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EADS Innovation Works … the spirit of innovation, Advanced Concepts & Scenarios
2012 January the 30th
J-P Domergue
Head of Operations
© EADS 2012 EADS INNOVATION WORKS general presentation
Page 2
EADS Management Structure EADS Innovation Works is part of the
Chief Technical Officer’s organization
Jussi Itävuori
Human Resources
Sean O’Keefe
EADS North America
Jean J. Botti
Chief Technical Officer
Marwan Lahoud
Strategy & Marketing
Hans-Peter Ring
Finance
Chairman of the Board Bodo Uebber
Louis Gallois Chief Executive Officer (CEO)
Eurocopter
Lutz Bertling (CEO)
Cassidian
Stefan Zoller (CEO)
Astrium
François Auque (CEO)
Coordination Cassidian Astrium
François Auque
Airbus
Fabrice
Brégier (COO)
Tom Enders (CEO)
Airbus Military Domingo
Ureña-Raso
Page 3
EADS Innovation Works within the Corporate Technical Office
EADS
Innovation Works
R&T Enablers
Support Group
Chief Information
Officer
COO Innovation
CTO Deputy
Innovation Operations
and Networks
Chief of Staff
Quality & Business
improvement
Chief Technical Officer
© EADS 2012 EADS INNOVATION WORKS general presentation
Page 4
A transnational organisation
Head of
Innovation Works CTO IW
Composites Technologies
CTO IW CT
Metallic Technologies & Surface Engineering
CTO IW MS
Structure Engineering Production
& Aeromechanics
CTO IW SP
Sensors, Electronics & Systems Integration
CTO IW SI
Engineering, Physics, IT, Security
Services & Simulation
CTO IW SE
Head of International Operations
CTO IW IO
Innovative Concepts &
Scenarios
CTO IW IC
Dean of College of Experts
Executive Experts
CTO IW CE
Energy
&
Propulsion
CTO IW EP
Innovation Works United Kingdom
CTO IW MU
Innovation Works Coordination in Germany CTO IW MG
Innovation Works Coordination in Spain
CTO IW MS
Innovation Works Coordination in France
CTO IW MF
Executive Advisor
CTO IW EA
Deputy to Head of IW
Head of Operations
CTO IW OP
Finance & Controlling
Human Resources
Technical Capabilities Centers
© EADS 2012 EADS INNOVATION WORKS general presentation
EADS Innovation Works : key figures (2010)
16 sites
9 countries
81 new patent applications
More than 700 Engineers
Page 5 © EADS 2010
© EADS 2012 EADS INNOVATION WORKS general presentation
…Partnerships policy
Page 6
A network based on talent & innovation
Optimize networking synergy to get innovations
CFK Valley
Stade
© EADS 2012 EADS INNOVATION WORKS general presentation
Competencies sharing (headcount 2010)
Page 7
© EADS 2012 EADS INNOVATION WORKS general presentation
Composites
Technologies 13% Metallic
Technologies & Surface
Engineering 12%
Structure
Engineering, Production &
Aeromechanics 21%
Sensors,
Electronics & Systems
Integration 20%
Engineering,
Physics, IT, Security
Services & Simulation
20%
Energy &
Propulsion 7%
Innovative
Concepts & Scenarios
7%
Composites Technologies (TCC1)
Page 8
Main activities:
Research in Composite Materials and Processes
with a multidisciplinary approach by means of
prediction, simulation, process testing and
mechanical testing.
© EADS 2012 EADS INNOVATION WORKS general presentation
A center dedicated to develop advanced light and robust
materials and processes applicable to new products
Metallic Technologies & Surface Engineering (TCC2)
Page 9
A center dedicated to develop cost efficient, light, reliable and
environmental friendly surface treatments, metallic/hybrid
structures and associated intelligent production routes.
Main activities:
Integrated research on new materials,
surface treatments and structural concepts
with related robust manufacturing processes.
