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© AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document.
Continuous High Volume Part Production Technologies
Innovation Day 31.05.2016
Alexander Gillessen
R&T Programme EngineerCluster Leader – Generic Technologies
© AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document.
May 2016
Agenda
Page 2
CTC
Continuous Profile Production – Part Portfolio
Continuous Profile Production – Technologies
© AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document.
May 2016
Composite Technology Centre Stade (CTC)
Page 3
© AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document.
May 2016
Composite Technology Centre Stade (CTC)
Page 4
TRL 2 TRL 4 TRL 6
-10 years -4 years Start of production
+ 20 years
End-userorientedresearch
Preparationfor serial
production
Serial production
End of life
Airc
raft
mat
urity
leve
l Product Life Cycle
Academic research
Recycling CompanyRecycling CompanyCFK NordCFK Nord OEMOEMCTC GmbHCTC GmbH
© AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document.
May 2016
Agenda
Page 5
CTC
Continuous Profile Production – Part Portfolio
Continuous Profile Production – Technologies
© AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document.
May 2016
Continuous Profile Production – Part PortfolioGeneral Overview
Page 6
A320 A330 A340 A350 A380
StringerFrames
Fuselage VTP / HTP Wing
RibFloor Structure
© AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document.
May 2016
Continuous Profile Production – Part PortfolioCFRP Fuselage Frames
Typical Frame
potential rate: 13 a/c per month
high level of variants
~ 50.000 frames/year
A350 XWB NSR
Typical Frame
potential rate: 60 a/c per month
low level of variants
~ 150.000 frames/year
A350 XWB NSR
© AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document.
May 2016
Continuous Profile Production – Part PortfolioA320 VTP Stringer
Page 8
Assumptions
Rate: 60 ac/month from 2019
Stringer: 100m T-stringer per VTP centerbox
6.000m T stringer per month 70 km T stringer per year
© AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document.
May 2016
Continuous Profile Production – Part PortfolioNew Short Range WING Stringer
Page 9
Assumptions
Rate: 60 ac/month Part: 2 x wing upper cover + 2 x wing lower cover per ac 240 WUC+WLC /month
Stringer: 11 stringer per WUC + 10 stringer per WLC ~100 m stringer per WUC + ~ 80 m per WLC 21.600m stringer per month
© AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document.
May 2016
Continuous Profile Production – Part Portfolio GeometricalProfile Complexity
Page 10
Geometry (example fuselage frame)
R1 R2
R1≠ R2
variableweb high
local reinforcement(web and/or flanges(s))
global reinforcement(web and/or flanges(s))
0° plies web
twist
0° plies flange(s)
Fiber-Angle-Deviationdue to :Geometry- / Process- / Reproducing- Factors
Ondulation
Gaps / Overlaps
Thickness-Tolerance
Contour Tolerance
Reproducibility
Buy to Fly
€/kg
Key Characteristics
© AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document.
May 2016
Agenda
Page 11
CTC
Continuous Profile Production – Part Portfolio
Continuous Profile Production – Technologies
© AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document.
May 2016
Continuous Profile Production – TechnologiesWhat profiles can we buy today and where we want to go
Page 12
Continuous/high volume
Discontinuous/Small volumes
Simple
Complex
com
plex
ity
manufacturing volume
UD Pultrusion profiles
Manual labour dominated, high production cost
*1) Image source: DPP (vDijk Pultrusion Products)
e.g. A350 fuselage frame
*2) Image source: Maschinenmarkt (Thomas Technik)
UD & multiaxial textile
Web height variation
Local patches
*1) *2)
Full automation for complex products
Fast and/or continuousimpregnation
© AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document.
May 2016
Continuous Profile Production – TechnologiesCTC – Portfolio
Page 13
2004 2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015 2016 2017 20182001 2002 2003 2019
3D Preforming (LOKOST)for complex, curved profiles -> Frames
PRTMfor complex profiles -> Stringer
NCFPrepreg
RTMAuto-RTM
RTMHP-RTM
Window Frame
A380 A350-900 A350-1000
Barrel Test-Part ManufacturingBarrel 1b, Barrel 1bR2
Manufacturing Feasibility Evaluation (NCF & Prepreg): Typical-Frame & Door Frame
Generic, NSR, A350-900, A350-1000
P4 - Prepreg Frame
Technology SpecificPart Specific
ALCAS LCO7 V3Door Surround Structure
KAPSDigital Factory
NSRDoor Frame
CoFuI²LCF Frame
A350Typical Frame
Airbus Supplier
Wing-Profiles
© AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document.
