Gif2008 Workshop Composites Hellard

Presented by
Guy Hellard
Composites in Airbus
A Long Story of Innovations and Experiences
Composites in Airbus @ Global Investor Forum by Dr Roland Thvenin _V51PR0800355_v1
Table of Content
1. Market Situation and Industrial Composite Applications
2. A350
Structures
AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.
3. Conclusions
Table of Content
A step by step gain of composite experience

Composites Introduction
Within primary structures
1980
1990
2000
2010
4

Composites Introduction
A350XWB
+ Outer wing,
Fuselage
Within primary structures

V10F
+ Outer wing
ATR72
+ Outer wing
A330/A340
+ HTP as fuel tank
A320
+ HTP, Flaps, Ailerons,
Spoilers
A310-300
Fin, Rudder, Elevators
1980
A380
+ Rear Fuselage, Center Wing Box,
Wing Ribs
A340-600
+ Rear Pressure Bulkhead,
Keel Beam
Unique experience
with more than 70
million FH cumulated
1990
A400M
+ Cargo door,
Outer wing
2000
2010
5

Composite structure / Structure weight (%)
step by step
approach
60
A350XWB
53%
40
A400 M
25%
20
A320
10
5%
A330
A380-800
A340-600
A310-300
0
1985 1988
1993
2002
2007
2013
Why Composites?
Technology introduction
Design
Manufacturing
Use
Improve performances
Lower production cost
Quality robustness
Reduce lead time
Reduce Lifecycle cost

(maintenance cost)
Achieved by trade-off
Need to design for CFRP
CFRP: Supply vs. Demand
Main growth drivers: civil

aviation & wind power
industries
Suppliers increase
investment budgets
EADS demand to increase
substantially beyond 2010
tons
EADS Carbon Fiber Demand
20.000
10.000
0
2005
2010
2015
2020
Close cooperation with current and potential suppliers to

ensure smooth ramp up
Outlook: supplier production capacities to double by 2010
How composites are manufactured?

Typical
Single Part
Production 1
Manufacturing
Process
Wing Panel : CFRP Prepreg
1) Preparation of mould
5) Curing
2) Automatic tape laying
6) Non destructive testing
3) Stringer integration
7) Milling
4) Vacuum bagging
8) Painting
Industrialisation
Optimisation and assurance of processes
From repair intensive CFRP
Ni-alloy jig
tool to Nickel-Alloy jig

From manual tape laying to
automated processes
From manual 1-channel NonDestructive Testing (NDT) to
automated multi-channel
testing methods (192 channels)
From manual drilling to
automated processes on multi
flexible tooling.
From manual painting to
automated process
From manual riveting to
half/fully automated riveting
machines
3D-Tape layer
Multi-channel NDT
Trimming machine
Paint robot
Riveting robot
10
10
Composites applications @ EADS

CFRP
Eurocopter
NH90, Tiger:
fuselage
Upper
parts
Segments
EC135:
Primary
Main
structures
rotor
Tailboom
Squirrel and Dolphin

Rotor
Astrium (contd)
Arianne 5
hub
Astrium
Satellites antenna
Launchers and Missiles

Upper
parts and
fairings
Criogenic tanks
EF-2000
wing
fuselage
fairings
stabilizers
BARRACUDA
(UAV)
MTAD
CN 235/C295
Elevators,
MAS
wing
Fairings
A400M
HTP, VTP, Wing covers
Elevator
fuselage
fairings
stabilizers
11
11
Composites applications @ EADS

CFRP structure examples
Bottom Shell NH90
NH90
Antenna deflector ASTRA

ST
Wing panel EF2000

12
12
A380 Composites applications
Major applications
13
13
A400M Composites applications
New major applications
14
14
Table of Content
2. A350
Structures
15
15
A350
Structures
Intelligent airframe
Fuselage:
Empennage (VTP, HTP)
Skin
Frame
Keel Beam
Rear Fuselage
CFRP
Al/Al-Li:
Al & Al-Li
Ribs,
Floor beams,
Gear bays,..
Titanium:
Landing Gears,
Pylons,
Attachments
Titanium
Steel
A350-900 XWB
Misc.
Material Breakdown (%)

Including Landing Gear
Misc.
8%
Al/Al-Li
19%
6% Steel
Outer Wing Box:

Covers / Stringers / Spars
Centre Wing Box:
Composite
53%
14%
Covers / Stringers / Spars
Titanium
Technologies selected to improve

performance and lower maintenance tasks
16
16
A350
Structures
RATIONALE
Reduce operational cost

Reduce global environmental impact
SOLUTION
Use of CFRP panels, stringers, frame, Keel Beam

Panel as long as possible to reduce the amount of circumferential joints
Optimisation of each panel for its design case
BENEFIT
Fuselage Innovations : CFRP
Improve passenger comfort by higher cabin pressure

Weight reduction : Fuel-burn savings
Cost reduction and environmental impact reduction
Fatigue- and corrosion-free: Reduce maintenance costs
17
17
A350
Structures
Fuselage Innovations : CFRP - 4 Panels
Status of developments
18
18
A350
Structures
Fuselage Innovations : CFRP - Barrel

