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Presented by

Guy Hellard

Composites in Airbus
A Long Story of Innovations and Experiences

Composites in Airbus @ Global Investor Forum by Dr Roland Thvenin _V51PR0800355_v1

Composites in Airbus
Table of Content
1. Market Situation and Industrial Composite Applications
2. A350

Structures

AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.

3. Conclusions

Composites in Airbus @ Global Investor Forum by Dr Roland Thvenin _V51PR0800355_v1

Composites in Airbus
Table of Content

AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.

1. Market Situation and Industrial Composite Applications

Composites in Airbus @ Global Investor Forum by Dr Roland Thvenin _V51PR0800355_v1

A step by step gain of composite experience


Composites Introduction

AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.

Within primary structures

1980

1990

Composites in Airbus @ Global Investor Forum by Dr Roland Thvenin _V51PR0800355_v1

2000

2010
4

A step by step gain of composite experience


Composites Introduction
A350XWB
+ Outer wing,
Fuselage

Within primary structures


V10F
+ Outer wing

ATR72
+ Outer wing

AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.

A330/A340
+ HTP as fuel tank
A320
+ HTP, Flaps, Ailerons,
Spoilers
A310-300
Fin, Rudder, Elevators

1980

A380
+ Rear Fuselage, Center Wing Box,
Wing Ribs
A340-600
+ Rear Pressure Bulkhead,
Keel Beam

Unique experience
with more than 70
million FH cumulated

1990

Composites in Airbus @ Global Investor Forum by Dr Roland Thvenin _V51PR0800355_v1

A400M
+ Cargo door,
Outer wing

2000

2010
5

A step by step gain of composite experience


Composite structure / Structure weight (%)
step by step
approach

60

A350XWB

53%

40

A400 M

25%

AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.

20

A320

10

5%

A330

A380-800

A340-600

A310-300

0
1985 1988

1993

Composites in Airbus @ Global Investor Forum by Dr Roland Thvenin _V51PR0800355_v1

2002

2007

2013

Why Composites?
Technology introduction
Design
Manufacturing

Use

AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.

Improve performances
Lower production cost
Quality robustness
Reduce lead time

Reduce Lifecycle cost


(maintenance cost)

Achieved by trade-off
Need to design for CFRP
Composites in Airbus @ Global Investor Forum by Dr Roland Thvenin _V51PR0800355_v1

CFRP: Supply vs. Demand

AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.

Main growth drivers: civil


aviation & wind power
industries
Suppliers increase
investment budgets
EADS demand to increase
substantially beyond 2010

tons

EADS Carbon Fiber Demand

20.000

10.000

0
2005

2010

2015

2020

Close cooperation with current and potential suppliers to


ensure smooth ramp up
Outlook: supplier production capacities to double by 2010
Composites in Airbus @ Global Investor Forum by Dr Roland Thvenin _V51PR0800355_v1

How composites are manufactured?


Typical
Single Part
Production 1
Manufacturing
Process
Wing Panel : CFRP Prepreg
1) Preparation of mould

AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.

5) Curing

2) Automatic tape laying

6) Non destructive testing

Composites in Airbus @ Global Investor Forum by Dr Roland Thvenin _V51PR0800355_v1

3) Stringer integration

7) Milling

4) Vacuum bagging

8) Painting

Industrialisation
Optimisation and assurance of processes
From repair intensive CFRP

AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.

Ni-alloy jig

tool to Nickel-Alloy jig


From manual tape laying to
automated processes
From manual 1-channel NonDestructive Testing (NDT) to
automated multi-channel
testing methods (192 channels)
From manual drilling to
automated processes on multi
flexible tooling.
From manual painting to
automated process
From manual riveting to
half/fully automated riveting
machines

3D-Tape layer
Multi-channel NDT

Trimming machine

Paint robot
Composites in Airbus @ Global Investor Forum by Dr Roland Thvenin _V51PR0800355_v1

Riveting robot
10

10

Composites applications @ EADS


CFRP

Eurocopter
NH90, Tiger:
fuselage

Upper

parts
Segments

EC135:
Primary
Main

structures

rotor

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Tailboom

Squirrel and Dolphin


Rotor

Astrium (contd)
Arianne 5

hub

Astrium
Satellites antenna

Launchers and Missiles


 Upper

parts and
fairings
 Criogenic tanks

EF-2000
 wing
 fuselage
 fairings
 stabilizers

BARRACUDA
(UAV)

MTAD
CN 235/C295
 Elevators,

MAS

 wing

Fairings

A400M
HTP, VTP, Wing covers
Elevator

Composites in Airbus @ Global Investor Forum by Dr Roland Thvenin _V51PR0800355_v1

 fuselage
 fairings
 stabilizers

11

11

Composites applications @ EADS


CFRP structure examples

AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.

Bottom Shell NH90

NH90

Antenna deflector ASTRA


Composites in Airbus @ Global Investor Forum by Dr Roland Thvenin _V51PR0800355_v1

ST

Wing panel EF2000


12

12

A380 Composites applications

AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.

