25.11.

2014

Compositeclass:developingtheAirbusA350XWB|Indepth|TheEngineer

Compositeclass:developingtheAirbusA350XWB
20June2011|ByStuartNathan
EuropesanswertotheDreamliner,theAirbusA350XWBisbeginningtotakeshape
Thefutureisplastics,astheyoungDustinHoffmanwasmemorablytoldinthe1960sclassicfilmThe
Graduate.Fortheaerospaceindustry,itwascertainlysomedistanceintothefuture.Itsonlynow,more
than40yearslater,thatpolymersarestartingtomakeseriousinroadsintheconstructionofaircraftbut
theeraoftheplasticplaneiswellandtrulywithus.Boeings787,thefirstmajorairlinertobe
predominantlymadefromcomposites,isexpectedtobecertifiedlaterthisyear.Meanwhile,theAirbus
A350XWB,whichalsomakesheavyuseofthelightweightmaterial,iscurrentlyinthefinalstagesof
preparationbeforeaplannedfirstflightin2013.
TheXWBinthedesignationstandsforextrawidebody,andtheA350scabinwillseatnineabreastin
standardclassandeightinpremiumclassthecompanyclaimsthateachseatwillbe1.3cmwiderthanthe
equivalentconfigurationoftheaircraftschiefcompetitor,theBoeing787Dreamliner.Infact,theentire
conceptoftheaircraftwasoriginallyconceivedasaresponsetotheBoeing787.Initiallyproposingan
updatedversionofitspreviouswidebodyjet,theA330,thecompanyrespondedtocriticismofalackof
ambitionbylaunchingaprogrammetodesignalighterweight,moreaerodynamicairlinerthatcould
matchtheDreamlinersclaimed25percentreductioninfuelconsumptioncomparedwithitspredecessor.
Infact,thecompanyhasendedupdesigninganaircraftthatwillcompetemorewiththeBoeing777than
theDreamliner,asitsaslightlylargeraircrafttheA350familywillseat270440people,tothe787s
210330.TherearethreeaircraftintheA350family,withthebasicmodelactuallybeingthemiddleone,
designatedtheA350XWB900,witha65mlongfuselageandamaximumtakeoffweightof268tonnes
thesmaller800isashortenedfuselagevariant,whilethelarger1000isstretched.
Mostpartsoftheaircraftareamixtureofcompositeandalloy
TheA350alsohasaslightlyhigherproportionofcompositesinitsconstructionthantheDreamliner53per
cent,asopposedto50percent.Theremaining47percentiscomposedoftitaniumandaluminium
lithiumalloy.Mostpartsoftheaircraftareamixtureofcompositeandalloyinthewings,themainmetal
componentsareintersparribs(thesparsbeingthesupportingstructuresrunningalongthewingfromtip
toroot,andtheribsrunningacrossthewidthofthestructure).Inthefuselage,theouterskinpanelsare
carbonfibre,asistheframe,althoughtheframeincludesaluminiumstripstoensurethatlightningstrikes
canbedissipated.Thesupportingcrossbeamsaremetallic.
AsthisisthefirstcompositefuselageAirbushasmanufactured,testingisunderway,withacomposite
panelreplacinganaluminiumoneonanA340testbed,providinginformationontheacousticperformance
ofthematerial.Compositeisneitherworsenorbetter[intermsofacoustics]itsjustdifferent,said
DidierEvrard,A350XWBprogrammemanager.Wethoughtweneededtogetinformationonadjustingthe
acousticdampeners.
AirbushasbuilttwofuselagedemonstratorsatitsHamburgfacility,includingafullscaledemonstrator
thatitisusingtotestinstallationandsystemsanapproachitadoptedafterproblemswiththewiring
systemsoftheA380,whichweredesignedindigitalmockups.Difficultieswithtranslatingthisontothe
realaircraftledtodelaysinthedeliveryofthesuperjumbo.Wearetrainingourprefinalassemblyline
peopleandtestingthesysteminstallationprocessonthephysicalmockupatHamburg,saidEvrard.The
teamstrainoninstallingtheharnesses,pipes,tubesandwiresbeforewemovetotheaircraftforreal.It
hasbeenreallyuseful,withthetechniciansanddesignersinformingeachotheronchangesand
improvements.
ThewingoftheA350XWBisanintegralpartoftheoveralldesignforfueleconomy,andmaybethemost
distinctivepartoftheaircraft,withitsthincrosssectionandupwardscurvingtips.Itisthesecond
compositewingthatAirbushastackled,butthefirstforacommercialairlinerthefirstwasfortheA400M
militarytransportaircraft.
Thewaythewingswillbeconstructeddoes,however,representafirstforthecompany:theywillbebuilt
inahorizontalconfiguration,insteadofvertically,likepreviouswings.Thisistoallowaccesstothe
centralwingboxareaandtomaketheholesforthecomponentsinstalledunderneaththewingseasierto
getto.
ThewingswillbeassembledatAirbussfacilityinBroughton,nearManchester,usingpartsfromallover
http://www.theengineer.co.uk/indepth/thebigstory/compositeclassdevelopingtheairbusa350xwb/1009059.article

