Materials and the Aerospace Industry
Enhancing Innovation and Competitiveness Through
Investments in Fundamental Research
Westin Hotel, Arlington, VA
December 3-5, 2006
Krishnan K. Sankaran, Ph.D.
Senior Technical Fellow
Materials and Processes Technology
Boeing Phantom Works
Questions to Consider for Enhancing Innovation and
Competitiveness
Engineering, Operations & Technology | Phantom Works
AM&ST
• Expanded federal investments in research and
education and the impact
• Acceleration of ROI in basic research
• Collaboration models for research
• Specific areas of fundamental research
• Workforce challenges
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Boeing Products
Engineering, Operations & Technology | Phantom Works
Copyright © 2006 Boeing. All rights reserved.
AM&ST
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Materials Research to Meet 21st Century Defense Needs
DoD Sponsored, NRC/NMAB Study - 2003
Engineering, Operations & Technology | Phantom Works
AM&ST
• Revolutionary capabilities from R&D in
•
•
•
•
•
Structural and multifunctional materials
Energy and power materials
Electronic and photonic materials
Functional organic and hybrid materials
Bio-derived and bio-inspired materials
• Five recommendations made
•
•
•
•
•
Accelerate materials transition from concept to service
Computational modeling
Integrate research in various materials classes
Discover materials with substantially improved properties
Materials research from conception to service to retirement
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Strength and Corrosion Resistance Improvements
Relative to 7075-T651 in New 7XXX-Series Alloys
Engineering, Operations & Technology | Phantom Works
AM&ST
700
650
Corrosion Resistance
600
Low
Medium
High
Yield 550
Strength
(MPa) 500
Thin Products < 75 mm
7055-T7751
7150-T7751
7150-T651
7075-T651
7085-T7651
7050-T7451
450
Thick Products 75 - 200 mm
7075-T7651
7075-T7351
400
1940
1950
1960
1970
1980
1990
2000 2005
Year First Used in Aircraft
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Composition (Wt. %) of 7XXX Series Alloys
Engineering, Operations & Technology | Phantom Works
AM&ST
7075 7050 7055 7085
Zn
Mg
Cu
Copyright © 2006 Boeing. All rights reserved.
5.6
2.5
1.6
6.2
2.3
2.3
8.0
2.0
2.3
7.5
1.5
1.6
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Industry Perspective
Engineering, Operations & Technology | Phantom Works
AM&ST
• Technologies fuel growth
• Products – 787 Dreamliner
• Services – Expand the value of products to customers
• Technologies reduce the bottom line
• Design – Enables more efficient structures
• Manufacturing – Enables streamlined production
• Breakthrough Technologies - What will the future bring?
• Fundamental research
• What are the gaps and what is needed to close them?
• Workforce challenges
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Growth: New Technologies Enable New Products and
Services
Engineering, Operations & Technology | Phantom Works
AM&ST
• Large-scale composite components
• Advanced manufacturing processes
• System health monitoring
• Next-generation engines
• More-electric power systems
• Enabling interior architecture
• Integrated avionics
• Advanced flight controls
• Wireless IFE and other technologies improve the
cabin
• Noise reduction technologies
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• Advanced Recycling Technologies for Airplanes
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Growth: New Technologies Enable New Products and
Services
Engineering, Operations & Technology | Phantom Works
AM&ST
Integrating
Breakthrough
Technologies
• Best introduction of a new Boeing Commercial
Airplane ever
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Composites Serve as 787 Primary Structural
Material
Engineering, Operations & Technology | Phantom Works
Other
Steel
787-8
Titanium
Aluminum
Composites
AM&ST
•
Lighter
•
More durable
•
Reduced corrosion and
fatigue
•
Reduced scheduled
maintenance
•
Opens new design possibilities
CFRP
43%
One Piece Fwd Fuselage
Copyright © 2006 Boeing. All rights reserved.
One Piece Barrel Section
Misc.
