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ILA 2006 May 2006

Presented by

Jürgen Pleitner
Airbus

Airbus Customers Benefit from


Fiber Metal Laminates
Application of smart structures
in the aircraft industry

Airbus Costumer Benefit from Fiber Metal Laminates - ESAS - Ref. L53PR0605135 - Issue 1
Airbus Customers Benefit from Fiber Metal Laminates

1+1
1+1 == 33 !! Attractive
Attractive Properties
Properties of
of Fiber
Fiber Metal
Metal Laminates
Laminates

Application of GLARE® Provides Substantial Improvements

Investments of Airbus to Bring the Benefit to our Customers


© AIRBUS DEUTSCHLAND GMBH. All rights reserved. Confidential and proprietary document.

There are Still Treasures to be Explored

Airbus Costumer Benefit from Fiber Metal Laminates - ESAS - Ref. L53PR0605135 - Issue 1 May 2006 Page 2
Fiber Metal Laminates – A Proven Concept

Aluminium layer
Glass fiber/adhesive layer
Aluminium layer
Glass fiber/adhesive layer
Aluminium layer

Fiber Metal Laminates are thin metal sheets bonded together with prepregs

Bonding of Metals
© AIRBUS DEUTSCHLAND GMBH. All rights reserved. Confidential and proprietary document.

Ø Well established in the aerospace industry since WWII.


Ø Bonded structures show improved fatigue properties over monolithic structures.

Fiber Metal Laminate


Ø Introduction of fibers into the bond film leads to further improvement of properties.
Ø Generation of the class of “Fiber Metal Laminates”.
GLARE® Is an Advanced Product of the FML class.
Airbus Costumer Benefit from Fiber Metal Laminates - ESAS - Ref. L53PR0605135 - Issue 1 May 2006 Page 3
Higher Crack Resistance

Fiber Metal Lamination


Crack grows completely through first layer
and can be bridged by the strong fiber
material

Multiple Aluminium Layers


Crack grows completely through first layer
© AIRBUS DEUTSCHLAND GMBH. All rights reserved. Confidential and proprietary document.

and can be stopped to continue through the


bonded seal due to distributed force (only
x 1.25 instead of x 2 with two layers)

Two Aluminium Layers


Crack grows completely through first layer and
continues along the bonded seal
Pure Aluminium
Crack grows completely
through the material

Airbus Costumer Benefit from Fiber Metal Laminates - ESAS - Ref. L53PR0605135 - Issue 1 May 2006 Page 4
GLARE® Design Features – “Giant” Tool Box
Splice in skin panel or doubler Additional glass fiber layers

Limitation of aluminum sheet width


Internal stress level in double curved panels embedded at frame locations

Inter-laminar doublers Fiber Orientation and Lay-up


© AIRBUS DEUTSCHLAND GMBH. All rights reserved. Confidential and proprietary document.

spliced or go thru depending on length Adjust properties to loading condition


and orientation

Transition of GLARE® type Additional layers

Aluminum sheet locally at frame station


e.g. from GLARE® 4 to GLARE® 3 Glass fiber layers locally between two
aluminum sheets
Airbus Costumer Benefit from Fiber Metal Laminates - ESAS - Ref. L53PR0605135 - Issue 1 May 2006 Page 5
Airbus Customers Benefit from Fiber Metal Laminates

1+1 = 3 ! Attractive Properties of Fiber Metal Laminates

Application
Application of GLARE®® Provides
of GLARE Provides Substantial
Substantial Improvements
Improvements

Investments of Airbus to Bring the Benefit to our Customers


© AIRBUS DEUTSCHLAND GMBH. All rights reserved. Confidential and proprietary document.

There are Still Treasures to be Explored

Airbus Costumer Benefit from Fiber Metal Laminates - ESAS - Ref. L53PR0605135 - Issue 1 May 2006 Page 6
A380 – Weight Saving

Ø Superior F&DT properties of FML


Ø Splice concept allows elimination of
© AIRBUS DEUTSCHLAND GMBH. All rights reserved. Confidential and proprietary document.

longitudinal joints
Ø Additional fibers underneath stringer allow
use of un-reinforced frames
Ø Static properties sufficient
⇒ FML (GLARE® ) in sections 13, 15 and18
allow about 800 kg weight reduction
Transition
Airbus Costumer Benefit from Fiber Metal Laminates - ESAS - Ref. L53PR0605135 - Issue 1 May 2006 Page 7
Crack Propagation is no Sizing Parameter

2024-
General differences of GLARE®

Half Crack Length


T3

compared with Aluminium: l

Ø Fatigue life is longer 2a

Glare 3 W

Ø Crack initiation is earlier


Ø Contribution of crack
Glare 2
propagation period on total
fatigue life is larger
Fatigue Cycles
© AIRBUS DEUTSCHLAND GMBH. All rights reserved. Confidential and proprietary document.

