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Eco-Design ITD Airframe Application
Innovative metallic developments : example of synergies
Lorane Jammaron, Matthieu Pachoutinsky
Dassault Aviation
Paris Le Bourget, June 20th 2013
1
This document is the property of one or more Parties to the Clean Sky Eco-Design ITD consortium and shall not be distributed or reproduced without their formal approval
• Development of A/C technologies to reduce environmental impacts during out-of-operation phases of the A/C lifecycle
Eco-Design for Airframe (EDA) Objectives
Reduction of
inputs and
outputs
Technology
areas along
the lifecycle
WP 2.1
WP 2.2
2
This document is the property of one or more Parties to the Clean Sky Eco-Design ITD consortium and shall not be distributed or reproduced without their formal approval
Materials Processes
WP2.1 WP2.2
1) Partners within ECEFA
2) EDA members
Manufacturing tools
Machining process / forming process
Panel A
Panel geometry:
Length: 40” – 80”
Radius (OML): 1100mm (43.3”)
Panel BPanel C
Panel D
Panel A
Panel geometry:
Length: 40” – 80”
Radius (OML): 1100mm (43.3”)
Panel BPanel C
Panel D
B2 (IAI leader)
WP 4 definition
WP 5 detailed design
WP 6 fabrication and test
Rolling process/mechanical machining process
Dassault
panel B
Architecture of study
AlMgLi
Mg
pre-demonstration activities
Surface treatments
Other aluminums
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This document is the property of one or more Parties to the Clean Sky Eco-Design ITD consortium and shall not be distributed or reproduced without their formal approval
• Partners involved in this Call for Proposal: Constellium (Partner selected through CfP process), DAv (topic manager), HAI, EADS-IW, IAI
• Objectives: develop and characterize a new aluminium for fuselage applications
• Specification : same properties as 2024T3, better intrinsic corrosion behaviour to compensate lower corrosion protection efficiency due to chromates replacement (REAch) , lower density
• Answer from Constellium: AlMgLi, 5XXX series with precipitation hardening
• Results : characterization in accordance with all industrials.
• Challenge: combination of mechanical performance, better intrinsic corrosion, same ability to forming
Low density aluminium alloy development (CfP ECEFA)
4
This document is the property of one or more Parties to the Clean Sky Eco-Design ITD consortium and shall not be distributed or reproduced without their formal approval
212-01-03 New magnesium alloys
• Partners involved in this topic: Aero Magnesium (CfP Partner), IAI (topic manager), DAv
• CfP: DIMAG Hot forming of magnesium in sheet E43, leading to shelf demonstrator.
• Outputs of DIMAG used by IAI and DAv for shaping parts on demonstrator
• CfP: COMAG conductive coating for Magnesium.
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This document is the property of one or more Parties to the Clean Sky Eco-Design ITD consortium and shall not be distributed or reproduced without their formal approval
• Partners involved in those tasks: Dav; IAI
222-02-01 Metallic green processes
Type of part
Bracket
Frame
Rib
Stringer
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This document is the property of one or more Parties to the Clean Sky Eco-Design ITD consortium and shall not be distributed or reproduced without their formal approval
• Partners involved in those tasks: Dav; IAI
• Replacement of chemical machining by mechanical machining Chrome VI involved in acid bath
222-02-02 Metallic green processes
Rolling on raw material
sheet back in its former flat shape
Mechanical machining process
Final shaping
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This document is the property of one or more Parties to the Clean Sky Eco-Design ITD consortium and shall not be distributed or reproduced without their formal approval
TP a/c structures TP a/c
structures
Metallic alloys,
processes and surface treatments
Low Energy Curing
Low Energy Curing
Low Energy Curing
Mg alloys
Low Energy Curing
Light Alloys / Green
metallics
Panel A
Panel geometry:
Length: 40” – 80”
Radius (OML): 1100mm (43.3”)
Panel BPanel C
Panel D
Panel A
Panel geometry:
Length: 40” – 80”
Radius (OML): 1100mm (43.3”)
Panel BPanel C
Panel D
Examples of EDA Demonstrators
Integrating technologies all in one: the B2
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This document is the property of one or more Parties to the Clean Sky Eco-Design ITD consortium and shall not be distributed or reproduced without their formal approval
Low weight green metallic fuselage section B2 Demonstrator
• Partners involved in this demonstrator: Leader IAI; DAv; HAI, EADS-IW
• Objectives of the demonstrator: • To integrate new green metallic materials, technologies and surface
treatments thereby decreasing the environmental impact of the fuselage
• To demonstrate manufacturability of those materials and technologies on a fuselage section
• To optimize environmental benefits and weight reduction compared to a similar fuselage section made of conventional alloys
• To demonstrate corrosion resistance by using new alloys with higher intrinsic corrosion resistance and chromate free surface treatments.
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This document is the property of one or more Parties to the Clean Sky Eco-Design ITD consortium and shall not be distributed or reproduced without their formal approval
• Geometry – The demonstrator represents a fuselage panel of a business jet,
designed to withstand typical loads and bending cases
– It is divided into 4 panels, each made by a specific partner: Panels A & D – IAI, Panel B – DAv, Panel C – HAI ; EADS-IWF- Frame in Panel A
– Each panel includes parts such as: Skin, Frames, Intercostals, stringers, etc.
B2 demonstrator
Panel B - Dav
Panel A
Panel geometry:
Length: 40” – 80”
Radius (OML): 1100mm (43.3”)
Panel BPanel C
Panel D
Panel A
Panel geometry:
Length: 40” – 80”
Radius (OML): 1100mm (43.3”)
Panel BPanel C
Panel D
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This document is the property of one or more Parties to the Clean Sky Eco-Design ITD consortium and shall not be distributed or reproduced without their formal approval
B2 demonstrator
• Panel B (including parts)
Stringer hot forming Mg E43 and AlMgLi, or extruded from AlMgLi tagnite/oxylan(Mg),spray sol gel (AlMgLi)
Sheet metal frame AlMgLi and 2198E-coating
Machined junction between skin 2050spray sol gel
Skin AlMgLi from ECEFA
E-coating
spray sol gel
SAA
11
This document is the property of one or more Parties to the Clean Sky Eco-Design ITD consortium and shall not be distributed or reproduced without their formal approval
• Good synergy between partners
• Win-win relationship
How do we meet the objectives?
212-01-01 Aluminium Spine bone ECEFA
212-01-03 Magnesium Spinebone DIMAG
212-02-01 Surface treatments
222-02-02 Replacement of chemical milling
WP6 Natural ageing Demonstrate robustness of our choice
WP6 LCA and dismantling True environmental impact reduction
221-01-06 Replacement of shot peening
B2 Demonstrator
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This document is the property of one or more Parties to the Clean Sky Eco-Design ITD consortium and shall not be distributed or reproduced without their formal approval
Conclusions
• Everybody involved in work and results shared in details
• Sustainable partnerships created
• Focus on challenging development from TRL3 to 6 • New Alloy very low density
• Green surface treatments,
• New Mg alloy (sheet)
• Replacement of chemical machining by mechanical machining
• Global system approach for managing environmental impact
• Link between elementary development and demonstrator technologies
• Concept proof through physical tests
IW 13
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