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BOE021711-120
Aerospace StructuralAerospace Structural Material CertificationMaterial CertificationDave FurdekDave Furdek Mgr – Next Generation Composite MaterialsBoeing Research and Technology
28 February 2011
BOEING is a trademark of Boeing Management Company.Copyright © 2006 Boeing. All rights reserved.
BOE021711-120
BOE021711-120
Boeing Products
767767767767 717717717717 C-17C-17
F-18F-18
BBJBBJBBJBBJ
WeaponsWeaponsJTRSJTRS
ISSISS LaunchLaunch
Ad d S tAd d S t787787787787 747747747747
Advanced SystemsAdvanced SystemsUnmannedSystemsUnmannedSystems
777777777777 737737737737
RotorcraftRotorcraft
TankersTankers
SatellitesSatellites
Copyright © 2006 Boeing. All rights reserved. BOE021711-120
Boeing Commercial Aircraft
Boeing Defense, Space, and Security
BOE021711-120
Material Selection Drivers
225 SEATS 275 SEATS225 SEATS 275 SEATS225 SEATS 275 SEATS225 SEATS 275 SEATS225 SEATS 275 SEATS
per s
eat
300 SEATS225 SEATS
250 SEATS275 SEATS
350 SEATS 400 SEATS
450 SEATS
500 SEATS
200 SEATS
Current Quadsper s
eat
300 SEATS225 SEATS
250 SEATS275 SEATS
350 SEATS 400 SEATS
450 SEATS
500 SEATS
200 SEATS
per s
eat
300 SEATS225 SEATS
250 SEATS275 SEATS
350 SEATS 400 SEATS
450 SEATS
500 SEATS
200 SEATS
per s
eat
300 SEATS225 SEATS
250 SEATS275 SEATS
350 SEATS 400 SEATS
450 SEATS
500 SEATS
200 SEATS 300 SEATS225 SEATS
250 SEATS275 SEATS
350 SEATS 400 SEATS
450 SEATS
500 SEATS
200 SEATS
Current Quads
Fuel
con
sum
ptio
n p
550 SEATSCurrent Twins
Current Quads
20% Better
Fuel
con
sum
ptio
n p
550 SEATS
Fuel
con
sum
ptio
n p
550 SEATS
Fuel
con
sum
ptio
n p
550 SEATS
550 SEATSCurrent Twins
Current Quads
20% Better
Fuel Efficiency is DrivingFuel consumption per trip
F
787
Fuel consumption per trip
F
Fuel consumption per trip
F
Fuel consumption per trip
F
787
Payload, Performance, and Cost Fuel Efficiency is Driving Commercial Focus on Structural Materials
y , ,are Driving the Boeing Defense Focus on Structural Materials
Copyright © 2006 Boeing. All rights reserved. BOE021711-120
Performance Gains from Weight Reductions are Driving the Increased Usage of Composite Materials
BOE021711-120
Commercial Production DrivingIncreased Usage of Composite MaterialsIncreased Usage of Composite Materials
site
s n
50% of the 787 Is Composite Structure
Com
pos
oduc
tion
787’s Primary Structural Composite Material System was developed in the 1990’s
truc
tura
lsp
ace
Pro developed in the 1990 s
ume
of S
tin
Aer
osVo
lu
Time
Copyright © 2006 Boeing. All rights reserved. BOE021711-120
Material Development Must Begin Well in Advance of Conceptual Design
BOE021711-120
A New Material System Must EarnIts Way onto the Airplaney p
Targeted ApplicationBreakthrough Performance
Design loads
Static strength
Environment & discrete events
Design loads
Static strength
Environment & discrete events
Breakthrough Performance ImprovementsMaterial Substitution
Stiffness and
Durability• Fatigue
C i
Producibility
Maintainability• Repairability• Inspectability Structures
DesignCriteria
Stiffness andflutter
Durability• Fatigue
C i
Producibility
Maintainability• Repairability• Inspectability Structures
DesignCriteria
Reduced Minimum Gauge System Level Functionality
Value / Affordability Across
• Corrosion
Fail safetyCrashworthiness
Damage toleranceor safe -life
• Corrosion
Fail safetyCrashworthiness
Damage toleranceor safe -life
Value / Affordability Across the Life CycleMaterial Cost
Systems
Materials
Engines
Fabrication Service
Aerodynamics
Copyright © 2006 Boeing. All rights reserved. BOE021711-120
Significant Improvements Must Be Realized to offset the Development and Certification Costs
BOE021711-120
Certification of New Material SystemsyDevelopment Phase Development Time
Modification of an 2-3 yearsexisting material for a non-critical component
y
Modification of an existing material for a
Up to 4 yearsAnalysis
Verification
Full-scaletests Analysis
Verification
Full-scaletests
critical structural component
New material within a system for which there i i
Up to 10 years – includes time to define the material’s
iti d iDesign-valued l t
Componenttests
Sub-component tests Design-valued l t
Componenttests
Sub-component tests
is experience composition and processing parameters
New material class Up to 20 years or more –includes time required to develop design practices that fully exploit
development
Material property
Structural elements tests
Allowable development
Material specification development
development
Material property
Structural elements tests
Allowable development
Material specification development
SOURCE: R. Schafrik, GE Aircraft Engines, Technology Transition in Aerospace Industry, briefing presented at the Worksop on Accelerating Technology Transition, National Research Council, Washington DC, November 24, 2003
g p y pthe performance of the material and establish a viable industrial base
propertyevaluationMaterial screening and selection
propertyevaluationMaterial screening and selection
Copyright © 2006 Boeing. All rights reserved. BOE021711-120
Significant Risk Mitigation is Required to Certify a New Structural Material
BOE021711-120
Blocking Block Approach to Materials Maturity and Risk ReductionMaterials Maturity and Risk Reduction
1. Basic Material Physical 2 Mechanical Properties2. Mechanical Properties3. Process Feasibility 4. Material and Process Scalability - Specifications5. Design Allowables & Subcomponent Article
Demonstration6. Critical Feature/Full Scale Component Testing
AAAAAA
Copyright © 2006 Boeing. All rights reserved. BOE021711-120
Processing and Process Variability Can Significantly Impact Structural Performance
BOE021711-120
Material Processing Can Significantly Impact Structural PerformanceImpact Structural Performance
Scale and Complexity of Design Matter …Alot
Processing anomalies
• Surface irregularities
• Splicing
Pristine materials
Reduction of the allowable
Processing Variability Impacts Weight Reduction Potential
• Waviness
• Inclusions
• VoidsDamage
• Visible damage
• BVID (For Ultimate)Allowable
Stress
stress
Materials Development Must Include Processing Needs
Can the New Materials Be Used with
BVID (For Ultimate)
• Repair (holes, etc.)Design
• Environment
Allowable design region
Strain
Can the New Materials Be Used with an Existing Process or Is a New Fabrication Technique Required?
