Composites R&D challenges

for EMBRAER aerostructures SAMPE BRAZIL CONGRESS 2017

October 5th, 2017

Luciana Selmi Marques

AGENDA

1. EMBRAER OVERVIEW

2. EMBRAER PORTUGAL ESTRUTURAS EM COMPÓSITOS, S.A.

3. COMPOSITES TODAY

4. EMBRAER R&D

5. R&D CHALLENGES

AGENDA

1. EMBRAER OVERVIEW

2. EMBRAER PORTUGAL ESTRUTURAS EM COMPÓSITOS, S.A.

3. COMPOSITES TODAY

4. EMBRAER R&D

5. R&D CHALLENGES

1969

2014

1994

1949

Embraer is privatized, fusing technological and industry expertise with an entrepreneurial approach.

Embraer is one of the world’s leading manufacturers of commercial and executive jets, with substantial and growing operations in defense and security.

Federal Government creates Embraer to develop aeronautical engineering and manufacture aircraft in Brazil.

Brazil launches a national strategic aerospace initiative via the Aeronautics Technical Center (CTA) and the Technological Institute of Aeronautics (ITA).

Today Embraer is the market leader in commercial jets with up to 130 seats

COMMERCIAL AVIATION

EXECUTIVE AVIATION

EMBRAER DEFENSE & SECURITY

We have developed our business in the areas of …

- 70’s: Bandeirante - 80’s: Brasília - 90’s: 145 Family - 2000’s: E-Jets - 2018: E2

EXECUTIVE AVIATION

EMBRAER DEFENSE & SECURITY

We have developed our business in the areas of …

COMMERCIAL AVIATION

2000 to 2015 - Legacy 600 - Phenom 100/300 - Lineage 1000 - Legacy 650 - Legacy 500/450

EMBRAER DEFENSE & SECURITY

We have developed our business in the areas of …

COMMERCIAL AVIATION

EXECUTIVE AVIATION

- Bandeirante - Tucano & Super Tucano - AMX - ISR: Intelligence,

Surveillance & Reconnaissance

- KC390

We have developed our business in the areas of …

GLOBAL PRESENCE

DIVERSITY IS WEALTH

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USA Nashville

Fort Lauderdale Melbourne

Mesa Windsor Locks

Jacksonville Irwindale

BRAZIL São José dos Campos Gavião Peixoto Botucatu Taubaté Brasília Belo Horizonte São Paulo Rio de Janeiro Sorocaba Campinas

PORTUGAL Évora

Alverca - OGMA

UNITED

KINGDOM Farnborough

FRANCE Le Bourget

UAE Dubai

CHINA Beijing

SINGAPORE Singapore

IRELAND Dublin

WHERE WE OPERATE

NETHERLANDS Amsterdam

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AGENDA

1. EMBRAER OVERVIEW

2. EMBRAER PORTUGAL ESTRUTURAS EM COMPÓSITOS, S.A.

3. COMPOSITES TODAY

4. EMBRAER R&D CASE

5. R&D CHALLENGES

EMBRAER Portugal

Évora

32.000m2 37.000m2

Metallic Excellence

Center

Composite Excellence

Center

Industrial area

RTM

Hot Drape

Autoclave

The plant

Painting

ATL

AFP

CNC Water Jet

Ultrasonic

inspection

Assembling

Packing

Production in Portugal at Embraer Composites, S.A.

KC-390 Horizontal Stabilizer

Legacy 500/450 Horizontal, Vertical Stabilizer & Tailcone

E175-E2 Horizontal Stabilizer &

Outboard Flaps

AGENDA

1. EMBRAER OVERVIEW

2. EMBRAER PORTUGAL ESTRUTURAS EM COMPÓSITOS, S.A.

3. COMPOSITES TODAY

4. EMBRAER R&D CASE

5. R&D CHALLENGES

Empennages Carbon/Epoxy • Hand Layup • ATL

Ribs • Thermoplastics

Phenom 300 & Phenom 100E

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Aft Pressure Bulkhead Carbon/Epoxy, Sandwich • Hand Layup