May 2016
Continuous Profile Production – TechnologiesCFRP Profile Production Line - Frames
Page 14
DLREvo
CTCAuto-RTM
Fully Automated Process Chain Variable Continuous 3D Preforming High-Pressure-Auto- RTM
Preforming Curing Net-Shape Part
- Profile
- Profile
- Profile
High-Pressure RTM
Auto-RTM
LoKost 2.0 plant
LoKost 1.0 plant
+
© AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document.
May 2016
Continuous Profile Production – TechnologiesCFRP Profile Production Line - Frames
Page 15
LoKost 1.0: Automated 3D Preforming LoKost 2.0: Automated complex 3D PreformingVariably curved Z- and LCF-profile preforms Variably curved omega-profile preforms
with interleaved patches and variation in the cross-section
…basic preforming system for continuous preforming…curved preforming
…variable curvature
...global patch integration
...local patch integration
...web height variation
...in-line quality check for single textile layer
...in-line cutting
...automated handling of preforms
© AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document.
May 2016
Continuous Profile Production – TechnologiesComparison of processing rates for complex profiles
Page 16
Preforming Infusion & curing
Trimming NDI
Productivity
High
Medium
Low Productivity bottleneck with current production systems
Continuous or high pressure impregnation
In-line NDT
In-line trimming
© AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document.
May 2016
Continuous Profile Production – TechnologiesHigh Pressure RTM Technology
TargetDevelopment and Enhancements of High-Pressure-RTM Technology (HP-RTM) for Aeronautical Application
technology feasibility validation for aerospace part production ( aerospace quality requirements)
process-time reduction for RTM-Part production from today ~3hrs to ~15 min
aerospace adapted fast curing 2K epoxy resin
innovative injection strategies and technologies
internal release agent application
isotherm process, no heating no cooling rates
mixing head mounted to tool, no cleaning of neat resin HP-RTM in aerospace industry
HP-RTM in automotive industry
© AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document.
May 2016
Continuous Profile Production – TechnologiesHigh Pressure RTM Technology
Page 18
Gefördert durch das Land Niedersachsen und die Hansestadt Bremen
CTC HD-RTM
• KraussMaffei RIM Star Thermo• 2 mixing heads, multipoint injection• 250to press • 2,5m x 1,5m press bolster• 15kW Heating- / Cooling system• Compression RTM capable• Qualified staff
Z-Frame Tool
• Straight Z-Frame, length 1200mm• Applicable for 4-pt-bending test-part production• Applicable for manufacturing feasibility demonstrator part
production
Coupon Tool
• Coupon t=2mm• Applicable for typical tests
(e.g. CAI, ILSS)• Applicable for generic analyses
© AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document.
May 2016
Continuous Profile Production – TechnologiesCFRP Profile Production Line - Stringer
Page 19
Fully Automated Process Chain Variable Continuous 2D & 3D Profile Manufacturing Preforms, Net-Shape Prepreg Profiles
and Fully Cured Parts
Curing - Line Cured Part
Net-Shape Prepreg Part
Preforming - Line
Net-Shape Prepreg - Line
Preform
© AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document.
May 2016
Continuous Profile Production – TechnologiesCFRP Profile Production Line - Stringer
Page 20
Pultrusion + RTM
© AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document.
May 2016
Continuous Profile Production – TechnologiesCFRP Profile Production Line - Stringer
Page 21
- significant part cost reduction through increase of manufacturing speed by a factor of 10 - manufacturing and material technology applicable to many part families (stringer, beams, struts)- no internal release agent, potential weight reduction (NCF instead of woven fabric)
Pultrusion + RTMFuture Potential:
Proven Feasibility:
Manufacturing Throughput per Line:
Jamco ADP prepreg stringer: up to 2m per hour*
PRTM textile stringer: more than 18m per hour
Summary:
*: Source: Patent DE 102007018052 A1
e.g. floor beam structures
T- / I-profiles
© AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document.
May 2016
Continuous Profile Production – TechnologiesCFRP Profile Production Line – Prepreg Frame
Page 22
© AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document.
May 2016
DryFibre Wing of the Future (WotF)
Page 23
Profile Production
Example: CFRP Profile Production Line
Profile Production
Example: CFRP Profile Production Line
Profile Production
Example: Prepreg Process Chain
Profile Integration
Example: AutoVac
© AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document.
May 2016
Marketplace and Facility Demonstration CTC
Page 24
PRTM
LoKost 1.0: Automated 3D Preforming LoKost 2.0: Automated complex 3D Preforming
HP-RTM
© AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document.
May 2016
© CTC GMBH. All rights reserved. Confidential and proprietary document.CTC GmbH is a100% subsidiary of AIRBUS Operations GmbH© CTC GMBH. All rights reserved. Confidential and proprietary document.CTC GmbH is a100% subsidiary of AIRBUS Operations GmbH
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