‘Wing of the Future’ - easyfairs.com · FLIGHTPATH 2050 – Our Target Aerospace Engineering...

November 2015 Aerospace Engineering 2015

‘Wing of the Future’

2025 and beyond

Aerospace Engineering 2015

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© AIRBUS Operations LTD. All rights reserved. Confidential and proprietary document.

A Product Perspective


November 2015

© AIRBUS Operations LTD. All rights reserved. Confidential and proprietary document.

FLIGHTPATH 2050 – Our Target


Baseline 2000 2010 2020 2050

Fuel Burn - 15% Fuel Burn - 50%

Maintenance - 15% No Unscheduled Maintenance

Versatile Cabin Accident Rate - 80%

Turn Around Time -30%

Cost - 20% Cost - 40%

Time to Market - 20% Time to Market - 50% Cost of Certification - 50%

CO2 - 15% CO2 - 50% CO2 - 75%

NOX - 20% NOX - 80% NOX - 90%

Noise - No Increase from 20

Years Passenger Growth

(Percieved)

Noise - 50% (Perceived) Noise - 65% (Perceived)

Emission Free Taxiing

Product Performance

Business Performance

Environmental Performance

BREAKTHROUGH

TECHNOLOGY

EVOLUTIONARY

TECHNOLOGY

DISRUPTIVE

TECHNOLOGY

November 2015

© AIRBUS all rights reserved. Confidential and proprietary document.


• The Engineering Exhibition

• Performance Materials Engineering

• Composites Engineering

• Appropriate that we look to the future of materials

• Not just for their performance

• Raw material now accounts for ~60% of the aircraft cost

• Cannot keep challenging the ‘Value Added’ portion of the supply chains cost.

• Airbus wants to build aircraft with less material

• Don’t worry, with air travel demand set to double over the next 15 years, the material market will still

see a growth!

November 2015



Typical Major Aerostructure Cost Breakdown


50

17

20

8 5

Final Assembly Costs - 'as seen'

Material

Machining

Bought-Out Parts

Assembly

Paint50

17

20

8 5

Bought-Out Costs (20% of 'as seen')

Material

Machining

Bought-Out Parts

Assembly

Process & Paint

60 20

4 10 6

Total Cost Breakdown

Material

Machining

Bought-Out Parts

Assembly

Paint

November 2015


Materials

• The ‘Needs’

• Lightweight

• Good fatigue

• Corrosion resistant

• The ‘Options’

• Composites

• More than 50% of A350XWB

• Metallics

• Response from the industry

• ‘New Business Cases’

November 2015



Reductive Approaches

• Traditional methods

• Forgings

• High Buy-to-Fly ratio (up to 10:1)

• We understand forgings, or do we? (Modelling limitations)

• Close to form forgings assist, but still too much material being bought per part

• Adoption of latest machining techniques always a challenge.

• Focus needed on the science and dynamics of machining rather than ‘trial and error’.

• Having stated this, there still is a place for forgings on critical parts.

November 2015



Additive Approaches

• Additive manufacturing has been with us since the first fabricated part.

• It cannot be considered as just ALM (Additive Layer Manufacturing), even if this technology is ‘in

vogue’.

• Alternative approaches

• Fabrication (various types of welded structures, Friction Stir, Linear Friction, Electron Beam, etc)

• Additive Layer Manufacturing (Powder, Wire Feed)

• Casting

• Powder and HIP

November 2015



Examples of ‘Flying’ Additive Parts

November 2015



Enablers to Additive

• The Raw Material

• Control of the new

• Control of the recycled

• The Processes

• New machines

• Greater energy

• Modelling

• One of the biggest opportunities as we design for additive processes

• Certification

• Robust documented processes

• Standards

• Qualification

• Rules

November 2015



The Future for Additive

• The ‘Best’ process applied for the part

• New modelling tools

• Regional production of parts for Repair & Overhaul

• Reduction of component recurring costs up to 25%

• New Business Models

November 2015



More than 2.5 trillion parts built into 629 aircraft in 2014

November 2015 Aerospace Engineering 2015

‘Wing of the Future’ - easyfairs.com · FLIGHTPATH 2050 – Our Target Aerospace Engineering...

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