9%
Test Wing Box
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The Future of Composites
Enabling High Rate Production
Engineering, Operations & Technology | Phantom Works
2005-2024
Regional jets
Single-aisle
Twin-aisle
747 and larger
AM&ST
3%
11% 5%
15%
&
ign ring
s
e
D actu
gy
nuf
ma hnolo ugh
tec kthro
a
bre
22%
39%
45%
60%
2.1 trillion
delivery dollars*
25,700
airplanes
777
50%
11%
*In year 2004 dollars
757/767
747
787
3%
1%
r
Inc
ed
eas
te
osi
p
com
s
ge
usa
o
ti
ver
me
Materials
Composite
Steel
Titanium
Aluminum
Miscellaneous
Continued
Continued Development
Development of
of Advanced
Advanced Composites
Composites Will
Will Be
Be
Required
Required to
to Affordability
Affordability Satisfy
Satisfy High
High Rate
Rate Production
Production Needs
Needs
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Titanium Usage in Aircraft Has Been Increasing
Engineering, Operations & Technology | Phantom Works
AM&ST
Percent Ti as Function
of OEW
Other
20
18
16
14
12
10
8
6
4
2
0
1950
Steel
Titanium
Composites
787 (Projected)
787 (Projected)
777
757
Aluminum
747 SP
727
737 747
Composites are also
Driving Growth in
Titanium
767
707
1960
1970
1980
1990
2000
2010
2020
Year of Roll Out
Continued
Continued Development
Development of
of Improved
Improved Alloys
Alloys Are
Are Needed
Needed to
to Improve
Improve
Performance,
Performance, Manufacturability,
Manufacturability, and
and Affordability
Affordability
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7 Characteristics of Future Products, Processes &
Services
Engineering, Operations & Technology | Phantom Works
AM&ST
Extreme
ExtremeAffordability
Affordability
Cost improvements of factors from 2-100
“Universally”
“Universally”Friendly
Friendly
Minimal to no environmental impact of a
product throughout its full lifecycle
Network
NetworkCentric
Centric
Multiple assets that collaborate on a
network to optimize the system
performance
Super-Human
Super-HumanIntelligence
Intelligence
Platforms and systems with decision
making capabilities better than human
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7 Characteristics of Future Products, Processes &
Services
Engineering, Operations & Technology | Phantom Works
AM&ST
Highly
HighlyIntegrated
Integrated
Integration of many functions into a single
component
Breakthrough
BreakthroughPerformance
Performance
2 to 100-fold performance improvements
Adaptability
Adaptabilityto
toChange
Change
Easy to upgrade with the latest
technological advancements
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Growth: New Technologies Enable New Products and
Services
Engineering, Operations & Technology | Phantom Works
AM&ST
Product Support – Integrated Vehicle Health Management
Develop diagnostic/prognostic technologies that will allow us to
monitor the performance of our products in the field to ensure optimum
performance and maximum availability to our customers
Monitor
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Detect
Analyze
Plan
Manage
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Growth: New Technologies Enable New Products and
Services
Engineering, Operations & Technology | Phantom Works
AM&ST
Product Support – Maintenance, Mods, & Repairs
Develop advanced technologies which will improve the quality and
reduce the cost of Maintenance, Modifications and Repair
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Productivity Improvements: Design
Technologies Enabling More Efficient Structures
Engineering, Operations & Technology | Phantom Works
AM&ST
Lower Cost & Lower Weight
Develop innovative structural concepts which will be lighter, easier
to build and maintain, and cost less to fabricate and support
Fewer parts
Fewer fasteners
Less assembly
Lower weight
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Productivity Improvements: Design
Technologies Enabling More Efficient Structures
Engineering, Operations & Technology | Phantom Works
AM&ST
Design & Analysis Tools
Develop the necessary analysis capabilities needed to support the
advanced concepts and integrate those into common design tools
and processes
H a t p lie s
x d ire c tio n
N o o d le a n d sk in
x d ire c tio n
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Faster Designs
More Iterations
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Productivity Improvements: Design
Technologies Enabling More Efficient Structures
Engineering, Operations & Technology | Phantom Works
AM&ST
Materials by Design