Fairings Wing to fuselage fairing Fiber Glass/Epoxy • Hand Layup

1,178 nm 5 - 7 7 - 10 1,971 nm

Landing gear doors Carbon/Epoxy • Hand Layup

Dorsal Fin Fiberglass/Epoxy • Hand Layup

Radome Fiberglass/Epoxy Control Surfaces

Flap, Aileron, Rudder, Elevator, Spoilers Carbon/Epoxy • Hand Layup

Empennages Carbon/Epoxy • Hand Layup • ATL

Ribs • Thermoplastics

HS Tip Carbon/Epoxy • VARTM

Pylon Fairing Carbon/epoxy • RTM

Aft Pressure Bulkhead Carbon/Epoxy • RFI

Wing Fus. Fairing Fiberglass/epoxy • Hand Layup

Legacy 500/450

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3,125 nm 8 - 12

Radome Fiberglass/Epoxy

Control Surfaces Flap, Aileron, Rudder, Elevator, Spoilers Carbon/Epoxy • Hand Layup

Control Surfaces Flap, Aileron, Rudder, Elevator, Spoilers Carbon/Epoxy • Hand Layup • AFP • Hot forming

E175 – E2

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Landing Gear Doors NLG door, MLG doors Carbon/Epoxy • Hand Layup

Radome Fiberglass/Epoxy

97 - 106 2,800 nm

Wing Fus. Fairing Fiberglass/epoxy • Hand Layup

Floor panel Carbon or Fiberglass • Sandwich panels

Empennage Horizontal Tail Carbon/Epoxy • ATL • AFP • Hot forming

Outboard Flap Carbon/Epoxy • ATL • Hot forming Thermoplastic • Thermophorming

Fairings & Radome

+ Control Surfaces

+ Empennage & Pressure Bulkhead

+ Rear Fuselage

+ Wing box & Fuselage

50%

15%

25%

Fairings & Radome

+ Control Surfaces

+ Empennage & Pressure Bulkhead

Composites % - airframe weight

1970 1980 1990 2000 2010 2020

Larger

Aircraft

20% Embraer

Fairings & Radome

+ Control Surfaces

+ Empennage & Bulkhead

+ Rear Fuselage

+ Wing box & Fuselage

50%

15%

25%

Fairings & Radome

+ Control Surfaces

+ Empennage & Bulkhead

Composites % - airframe weight

1970 1980 1990 2000 2010 2020

Larger

Aircraft

20% Embraer

Why should % of composites be increased?

AGENDA

1. EMBRAER OVERVIEW

2. EMBRAER PORTUGAL ESTRUTURAS EM COMPÓSITOS, S.A.

3. COMPOSITES TODAY

4. EMBRAER R&D CASE

5. R&D CHALLENGES

Wing, Empennage & Fuselages Demonstrators

WING DEMO R&D CASE | TECHNOLOGY VALIDATION

Ref. E190

Wing Demo Project

Ref. E190

Wing Demo Project

Ref. E190

Wing Demo Project

CMH-17: Test sequence recommendations

Ref. E190

Wing Demo Project

AGENDA

1. EMBRAER OVERVIEW

2. EMBRAER PORTUGAL ESTRUTURAS EM COMPÓSITOS, S.A.

3. COMPOSITES TODAY

4. EMBRAER R&D CASE

5. R&D CHALLENGES

Why should % of composites be increased?

Special Application

Weight

Performance DMC

NEEDS

Why should % of composites be increased?

Specific Requirements

Environment

Costs Inspections

CONCERNS

R&D Challenges

Specific Requirement

Lightning

• Small aircrafts have higher

current density

Flammability

• Small aircrafts have thinner skins

less fire resistant

Bigger composite components, as wing, require more tests

no historical data

R&D Challenges

Special Application

New Materials

• Erosion protection

• Damage tolerance

• Conductive materials

• Preform/3D fabric

R&D Challenges

Costs

Manufacturing Process

• Special process: bonding quality

control; inspection

• Production rate automation;

integration

• OOA process

• Scraps new technologies

recycling

Certification Process

• Extensive testing and time

consuming virtual testing

Maintenance

• DMC material properties

(fatigue, corrosion); SHM

Fairings & Radome

+ Control Surfaces

+ Empennage & Bulkhead

+ Rear Fuselage

+ Wing box & Fuselage

50%

15%

25%

Fairings & Radome

+ Control Surfaces

+ Empennage & Bulkhead

This is not the right question!

1970 1980 1990 2000 2010 2020

Larger

Aircraft

20% Embraer

Why should % of composites be increased?

Make the best decision!

Composites technologies

Aircraft mission

Non-recurring costs

Supply chain

Strategy

Partnership

Biggest Challenge?

THIS INFORMATION IS THE PROPERT OF EMBRAER AND CANNOT BE USED OR REPRODUCED WITHOUT AUTHORIZATION IN WRITING.