Major applications

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13

A400M Composites applications

AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.

New major applications

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Composites in Airbus
Table of Content
1. Market Situation and Industrial Composite Applications

AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.

2. A350

Structures

Composites in Airbus @ Global Investor Forum by Dr Roland Thvenin _V51PR0800355_v1

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15

A350

Structures

Intelligent airframe
Fuselage:

Empennage (VTP, HTP)

Skin
Frame
Keel Beam
Rear Fuselage

CFRP

Al/Al-Li:

Al & Al-Li

Ribs,
Floor beams,
Gear bays,..

Titanium:
Landing Gears,
Pylons,
Attachments

Titanium
Steel

A350-900 XWB
Misc.

Material Breakdown (%)


Including Landing Gear

Misc.

AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.

8%

Al/Al-Li
19%
6% Steel

Outer Wing Box:


Covers / Stringers / Spars

Centre Wing Box:

Composite

53%

14%

Covers / Stringers / Spars

Titanium

Technologies selected to improve


performance and lower maintenance tasks
Composites in Airbus @ Global Investor Forum by Dr Roland Thvenin _V51PR0800355_v1

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A350

Structures

RATIONALE

Reduce operational cost


Reduce global environmental impact

SOLUTION

Use of CFRP panels, stringers, frame, Keel Beam


Panel as long as possible to reduce the amount of circumferential joints
Optimisation of each panel for its design case

BENEFIT

AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.

Fuselage Innovations : CFRP

Improve passenger comfort by higher cabin pressure


Weight reduction : Fuel-burn savings
Cost reduction and environmental impact reduction
Fatigue- and corrosion-free: Reduce maintenance costs
Composites in Airbus @ Global Investor Forum by Dr Roland Thvenin _V51PR0800355_v1

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A350

Structures

Fuselage Innovations : CFRP - 4 Panels

AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.

Status of developments

Composites in Airbus @ Global Investor Forum by Dr Roland Thvenin _V51PR0800355_v1

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A350

Structures

Fuselage Innovations : CFRP - Barrel


Status of developments
RTM Frames

AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.

Full barrel technology for Rear fuselage

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A350

Structures

Aeroelastic tailoring as a passive


adaptive structure
Reduce operational cost
Reduce global environmental impact

Use of CFRP spars, skins

CFRP outer wing box

CFRP center wing box

and stringers

Fuel-burn savings through weight


BENEFIT

AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.

SOLUTION

RATIONALE

Wing Innovations : CFRP

reduction: cost and environmental


improvement
Fatigue- and corrosion-free
composites save maintenance costs
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A350

Structures

Maintainability / Reparability

AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.

Robustness

Robustness will override the other sizing criteria


within the areas prone to accidental damage.
Composites in Airbus @ Global Investor Forum by Dr Roland Thvenin _V51PR0800355_v1

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A350

Structures

Maintainability / Reparability
Repairs
Standard

bolted repair concept for


structural damages
Existing tools and skills
Similar repair times

AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.

Bonded

repairs for minor cosmetic damage

Most of the former principles still apply


Composites in Airbus @ Global Investor Forum by Dr Roland Thvenin _V51PR0800355_v1

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Composites in Airbus
Table of Content
1. Market Situation and Industrial Composite Applications
2. A350

Structures

AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.

3. Conclusions

Composites in Airbus @ Global Investor Forum by Dr Roland Thvenin _V51PR0800355_v1

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Conclusions
1/2

Long term and unique experience in composite technologies


Comprehensive experience of primary composite parts:
design, certification and maintenance

Multi function approach (e.g. electrical & structural) to improve


performance and associated lightning strike protection

Good long term behavior of carbon composites (corrosion,


AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.

fatigue) decreases maintenance cost

Use of multi panel concept to allow best design optimization


and large repair capability

A350 XWB composite fuselage optimal compromise


between longitudinal & circumferential integration:
- long panel concept in the main fuselage area
- full barrel concept in the non-pressurised area
Composites in Airbus @ Global Investor Forum by Dr Roland Thvenin _V51PR0800355_v1

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Conclusions
2/2

Better structure weight efficiency


Capital intensive production investments determine ramp up
flexibility

Extremely high quality requirements of CFRP parts


4-Panels CFRP Fuselage structure is a risk averse manufacturing

AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.

solution:

Avoids fitting issues encountered in final assembly line


More flexibility during assembly process
Easier part handling for large diameter
Less complex and lighter tooling
Higher manufacturing speed
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AIRBUS S.A.S. All rights reserved. Confidential and


proprietary document.
This document and all information contained herein is the sole
property of AIRBUS S.A.S.. 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 S.A.S. 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
in good faith. Where the supporting grounds for these
statements are not shown, AIRBUS S.A.S. will be pleased to
explain the basis thereof.

AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.

AIRBUS, its logo, A300, A310, A318, A319, A320, A321,


A330, A340, A350, A380, A400M are registered trademarks.

Composites in Airbus @ Global Investor Forum by Dr Roland Thvenin _V51PR0800355_v1

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