Light Materials for energy efficient structures High ...Metallic & Manufacturing Light Materials for energy efficient structures •New light weight materials : Al, Mg, cellular

Metallic & Manufacturing

Light Materials for energy efficient structures •New light weight materials : Al, Mg, cellular...•Multifunctional/hybrid materials : FML, foams•Unitized structures concepts: co-extrusion

High performance material concepts•High specific properties light materials: Metal Matrix Composites•Nano-structured and nano-reinforced•High specific properties hard materials : Ti, steel•Extreme environment materials : metallics and ceramics

Eco efficient joining & assembly •Robust joining technologies (FSW, LBW)•Hybrid material fastening & machining

Near Net Shape Manufacturing•Additive layer manufacturing•Innovative forming technologies

© EADS 2012 EADS INNOVATION WORKS general presentatio n

Surface Engineering

Green surface technology: avoid direct environmental impact by toxic coating materials or auxiliary process materials

•Replacement of hazardous materials (Chromates, Cd, VOC…)•New corrosion inhibition concepts•Out-of-bath surface treatments: Dry (Plasma, laser) & Wet (spraying)

•One-coat layer concept

Sustainable functional surfaces : reduce environmental impact during operations (low weight, low drag, durability)

•Wear (erosion, abrasion, scratch) and fretting protection systems •Advanced Functional Coatings - Structures, Cabin and Systems•Aerodynamic surfaces•Metallic solution for CFRP lightning strike protection

SurTech enabling cost and/or lead time reduction•Cleaning and activation•Surfaces for moulds and tools


Failure, Material and Surface Analysis Skills

Materials and surface characterisation: •Physical & Chemical analysis (FTIR, Thermal, X-ray, XRF,…)•Microscopic material and surface characterization by electron microscopy (SEM-EDS) and surface analysis (XPS, SIMS)

•Tribological and corrosion testing, electrochemistry•Mechanical testing : static, fatigue and fracture mechanics•Destructive (hole-drilling) and non-destructive (X-ray) residual stress measurements

Operational durability: Understand and prevent failure and degradation of materials and coating �� extend service life

•Correlation of processing parameter and in-service behaviour•Failure analysis and understanding of long term materials and coatings degradation behavior

•Failure prevention and enhancement of durability (residual stresses induction)


• Al-alloys : screening and characterization of weldable & improved AlCuLi, 7xxx and AlMgSc alloys, development of thermo-mechanical treatments, fundamental understanding of failure, corrosion and long therm behavior

• Mg-alloys: screening and characterisation of spec. high strength alloys with improved corrosion and flammability behavior, development of surface protection, development and simulation of cold and hot forming processes to produce

• Others: metal laminates, foams,…

Trolleys,Interior components

Raceways

Hatrack brackets, various other brackets

Fuel connectors

Seat structures

Door hingesElectronic bayaccess door

Shear-compr. Panel (Airbus, Aleris) Potential Mg applications

Light Materials for energy efficient structures


• Ti-alloys: challenge Ni-alloys with new near β titanium alloys. Taylor properties by improved heat treatments. Optimize castability and forming processes

• Nano structured and nano-re-inforced Al-, Mg- and Ti-alloys

• Steels: development of heat treatments to improve aging behavior of 15-5-PH

• Extreme environment metallics: low cost metallic high temperature alloy for satellite thrusters and missiles (Pt replacement). Cu based liner materials.

• Extreme environment ceramics: ceramic matrix composites for appl. at >1700 °C (combustion chambers, nozzles, ram-jets, TPS for re-entry, brake materials)

Milling time: 30 minMilling time: 30 min

Manufacturing in textile technique (braiding), TCC 1

High Performance Material Concepts


Eco-efficient joining and assembly

Friction Stir Welding : tooling concepts and robotized and self-reacting FSW for final assembly lane and major component assembly

Metal / CFRP hybrid joints : optimization of one-shot drilling of hybrid stacks, cold hole expansion of metal side of hybrid stacks, corrosion prediction and protection, metal-CFRP rivetless assembly(Hyperjoints, nanofoils)

Robotic FSW of A330 panel

CFRPMetal

FS welded Rib 1


Additive Layer Manufacturing: cost savings for high value parts (improved buy/fly ), weight savings through topol. optimisation, improved carbon footprint (waste material and weight savings), reduced lead-time and late design freeze

• powder bed for net shape complex parts (Ti, Al, Ni, steel..)

• large near-net parts by wire/powder feed (Ti,..)

Forming technologies: dieless and rapid forming of Ti-, Al- and steel sheets through incremental sheet or laser forming.

Page 7

Near-net shape Manufacturing

combined stretch and incremental

forming


Green Surface Technologies

Compliance with environmental regulation REACH , anticipate supply chain disruption, competitive advantage through 2nd generation protection concepts , lead time and weight reduction reduction

• replacement of hazardous chemicals (Cr6, Cd, VOC, …) in anodizing and coversionpre-treatments, 1s gen primers, Cd and hard-Cr replacement

• active corrosion inhibition through encapsulation , release on demand

• one-coat layer (SolGel, E-coat)

• dry (plasma, laser) and wet (SolGel) out-of-bath treatments

Corrosion inhibitors in core of silica particles

Pre-treated Surface

Sol-GelONE-COAT

Pre-treated Surface

Sol-GelONE-COAT

ONE COAT CONCEPT

Pre-treated Surface

Sol-GelOne-COAT

Top Coat

Pre-treated Surface

Sol-GelOne-COAT

Top Coat

Pre-treatedSurface Anodising/conversion

InhibitedPrimer

Top Coat



InhibitedPrimer

Top Coat

STATE OF ART


9� Active & passive

surfaces

� Rain/ Sand

� Anti-Icing concept for CFRP leading edge

� Energy saving

� Paints, foils � Riblets

Drag reduction via multifunctional surfaces

Anti-Icing coatings

Anti-Contamination

Structured surfaces

Erosion Protection

� Active & passive surfaces

� Rain/ Sand


� Energy saving



Anti-Icing coatings

Anti-Contamination

Structured surfaces

Erosion Protection

� Rain/ Sand


� Energy saving



Anti-Icing coatings

Anti-Contamination

Structured surfaces

Erosion Protection

• Aerodynamic Surfaces : Development of tailored surfaces/coatings for sand/rain erosionprotection of metallic and CFRP structures. Coatings enabling new anti-icing concepts. Anti-contamination (e.g. photocatalytic coatings). Structured surfaces /paints/foils (e.g. riblets). Development of cheap and reliable lab testing facilities.

• Wear and fretting protection: green and cost effective lifetime enhancement through organic, inorganic, multilayer, self-lubricating coatings. Fast and meaningful test methods.

• Cabin application: Improved passenger comfort through easy-to-clean, scratch resistant, anti-bacterial, anti-fingerprint coatings based on SolGel- and nanotechnology.

• Assembly, maintenance and repair: Development of processes and coatings for local/assembly integrated application. Dry and wet pre-treatments for structural bonding based on SolGel) and atm. plasma, laser, thermal spray technologies .

Functional Surfaces for Sustainability


Documents

Light Materials for energy efficient structures High ...Metallic & Manufacturing Light Materials for energy efficient structures •New light weight materials : Al, Mg, cellular