1/5

25.11.2014

Compositeclass:developingtheAirbusA350XWB|Indepth|TheEngineer

theworld:frontsparfromSpiritAerosystemsintheUSrearsparfromGKNinFilton,nearBristol
leadingedgealsofromSpirit,butthistimefromPrestwickinScotlanduppercoverfromGermanyand
lowercoverfromSpain.
OnceshippedtoBroughton,thesparswillbeattachedtothealuminiumlithiumribs,andthecoverswill
befixedtemporarilyintoplacefordrilling.Thecoversareasinglepiece,ratherthanmultiplepartsason
themuchlargerA380wingand,againincontrasttotheA380,theskinsforthewingsarebondedrather
thanboltedintoplace,sofarfewerholesareneededonly5,000percover,ratherthanthequarterofa
millionforanA380cover.Oncedrilled,thecoversareremovedfordeburringandsealing,andthen
replacedforfasteningontothestructure.Theinternalstructuresfueltanksandsomeofthehydraulicsare
installed,beforethewingissentforpaintingandthenflownovertoanotherAirbusplant,inBremen,
wheretheelectrics,pneumatics,controlsurfacesandremaininghydraulicsareputintoplace.Whenthat
isdone,itsofftothefinalassemblyinToulouse.
Theshifttocompositepartsratherthanmetallicputsadifferentemphasisonthemanufacturingprocess.
Metallicpartsaregenerallyproducednearnetthatis,closetothespecificationsneededbutnotspoton,
withmachiningprovidingthefinaltouchestogetwithintheengineeringtolerances.Butcompositeparts
aremadetherightsizefromthestart,sothemostpreciseengineeringhastogointomakingthetoolsto
producetheparts,ratherthanintomakingthepartsthemselves.
TheA350hasaslightlyhigherproportionofcompositesinitsconstructionthantheDreamliner
aircraft
ElectronicsystemsfortheaircraftcomefromThales,whichisprovidingboththecockpitandtheinflight
entertainmentsystems.ThecockpitwillhaveasimilarfeeltootherAirbusmodelswhichispartofthe
companyspolicytoensurepilotscanmakethetransitiontothenewaircrafteasilyandThaleshas
customiseditsheadupdisplay(HUD)system,usedontheA380,fortheA350family.
Thecockpitdesign,currentlybeingtestedinToulouse,hassixdisplays,withtheHUDandtheonboard
airportnavigationsystemintegratedintothedisplaysystem,whichwillhostthesoftwaredirectly.This
hasallowedThalestodispensewithaseparateprocessingunitforthesesystems,whichissaidtofreeup
cockpitspacewhilereducingweightbyabout15kgandcuttingelectricityconsumptionby150W.
HUDisarelativenewcomertocommercialairlinecockpits,althoughithasbeenusedbymilitarypilots
foryears.However,Airbusbeganusingitin2009,andhaditonitswishlistfortheA350seriesfromthe
start,saidMichelSolerofThalesAvionics.ThalessHUDwaspartoftheinitialdesignoftheA350andwill
getcertificationwhentheaircraftentersintoservice,meaningquickerdeliveryforcustomers,hesaid.
HUDoncommercialairlinersisnowarealtrend.Ourgoalisforthistypeofproducttobecomestandard
onallAirbusaircraftinthenearterm.
InanothersimilaritytotheA380,theA350willhaveitsownengine,developedbyRollsRoyce.Thelatest
versionoftheTrentrangeofturbofanengines,theTrentXWB,underwentitsfirsttestlastJune.The
TrentXWBhasthelowestcarbonemissionsofanywidebodyengine,andwillbethemostfuelefficient
engineonthemarket,saidIanCrawford,directorofAirbusprogrammesatRollsRoyce.
OurgoalisfortheheadupdisplaytobecomestandardonallAirbusaircraft
MichelSoler,ThalesAvionics
TheTrentXWB,asitsnameimplies,isadevelopment,ratherthanastepchange,inenginedesign.Itisa
threeshaftturbofan,lighterthanpreviousmembersoftheTrentfamilyowingtotheuseofbladeddiscs
(blisks)initscompressorstages,ratherthanturbinediscswherethebladesareattachedtothecentral
sectionthefirststageoftheeightfanintermediatepressurecompressorisablisk,asarethefirstthree
ofthesixfansofthehighpressurecompressor.Themainfanoftheengineishuge3macross,widerthan
theentirefuselageofaConcorde,andsizedtokeeptheengineoperatingquietlywhenithastohandle
heavierloads.
Otherinnovationsincludeimprovedheatresistantmaterials,whichenhanceefficiency,andlarger
bearingsabletohandlegreaterload.
OneissuethatremainstoberesolvediswhetherthesameenginewillserveallmodelsoftheA350XWB
fleet.Thiswastheinitialplan,butairlineshaveexpressedconcernthattheengineascurrentlydesigned
willnotdeliverenoughpowerforthelargestversionoftheaircraft,theA3501000.Thereisspeculation
thatRollsRoycewilldevelopamorepowerfulvariantoftheTrentXWBfortheA3501000,withnews
agencyReutersquotingamajorA350customer,thechiefexecutiveofAirLeaseCorporation,sayingthe
currentconfigurationwasntsufficientforpayload,rangeandrunwayperformanceonthelargeraircraft
andthatRollsRoycehadagreedtolookagainatanewdesign.AnannouncementisexpectedattheParis
AirShow,afterthisissueofTheEngineerhasgonetopress.

