Boeing'sPlasticPlane.pptx

7/29/2019 Boeing'sPlasticPlane.pptx

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Michael Grese

Michael Hawley

Michael Lyrenmann

Timothy Smith


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Dreamliner 787

Boeings latest aircraft, the Dreamliner 787, is

pushing the barriers of aircraft construction

and component technologies.

The biggest departure from previous aircraft is

the use of composite structures in its design,

about 50% by weight. The highest amounts of

composites used before the Dreamliner wereabout 12% in Boeings own 777.


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Material make-up of the 787


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Carbon FiberComposites


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Making Carbon Fiber

Figures courtesy ofThe Macrogalleria
http://pslc.ws/macrogcss/carfsyn.htmlhttp://pslc.ws/macrogcss/carfsyn.html


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Making Carbon Fiber (contd)


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Carbon Fiber woven ribbons


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The lay-up process


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Thermally Conductive Plastics

Thermally conductive plastics are becomingviable solutions for handling heat in somespecific, high-tech applications.

Some modified plastics can approach thethermal conductivity of die-cast aluminum,one of the most widely used heat sinkmaterials today.

Considerations: lightweight, moldable, cost, etc.


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Traditional Aircraft Interior

Applications

Figure courtesy ofSABIC Innovative Plastics
http://www.aircraftinteriorsexpo-us.com/ExhibitorLibrary/108/Islands_in_the_sky_3.pdfhttp://www.aircraftinteriorsexpo-us.com/ExhibitorLibrary/108/Islands_in_the_sky_3.pdf


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Typical Airplane Composites

Ultem 9085 resin Polyetherimide

Decompression

grilles, window revels, bezels

Extruded, thermoformed, injection molded

Noryl LS6010 resin

Polyphenylene ether + Polystyrene

Rub strips and seat track covers

Injection molding, profile extrusion,

sheet extrusion


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Examples

(Below) Cabin seat on the 787

(Left) Vacuum-formed panel

(Ultem), overhead bin (Noryl)


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Typical Airplane Composites

Lexan FST9705 resin

Polycarbonate copolymer

Personal service units, window revels, and bezels

Injection molding

Bismaleimide (BMI) resins

External structural applications

Autoclaving process

PR Domain: GE Plastics LaunchesThree New High-performance

Materials for Aircraft Industry.


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Assembly - A Global Undertaking


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Reprocessing Techniques

Thermoplastics can be repaired using a number ofdifferent techniques:

Fusion Bonding

Heat, molecule diffusion, cooling Frictional, thermal, electromagnetic welding

Patch Repair

Wide variety of techniques

Mechanical fastening, adhesive bonding, focused infrared


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Reprocessing Techniques

Thermo-reforming

Heated to create viscous polymer

Use same technique as when originally formed

Vodicka, Roger. Thermoplastics for Airframe

Applications: A Review of the Properties and

Repair Methods for Thermoplastic Composites


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Advantages over Metals

Lightweight

Density of composites: about 1.4 g/cm3

Density of aluminum: 2.7 g/cm3

Density of titanium: 4.5 g/cm3

Large single-piece construction

80% reduction in number of fasteners

Resistant to corrosion and fatigue

Lower maintenance cost


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Disadvantages

High material cost

Difficult repairs

(composites) Specialized tools

needed

Figure courtesy

www.compositecarbonfiberprop.com
http://www.compositecarbonfiberprop.com/avolonte_brochure.htmhttp://www.compositecarbonfiberprop.com/avolonte_brochure.htm


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Cost of Boeing 787

767 Family

767-200ER $127.5 -- 139.0 Million 255 passengers 6,385 nmi

767-300ER $144.5 -- 161.5 Million 350 passengers 5,990 nmi

767-400ER $158.0 -- 173.0 Million 375 passengers 5,625 nmi.

787 Family787-3 $150.0 -- 155.5 Million 290-330

passengers2,500 to 3,050nmi.

787-8 $161.0 -- 171.5 Million 210-215passengers

7,650 to 8,200nmi.

787-9 $194.0 -- 205.5 Million 250-290passengers

8,000 to 8,500nmi.

Source: www.boeing.com


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Weight/ Maintenance Costs

Boeing: Dreamliner 787 will be 20% more

efficient

Light weight also affects landing taxes

Boeing: 30% reduction in maintenance costs

over aluminum fuselage airplane


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Electrical Improvements

8% efficiency improvement from engine design: GE GENX andRolls Royce Trent 1000

Electrical Reconfigurations: more reliance on electrical

starters

Bleed air-hot compressed air

from engines used in de-icing,

cabin pressurization

787 will use pneumaticcompressors


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Problems with Cost Estimates

Cost estimates released by Boeing: incentive

to make the plane sound better

Boeing 787 has yet to actually be released

So many new innovations


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Questions?

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Boeing'sPlasticPlane.pptx

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