Testing and understanding of properties and
productivity. Failure analysis.
© EADS 2012 EADS INNOVATION WORKS general presentation
Structure Engineering, Production & Aeromechanics (TCC3)
Page 10
A center dedicated to engineering of processes in the design and manufacture of advanced crossing mechanics, electronics and IT expertises.
Main activities:
Mechanical modelling and advanced testing of
composites and metallic materials & dynamic loads,
virtual structural testing methods & software,
acoustics, vibrations analysis & treatments.
Automated assembly & systems installations, digital
manufacturing, mediated workers, structural health
engineering (NDI & SHM). Active flow control
systems, advanced actuators technologies, control
algorithms & systems , morphing technologies.
Basic and upstream research to development of
prototypes, software & systems.
© EADS 2012 EADS INNOVATION WORKS general presentation
Sensors, Electronics & Systems Integration (TCC4)
Page 11
Main activities:
Multidisciplinary system design (embedded
SW/HW, optronics, microwaves, radiation,
chemistry & biology, human machine interface)
and test in lab, field and flight
© EADS 2012 EADS INNOVATION WORKS general presentation
A center specialized in the development and integration of
sensor, communication and avionic systems to enable
functional and operational improvements in safety & security,
autonomy, availability and efficiency.
Simulation, Information Technologies & Systems Engineering (TCC5)
Page 12
Main activities:
Advanced design, visualisation and simulation,
systems and software engineering, learning
systems development, signature and stealth
concepts, applied mathematics high performance
computing and computer security.
A center dedicated to improving the quality of chain of value
from initial design to after sales follow-up, by means of
simulation and virtual architecture enhanced by IT
technologies.
© EADS 2012 EADS INNOVATION WORKS general presentation
Energy & Propulsion (TCC6)
Page 13
Main activities:
Energy & Power management architectures,
Electrical Power & Actuation, Propulsion
Systems, Power Generation, Fuel Systems,
Alternative Fuels
© EADS 2012 EADS INNOVATION WORKS general presentation
A center dedicated to identifying new sources of energy,
energy transformation, but also to optimizing the on board
energy with respect to environmental constrains.
Innovative Concepts & Scenarios (TCC7)
Page 14
A center dedicated to identifying new technologies for future and
competitive products and defining the associated roadmaps with
each division by means of concept-demonstrators.
Main activities :
Maturing of technologies to enable their
application to the products of the different
Divisions, management and coordination
of transverse projects.
© EADS 2012 EADS INNOVATION WORKS general presentation
Page 15
Innovative Concepts & Scenarios (TCC7)
© EADS 2012 EADS INNOVATION WORKS general presentation
Some snapshots on Structures & Materials activities of TCC1 and TCC2
Preform technologies
Thermoplastic technologies
Thermoset technologies
Bonding & Repair tehnologies
Chemistry
Multifunctional materials
Structures integration & assembly
Metallic & Manufacturing
Surface engineering
Failure, Material and Surface Analysis Skills
Light Materials for energy efficient structures
High performance material concepts
Eco-efficient joining and assembly
Near net shape manufacturing
Green surfaces technologies
Functional Surfaces for Sustainability
© EADS 2012 EADS INNOVATION WORKS general presentation
Dry fiber placement
• 2D Embroidery
• 7 axis dry fibres placement
