Engineering, Operations & Technology
BR&T
The Challenge of New Materials
In the Aerospace Industry
Gerould Young
Director Materials & Fabrication Technology
Georgia Institute of Technology
May 15th, 2013
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Boeing Almost 100 Years of Innovation
Engineering, Operations & Technology | BR&T
Copyright © 2011 Boeing. All rights reserved.
Year
1916
1928
1932
1935
1935
1938
1939
1941
1949
1956
1957 - 58
1958
1959
1961
1960's
1969
1969
1970 - 1980
1978
1981
1982
1982 - 1984
1986
1993
1995
1995
1998
2009
Model
B&W - Model 1
Model 80
P26 Peashooter
TBD Devastator
B17
314 Clipper
B29
P51 Mustang
B47
KC-135
707 & DC-8
F4 Phanton
X-15
CH47
Mercury & Gemni
747
Apollo & Lunar Landed
F15 & F18
AV8
Space Shuttle
B1B
757 - 767
V22 Osprey
B2
C17 Globemaster
777
Space Station
787
Materials & Fabrication Technology
Innovation
Boeing's first airplane - spruce construction
America's first airliner specifically for passenger comfort
Fastest air cooled pursuit fighter in the world
First all metal monoplane torpedo bomber
Multi-engine long range bomber
3500 mile range - Transatlantic Flight
Long range pressurized bomber
First fighter to fly Britain to Berlin and back
First swept wing multi-engine bomber
Strategic Air Command aerial tanker
Swept wing jet transport
Jet fighter - 16 speed, altitude and time to climb records
Rocket powered airplane - 354,000ft and 4,104mph
Two rotor heavy lift
Manned Spacecraft
Largest airliner built
Manned spaceflight to the moon
Air superiority and multi-role fighter
Fixed wing vertical take off aircraft
Space access with return flight
Swing wing supersonic bomber
Narrow and Wide Body with nearly identical cockpits
Tilt rotor aircraft
All composite stealth long range bomber
Heavy lift and short field capability
Wide body with composite empennage - 100% digital definition
International space station assembled in space
First mostly composite airliner
Airframe Metallic Materials Evolution
Materials & Fabrication Technology
Engineering, Operations & Technology | BR&T
AL ALLOY DEVELOPMENT (EIS for System Utilizing Alloy)
2017
2024
7075
7075
7178
7178
1910
1920
1930
DC -3
B-17
B-247
1940
B-29
2618
2618
2014
2014
7175
7175
2027
2027
6061
7475
7475
2219
2219
7050
7050
2124
2124
1950
1960
1970
B-707 B-727 B-747 L1011
DC-8 B-737 DC-10
COMET
AIRCRAFT
SR 71
7150
8090
8090
7150
6056
2324
2324
6056
6013 2090
2224 6013
2224
2090
7349
7349
2195
2195
7055
7055
2524
2524
7449
7449
7039
7039
1980
1990
B-757
C-17 F18
B-767
SLWT
CONCORDE A-319
A-340
A-330
F-15
4340 15-5PH 13-8PH
TITANIUM AND STEEL ALLOYS
Ti-6242
Ti-662
Ti-811
Ti-6242
Ti-64
Ti-13-11-3
2397
2397
2297
2297
7040
7040
7055
7055
6019
6019
2524
2524
7081, 2027
2050, 2022
2196, 6056 7081, 2023
2056, 6156 2139, 2013
7036
7056
7056
7140
2098
2098
7140
7055-T62
2198
2099,
2199
2099, 2199 2198
7085
7136
7136
7085
2000
B-777
EMB 170
F16 Retro F-22
747-8
Ti5553
C465
F18-E/F
Aermet 100
β-C
Ti-10-2-3
β21S
Increasing # Materials, Tailoring and Differentiation
Copyright © 2011 Boeing. All rights reserved.
747-LCF
A380
787
Ti62222
Composite Materials Have Enabled Next
Generation of Military and Commercial Aircraft
Materials & Fabrication Technology
Engineering, Operations & Technology | BR&T
High Strength Fibers
Brittle Epoxies
Fiber
Matrix
Fabrication
Structures
Platform
EIS
Intermediate Stiffness Fibers
Toughened Epoxies
Fiberglass
Boron
Carbon
T-300, AS4
Polyester
IM6, AS4D
Kevlar
Hand layup,
woven cloth
Fairings, radomes
Marine
CTLM
Prepreg tape
Bolted assembly
Sports Equip
Military aircraft
F-15, F-14
1970’s
Copyright © 2011 Boeing. All rights reserved.