GLARE ® 3-3/2-0.3
Glare N (initiation)
2024T3 N (crack growth)

0 100000 200000 300000


N
Cycles to failure

Airbus Costumer Benefit from Fiber Metal Laminates - ESAS - Ref. L53PR0605135 - Issue 1 May 2006 Page 8
A380 - Large Damage Capability (LDC)

accidental damage, growing

no demand to
design outer frame
flange against LDC

GLARE® 3 improved:
© AIRBUS DEUTSCHLAND GMBH. All rights reserved. Confidential and proprietary document.

Additional Glass fibre layers in circumferential direction:


Ø Crack Turning
Ø Higher allowable circumferential stress levels
Ø Damage tolerant, light weight design
Ø Weight saving

Airbus Costumer Benefit from Fiber Metal Laminates - ESAS - Ref. L53PR0605135 - Issue 1 May 2006 Page 9
Improved Impact Resistance

Minimum impact energy to initiate first crack(J)


100 95

90
Static
80 Low Velocity (m=575 g)
Low Velocity (m=2333 g)
70
High Velocity (m=23.3g)
60

50

40 37 >38

30
21
© AIRBUS DEUTSCHLAND GMBH. All rights reserved. Confidential and proprietary document.

20 18
13 12
9
10 5 6 6 4 3 3
0
2024-T3 bare GLARE®3-3/2-0.3 Carbon/PEEK Carbon/PEEK
t=1.4mm t=1.4mm quasi isotropic, t=2.1mm cross-ply, t=1.4mm

The impact energy threshold for first crack in GLARE® is found to be equal or better than
for aluminium alloys and superior to composites.

Airbus Costumer Benefit from Fiber Metal Laminates - ESAS - Ref. L53PR0605135 - Issue 1 May 2006 Page 10
Airbus Customers Benefit from Fiber Metal Laminates

1+1 = 3 ! Attractive Properties of Fiber Metal Laminates

Application of GLARE® Provides Substantial Improvements

Investments
Investments of
of Airbus
Airbus to
to Bring
Bring the
the Benefit
Benefit to
to our
our Customers
Customers
© AIRBUS DEUTSCHLAND GMBH. All rights reserved. Confidential and proprietary document.

There are Still Treasures to be Explored

Airbus Costumer Benefit from Fiber Metal Laminates - ESAS - Ref. L53PR0605135 - Issue 1 May 2006 Page 11
Mature and Effective Manufacturing Process

1. De-coiling from roll 2. Chemical treatment line 3. Robot spraying


© AIRBUS DEUTSCHLAND GMBH. All rights reserved. Confidential and proprietary document.

4. Prepreg cutting 5. Inspections 6. First aluminium layers

7. Prepreg layer 0° 8. Prepreg layer 90° 9. Top aluminium layers

Airbus Costumer Benefit from Fiber Metal Laminates - ESAS - Ref. L53PR0605135 - Issue 1 May 2006 Page 12
Mature and Effective Manufacturing Process

10. Autoclave 11. Cured Glare skin 12. C-Scan


© AIRBUS DEUTSCHLAND GMBH. All rights reserved. Confidential and proprietary document.

13. Machining 14. 2nd bonding for doublers and/or stringers

Airbus Costumer Benefit from Fiber Metal Laminates - ESAS - Ref. L53PR0605135 - Issue 1 May 2006 Page 13
Engineers Systematically Support the Aircraft
Development Cycle
Pre Design
Pre Design Structure design
Structure Design + Analysis Manufacturing
Manufacturing
- Feasibility Studies - Extended Enterprise - Acceptable Damage Limits
- Rapid Sizing - Automation & Standardization - Handling of Concessions
- Rapid What If Analysis Capability - Support & Training - Manufacturing Defects
- Robust design optimization - Robust processes
- Selection of Material and Design - Handbooks
Principles

Research
Research Maintenance
Maintenance
- New Materials - Allowable Damages
- New Design Principles Structure - Standardization and Simplification
- New Technologies of Repair Design Principles,
Engineering
© AIRBUS DEUTSCHLAND GMBH. All rights reserved. Confidential and proprietary document.

