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BOE021711-120 Aerospace Structural Aerospace Structural Material Certification Material Certification Dave Furdek Dave Furdek Mgr – Next Generation Composite Materials Boeing Research and Technology 28 February 2011 BOEING is a trademark of Boeing Management Company. Copyright © 2006 Boeing. All rights reserved. BOE021711-120

Aerospace StructuralAerospace Structural Material ... · Structural elements tests ... Materials must earn their way onto the airplane Significant Performance improvements required

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Page 1: Aerospace StructuralAerospace Structural Material ... · Structural elements tests ... Materials must earn their way onto the airplane Significant Performance improvements required

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

Page 2: Aerospace StructuralAerospace Structural Material ... · Structural elements tests ... Materials must earn their way onto the airplane Significant Performance improvements required

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

Page 3: Aerospace StructuralAerospace Structural Material ... · Structural elements tests ... Materials must earn their way onto the airplane Significant Performance improvements required

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

Page 4: Aerospace StructuralAerospace Structural Material ... · Structural elements tests ... Materials must earn their way onto the airplane Significant Performance improvements required

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

Page 5: Aerospace StructuralAerospace Structural Material ... · Structural elements tests ... Materials must earn their way onto the airplane Significant Performance improvements required

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

Page 6: Aerospace StructuralAerospace Structural Material ... · Structural elements tests ... Materials must earn their way onto the airplane Significant Performance improvements required

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

Page 7: Aerospace StructuralAerospace Structural Material ... · Structural elements tests ... Materials must earn their way onto the airplane Significant Performance improvements required

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

Page 8: Aerospace StructuralAerospace Structural Material ... · Structural elements tests ... Materials must earn their way onto the airplane Significant Performance improvements required

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

Page 9: Aerospace StructuralAerospace Structural Material ... · Structural elements tests ... Materials must earn their way onto the airplane Significant Performance improvements required

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

Page 10: Aerospace StructuralAerospace Structural Material ... · Structural elements tests ... Materials must earn their way onto the airplane Significant Performance improvements required

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

Page 11: Aerospace StructuralAerospace Structural Material ... · Structural elements tests ... Materials must earn their way onto the airplane Significant Performance improvements required

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

Page 12: Aerospace StructuralAerospace Structural Material ... · Structural elements tests ... Materials must earn their way onto the airplane Significant Performance improvements required

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

Page 13: Aerospace StructuralAerospace Structural Material ... · Structural elements tests ... Materials must earn their way onto the airplane Significant Performance improvements required

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

Page 14: Aerospace StructuralAerospace Structural Material ... · Structural elements tests ... Materials must earn their way onto the airplane Significant Performance improvements required

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)

Page 15: Aerospace StructuralAerospace Structural Material ... · Structural elements tests ... Materials must earn their way onto the airplane Significant Performance improvements required

BOE021711-120

Thank You

BOEING is a trademark of Boeing Management Company.Copyright © 2006 Boeing. All rights reserved.

BOE021711-120