Status of developments
RTM Frames
Full barrel technology for Rear fuselage
19
19
A350
Structures
Aeroelastic tailoring as a passive

adaptive structure
Reduce operational cost
Reduce global environmental impact
Use of CFRP spars, skins
CFRP outer wing box
CFRP center wing box
and stringers
Fuel-burn savings through weight

BENEFIT
SOLUTION
RATIONALE
Wing Innovations : CFRP
reduction: cost and environmental

improvement
Fatigue- and corrosion-free
composites save maintenance costs
20
20
A350
Structures
Maintainability / Reparability
Robustness
Robustness will override the other sizing criteria

within the areas prone to accidental damage.
21
21
A350
Structures
Maintainability / Reparability
Repairs
Standard
bolted repair concept for

structural damages
Existing tools and skills
Similar repair times
Bonded
repairs for minor cosmetic damage
Most of the former principles still apply

22
22
Table of Content
2. A350
Structures
3. Conclusions
23
23
Conclusions
1/2
Long term and unique experience in composite technologies

Comprehensive experience of primary composite parts:
design, certification and maintenance
Multi function approach (e.g. electrical & structural) to improve

performance and associated lightning strike protection
Good long term behavior of carbon composites (corrosion,

fatigue) decreases maintenance cost
Use of multi panel concept to allow best design optimization

and large repair capability
A350 XWB composite fuselage optimal compromise

between longitudinal & circumferential integration:
- long panel concept in the main fuselage area
- full barrel concept in the non-pressurised area
24
24
Conclusions
2/2
Better structure weight efficiency

Capital intensive production investments determine ramp up
flexibility
Extremely high quality requirements of CFRP parts

4-Panels CFRP Fuselage structure is a risk averse manufacturing
solution:
Avoids fitting issues encountered in final assembly line

More flexibility during assembly process
Easier part handling for large diameter
Less complex and lighter tooling
Higher manufacturing speed
25
25
AIRBUS S.A.S. All rights reserved. Confidential and

proprietary document.
This document and all information contained herein is the sole
property of AIRBUS S.A.S.. No intellectual property rights are
granted by the delivery of this document or the disclosure of
its content. This document shall not be reproduced or
disclosed to a third party without the express written consent
of AIRBUS S.A.S. This document and its content shall not be
used for any purpose other than that for which it is supplied.
The statements made herein do not constitute an offer. They
are based on the mentioned assumptions and are expressed
in good faith. Where the supporting grounds for these
statements are not shown, AIRBUS S.A.S. will be pleased to
explain the basis thereof.
AIRBUS, its logo, A300, A310, A318, A319, A320, A321,

A330, A340, A350, A380, A400M are registered trademarks.
26
26

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Presented by

Composites in Airbus @ Global Investor Forum by Dr Roland Thvenin _V51PR0800355_v1

AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.

Composites in Airbus @ Global Investor Forum by Dr Roland Thvenin _V51PR0800355_v1

AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.

1. Market Situation and Industrial Composite Applications

Composites in Airbus @ Global Investor Forum by Dr Roland Thvenin _V51PR0800355_v1

A step by step gain of composite experience

AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.

Within primary structures

Composites in Airbus @ Global Investor Forum by Dr Roland Thvenin _V51PR0800355_v1

A step by step gain of composite experience

Within primary structures

AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.

Composites in Airbus @ Global Investor Forum by Dr Roland Thvenin _V51PR0800355_v1

A step by step gain of composite experience

AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.

Composites in Airbus @ Global Investor Forum by Dr Roland Thvenin _V51PR0800355_v1

AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.

Reduce Lifecycle cost

CFRP: Supply vs. Demand

AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.

Main growth drivers: civil

EADS Carbon Fiber Demand

Close cooperation with current and potential suppliers to

How composites are manufactured?

AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.

2) Automatic tape laying

6) Non destructive testing

Composites in Airbus @ Global Investor Forum by Dr Roland Thvenin _V51PR0800355_v1

AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.

tool to Nickel-Alloy jig

Composites applications @ EADS

AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.

Squirrel and Dolphin

Launchers and Missiles

Composites in Airbus @ Global Investor Forum by Dr Roland Thvenin _V51PR0800355_v1

Composites applications @ EADS

AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.

Bottom Shell NH90

Antenna deflector ASTRA

Wing panel EF2000

A380 Composites applications

AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.

Composites in Airbus @ Global Investor Forum by Dr Roland Thvenin _V51PR0800355_v1

A400M Composites applications

AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.

New major applications

Composites in Airbus @ Global Investor Forum by Dr Roland Thvenin _V51PR0800355_v1

AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.

Composites in Airbus @ Global Investor Forum by Dr Roland Thvenin _V51PR0800355_v1

Empennage (VTP, HTP)

Material Breakdown (%)

AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.

Outer Wing Box:

Centre Wing Box:

Covers / Stringers / Spars

Technologies selected to improve

Reduce operational cost

Use of CFRP panels, stringers, frame, Keel Beam

AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.

Fuselage Innovations : CFRP

Improve passenger comfort by higher cabin pressure

Fuselage Innovations : CFRP - 4 Panels