Form3
T-800
IM7
GLARE
TiGR
T-Epoxy
8552
8551-7
3900
977-3
Epoxy
Epoxy
934, 3501-6
R6376
737, 757, 767
AV-8B,
F/A-18A-D
1980’s
RTM / VARTM
Co-cured Stringers
Determinate assembly
Press formed T-plastics
Spacecraft
Commercial tails
B-2
737 tail(5)
IM8, IM10,
Other IM++
HM
PPS, PEI
Tailored
PEEK, IBMS8-399
T-Epoxy
T-plastic
TP
polymers
PEKK
5320-1
BMI / PMI T-plastic T-Epoxy
Nanos
Next Gen
Ceramics
5215
Epoxies
5250-4
Benzoxazine
Co-bonded stringers
Hot draping
Thermoplastic
Welding
Commercial
Ctrl. Surfaces
Intermediate Stiffness Plus Fibers
Toughened Plus Epoxies
F-22
F/A-18E/F
A340 tail
777 tail
1990’s
CCM
OOA
Multihead
Robotics
Tow placement
Braiding
Stitching
Automotive?
Commercial
Aircraft
A380
V-22
787
A350
F-35
Next Gen Military
& Commercial
Aircraft
2000’s
2010’s
Commercial Transport Performance Improvement
Materials Contribution
Materials & Fabrication Technology
Baseline
30%
Block Fuel* – 3,000 nmi
Total A/C Structural
Weight Reduction (%)
Engineering, Operations & Technology | BR&T
Composite Structure
Improvement
707-320B
747-200B
DC-10-30
747-400
767-300ER
Metallic Structure
Improvement
777-200ER
Total Airframe
787-9 Structure
Systems
Engines
Total Fuel Burn
Savings (%)
Materials
Aerodynamics
1960
1970
1980
1990
2000
2010
Entry into Service (EIS)
Materials Improvements Pace Airplane Performance Improvements
*Block Fuel = gals/seat over 3,000 miles
E Kaduce, 2012, The Boeing Company, based on publically-available data
Copyright © 2011 Boeing. All rights reserved.
2020
A Conclusion
Materials Are A Critical Enabler
Engineering, Operations & Technology | BR&T
Materials & Fabrication Technology
History Says………..
 Demand for improved aircraft performance will continue
 Properties of existing materials will improve
 New materials will be discovered
 Optimization capability will improve
 More materials will be used
 But ……….
 Development costs climb
 Development schedules increase
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Development Trends in Different Industries
Engineering, Operations & Technology | BR&T
Materials & Fabrication Technology
Development Time Is Increasing At Unsustainable Rate
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Airplane Development vs. Material Development
Materials & Fabrication Technology
Engineering, Operations & Technology | BR&T
5-7 Years
Market
Airplane
Dev
Airplane
Study
Launch
Firm
Config.
Build
EIS
Production
Materials Orders
2-3 Years (ideal)
8-10 Years (reality)
Materials
Dev
Materials
Need ID’d
R&D
ScaleUp
Design
Allowables
Prod.
Ready
Previous Dev Efforts
Time (Years) 
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Materials Data Required for Airframe Design
Engineering, Operations & Technology | Boeing Research & Technology
Physical
Properties
Static Mech.
Properties
Durability and Damage
Tolerance Properties
Environmental
Effects
Tensile
Strength
Temperature
Humidity
Fatigue Strength
Heat Capacity
Thermal
Conductivity
Poisson’s
Ratio
Tensile,
Compression,
Shear and
Bulk Modulus
Certification
Castability
Density
Thermal
Expansion
Producibility
Compressive
Strength
Shear
Strength
Bearing
Strength
Copyright © 2012 Boeing. All rights reserved.
Notch Sensitivity
Chemical
Resistance
Crack Growth
Wear
Toughness
Corrosion
Resistance
Special Design Factors
Oxidation
Resistance
Formability
Deformation
Characteristics
Weldability
Machinability
Material
Specs
Process
Specs
Approved
Supplier List
Assembly
Repair
Methods
Chemical
Processing
Safety
Inspection
Methods
MSDS
EOT_RT_Template.ppt | 9
Building Block Approach
Engineering, Operations & Technology | BR&T
Manufacturing Qualification
Building Blocks
First
Part
Qual
PreProduction
Verification
Pre-Production
MfgTrials & Scale
Up
Demonstration
Sub-Scale
Demonstration &
Robustness Tests
Materials & Fabrication Technology
Structures Certification
Building Blocks
Full
Scale
Tests
Component
Tests
Sub-Component
Tests
Structural Element
Tests
Effect of Defects & Sensitivity
Testing
Allowables Development
Process & Equipment Development,
Stable Materials & Processes
Materials & Process Specification
Development
Process & Equipment Screening &
Selection
Material and Process Screening and
Selection
Copyright © 2011 Boeing. All rights reserved.
