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Innovations for Future Aircraft Wings: Aluminum's Step-Change Possibilities

Explore the transformative opportunities presented by aluminum in advancing Airbus's upcoming aircraft models for enhanced performance and sustainability until 2030.

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Innovations for Future Aircraft Wings: Aluminum's Step-Change Possibilities

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  1. Single-Aisle Wing: Step-Change R&DOpportunities for AluminiumTristan CrawfordConstellium Customer Application Engineering, Aerospace12th December 2013IOM3, London

  2. Step-change is required for Airbus’s biggest product across the board… Entry Into Service 2025 - 2030 Entry Into Service: 2015 A30X (Being defined) A320 New Engine Option (NEO) Step-Change Performance: 5-15% DOC reduction vs 20-50% higher fuel price 20% reduced acquisition cost 50% reduced CO2, 80% reduced NOx (ACARE) 10% to 20% production rate increase Demonstrated TRL6 by 2020: -25% to -30% • Density Reduction • Improved Strength, Toughness • Enables Part Redesign & Integration Structural Weight -25% • Affordable Alloys • Improved Dimensional Stability & Process Cycle Times • Near Net-Shape Engineered Products Manufacturing RC -5% Non-Lift Dep. Drag • Enables Laminar Flow • Aero-elastically tailorable Scheduled & Unscheduled Inspection -50% • Enables Health Monitoring • Fatigue & Corrosion Resistant • Low risk, fast repair Environmentally Sustainable • Recyclable

  3. Step-change is required for Airbus’s biggest product across the board… Entry Into Service 2025 - 2030 Entry Into Service: 2015 A30X (Being defined) A320 New Engine Option (NEO) Step-Change Performance: 5-15% DOC reduction vs 20-50% higher fuel price 20% reduced acquisition cost 50% reduced CO2, 80% reduced NOx (ACARE) 10% to 20% production rate increase Demonstrated TRL6 by 2020: -25% to -30% • Density Reduction • Improved Strength, Toughness • Enables Part Redesign & Integration Structural Weight -25% • Affordable Alloys • Improved Dimensional Stability & Process Cycle Times • Near Net-Shape Engineered Products Manufacturing RC -5% Non-Lift Dep. Drag • Enables Laminar Flow • Aero-elastically tailorable Scheduled & Unscheduled Inspection -50% • Enables Health Monitoring • Fatigue & Corrosion Resistant • Low risk, fast repair Environmentally Sustainable • Recyclable

  4. Reducing Structural Weight • Density Reduction • Improved Strength, Toughness • Enables Part Redesign & Integration { Design stress / density } = index of Structural Efficiency New Part Geometries / Lighter jointing Wingskin Wt Saving Improving Structural Efficiency • Trend is no saturation to improvement in metallic structural efficiency • Further potential in Al-Cu-Li & Al-Mg-Li alloy systems • Improve density via stable increase in % Li and % Mg • Improve strength via higher solute + work hardening + nucleants • Improve toughness via texture modification using intermediate heat treatments • Extrapolation to 2030 would give +10 to +15% improvement in stress allowables hence  further saving -7 to -10 % on covers mass -10% to -15% -10% to -15% Enabling New Part Geometries / Lightweight Jointing

  5. Step-change is required for Airbus’s biggest product across the board… Entry Into Service 2025 - 2030 Entry Into Service: 2015 A30X (Being defined) A320 New Engine Option (NEO) Step-Change Performance: 5-15% DOC reduction vs 20-50% higher fuel price 20% reduced acquisition cost 50% reduced CO2, 80% reduced NOx (ACARE) 10% to 20% production rate increase Demonstrated TRL6 by 2020: -25% to -30% • Density Reduction • Improved Strength, Toughness • Enables Part Redesign & Integration Structural Weight -25% • Affordable Alloys • Improved Dimensional Stability & Process Cycle Times • Near Net-Shape Engineered Products Manufacturing RC -5% Non-Lift Dep. Drag • Enables Laminar Flow • Aero-elastically tailorable Scheduled & Unscheduled Inspection -50% • Enables Health Monitoring • Fatigue & Corrosion Resistant • Low risk, fast repair Environmentally Sustainable • Recyclable

  6. Reducing Recurring Costs Al-Cu-Li Alloy Costs • Affordable Alloys • Improved Dimensional Stability & Process Cycle Times • Near-Net-Shape Engineered Products $ OEM Wt Performance Premium Process & Ship Standard Alloy Costs* Affordable Alloys • New Cu-Li and Mg-Li alloy systems produced in volume will give value to OEMs • Al-Cu-Li alloys for A350 are priced high to reflect early low production volume • *Wingskin product cost-base is approx 20% LME, 30% production, 50% final process & ship • Future alloy systems will have on-cost due to LME for Li, Mg and Ag • However value of increased performance to Airbus more than outweighs this • Will further improve when large-scale closed-loop recycling is established Prod Process & Ship LME Process & Ship Prod LME Prod LME High Production Low Production Improved Dimensional Stability / Process Cycle Times • Industrial re-configuration to reduce quench-stretch delay time • Airbus-compatible residual stress modelling capability • Reduction of Age-Forming cycle times / Laser-shock peening 2014 2018 Near-Net-Shape Engineered Products • Improved Fly:Buy Products via: • LFW tailored blanks • FSW tailored blanks • Tapered rolling