Create high-performance materials and leverage with design
concepts to improve performance and/or lower costs
• Materials by Trial and Error
• Lots of testing
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• Architect the materials necessary to
enable higher performance designs
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Productivity Improvements: Design Technologies
Enabling More Efficient Structures & Operations
Engineering, Operations & Technology | Phantom Works
AM&ST
Modeling and Simulation
Develop, design, and build multiple iterations virtually to reduce costs
and speed development
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Physical
Virtual
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Productivity Improvements: Design
Technologies Enabling More Efficient Structures
Engineering, Operations & Technology | Phantom Works
AM&ST
Analytical Techniques Replace Empirical Testing
Traditional:
Test
Supported
by Analysis
RISK
Develop methods to verify and certify new structural concepts and
material forms to speed those advancements product lines
A
Goal: Analysis
Supported by
Experience,
Test & Demo
RISK
Time to Insertion Readiness
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A
A
Time to Insertion Readiness Reduced by 55%
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Productivity Improvements: Technologies
Enable Lower Cost Structures
Engineering, Operations & Technology | Phantom Works
AM&ST
Network Enabled Manufacturing
Develop open architecture model for linking system-of-systems,
e.g., Indoor GPS, RFID, SmartTools, Laser Projection all linked to
manufacturing work instructions and Quality Management System
NEM
Converts
today’s
aerospace
factories
where
NEM
NEM
Converts
today’s
aerospace
factories
where
NEMConverts
Convertstoday’s
today’saerospace
aerospacefactories
factorieswhere
where
information
collection
and
diagnostics
are
mostly
information
information
collection
and
diagnostics
are
mostly
informationcollection
collectionand
anddiagnostics
diagnosticsare
aremostly
mostly
manual
to
state-of-the-art
automated
information
manual
manual
to
state-of-the-art
automated
information
manualto
tostate-of-the-art
state-of-the-artautomated
automatedinformation
information
database
resource
in
real
time.
This
methodology
is
database
database
resource
resource
in
in
real
real
time.
time.
This
This
methodology
methodology
database resource in real time. This methodologyisis
is
well
adaptable
to
the
future
engineering
work
force
well
well
adaptable
to
the
future
engineering
work
force
welladaptable
adaptableto
tothe
thefuture
futureengineering
engineeringwork
workforce
force
who
are
familiar
with
intelligent
computerized
systems
who
who
are
familiar
with
intelligent
computerized
systems
whoare
arefamiliar
familiarwith
withintelligent
intelligentcomputerized
computerizedsystems
systems
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Aerospace Direction
Engineering, Operations & Technology | Phantom Works
AM&ST
• Increased global sourcing of subcomponents and materials
• Global sourcing of assembly
• Airbus to assemble planes in China (2006)
• Networked manufacturing
• “Materials by Design”
• Lean manufacturing
• “Green” materials and processes
• Networked aircraft, satellites, etc.
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Aerospace Workplace Needs
Engineering, Operations & Technology | Phantom Works
AM&ST
• Educated Scientists and Engineers
• Globally sourced
• “Clearable” for Defense-relatd projects
• Mathematical and Analytical capability
– Probability and Statistics
• Communications across various disciplines
– Not just interdisciplinary studies, but interaction
Boeing
Boeing invests
invests significantly
significantly in
in employee
employee training
training
both
-house and
both in
in-house
and at
at universities
universities
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Fundamental Research Gaps and Needs
Engineering, Operations & Technology | Phantom Works
AM&ST
• Modeling and simulation
• Materials Informatics
• Simulation of manufacturing processes
• Multi-functional materials
• Lower cost or affordable replacement for strategic materials
• Self assembled structures – “Grow the parts”
• In-service assessment of the health of materials
• Diagnostics and prognostics
Materials
Materials are
are Key
Key to
to Maintaining
Maintaining Competitiveness
Competitiveness
Copyright © 2006 Boeing. All rights reserved.
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