Beyond the 787: Developing the Future of Structures And ... · Single-aisle . Regional jet . 2012...

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Beyond the 787: Developing the Future of Structures And Materials That Shape Aerospace Dr. Greg Hyslop Vice President / General Manager Boeing Research & Technology The Boeing Company November 12, 2013 CMI - 2013

Copyright © 2013 Boeing. All rights reserved.

The Future, Delivered Today

More than 90 787’s in service 2


World Air Travel: Steady Growth

Despite short-term issues, world air travel grown 5% annually since 1980 3

RPKs = Revenue Passenger Kilometers. Source: ICAO Scheduled Traffic


World’s fleet will nearly double in next 20 years 4

Air Travel Projected to Keep Growing

Large Twin-aisle Single-aisle Regional jet

2012

4%

64%

19% 13%

20,310 airplanes

2032

2%

70%

22% 6%

41,240 airplanes


Traffic forecast

7.8

7.5

5.8

6.6

5.1

6.6

7.0

5.6

5.1

3.2

4.1

4.3

4.9

0 2 4 6 8

China

Southwest Asia

Africa

Southeast Asia

CIS

Middle East

South America

Central America

Oceania

North America

Europe

Northeast Asia

WORLD

Annual growth, 2009 - 2028

Percentage

7.8

7.5

5.8

6.6

5.1

6.6

7.0

5.6

5.1

3.2

4.1

4.3

4.9

0 2 4 6 8

China

Southwest Asia

Africa

Southeast Asia

CIS

Middle East

South America

Central America

Oceania

North America

Europe

Northeast Asia

WORLD

Annual growth, 2009 - 2028

Percentage

Environment

Airplane capabilities Economic growth

Fuel price

Infrastructure

Airline strategies & business models

Market liberalization

Network development

Ground Transportation

What Drives Innovation In Aerospace?

5


Extreme Affordability

… in development, production, operations, and support

… easy to mod, open system architecture, easy to upgrade

…to meet the customer needs (range, payload, speed, mission effectiveness, availability, reliability, etc.)

… non-polluting in production (no VOC, lead free solder, no carcinogens, no chromium), quiet, non-polluting, fuel efficient in operation, disposable/ recyclable at end of life

Breakthrough Performance

Enduring Sustainability

Environmentally Responsible

Focusing Technology Investments on Future Needs

6


Sources Of Improved Capabilities

7

Systems

Materials

Aerodynamics

Engines

Multiple sources complement each other – but must be integrated


Key benefits: Tailorable properties Reduced drag and weight Less susceptible to fatigue Corrosion resistance

Composites: A Key Element In Airplane Performance Improvement

8

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• Wood and Fabric

• Low Strength Al

• High Strength/ Stiffness Al

• Fiberglass • CRES • Ti

• Carbon Thermoset Composites • Ti

Tremendous strides in Material Science over the last century

Higher performance at lower cost

• Extreme environmental requirements

• Decades of required reliability

New Chemistries, Materials Enable Product Advances and Product Differentiation


Boeing’s Composites Usage Increases

10

Many advances in the past 40+ years

Key enabler: Low-cost, large-scale composite manufacturing technology allowed significant increase in use of composites on the 787.


787: Composite Structure

11

Composites are the right material choice for the 787

Lighter More durable Negligible corrosion

and fatigue Reduced scheduled

maintenance Opens new design

possibilities


Significant improvements must be realized to offset the development and certification costs

New Material System Must Earn Its Way Onto an Aircraft

Targeted application Breakthrough performance

improvements Material substitution Reduced minimum gauge System level functionality Value / affordability across

the lifecycle Material cost Fabrication Service

Design loads

Static strength

Stiffness and flutter

Durability: Fatigue, corrosion

Fail safety Crashworthiness

Producibility

Maintainability: Repairability, inspectability

Environment & discrete events

Structures

Design

Criteria

Damage tolerance or safe-life

Structures Design Criteria

12


Composites Grand Challenges, for the Next 20 Years

13

Anisotropy for efficiency Certification by analysis Simulation-based manufacturing Robust multi-scale simulation Multifunctional nanocomposites arrive Pervasive composites knowledge and

learning

Courtesy Prof. Byron Pipes, Purdue University


Extensive testing, done to support analysis

14

Design Value Development

Material Property

Evaluation Tier 1

Tier 2

Tier 3 Analysis Validation

Testing and Certification, Today


Computational Materials

Material Models

Process and Manufacturing Simulation for Quality Aspects

of Full Size Parts

Tolerances & Assembly Simulation

Processing and Quality Simulation

15

Advanced computational technologies

Constituent Design

Material System & Forms

Vehicle

Process Development

Scale Up Assembly

Improvements: Qualification, certification Reduced cost, time to market

Testing and Certification, In the Future


NASA Boeing ERA Environmentally Responsible Aviation

• Blended Wing Body (BWB) for high aero efficiency • Non-circular pressure vessel • Advanced composites • Structural health monitoring

Materials Challenges In Future Concepts


Knowledge Base

17

Beyond the 787: Developing the Future of Structures And ... · Single-aisle . Regional jet . 2012...

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