  7. Step-change is required for Airbus’s biggest product across the board… Entry Into Service 2025 - 2030 Entry Into Service: 2015 A30X (Being defined) A320 New Engine Option (NEO) Step-Change Performance: 5-15% DOC reduction vs 20-50% higher fuel price 20% reduced acquisition cost 50% reduced CO2, 80% reduced NOx (ACARE) 10% to 20% production rate increase Demonstrated TRL6 by 2020: -25% to -30% • Density Reduction • Improved Strength, Toughness • Enables Part Redesign & Integration Structural Weight -25% • Affordable Alloys • Improved Dimensional Stability & Process Cycle Times • Near Net-Shape Engineered Products Manufacturing RC -5% Non-Lift Dep. Drag • Enables Laminar Flow • Aero-elastically tailorable Scheduled & Unscheduled Inspection -50% • Enables Health Monitoring • Fatigue & Corrosion Resistant • Low risk, fast repair Environmentally Sustainable • Recyclable

  8. Hybrid material concept = GLARE sandwiched between thicker Al - Li sheets Fiberglass Fiberglass Thin Thin Pre Pre - - Preg Preg Al Sheet Al Sheet (0.3 mm) (0.3 mm) 2mm outer Al - Li sheet 1.6mm inner Al - Li sheets 1 + More later on potential for alternative configurations … . Enabling Improved Aerodynamics LamFlow Metallic Wingbox Concept • Enables Laminar Flow • Aero-elastically tailorable Laminar Flow • New Cu-Li and Mg-Li alloy systems are compatible with: • Fastener-less joining (bonding, welding) • Closing external gaps (external machining / welding / ALM / US consolidation) • Ultra-high quality surface aspect finish • Advanced forming for complex geometry and curvatures Aero-elastic Tailoring • Engineered Metal Laminates enable design for aero-elastic response • Combination of Al-Cu-Li thin plates & GLARE • FML fibre orientation to optimise stiffness response • Fully compatible with optimisation of rib & stringer pitch & orientation

  9. Step-change is required for Airbus’s biggest product across the board… Entry Into Service 2025 - 2030 Entry Into Service: 2015 A30X (Being defined) A320 New Engine Option (NEO) Step-Change Performance: 5-15% DOC reduction vs 20-50% higher fuel price 20% reduced acquisition cost 50% reduced CO2, 80% reduced NOx (ACARE) 10% to 20% production rate increase Demonstrated TRL6 by 2020: -25% to -30% • Density Reduction • Improved Strength, Toughness • Enables Part Redesign & Integration Structural Weight -25% • Affordable Alloys • Improved Dimensional Stability & Process Cycle Times • Near Net-Shape Engineered Products Manufacturing RC -5% Non-Lift Dep. Drag • Enables Laminar Flow • Aero-elastically tailorable Scheduled & Unscheduled Inspection -50% • Enables Health Monitoring • Fatigue & Corrosion Resistant • Low risk, fast repair Environmentally Sustainable • Recyclable

  10. Reducing Scheduled / Unscheduled Maintenance • Enables Health Monitoring • Fatigue & Corrosion Resistant • Simple fast repair Health Monitoring • Engineered Metal Laminates compatible with integration of HUMS • Stringer profiles can be extruded with sensors built-in + More later on potential for alternative configurations … . Fatigue & Corrosion Resistance • has proven 25% improvement in spectrum fatigue over 2027 (A320) • has proven step-change improvement in all corrosion types • 50% higher than 7449 in SCC and rated EA/P for Mastmaasis Low Risk, Fast Repair • All Al-Cu-Li are 100% compatible with all conventional repair schemes

  11. Step-change is required for Airbus’s biggest product across the board… Entry Into Service 2025 - 2030 Entry Into Service: 2015 A30X (Being defined) A320 New Engine Option (NEO) Step-Change Performance: 5-15% DOC reduction vs 20-50% higher fuel price 20% reduced acquisition cost 50% reduced CO2, 80% reduced NOx (ACARE) 10% to 20% production rate increase Demonstrated TRL6 by 2020: -25% to -30% • Density Reduction • Improved Strength, Toughness • Enables Part Redesign & Integration Structural Weight -25% • Affordable Alloys • Improved Dimensional Stability & Process Cycle Times • Near Net-Shape Engineered Products Manufacturing RC -5% Non-Lift Dep. Drag • Enables Laminar Flow • Aero-elastically tailorable Scheduled & Unscheduled Inspection -50% • Enables Health Monitoring • Fatigue & Corrosion Resistant • Low risk, fast repair Environmentally Sustainable • Recyclable

  12. Improving Material Costs & Reducing Environmental Impact • Recyclable • Typically able to recover around 85% of scrap & swarf returned for full use in aerostructures • Tolling will enable customers to carry ‘credit’ for Al-Cu-Li that is returned to Constellium • Will reduce overall purchase costs of Al-Cu-Li to customer • Reduces energy consumed to source primary metals • Reduces environmental impact by 80% (2 tons CO2 per t recycled vs 10t CO2 per t new alloy)

  13. Delivering TRL6 for Future Single-Aisle requires integrated R&D • The challenge is significant • Future supply chain and future production infrastructure will be as critical as future aircraft performance • Growing recognition of importance of reducing environmental impact… 60 a/c per month 40 a/c per month Production Rate • Environmental Impact • aircraft production • fuel burn • aircraft decommissioning 2015 2020 2030 2025

  14. Delivering TRL6 for Future Single-Aisle requires integrated R&D ? ? ?

  15. We need demonstrators to validate feasibility Wingbox Manufacturing Demonstrators Aerodynamic & SHM Sub-Demonstrators • Wing of the Future • Factory of the Future • Other OEM / Tier 1 Programmes • New Calls..? Future Supply-Chain Demonstration Material Recycling & Aircraft Decommissioning Demonstrator

  16. Delivering TRL6 for Future Single-Aisle requires integrated R&D Thank You Tristan Crawford Customer Application Engineering, Group Leader Aerospace Constellium Aerospace & Transportation Tristan.crawford@constellium.com +44(0)7585662042

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