- Improved Methods Analysis Methods and Tools


- Virtual Testing - Bonded Repair
- Robust Failure Analysis

Certification & Safety/ Technical Authority


- Static Test Working Group
- MoC; Top Level RequirementsFull Scale Test
- Test/Analysis Pyramid Optimization - DCS Network
Components
- Audits
Test Pyramid
and Technical Reviews Sub Components
- ES Analysis Group
Elements
- A/L Integration Details - Validation Testing
Coupons

Airbus Costumer Benefit from Fiber Metal Laminates - ESAS - Ref. L53PR0605135 - Issue 1 May 2006 Page 14
Airbus Customers Benefit from Fiber Metal Laminates

1+1 = 3 ! Attractive Properties of Fiber Metal Laminates

Application of GLARE® Provides Substantial Improvements

Investments of Airbus to Bring the Benefit to our Customers


© AIRBUS DEUTSCHLAND GMBH. All rights reserved. Confidential and proprietary document.

There
There are
are Still
Still Treasures
Treasures to
to be
be Explored
Explored

Airbus Costumer Benefit from Fiber Metal Laminates - ESAS - Ref. L53PR0605135 - Issue 1 May 2006 Page 15
There are still treasures to be explored

GLARE Demonstrator
Panel

AIRBUS A380

They will show their good properties in- Fiber Metal Laminates have been
service (A310 demo panel flying since 1999 successfully introduced into the Airbus A380.
without problems).
© AIRBUS DEUTSCHLAND GMBH. All rights reserved. Confidential and proprietary document.

Continuous improvement and wider application range:


4 FML stringers
4 New aluminum alloys: 7475, Al-Li
4 New prepregs
4 Application in other areas of aircraft
4 Support future development of A380 family, e.g. A380 freighter

Transfer knowledge and benefits of FMLs to new Airbus aircraft

Airbus Costumer Benefit from Fiber Metal Laminates - ESAS - Ref. L53PR0605135 - Issue 1 May 2006 Page 16
Airbus Customers Benefit from Fiber Metal Laminates
1+1 = 3 ! Attractive Properties of Fiber Metal Laminates
Applications of GLARE® Provides Substantial Improvements
Investments of Airbus to Bring the Benefit to our Customers
There are Still Treasures to be Explored for Applications in Future Airbus Aircrafts
© AIRBUS DEUTSCHLAND GMBH. All rights reserved. Confidential and proprietary document.

Thank you very much for your attention!


Airbus Costumer Benefit from Fiber Metal Laminates - ESAS - Ref. L53PR0605135 - Issue 1 May 2006 Page 17
This presentation has been made possible by contribution from:
T. Beumler, F. Pellenkoft, A. Tillich, W. Wohlers, C. Smart, Airbus,
Fokker Aerospace

© AIRBUS DEUTSCHLAND GMBH. All rights reserved.


Confidential and proprietary document.
This document and all information contained herein is the sole
property of AIRBUS DEUTSCHLAND GMBH. No intellectual
property rights are granted by the delivery of this document or
the disclosure of its content. This document shall not be
reproduced or disclosed to a third party without the express
written consent of AIRBUS DEUTSCHLAND GMBH. This
document and its content shall not be used for any purpose
other than that for which it is supplied.
The statements made herein do not constitute an offer. They
are based on the mentioned assumptions and are expressed
© AIRBUS DEUTSCHLAND GMBH. All rights reserved. Confidential and proprietary document.

in good faith. Where the supporting grounds for these


statements are not shown, AIRBUS DEUTSCHLAND GMBH
will be pleased to explain the basis thereof.
AIRBUS, its logo, A300, A310, A318, A319, A320, A321,
A330, A340, A350, A380, A400M are registered trademarks.

Airbus Costumer Benefit from Fiber Metal Laminates - ESAS - Ref. L53PR0605135 - Issue 1 May 2006 Page 18

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