• Fiber Patch Preforming
Preform assembly technologies
• Robot 3D Stitching with 3 stitching heads
• Automated pinning for thick preforms
Preform Technologies 1/2
© EADS 2012 EADS INNOVATION WORKS general presentation
Preform Technologies 2/2
© EADS 2012 EADS INNOVATION WORKS general presentation
Braiding technologies
– Robot assisted Braider with 144 bobbins
– Braided Frames prototype production line
One step thermoplastic part M&P
• 7 axis TP fibre placement
• LSP deposition
• New materials
Two steps part M&P
• Automated TP flat tape deposition
• 3D TP Multitows deposition with
Laser heating
• LSP deposition
Assembly of sub structure M&P
• 3D US Welding, co consolidation ,
Injection
Demonstrator
Ultrasounds
Head (20kHz)
Thermoplastic Technologies
© EADS 2012 EADS INNOVATION WORKS general presentation
process control and monitoring
• PC Controlled Flow and heating control
out of autoclave
• 2m *2m * 3m 400°C oven
tooling technologies
Thermoset Technologies
© EADS 2012 EADS INNOVATION WORKS general presentation
Bonding
• Robot assisted adhesive
application head
• Automated surface treatment
methods and monitoring
• Alternative curing techniques
• Fast bonding brackets
• Debonding on demand
Repair
• Guided milling machine / Robot
for complex surfaces
• Surface contamination detection
• On site structural repair
Bonding and repair technologies
© EADS 2012 EADS INNOVATION WORKS general presentation
Material Specification / QC
Selection / Modification
Optimization Cure Cycles
Resin flow / impregnation
FST Determination
Nano Composites
Chemistry
© EADS 2012 EADS INNOVATION WORKS general presentation
Composite material and electrical conductivity
Composite material for toughness
improvement
Fire smoke toxicity improvement
Self healing composite
Composite materials for high temperature and
durability
New fibre high performances
Epoxy IM7/977-2
y = -0,000010x - 0,231 R2 = 0,991
y = -0,000010x - 0,190 R2 = 0,992
y = -0,000013x - 0,167 R2 = 0,987
y = -0,000059x - 0,102 R2 = 0,993
y = -0,000059x - 0,129 R2 = 0,995
y = -0,000065x - 0,212 R2 = 0,995
y = -0,000140x - 0,824 R2 = 0,997
y = -0,000148x - 0,832 R2 = 0,997
y = -0,000160x - 0,984 R2 = 0,994
-16
-14
-12
-10
-8
-6
-4
-2
0
0 20 000 40 000 60 000 80 000
Time (Hours)
Weig
ht
loss (
%)
120°C no initial cracks150°C no initial cracks180°C no initial cracks120°C limited initial cracks150°C limited initial cracks180°C limited initial cracks120°C many initial cracks150°C many initial cracks180°C many initial cracksLinéaire (120°C no initial cracks)Linéaire (120°C limited initial cracks)Linéaire (120°C many initial cracks)Linéaire (150°C no initial cracks)Linéaire (150°C limited initial cracks)Linéaire (150°C many initial cracks)Linéaire (180°C no initial cracks)Linéaire (180°C limited initial cracks)Linéaire (180°C many initial cracks)
Merging condition on electrical conductivity
1,0E-09
1,0E-08
1,0E-07
1,0E-06
1,0E-05
1,0E-04
1,0E-03
1,0E-02
1,0E-01
1,0E+00
0,001 0,01 0,1 1
CNT content by weight (%)
co
nd
uc
tiv
ity
(S
/m)
50 rpm 500 rpm 2000 rpm
Hybrid particles Al2O3+NTC
Multi functional materials
© EADS 2012 EADS INNOVATION WORKS general presentation
Key objectives:
− highly integrated components
− reduced lead time / reduced cost
− Thermoset matrix, prepreg technology, RTM developments
− Double curvature reinforced panels, large cut-out, integrated stringers
+ beams, etc. One shot, no-fasteners philosophy
Structure integration & assembly
© EADS 2012 EADS INNOVATION WORKS general presentation
Metallic & Manufacturing
Light Materials for energy efficient structures •New light weight materials : Al, Mg, cellular...
