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Copyright © 2016 Boeing. All rights reserved.
Boeing Research & Technology
Engineering, Test & Technology
Boeing Research & Technology
Engineering, Test & Technology
The Next Decade of Carbon Fiber Composites:Challenges and Opportunities
Sam Tucker
Next Gen Composites
Boeing Research & Technology
Copyright © 2016 Boeing. All rights reserved.
Boeing Research & Technology
Copyright © 2016 Boeing. All rights reserved.
100 Years of Innovation
Copyright © 2016 Boeing. All rights reserved.
Boeing Research & Technology
Growing Market and Competition in Commercial Airplanes
Green Denotes Study Airplanes
Great market, but new and existing competitors taking a share
Copyright © 2016 Boeing. All rights reserved.
Boeing Research & Technology
The Pace Of Progress – Composite Innovation
It took 40 years to get from the Wright Brothers to widespread air transport.
It took 50 years for implementation of the composite wing and fuselage.
Composites timeline:
▪ 1950s: Invention of fiber reinforced plastics
▪ 1960s to 1970s: Use in secondary structure
▪ 1980s to 2000: Use in empennages, subcomponents
▪ 2003 to present: Use in wing and fuselage
Copyright © 2016 Boeing. All rights reserved.
Boeing Research & Technology
Growing Use of Composites in Aerospace
Boeing produces >1.4M LBS of composite structure per month
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Boeing Research & Technology
Challenges
Geo-political constraints / uncertainty
Changing market Value streams and business models
Customer needs
Designing for composite materials Structural efficiency, manufacturability
Speed of introducing new materials/processes Material development fitting into product design cycle
Qualification/certification of material and production system
Trading all the materials and processes available
Safety concerns addressed
Molecular – Continuum materials understanding Designing materials for processing and performance
Cost reduction
How do we address these challenges: Solve for creating value – deliver improved performance at lower costs
Innovation: New business models; new design, qualification and certification ideologies and
tools; new materials and processes
Complex Multidimensional Optimization
Cost break-down for composite parts
Copyright © 2016 Boeing. All rights reserved.
Boeing Research & Technology
BR&T Composite Research & Development Initiatives
Improving Cost, Quality and Schedule for Production Systems
Design for Manufacturing and Structural Efficiency
Industrialization of Composites
Lead Implementation of 21st Century Technology
Copyright © 2016 Boeing. All rights reserved.
Boeing Research & Technology
Improving Cost, Quality, Schedule for Production Systems
Continued innovation in our production systems leads to improved quality and reduced defects at a lower cost
Optimizing for automation and increased
Rate
Increased automation rates through:
− Understanding of material capabilities
− Reducing defects and inspection time
Advanced forming
− Innovative approaches to enable defect
free fabrication of stringers and spars
− Characterization of prepreg for forming
(tack, friction, drape)
Increased material and process robustness
Enhanced producibility assessments
Flexible processing windows
Design requirements aligned to the
manufacturing process
Acceptance criteria
(Composites Part A, 43,(2012), 423-434)
Copyright © 2016 Boeing. All rights reserved.
Boeing Research & Technology
Design For Manufacturing
Capturing the advantages of new materials and processes is essential to deliver value
Increased material and process suite enabling the
Right Material, Right Process and Right Design Out-of-autoclave
Rapid cure
Manufacturing influenced designs
Reduced part complexity
Well-defined material limits and design guides
Part count reductions and reduced assembly
Integrated co-cures and resin infusion
Structural bonding
Integrated system architectures
EME direct and indirect effects
Disruptive EME materials (i.e. conductive composites)
16-ft Curved Qtr Panel (PRSEUS)
Automation
Thermoplastics
Copyright © 2016 Boeing. All rights reserved.
Boeing Research & Technology
Copyright © 2016 Boeing. All rights reserved.
Industrialization of Composites
Leverage low-cost, high performance materials
Industrial fibers and chemistries – understand performance vs. price
Disruptive: prepreg successor(s)
Implement rapid and tailorable manufacturing processes for
production of affordable small composite parts:
High pressure resin-transfer molding
Continuous forming of thermosets and thermoplastics
Stamp forming of composites
Develop rate-independent manufacturing technologies
through reduction of non-recurring cost:
Adaptive manufacturing cells
Low-cost, innovative tooling
Increased automation of material handling and fabrication
Increased rate and decreased cost of composite parts
Copyright © 2016 Boeing. All rights reserved.
Boeing Research & Technology
Thermoplastic Components Save Weight and Cost for
Industrialization of Composites: Thermoplastic Composites
Wide-scale thermoplastic implementation from focused materials and process innovation
Production cost savings through:
Flexible part fabrication enabling high-rate, continuous
manufacturing
Infinite material shelf life
Weight savings enabled by high performance
High interlaminar properties / damage tolerance
Flam, smoke & toxicity resistance
Copyright © 2016 Boeing. All rights reserved.
Boeing Research & Technology
Implementation of 21st Century Technology
Forward innovation must focus on digital concepts for accelerated materials and
process decisions and insertion
Multi-scale modeling
Computational chemistry
Process modeling
Integration to macro-scale structural analysis
Processing/manufacturing science and prediction
Increased understanding of the production systems
Prediction of geometries and post process deformation
Digital inspection
In-process inspection instead of post process inspection
Additive manufacturing
Digital manufacturing for rapid prototypes (parts and tooling)
Flexible customization
Digitization
Real-time manufacturing data / capturing the digital thread
(Industry 4.0)
Increased use of the digital lab
Copyright © 2016 Boeing. All rights reserved.
Boeing Research & Technology
Implementation of 21st Century TechnologyComputational Materials & Processes
Leveraging computational methods to inform materials and process decisions
Computational and Experimental Approach:
Accelerated insertion through informed decisions and reduced trial and error
M&P process variability understanding from chemistry to structure
Iterative approach to continue to refine/improve approach
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Boeing Research & Technology
Adapted and accepted methods for process prediction
Residual strain understanding and prediction
Part distortion
Cure cycle optimization for controlled dimensional stability
Thermal analysis and prediction
Cure cycle optimization for thermal loads
Decreased manufacturing uncertainty and reduced trial and error
Implementation of 21st Century TechnologyProcessing Science and Prediction
Leveraging computational methods to inform materials and process decisions
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Boeing Research & Technology
Implementation of 21st Century Technology
Polymer additive manufacturing as a compliment to composites
Prototypes
Low-Rate / complex shapes
Localized stiffening
Flexible customization
Disruptive additive manufacturing
Structural components?
What material performance is required?
Polymer Digital and Additive Manufacturing
Additive manufacturing is a valuable compliment to traditional
composites manufacturing
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Boeing Research & Technology
Implementation of 21st Century TechnologyContinued Digitization – Industry 4.0
How do we define the Future of composites?
Industry 4.0 and Composites
Enhanced Accuracy and Tracking Through Live Metrology
Real-Time Manufacturing Data For Resource and Inventory Tracking
Automated Digital Inspection
Improved Safety Through Intelligent Human-Machine Interactions
Realization of the Digital Thread
http://www.enterrasolutions.com/
2015/07/the-coming-industrial-
revolution-the-internet-of-things-
and-industry-4-0.html
By ChristophRoser. Please credit "Christoph Roser at AllAboutLean.com." - Own work,
CC BY-SA 4.0, https://commons.wikimedia.org/w/index.php?curid=47640595
The Four Industrial Revolutions