Secondnature
ConceptCabinissupportedbyabionicstructurethatissaidtomimicthestructureofbirdbone
Airbussfuturedesignsdepartmenthaslookedintothefuturetopresentanideaofhowflyingmightlook
in2050,withaConceptCabindesignthatitclaimsisinspiredbynature.Someofthedetailsprovide
sometantalisingglimpsesoftheengineeringdevelopmentsthecompanyhasinmindforfuture
http://www.theengineer.co.uk/indepth/thebigstory/compositeclassdevelopingtheairbusa350xwb/1009059.article

2/5

25.11.2014

Compositeclass:developingtheAirbusA350XWB|Indepth|TheEngineer

generationsofaircraft.
Forexample,themoststrikingfeatureoftheConceptCabinisthatitcanbecomeneartransparent,with
anintelligentcabinwallmembranecontrollingairtemperaturethatcantransformthecabinintoanall
aroundview.Thismembraneissupportedbyabionicstructure,which,thecompanysaid,mimicsthe
structureofbirdboneandisoptimisedtoprovidestrengthwhereitisneeded.
Engineerswillrecognisethisdescriptionasbeingcharacteristicofadditivelayermanufacturing(ALM),
wherestructuraloptimisationsoftwareisusedtodesignacomplexshapetobeartheforcesexperienced
bythestructure,whichisthenbuiltlayerbylayerbymeltingfinepowderwithalaser.
AirbusisdevelopingALMtechniquesatEADSInnovationWorksinBristol,andhasdevelopedpartssuchas
ductingforairmanagementinsidetheA380wingandtrialsforcomponentsinlandinggear.Thecompany
hasanoverallplantobeabletoprintanentirewingwithin25years.
TheConceptaircraftalsoincludesdesignfeaturessuchasenginessemiintegratedwiththefuselage,
positionedaboveaUshapedtailtohelpreducethenoiseoftheaircraft,andwingsshapedtoprovidethe
laminarflowofairovertheaerodynamicandcontrolsurfaces,removingturbulencefromtheairflow,
whichincreasesthepowerneededtopushtheaircraftthroughtheair.Thinnerwingsreducethespace
availableforfuelstorage,butthisisatradeoffwiththeimprovedefficiencyofthedesign.
Otherengineeringfeaturesincludefullyrecyclablematerialswithinthecabinspacetheuseofself
cleaningmaterialstoreducemaintenanceandsystemstorecoverpassengerbodyheattopowerthe
cabinfeatures.
Tweet