•Multifunctional/hybrid materials : FML, foams
•Unitized structures concepts: co-extrusion
High performance material concepts •High specific properties light materials: Metal Matrix Composites
•Nano-structured and nano-reinforced
•High specific properties hard materials : Ti, steel
•Extreme environment materials : metallics and ceramics
Eco efficient joining & assembly •Robust joining technologies (FSW, LBW)
•Hybrid material fastening & machining
Near Net Shape Manufacturing •Additive layer manufacturing
•Innovative forming technologies
© EADS 2012 EADS INNOVATION WORKS general presentation
Surface Engineering
Green surface technology: avoid direct environmental impact by
toxic coating materials or auxiliary process materials
•Replacement of hazardous materials (Chromates, Cd, VOC…)
•New corrosion inhibition concepts
•Out-of-bath surface treatments: Dry (Plasma, laser) & Wet
(spraying)
•One-coat layer concept
Sustainable functional surfaces: reduce environmental impact
during operations (low weight, low drag, durability)
•Wear (erosion, abrasion, scratch) and fretting protection systems
•Advanced Functional Coatings - Structures, Cabin and Systems
•Aerodynamic surfaces
•Metallic solution for CFRP lightning strike protection
SurTech enabling cost and/or lead time reduction •Cleaning and activation
•Surfaces for moulds and tools
© EADS 2012 EADS INNOVATION WORKS general presentation
Failure, Material and Surface Analysis Skills
Materials and surface characterisation: •Physical & Chemical analysis (FTIR, Thermal, X-ray, XRF,…)
•Microscopic material and surface characterization by electron
microscopy (SEM-EDS) and surface analysis (XPS, SIMS)
•Tribological and corrosion testing, electrochemistry
•Mechanical testing : static, fatigue and fracture mechanics
•Destructive (hole-drilling) and non-destructive (X-ray) residual
stress measurements
Operational durability: Understand and prevent failure and
degradation of materials and coating extend service life
•Correlation of processing parameter and in-service behaviour
•Failure analysis and understanding of long term materials and
coatings degradation behavior
•Failure prevention and enhancement of durability (residual
stresses induction)
© EADS 2012 EADS INNOVATION WORKS general presentation
• Al-alloys: screening and characterization of weldable & improved AlCuLi, 7xxx and
AlMgSc alloys, development of thermo-mechanical treatments, fundamental
understanding of failure, corrosion and long therm behavior
• Mg-alloys: screening and characterisation of spec. high strength alloys with improved
corrosion and flammability behavior, development of surface protection, development
and simulation of cold and hot forming processes to produce
• Others: metal laminates, foams,…
Trolleys,
Interior components
Raceways
Hatrack brackets,
various other brackets
Fuel connectors
Seat structures
Door hingesElectronic bay
access door
Shear-compr. Panel (Airbus, Aleris) Potential Mg applications
Light Materials for energy efficient structures
© EADS 2012 EADS INNOVATION WORKS general presentation
• Ti-alloys: challenge Ni-alloys with new near titanium alloys. Taylor properties by
improved heat treatments. Optimize castability and forming processes
• Nano structured and nano-re-inforced Al-, Mg- and Ti-alloys
• Steels: development of heat treatments to improve aging behavior of 15-5-PH
• Extreme environment metallics: low cost metallic high temperature alloy for satellite
thrusters and missiles (Pt replacement). Cu based liner materials.
• Extreme environment ceramics: ceramic matrix composites for appl. at >1700 °C
(combustion chambers, nozzles, ram-jets, TPS for re-entry, brake materials)
Milling time: 30 min
Milling time: 5 min
Milling time: 30 min
Milling time: 5 min
Manufacturing in textile
technique (braiding), TCC 1
High Performance Material Concepts
© EADS 2012 EADS INNOVATION WORKS general presentation
Eco-efficient joining and assembly
Friction Stir Welding: tooling concepts and robotized and self-reacting
FSW for final assembly lane and major component assembly
Metal / CFRP hybrid joints: optimization of one-shot drilling of hybrid
stacks, cold hole expansion of metal side of hybrid stacks, corrosion
prediction and protection, metal-CFRP rivetless assembly
(Hyperjoints, nanofoils)
Robotic FSW of A330 panel
CFRP
Metal
HORIZONTAL
TEE
REAR
VERTICAL TEE
FRONT
VERTICAL TEE
VEIL
CRUX
FS welded Rib 1
Cathode
Current density distribution (mA/mm2)
Cathode
Current density distribution (mA/mm2)
© EADS 2012 EADS INNOVATION WORKS general presentation
Additive Layer Manufacturing: cost savings for high value parts (improved buy/fly),
weight savings through topol. optimisation, improved carbon footprint (waste material
and weight savings), reduced lead-time and late design freeze
• powder bed for net shape complex parts (Ti, Al, Ni, steel..)