Do the Support Materials Exist –Consumables, Adhesives, etc…
Copyright © 2006 Boeing. All rights reserved. BOE021711-120
Variability Impacts Both Processing and Structural Performance
BOE021711-120
Aerospace Requires Enhanced Quality Control in the Supply BaseQuality Control in the Supply Base
Industrial Scale QuantitiesProduction Ready EquipmentProduction Ready Equipment
and FacilitiesQuality / Verification Control y
CapabilityStandardization of Testing
~80X moreSupplier CertificationExpertise/Skill Base
~80X more composites, by
weight, in annual f ll t d ti Cost
Regulatory Compliance
full-rate production of 787 than F-22
Copyright © 2006 Boeing. All rights reserved. BOE021711-120
Aerospace Manufacturers Need to Understand a Materials Impact Beyond Acquisition
BOE021711-120
A New Material System Needs to Be Understood Throughout Its Life CycleUnderstood Throughout Its Life Cycle
FabricationAssembly
Surface Preparation for Finishingfor Finishing
Safe for
In-service MaintenanceRetire
Safe for Shop
rline
s &
ge
rsSaEnv
Energy Efficiency
Energy Efficiency
SolidWaste
Disposal
SolidWaste
Disposal In service Maintenance & Repair Part/Product
Safe
for A
irPa
ssen
afe For ironm
ent
Hazardous
Waste
Hazardous
WasteGreenHouseGases
GreenHouseGases
Reduce Footprint
SRecycle
Copyright © 2006 Boeing. All rights reserved. BOE021711-120EOT_RT_Sub_Template.ppt | 12/16/2009 | Materials & Fabrication Technology 10
NanoComposites Need to Be Safe and Meet Regulatory Compliance Throughout the LIfecycle
BOE021711-120
NanoComposites Have Tremendous Potential To Improve Our SystemsPotential To Improve Our Systems
Electrical Properties
Mechanical Properties
Potential for Potential for Multifunctional Multifunctional
CompositesCompositesThermal
Properties Manufacturing Enablers
CompositesComposites
Acoustic Properties Fire Retardant
Copyright © 2006 Boeing. All rights reserved. BOE021711-120
Need to Demonstrate the Performance Feasibility of NanoComposites to Create the Necessary Pull
BOE021711-120
Emerging Materials Focus
Investigate and MatureUnderstand the Modeling Simulation andInvestigate and Mature New Material Forms
Understand the Science
Modeling, Simulation, and Analysis will Accelerate the
Adoption
“Engineered” Materials“Engineered” Materialsgg
Functionality Improved Structural Properties Novel Processing
Copyright © 2006 Boeing. All rights reserved. BOE021711-120
Enabling Engineered Materials for System Level Enabling Engineered Materials for System Level Performance is Key Performance is Key
BOE021711-120
NanoComposites Transition Opportunities Across Time HorizonsAcross Time Horizons
Horizon 3: Horizon 3: Exploration for Future GenerationExploration for Future Generation
Horizon 2: Horizon 2: Horizon 1: Horizon 1:
Current Generation Current Generation ProgramsPrograms
• Multifunctional Coatings
Next GenerationNext Generation
•• Nano Enhanced, High Nano Enhanced, High Performance Primary Performance Primary StructureStructure• Multifunctional Coatings
• Enhancements to Secondary Structure
ties
• Coating Technology
Structure Structure
•• Multifunctional Multifunctional Structural Materials Structural Materials
• Payloads and Interior Applications
• Very High Cost/Weight
Cap
abili
t
• Sensor Materials & Technology
• Point Solution to
•• Engineered MaterialsEngineered Materials
•• Dynamic selfDynamic self--assembly of materialsassembly of materials
• Very High Cost/Weight Payoff TechnologyDifficult Problem
Copyright © 2006 Boeing. All rights reserved. BOE021711-120
Implementation of NanoComposites is Implementation of NanoComposites is Likely to Be Incremental Likely to Be Incremental
BOE021711-120
Summary
NanoComposites have significant potential a oCo pos tes a e s g ca t pote t a
Materials must earn their way onto the airplane Significant Performance improvements required to offsetSignificant Performance improvements required to offset development costs
Aerospace use requires rigorous building blockAerospace use requires rigorous building block approach and quality control system
Safety and Environmental issues are criticalSafety and Environmental issues are critical
Implementation likely to be incremental (builds fid d i d t di )
Copyright © 2006 Boeing. All rights reserved. BOE021711-120
confidence and improves understanding)
BOE021711-120
Thank You
BOEING is a trademark of Boeing Management Company.Copyright © 2006 Boeing. All rights reserved.
BOE021711-120