Future: Material Performance to Certification
Materials & Fabrication Technology
Engineering, Operations & Technology | BR&T
Materials, Structures, and Manufacturing
defined and certified in digital form to meet
platform requirements
Vehicle
Full Scale
SubComponent
Designs
Component
Designs
Element
Design
Virtual Testing
& Sim
Computational
Design Values
Material
Configurations
Failure Modeling
Constituent
Design
Computational
Allowables
Material
Models
Computational
Materials
• Material Development
• Process Development
Copyright © 2011 Boeing. All rights reserved.
• Producibility
• Accept/Reject
• Assembly
• NDT Standards
• Mechanical Props
• Knock-downs
• Environmental
• Effects of Defects
• Design Values
• DaDT
• Analysis Validation
• Structural Performance
• Damage Tolerance
• Static & Fatigue
• Analysis Validation
• Static
• GVT
• Fatigue
• Flight
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Future: Material Performance to Qualification
Materials & Fabrication Technology
Engineering, Operations & Technology | BR&T
Materials, Structures, and Manufacturing
defined and qualified in digital form to meet
platform requirements
Vehicle
Assembly
Scale Up
Process
Development
Constituent
Design
Material System
& Forms
Tolerances & Assembly
Simulation
Processing and Quality
Simulation
Material
Models
Computational
Materials
• Material Development
• Process Development
• Mat’l & Process
Capability
• Initial Accept &
Reject Criteria
Copyright © 2011 Boeing. All rights reserved.
• Producibility
• Inspection Standards
• Quality & Effects of
Defects
• Process Tolerances
Process and Manufacturing
Simulation for Quality
Aspects of Full Size Parts
• Manufacturing Scale up
• Full size fabricated elements
• Effects of Defects
• Expanded Mfg Limits
•Production System
Aerospace Composites- Rate and Volume Trend
Materials & Fabrication Technology
Engineering, Operations & Technology | BR&T
Platform
C-17
Percent
Composites
Total Wt (lbs)
Approx
Composite
Wt (lbs)
Approx
Delivery Rate
8%
277,000
22,714
1.5
B-2
High
F-18 c/d
10%
24,700
2,470
777
10%
300,000
30,000
7
F-22
20%
31,700
6,340
6
F-18 e/f
18%
30,500
5,490
4
V-22
43%
33,140
14,250
787
50%
250,000
125,000
Total
Wt
(lbs/Month)
# Delivered
Total Wt
Composites
Delivered
(lbs)
218
4,951,652
20
1,450
3,581,500
1066
31,980,000
339
2,149,260
21,960
500
2,745,000
1
14,250
160
2,280,000
5
625,000
130
16,250,000
210,000
871,210
63,934,360
 Boeing Has Fielded More than 63 Million Pounds of Composite Structure
 Boeing Will Field Nearly 10 Million Additional Pounds Every Year
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Industrialization of Aerospace Grade Composites
Materials & Fabrication Technology
Engineering, Operations & Technology | BR&T
Detail Component Size
1,200,000
Production Volume &25 Rate
1,000,000
800,000
15
600,000
10
400,000
Lbs of Material Delivered
Production Rate lbs/mo
20
lbs/mo 787
lbs/mo 777
lbs/mo V-22
lbs/mo F-22
lbs/mo F-18
lbs/mo C-17
Rate/mo 787
5
200,000
0
0
1985
1990
1995
2000
2005
2010
2015
2020
Structural Integration Coupled with Production Volume and Rate
Increases Will Drive a Tipping Point in Manufacturing Cost
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Parting Thoughts
Engineering, Operations & Technology | BR&T
Materials & Fabrication Technology
 Optimization will continue to increase number of materials
 Materials improvements are vital to aircraft performance
improvements
 Discovery is only a small part of materials development
 Computational materials & manufacturing tools will speed
decision making
 New material development must have:
 Reduced qualification and certification costs & schedule
 Concurrent scale-up and quality in manufacturing
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