• large near-net parts by wire/powder feed (Ti,..)
Forming technologies: dieless and rapid forming of Ti-, Al- and steel sheets
through incremental sheet or laser forming.
Page 31
Near-net shape Manufacturing
combined stretch
and incremental
forming
© EADS 2012 EADS INNOVATION WORKS general presentation
Green Surface Technologies
Compliance with environmental regulation REACH, anticipate supply chain disruption,
competitive advantage through 2nd generation protection concepts, lead time and
weight reduction reduction
• replacement of hazardous chemicals (Cr6, Cd, VOC, …) in anodizing and coversion
pre-treatments, 1s gen primers, Cd and hard-Cr replacement
• active corrosion inhibition through encapsulation, release on demand
• one-coat layer (SolGel, E-coat)
• dry (plasma, laser) and wet (SolGel) out-of-bath treatments
Corrosion inhibitors in
core of silica particles
Pre - treated Surface
Sol - Gel ONE - COAT
Pre - treated Surface
Sol - Gel ONE - COAT
ONE COAT CONCEPT
Pre - treated Surface
Sol - Gel One - COAT
Top Coat
Pre - treated Surface
Sol - Gel One - COAT
Top Coat
Pre - treated Surface
Anodising /conversion
Inhibited Primer
Top Coat
Pre - treated Surface
Anodising /conversion
Pre - treated Surface
Anodising /conversion
Inhibited Primer
Top Coat
STATE OF ART
© EADS 2012 EADS INNOVATION WORKS general presentation
33 Active & passive
surfaces
Rain/ Sand
Anti-Icing concept for
CFRP leading edge
Energy saving
Paints, foils
RibletsDrag reduction via
multifunctional surfaces
Anti-Icing coatings
Anti-Contamination
Structured surfaces
Erosion Protection
Active & passive
surfaces
Rain/ Sand
Anti-Icing concept for
CFRP leading edge
Energy saving
Paints, foils
RibletsDrag reduction via
multifunctional surfaces
Anti-Icing coatings
Anti-Contamination
Structured surfaces
Erosion Protection
Rain/ Sand
Anti-Icing concept for
CFRP leading edge
Energy saving
Paints, foils
RibletsDrag reduction via
multifunctional surfaces
Anti-Icing coatings
Anti-Contamination
Structured surfaces
Erosion Protection
• Aerodynamic Surfaces: Development of tailored surfaces/coatings for sand/rain erosion
protection of metallic and CFRP structures. Coatings enabling new anti-icing concepts.
Anti-contamination (e.g. photocatalytic coatings). Structured surfaces /paints/foils (e.g.
riblets). Development of cheap and reliable lab testing facilities.
• Wear and fretting protection: green and cost effective lifetime enhancement through
organic, inorganic, multilayer, self-lubricating coatings. Fast and meaningful test methods.
• Cabin application: Improved passenger comfort through easy-to-clean, scratch resistant,
anti-bacterial, anti-fingerprint coatings based on SolGel- and nanotechnology.
• Assembly, maintenance and repair: Development of processes and coatings for
local/assembly integrated application. Dry and wet pre-treatments for structural bonding
based on SolGel) and atm. plasma, laser, thermal spray technologies .
Functional Surfaces for Sustainability
© EADS 2012 EADS INNOVATION WORKS general presentation
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