BOE021711-120

Aerospace Structural
Material Certification
Dave Furdek
Mgr Next Generation Composite Materials
Boeing Research and Technology
28 February 2011

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Copyright 2006 Boeing. All rights reserved.

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Boeing Products

F-18
767

717

JTRS

BBJ

Weapons
C-17
Launch

ISS

Ad
Advanced
d Systems
S t
787

747

Unmanned
Systems
Satellites

Rotorcraft
777

737

Tankers

Boeing Commercial
Aircraft
Copyright 2006 Boeing. All rights reserved.

Boeing Defense, Space,

and Security
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Material Selection Drivers

225 SEATS
275 SEATS
300 SEATS
200 SEATS
250 SEATS

350 SEATS

400 SEATS

Fuel consumption p
F
per seat

450 SEATS

Current Quads

Current Twins

500
SEATS

550
SEATS

20% Better

787

Fuel consumption per trip

Payload,
y
, Performance,, and Cost
are Driving the Boeing Defense
Focus on Structural Materials

Fuel Efficiency is Driving

Commercial Focus on
Structural Materials

Performance Gains from Weight Reductions are

Driving the Increased Usage of Composite Materials
Copyright 2006 Boeing. All rights reserved.

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Volu
ume of Sttructural Compos
sites
in Aeros
space Pro
oduction
n

Commercial Production Driving

Increased Usage of Composite Materials
50% of the 787 Is Composite
Structure
787s Primary Structural
Composite Material System was
developed in the 1990s
1990 s

Time

Material Development Must Begin Well in Advance of

Conceptual Design
Copyright 2006 Boeing. All rights reserved.

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A New Material System Must Earn

y onto the Airplane
p
Its Way
Design loads
Environment &
discrete events

Static strength

Maintainability
Repairability
Inspectability

Producibility

Stiffness and
flutter

Structures
Design
Criteria

Durability
Fatigue
Corrosion
C
i

Crashworthiness

Fail safety

Targeted Application
Breakthrough Performance
Improvements
Material Substitution
Reduced Minimum Gauge
System Level Functionality

Damage tolerance
or safe -life

Value / Affordability Across

the Life Cycle

Systems

Engines
Materials

Material Cost
Fabrication

Aerodynamics

Service

Significant Improvements Must Be Realized to offset

the Development and Certification Costs
Copyright 2006 Boeing. All rights reserved.

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Certification of New Material Systems

y
Development Phase

Fullscale
tests

Analysis
Verification

Component
tests

Sub-component tests
Structural elements tests

Design-value
d
development
l
t

Allowable development
Material specification development
Material screening and selection

Development Time

Modification of an
existing material for a
non-critical component

2-3 y
years

Modification of an
existing material for a
critical structural
component

Up to 4 years

New material within a

system for which there
i experience
is
i

Up to 10 years includes

New material class

Up to 20 years or more

time to define the materials

composition
iti and
d processing
i
parameters
includes time required to develop
design
g p
practices that fully
y exploit
p
the performance of the material
and establish a viable industrial
base

Material
property
evaluation

SOURCE: R. Schafrik, GE Aircraft Engines, Technology Transition in Aerospace Industry, briefing presented at the Worksop on Accelerating
Technology Transition, National Research Council, Washington DC, November 24, 2003

Significant Risk Mitigation is Required to Certify a

New Structural Material
Copyright 2006 Boeing. All rights reserved.

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Blocking Block Approach to

Materials Maturity and Risk Reduction
1. Basic Material Physical
2 Mechanical Properties
2.
3. Process Feasibility
4. Material and Process Scalability - Specifications
5. Design Allowables & Subcomponent Article
Demonstration
6. Critical Feature/Full Scale Component Testing

Processing and Process Variability Can Significantly

Impact Structural Performance
Copyright 2006 Boeing. All rights reserved.

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Material Processing Can Significantly

Impact Structural Performance
Pristine materials

Processing anomalies

Reduction
of the
allowable
stress

Surface irregularities
Splicing

Scale and Complexity of Design

Matter Alot

Waviness
Inclusions
Voids
Damage

Stress

Visible damage

Allowable
design
region

BVID (For Ultimate)

Repair (holes, etc.)
Design
Environment

Strain

Processing Variability Impacts

Weight Reduction Potential
Materials Development Must Include
Processing Needs
Can the New Materials Be Used with
an Existing Process or Is a New
Fabrication Technique Required?
Do the Support Materials Exist
Consumables, Adhesives, etc

Variability Impacts Both Processing and

Structural Performance
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Aerospace Requires Enhanced

Quality Control in the Supply Base
Industrial Scale Quantities
Production Ready Equipment
and Facilities
Qualityy / Verification Control
Capability
~80X more
composites, by
weight, in annual
f ll t production
full-rate
d ti
of 787 than F-22

Standardization of Testing
Supplier Certification
Expertise/Skill Base
Cost
Regulatory Compliance

Aerospace Manufacturers Need to Understand a

Materials Impact Beyond Acquisition
Copyright 2006 Boeing. All rights reserved.

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A New Material System Needs to Be

Understood Throughout Its Life Cycle
Assembly
Surface Preparation
for Finishing

Safe for
Shop
Sa
afe For
Environment

Retire
Part/Product

Recycle

Energy
Efficiency

Solid
Waste
Disposal

Hazardous
Waste
Green
House
Gases

Reduce
Footprint

Safe for Airrlines &

S
Passengers

Fabrication

In-service
In
service Maintenance
& Repair

NanoComposites Need to Be Safe and Meet Regulatory

Compliance Throughout the LIfecycle
Copyright 2006 Boeing. All rights reserved.

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NanoComposites Have Tremendous

Potential To Improve Our Systems
Electrical
Properties

Mechanical
Properties

Potential for
Multifunctional
Composites
Thermal
Properties

Manufacturing
Enablers

Acoustic Properties

Fire Retardant

Need to Demonstrate the Performance Feasibility of

NanoComposites to Create the Necessary Pull
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Emerging Materials Focus

Understand the
Science

Investigate and Mature

New Material Forms

Modeling, Simulation,
Modeling
Simulation and
Analysis will Accelerate the
Adoption

Engineered
g
Materials

Functionality

Improved Structural Properties

Novel Processing

Enabling Engineered Materials for System Level

Performance is Key
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NanoComposites Transition Opportunities

Across Time Horizons
Horizon 3:
Exploration for Future Generation
Horizon 1:
Current Generation
Programs

Horizon 2:
Next Generation

Capabilitties

Multifunctional Coatings
Coating Technology

Enhancements to
Secondary Structure

Sensor Materials &

Technology

Payloads and Interior

Applications

Point Solution to
Difficult Problem

Very High Cost/Weight

Payoff Technology

Nano Enhanced, High

Performance Primary
Structure
Multifunctional
Structural Materials
Engineered Materials
Dynamic self
self-assembly of materials

Implementation of NanoComposites is
Likely to Be Incremental
Copyright 2006 Boeing. All rights reserved.

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Summary
NanoComposites
a oCo pos tes have
a e ssignificant
g ca t pote
potential
ta
Materials must earn their way onto the airplane
Significant Performance improvements required to offset
development costs

Aerospace use requires rigorous building block

approach and quality control system
Safety and Environmental issues are critical
Implementation likely to be incremental (builds
confidence
fid
and
d iimproves understanding)
d t di )
Copyright 2006 Boeing. All rights reserved.

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Thank You

BOEING is a trademark of Boeing Management Company.

Copyright 2006 Boeing. All rights reserved.

BOE021711-120