts

Time (Years) 

Copyright © 2011 Boeing. All rights reserved. 8


Materials Data Required for Airframe Design
Engineering, Operations & Technology | Boeing Research & Technology

Physical Static Mech. Durability and Damage Environmental


Producibility Certification
Properties Properties Tolerance Properties Effects

Castability
Density
Material
Formability
Thermal Temperature Specs
Expansion Tensile Humidity
Deformation
Strength Fatigue Strength Process
Characteristics
Heat Capacity Chemical Specs
Compressive Notch Sensitivity Resistance
Weldability
Thermal Strength Approved
Conductivity Crack Growth Wear Supplier List
Machinability
Shear
Poisson’s Strength Toughness Corrosion Repair
Assembly
Ratio Resistance Methods
Bearing Special Design Factors
Chemical
Tensile, Strength Oxidation Safety
Processing
Compression, Resistance
Shear and MSDS
Inspection
Bulk Modulus
Methods

Copyright © 2012 Boeing. All rights reserved. EOT_RT_Template.ppt | 9


Building Block Approach
Engineering, Operations & Technology | BR&T Materials & Fabrication Technology

Manufacturing Qualification Structures Certification


Building Blocks Building Blocks
First Full
Part Scale
Qual Tests
Pre-
Production Component
Tests
Verification
Pre-Production
MfgTrials & Scale Sub-Component
Up Tests
Demonstration
Sub-Scale
Structural Element
Demonstration &
Tests
Robustness Tests

Effect of Defects & Sensitivity


Allowables Development
Testing

Process & Equipment Development, Materials & Process Specification


Stable Materials & Processes Development

Process & Equipment Screening & Material and Process Screening and
Selection Selection

Copyright © 2011 Boeing. All rights reserved.


Future: Material Performance to Certification
Engineering, Operations & Technology | BR&T Materials & Fabrication Technology

Materials, Structures, and Manufacturing


defined and certified in digital form to meet Vehicle

platform requirements Full Scale


Component
Designs
Sub-
Component Virtual Testing
Designs & Sim

Element
Design Computational • Static
Design Values • GVT
Material • Fatigue
Configurations • Structural Performance • Flight
Failure Modeling • Damage Tolerance
Constituent • Static & Fatigue
Design Computational • Analysis Validation
• Design Values
Allowables
• DaDT
• Analysis Validation
• Mechanical Props
Material
• Knock-downs
Models
• Environmental
Computational • Producibility • Effects of Defects
Materials • Accept/Reject
• Assembly
• Material Development • NDT Standards
• Process Development

Copyright © 2011 Boeing. All rights reserved. Author, 8/6/2013, Filename.ppt | 11


Future: Material Performance to Qualification
Engineering, Operations & Technology | BR&T Materials & Fabrication Technology

Materials, Structures, and Manufacturing Vehicle

defined and qualified in digital form to meet


Assembly
platform requirements
Scale Up
Process
Development

Material System
& Forms Tolerances & Assembly
Constituent Simulation
Design

Process and Manufacturing


Simulation for Quality •Production System
Aspects of Full Size Parts
Processing and Quality
Simulation • Manufacturing Scale up
Material • Full size fabricated elements
Models • Effects of Defects
• Producibility • Expanded Mfg Limits
• Inspection Standards
Computational • Quality & Effects of
Materials • Mat’l & Process Defects
Capability • Process Tolerances
• Initial Accept &
• Material Development Reject Criteria
• Process Development
Copyright © 2011 Boeing. All rights reserved.
Aerospace Composites- Rate and Volume Trend
Engineering, Operations & Technology | BR&T Materials & Fabrication Technology

Platform Percent Total Wt (lbs) Approx Approx Wt # Delivered Total Wt


Composites Composite Delivery Rate (lbs/Month) Composites
Wt (lbs) Delivered
(lbs)
C-17 8% 277,000 22,714 1.5 218 4,951,652

B-2 High 20
F-18 c/d 10% 24,700 2,470 1,450 3,581,500
777 10% 300,000 30,000 7 210,000 1066 31,980,000
F-22 20% 31,700 6,340 6 339 2,149,260
F-18 e/f 18% 30,500 5,490 4 21,960 500 2,745,000
V-22 43% 33,140 14,250 1 14,250 160 2,280,000
787 50% 250,000 125,000 5 625,000 130 16,250,000
Total 871,210 63,934,360

 Boeing Has Fielded More than 63 Million Pounds of Composite Structure


 Boeing Will Field Nearly 10 Million Additional Pounds Every Year
Copyright © 2011 Boeing. All rights reserved. Author, 8/6/2013, Filename.ppt | 13
Industrialization of Aerospace Grade Composites
Engineering, Operations & Technology | BR&T Materials & Fabrication Technology

Detail Component Size 1,200,000


Production Volume &25 Rate

1,000,000
20

Production Rate lbs/mo

Lbs of Material Delivered


800,000
lbs/mo 787
15 lbs/mo 777
lbs/mo V-22
600,000 lbs/mo F-22
lbs/mo F-18
10 lbs/mo C-17

400,000 Rate/mo 787

5
200,000

0 0
1985 1990 1995 2000 2005 2010 2015 2020

Structural Integration Coupled with Production Volume and Rate


Increases Will Drive a Tipping Point in Manufacturing Cost
Copyright © 2011 Boeing. All rights reserved. Author, 8/6/2013, Filename.ppt | 14
Parting Thoughts
Engineering, Operations & Technology | BR&T Materials & Fabrication Technology

 Optimization will continue to increase number of materials

 Materials improvements are vital to aircraft performance


improvements

 Discovery is only a small part of materials development

 Computational materials & manufacturing tools will speed


decision making

 New material development must have:

 Reduced qualification and certification costs & schedule

 Concurrent scale-up and quality in manufacturing

Copyright © 2011 Boeing. All rights reserved. Author, 8/6/2013, Filename.ppt | 15

You might also like