eco-design itd airframe application innovative metallic ...rolling on raw material sheet back in its...

Eco-Design ITD Airframe Application

Innovative metallic developments : example of synergies

Lorane Jammaron, Matthieu Pachoutinsky

Dassault Aviation

Paris Le Bourget, June 20th 2013

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This document is the property of one or more Parties to the Clean Sky Eco-Design ITD consortium and shall not be distributed or reproduced without their formal approval

• Development of A/C technologies to reduce environmental impacts during out-of-operation phases of the A/C lifecycle

Eco-Design for Airframe (EDA) Objectives

Reduction of

inputs and

outputs

Technology

areas along

the lifecycle

WP 2.1

WP 2.2

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Materials Processes

WP2.1 WP2.2

1) Partners within ECEFA

2) EDA members

Manufacturing tools

Machining process / forming process

Panel A

Panel geometry:

Length: 40” – 80”

Radius (OML): 1100mm (43.3”)

Panel BPanel C

Panel D

Panel A

Panel geometry:

Length: 40” – 80”

Radius (OML): 1100mm (43.3”)

Panel BPanel C

Panel D

B2 (IAI leader)

WP 4 definition

WP 5 detailed design

WP 6 fabrication and test

Rolling process/mechanical machining process

Dassault

panel B

Architecture of study

AlMgLi

Mg

pre-demonstration activities

Surface treatments

Other aluminums

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• Partners involved in this Call for Proposal: Constellium (Partner selected through CfP process), DAv (topic manager), HAI, EADS-IW, IAI

• Objectives: develop and characterize a new aluminium for fuselage applications

• Specification : same properties as 2024T3, better intrinsic corrosion behaviour to compensate lower corrosion protection efficiency due to chromates replacement (REAch) , lower density

• Answer from Constellium: AlMgLi, 5XXX series with precipitation hardening

• Results : characterization in accordance with all industrials.

• Challenge: combination of mechanical performance, better intrinsic corrosion, same ability to forming

Low density aluminium alloy development (CfP ECEFA)

4


212-01-03 New magnesium alloys

• Partners involved in this topic: Aero Magnesium (CfP Partner), IAI (topic manager), DAv

• CfP: DIMAG Hot forming of magnesium in sheet E43, leading to shelf demonstrator.

• Outputs of DIMAG used by IAI and DAv for shaping parts on demonstrator

• CfP: COMAG conductive coating for Magnesium.

5


• Partners involved in those tasks: Dav; IAI

222-02-01 Metallic green processes

Type of part

Bracket

Frame

Rib

Stringer

6


• Partners involved in those tasks: Dav; IAI

• Replacement of chemical machining by mechanical machining Chrome VI involved in acid bath

222-02-02 Metallic green processes

Rolling on raw material

sheet back in its former flat shape

Mechanical machining process

Final shaping

7


TP a/c structures TP a/c

structures

Metallic alloys,

processes and surface treatments

Low Energy Curing

Low Energy Curing

Low Energy Curing

Mg alloys

Low Energy Curing

Light Alloys / Green

metallics

Panel A

Panel geometry:

Length: 40” – 80”

Radius (OML): 1100mm (43.3”)

Panel BPanel C

Panel D

Panel A

Panel geometry:

Length: 40” – 80”

Radius (OML): 1100mm (43.3”)

Panel BPanel C

Panel D

Examples of EDA Demonstrators

Integrating technologies all in one: the B2

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Low weight green metallic fuselage section B2 Demonstrator

• Partners involved in this demonstrator: Leader IAI; DAv; HAI, EADS-IW

• Objectives of the demonstrator: • To integrate new green metallic materials, technologies and surface

treatments thereby decreasing the environmental impact of the fuselage

• To demonstrate manufacturability of those materials and technologies on a fuselage section

• To optimize environmental benefits and weight reduction compared to a similar fuselage section made of conventional alloys

• To demonstrate corrosion resistance by using new alloys with higher intrinsic corrosion resistance and chromate free surface treatments.

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• Geometry – The demonstrator represents a fuselage panel of a business jet,

designed to withstand typical loads and bending cases

– It is divided into 4 panels, each made by a specific partner: Panels A & D – IAI, Panel B – DAv, Panel C – HAI ; EADS-IWF- Frame in Panel A

– Each panel includes parts such as: Skin, Frames, Intercostals, stringers, etc.

B2 demonstrator

Panel B - Dav

Panel A

Panel geometry:

Length: 40” – 80”

Radius (OML): 1100mm (43.3”)

Panel BPanel C

Panel D

Panel A

Panel geometry:

Length: 40” – 80”

Radius (OML): 1100mm (43.3”)

Panel BPanel C

Panel D

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B2 demonstrator

• Panel B (including parts)

Stringer hot forming Mg E43 and AlMgLi, or extruded from AlMgLi tagnite/oxylan(Mg),spray sol gel (AlMgLi)

Sheet metal frame AlMgLi and 2198E-coating

Machined junction between skin 2050spray sol gel

Skin AlMgLi from ECEFA

E-coating

spray sol gel

SAA

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• Good synergy between partners

• Win-win relationship

How do we meet the objectives?

212-01-01 Aluminium Spine bone ECEFA

212-01-03 Magnesium Spinebone DIMAG

212-02-01 Surface treatments

222-02-02 Replacement of chemical milling

WP6 Natural ageing Demonstrate robustness of our choice

WP6 LCA and dismantling True environmental impact reduction

221-01-06 Replacement of shot peening

B2 Demonstrator

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Conclusions

• Everybody involved in work and results shared in details

• Sustainable partnerships created

• Focus on challenging development from TRL3 to 6 • New Alloy very low density

• Green surface treatments,

• New Mg alloy (sheet)

• Replacement of chemical machining by mechanical machining

• Global system approach for managing environmental impact

• Link between elementary development and demonstrator technologies

• Concept proof through physical tests

IW 13

eco-design itd airframe application innovative metallic ...rolling on raw material sheet back in its...

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