Aircraft Parts Material(PDF)

8/13/2019 Aircraft Parts Material(PDF)

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Aerodays 2006, Vienna, the 18.06. 21.06.06, Ageform, F. Eberl 1

Leading the way with advanced aluminiumsolutions for aerospace structures

F. Eberl, Alcan R&D Center, Voreppe, France

S. Gardiner, Airbus UK Ltd, England

G. Campanile, ALENIA AERONAUTICA - Engineering, Italie

G. Surdon, Dassault Aviation, France

M. Venmans, SABCA, Belgium

P. Prangnell, UoM, England

[email protected]

AGEFORM: Forming advanced aerospace panels at reduced cost


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Lightweight solutions for metallic airframes

Objective

Development of competitive metallic solutions in the fields of

Design

Materials Manufacture

With the target of

Cost and

Weight reduction

cost

weight

20%

20%


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High performance and low cost airframes

cost

weight

20%

20%

20%

20%

Laser beam welding

technology

Welded monolithic structures

Ageforming

Integrally machined

monolithic structures

Friction stir weldingtechnology


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Advanced alloys

Advanced joining

and formingtechniques

Advanced DesignConcepts

Multi-disciplinary& Collaborative

approach!

Airframe structure performance

AND


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Alternative routing for assembling

surface treatment

ageforming

plate

machining

7xxx plateTAF temper

TOP wing skin

Currentfuselage

skin

surface treatment

ageforming

special features

2xxx plate(new material)

T3 temper

ageforming

Integral machining

Laser Beam Welding

Friction stir welding

Manhole/overthickness

machining

pocketing

Damage tolerant

structures

surface treatment

ageing

re-shaping

welding

3D machining

forming

(stretch forming)

6xxx sheet

T4 temper


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AGEFORM: Forming advanced aerospace panelsat reduced cost

Process principles

Metallurgical principles and mechanical properties

Ageform process for Aerospace applications

Summary and outlook


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AGEFORM process

agingtemperature

roomtemperature


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Metallurgical principles

Precipitation alignment in the 2022 alloy

No impact on static properties

No impact on anisotropy

340

350

360

370

380

390

400

0 10 20 30 40 50 60 70 80 90

Angle w ith longitudinal axis ()

0.2%YieldStress(M

Pa

2022 static 2022 dynamic


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Metallurgical principles

Precipitation alignment in the 2022 alloy

No impact on damage tolerance properties

R-Curves CCT760 (L-T)

Ageforming effect

50

70

90

110

130

150

170

190

0 20 40 60aeff (mm)

Kr(M

Pa

m)

2022clad T8 th 3.2 ref

2022clad T8 ageformed 3.2 mm (R 1 m)

2022clad T8 th 6 mm ref

2022clad T8 ageformed 6 mm (R 2 m)

R-Curves CCT760 (L-T)

Ageforming effect

50

70

90

110

130

150

170

190

0 20 40 60aeff (mm)

Kr(M

Pa

m)

2022clad T8 th 3.2 ref

2022clad T8 ageformed 3.2 mm (R 1 m)

2022clad T8 th 6 mm ref

2022clad T8 ageformed 6 mm (R 2 m)

Roll forming

Ageforming

Sample loading

in autoclave

no impact on R-curve

Ageformed panels canbe characterised in theflat shape


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AGEFORM: Forming advanced aerospace panelsat reduced cost

Process principles

Metallurgical principles and mechanical properties


Summary and outlook


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Example of a commercial aircraft fuselage panel

Including modern assembling features as Laser Beam Welded (LBW) stringers on the skin

Longitudinal Friction Stir Welded joints

Machining of fuselage skin: pocketing,


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Manufacturing of a commercial aircraft fuselage panel (1/2)

Skin Trimming Pocket Mechanical/Chemical Milling

FSW Skin Panels Cleaning / PicklingLaser BeamWelding of

Stringers


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Manufacturing of a commercial aircraft fuselage panel (2/2)

Dimension ChecksCleaning / Painting

NDECreep / Age Forming


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Evaluation of result obtained

-2

-1

0

1

2

3

4

5

- 500 -300 - 100 100 300 500w idth in mm

displacementinmm after welding

after ageforming

Quality increasebaseline: 2024/7175

6056 T6 welded

high str ength 2xxx,

riveted

high strength 2xxx,

welded

Al-Li, welded-25%

-20%

-15%

-10%

-5%

0%

2.65 2.70 2.75 2.80 2.85

average density in g/cm3

relativew

eightgain

baseline: 2024/7175

6056 T6 welded

high str ength 2xxx,

riveted

high strength 2xxx,

welded

Al-Li, welded-25%

-20%

-15%

-10%

-5%

0%

2.65 2.70 2.75 2.80 2.85

average density in g/cm3

relativew

eightgain

Al-Li, weldedAl-Li, weldedAl-Li, welded

Weight reduction Cost reduction


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Summary and outlook

Process demonstrated

Final properties evaluated

Micro-structural mechanisms well understood

Process demonstrated on LBW and FSW containing structures

Representative bottom wing structure demonstrated

Representative fuselage panel demonstrated

Ageform process can be applied to damage tolerant structures

Bottom wing skinComplex fuselage

structures

Aerospace

structures


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Summary and outlook

2024 T351

6156 T651

7475 T7651

2139 T851

2198 T851

2022 T851

100

110

120

130

140

150

160

170

180

230 330 430 530

CYS(LT) (MPa)

Kapp(T-L)

(MPa

m)

strength

toughness

Property Improvement of Al alloys:

Fuselage skin & stringers

80

100

120

140

160

180

1950 1970 1990 2010 2030

Year of AA registration

Relativevariation(%)

Skin - Kapp T-L

Stringer - TYS L

?

7075 7150

7349Al-Li

PA7662024

6156

2524

2139

2198

Still a lot of

improvement

anticipated !


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Aerodays exposition: Ageform, stand nr. 51

~1.5 m

~0

.5m

f ront spar

~1500 mm~500 mm

rib 42 rib 49rear sparstringers

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Aircraft Parts Material(PDF)