10

Like

Share

11

Share

Readers'comments(12)
brianm|20Jun20111:16pm
Alsoworthlookingattheworldofmodelaeronauticstoseehowplastictechnologyisbeing
embraced.CommerciallymademodelsareoftenmadeofEPOfoamandendupbeinglighter,lower
costandmoreamazingly,strongerthantraditionallybuiltmodels(intermsofcrashresistance).
Theuseofcarbonfibrestrengtheninghasincreasedthesizeofthesemodelaircrafttowingspansof
1.5mandmore(probablylimitedbythesizeofacarboot!).Electricpowerisnormallyusedinthis
typeofmodel,withhighperformanceLiPobatteriesflighttimessimilartoconventionallyIC
poweredmodels.
LivingclosetoaparkwheretheyareflowntheyarealsomercifullysilentcomparedtotheirIC
poweredbrethren!
DavidHolman|20Jun20111:23pm
Our[GoodrichActuationSystems,Wolverhampton]electricthrustreverseractuationsystemfor
A350XWBisratherfine.WhatothernovelandnewdevelopmentshastheEngineeroverlooked?
Editor'scomments|20Jun20111:23pm
Several,doubtless,butwehavelimitedspaceforfeaturessohadtochoosewhichsystemsto
discuss!
DavidLawton|22Jun20111:21pm
10/10forthearticlebut0/10forgeography'BroughtonnearManchester'??It's5milesfrom
CHESTER,25fromLiverpooland45fromManchester!!
Edward|24Jun20116:58pm
AmIrightinthinkingthatbycompositefuselagetheymeanasandwichofaluminiumsheetswith
polymerbetweeni.e.alaminateorisitatruecomposite?
Dutch|26Jun201111:25am
Thecaptionforthefirstimagereads,"A350XWBhasa64.8mwingspananda64mcockpit".
http://www.theengineer.co.uk/indepth/thebigstory/compositeclassdevelopingtheairbusa350xwb/1009059.article

3/5

25.11.2014

Compositeclass:developingtheAirbusA350XWB|Indepth|TheEngineer

A64mcockpit?Wow.That'sabigplane.
Shouldn'titread"64mfuselage"?
Editor'scomments|26Jun201111:25am
Itshould.Thankyou.
RobertTaylor|14Jul20119:29am
Areaircraftmanufacturersstilltreatingcarbonfibreas'blackmetal'?
IhadajobinterviewacoupleofyearsbackforaMaterialsScientistrolewheretheinterviewing
engineerscomplainedbitterlythataircraftmanufacturerswerestilltreatingcarbonfibrelike
aluminiumalloywhereindividualplateswererivettedtogetherratherthanmouldinglarge
assemblieswhichthemateriallendsitselfto.
Anonymous|19Jul201111:25am
WhataboutthecrashtestfortheCompositefuselage?Isairbusplanningthetestduring
certification?
AB|20Jul20114:04pm
@EdwardNo,itisafuselagewithsolidmonolithicCFCskinsandseparateboltedonframesand
stringers.Skinvarieshugelyinthicknessuptonearly100pliesinhighloadareas.
@RobertYesandnoBoeing787hasaonepiecefuselageskin,A350900hasaskinmadeoflarge
panels.TheAirbusapproachisbbetterforinservicerepairslikebeinghitbyatruck.Duetoscale
it'snotpossibletomakesomeofthesestructureslikewingsoutofonepiece.
Anonymous|7Jan20138:09am
WhatcouldbeexpectedasthicknesstolerancerangeforCFCT800wingskinssay5mmto16mm
whenmadebyhandlayupofprepregsorbyATLwithcompaction?Does+/2%lookfeasible?If
notwhatcouldbebest?
mikeblamey|17Jun20134:21pm
Fascinatingarticleandcommentaries:justasthecomputerindustry'took'ourtextileindustry
patterningsystems(developedbyJacquardetal)andusedthemfortheiradvances,sotheaircraft
industryhasdonethesame.Thistime,takingour'fabric'formingtechniquesandapplyingthemto
theirneeds.Dowegetaroyalty?
Ilookforwardtoreadingmore,particularlyaboutbraidingofcompletepartsindeedwithabraider
largeenough,itwouldbepossibletocreateacompletefuselageinonego!
IdorecallgivingalectureatBoeingin1973toaerospaceEngineerswhichallowedmetoguide
themawayfromthatconceptofcomposites/fabricsNOTbeingvthinflexiblemetal(s)but
designablestructuresintheirownright!
Bestwishes
MikeB
Editor'scomments|17Jun20134:21pm
Braidingiscertainlymakingitswayintospacecraftdesign.Abraidedaircraftfuselageisavery
interestingidea.You'dneedabigautoclave,though!

http://www.theengineer.co.uk/indepth/thebigstory/compositeclassdevelopingtheairbusa350xwb/1009059.article

4/5

25.11.2014

Compositeclass:developingtheAirbusA350XWB|Indepth|TheEngineer

Tweets

Follow

The Engineer
@TheEngineerUK

5h

Fugro nets giant offshore contract bit.ly/1yMLqvD

Expand
The Engineer
@TheEngineerUK

6h

Our Q&A on Rosetta and Philae is now closed.

Many thanks to everyone who sent in questions.
Expand
The Engineer
@TheEngineerUK

10h

Research aims for improvements in powered

prosthetics bit.ly/11Ob7Ri
Expand
The Engineer
@TheEngineerUK

11h

Tweet to @TheEngineerUK

http://www.theengineer.co.uk/indepth/thebigstory/compositeclassdevelopingtheairbusa350xwb/1009059.article

5/5