WMF - AIRBUS - 3rd Generation of Composites for Airframe June 2015

Procurement
Olivier Cauquil
SVP Material and Parts Procurement

3rd Generation of
Composite Materials
for Airframe
World Materials Forum
Workshop on Composites
WMF - AIRBUS - 3rd Generation of Composites for Airframe June 2015

Outline

Introduction
• Composite use evolution in Airbus
• Current composite technologies

Composite Airframe – Key development areas

• Cost reduction
• Performance & Multifunctionality
• Processability
• Reuse & Recyclability

Conclusions

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WMF - AIRBUS - 3rd Generation of Composites for Airframe June 2015

Composite use in Airbus A/C: a sustained increase

During the last 40 years, Airbus has A350

50 continuously and progressively
Composite Structural Weight [%]

introduced composite technology in

aircrafts, as a result of a successful and
40 accumulated experience in this field
A400M

However, continuous R&D effort

30 A380
in composites is key to maintain
their competition in Airframe
field for future Airbus programs
A340-600
20 A340-300

A320
A310-200
A300
10

0
1970 1980 1990 2000 2010

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WMF - AIRBUS - 3rd Generation of Composites for Airframe June 2015

Material use in Airbus Aircrafts

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WMF - AIRBUS - 3rd Generation of Composites for Airframe June 2015

Overview of current composite technologies for Airframe

Performance benchmark  Cost challenge!!
Thermoset
Prepreg
(epoxy + CF,
tape / fabric)
Process: ATL / AFP lay-up + autoclave curing Primary structure, wide use

Cost attractive  Performance challenge to reach prepreg!!

Dry CF textile /
Resin (epoxy)
infusion
Process: dry textile lay-up +
Liquid Resin Infusion + oven / Primary structure, still less used than
tool curing prepreg

High performance, low use  Cost & use increase challenges – Big parts!!
Thermoplastics
(PEEK/PEKK +
CF prepreg /
Process: prepreg lay-up Small parts, secondary structure
tape) (+oven/autoclave) ; press
forming, injection
moulding…
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WMF - AIRBUS - 3rd Generation of Composites for Airframe June 2015

Key composite research areas

3rd generation of NEOs –

COMPOSITE materials Incremental
development

 Damage  Fiber
tolerance  Matrix
 Conductivity  Prepreg
 Damping…  …
Performance &
Cost Reduction
Multifunctionality

Composite Materials  Lay-up

 Thermoset: development  Curing
uncured or  NDI, quality
cured control
 Thermoplastic  …
 Dry Fibers
Reuse &
Processability
Recyclability

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 WMF - AIRBUS - 3rd Generation of Composites for Airframe June 2015

Performance – Thermoplastic materials development

Towards long term
TRL
Processing Material Basic / technology 3 1st generation 2nd generation
Tª development Applications Application
PEKK – CF (UD Secondary Primary
300°C 400°C

tape) as alternative structure: structure as

• Material screening /
to PEEK - CF Moveables/LE/TE/ fuselage / cabin,
characterization
(reference) HTP/VTP structure wing, …
• Processability
Towards long term

New evaluation:
Low melting • Lay-up processes,
polymer injection moulding,
Pylon
Over-moulding…
• Welding (US,
ADVANCED TP Induction, resistance)
• Thermoplastic • Multifunctionality
new formulation integration: electrical
integrating multi
TBD

conductivity,
functionalities acoustic Floor structure
• Advanced attenuation…
assembly concept • Recyclability
• In-situ evaluation
consolidation

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WMF - AIRBUS - 3rd Generation of Composites for Airframe June 2015

Multifunctional composites: key development

Description / Objective: Integration of non-inherent
Today: “mono-skill”
composite properties to cover other functions (ex.:
Composites with structural properties
electrical conductivity)

Multifunctional Composites
Electrical Fuselage LE Erosion
Benefit: they will mean an important step forward in structural network acoustic solution protection
terms of the main drivers of future aircraft parts,
programs: weight and cost saving
Functions and technologies:
• Damage tolerance & high energy impact
Future: “multifunctional”
resistance: integrated shielding technologies
Composites with structural and
• Electrical: conductive particles, nanotechnology functional properties
• Acoustic & vibration attenuation: elastomeric
material integration (embedded damping)
• Erosion resistance: elastomeric surface film…
• Anti / de - ice: hydrophobic / heatable coatings Nanodoped
RTM resin
Embedded
damping
CFRP coated
with Cu
• Sensing: sensor integration inside CFRP

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WMF - AIRBUS - 3rd Generation of Composites for Airframe June 2015

Cost reduction

TECHNOLOGY DEVELOPMENT

Towards less Qualification New Approach

testing
Quality Control Approach

New Precursor Technologies for

Carbon Fiber

High Tow Fibers

Towards low cost
building blocks
New Resins

Pre-Impregnated Architecture

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WMF - AIRBUS - 3rd Generation of Composites for Airframe June 2015

Cost reduction: building blocks

Fiber Matrix
• Higher fiber tows  industrial fiber • Low cost polymers  Epoxy
alternative
K Cost • Monomer  Substitution of “Fossil”-
Monomers by “bio”-monomers
Towards (Source: vegetable oils  epoxy)
50K
• Precursor  main focus
 Lower cost
polymers
 Biosources:
lignin, Spinifex
grass
Precursor fiber
(PAN): high cost

Prepreg
• New architecture
• Interleaf system
• Resin content tailoring
• Higher areal weight

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WMF - AIRBUS - 3rd Generation of Composites for Airframe June 2015

Processability

New curing
approaches:
COCURING,
More Efficient semicuring 
Process: PART
QUICKER LAY-UP INTEGRATION
+ CURING Reuse &
(RAPID CURING) Recycling

On line IMPROVE Low Cost

Process & Tooling
NDI MANUFACTURING: Concept
Concept
HIGHER EFFICIENCY

Reduction /
Decrease of elimination of
Process New Part auxiliary
Control Design:
materials
Specimens Design to
Manufactu
ring

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WMF - AIRBUS - 3rd Generation of Composites for Airframe June 2015

Reuse & Recycling

Composite Reduction of raw materials residue

Materials Must Get
RECYCLABLE 1) Removal of resin by
pyrolysis.
Recycling of
2) Electric Cogeneration
composite
3) Getting fibers without
raw materials sizing for TP injection
moulding or matt prepregs

After Carbon Fiber

Scraps Cut Scraps
processing 0% Resins
Reuse of residue non cured material

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WMF - AIRBUS - 3rd Generation of Composites for Airframe June 2015

Conclusions

 Airbus has always bet on composite use as a way to improve A/C

performance and, then, save weight, until reaching more than 50% of structural
weight in composite for last generation aircraft: the A350 XWB

 Current composite technologies: composites made of epoxy resin and

carbon fibers are the predominant ones, while thermoplastic composite use in
airframe is still low. In terms of composite processing: prepreg is the most used
technology, followed by liquid resin infusion

 Composite materials need to compete again with metallic materials for

airframe applications that are made of composite in last generation A/C
(example: fuselage)
 A continuous R&D effort is needed to develop innovative composite
materials and processes: cost reduction, performance, multifunctionality,
processability & reuse / recycle are key development areas to maintain
composite presence / use in commercial aeronautical field  Research
community effort is key in these areas

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WMF - AIRBUS - 3rd Generation of Composites for Airframe June 2015

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Thank you
Presentation Prepared by:
for your attention
• Jose Sánchez Gómez – Composite Materials Senior
Expert, ESCAA
• Ivan Gayoso – Composites Procurement, PMCC
• Tamara Blanco – R&T Composite Materials, ESCRNM

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