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BOE021711-120

Mgr – Next Generation Composite MaterialsBoeing Research and Technology

28 February 2011

BOEING is a trademark of Boeing Management Company.Copyright © 2006 Boeing. All rights reserved.

BOE021711-120


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BOE021711-120

Boeing Products

767767767767 717717717717 C-17C-17

F-18F-18

BBJBBJBBJBBJ

WeaponsWeaponsJTRSJTRS

ISSISS LaunchLaunch

787787787787 747747747747

vance ys emsvance ys ems

UnmannedSystemsUnmannedSystems

777777777777 737737737737

RotorcraftRotorcraft

TankersTankers

SatellitesSatellites

Copyright © 2006 Boeing. All rights reserved. BOE021711-120

Boeing Commercial

Aircraft

Boeing Defense, Space,

and Security


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BOE021711-120

Material Selection Drivers

225SEATS 275SEATS225SEATS 275SEATS225SEATS 275SEATS225SEATS 275SEATS225SEATS 275SEATS

e r s e a t

300 SEATS

250 SEATS

350 SEATS 400 SEATS

450 SEATS

500

SEATS

200 SEATS

Current Quads e r s e a t

300 SEATS

250 SEATS

350 SEATS 400 SEATS

450 SEATS

500

SEATS

200 SEATS

e r s e a t

30

0 SEATS

250 SEATS

350 SEATS 400 SEATS

450 SEATS

500

SEATS

200 SEATS

e r s e a t

30

0 SEATS

250 SEATS

350 SEATS 400 SEATS

450 SEATS

500

SEATS

200 SEATS 30

0 SEATS

250 SEATS

350 SEATS 400 SEATS

450 SEATS

500

SEATS

2

00 SEATS

Current Quads

F u e l c

o n s u m p t i o n

550

SEATS

Current Twins

20% Better

F u e l c

o n s u m p t i o n

550

SEATS

F u e l c

o n s u m p t i o n

550

SEATS

F u e l c

o n s u m p t i o n

550

SEATS

550

SEATS

Current Twins

20% Better

Fuel Efficienc is Drivin

Fuel consumption per trip

787

Fuel consumption per tripFuel consumption per tripFuel consumption per trip

787

Pa load, Performance, and Cost

Commercial Focus on

Structural Materials

are Driving the Boeing DefenseFocus on Structural Materials


Performance Gains from Weight Reductions are

Driving the Increased Usage of Composite Materials


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BOE021711-120

Commercial Production Driving

i t e s

50% of the 787 Is CompositeStructure

C o m p

o

d u c t i

o 787’s Primary Structural

Composite Material System was’

r u c t u r a l

p a c e P r

m e o f S

i n A e r o s

V o l u

Time


Material Development Must Begin Well in Advance of

Conceptual Design


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BOE021711-120

A New Material System Must Earn

Its Wa onto the Air laneTargeted Application

Design loads

Static strength

Environment &

discrete events

Design loads

Static strength

Environment &

discrete events

Improvements Material Substitution

Stiffness and

Durability• Fatigue

Producibility

Maintainability• Repairability

• Inspectability StructuresDesign

Criteria

Stiffness andflutter

Durability• Fatigue

Producibility

Maintainability• Repairability

• Inspectability StructuresDesign

Criteria

Reduced Minimum Gauge

System Level Functionality

• Corrosion

Fail safetyCrashworthiness

Damage tolerance

or safe -life

• Corrosion

Fail safetyCrashworthiness

Damage tolerance

or safe -life

the Life Cycle

Material Cost

Systems

Materials

Engines

Fabrication

Service Aerodynamics


Significant Improvements Must Be Realized to offset

the Development and Certif ication Costs


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BOE021711-120

Certification of New Material SystemsDevelopment Phase Development Time

Modification of an 2-3 yearsexisting material for a

non-critical component

Modification of anexisting material for a

Up to 4 years Analysis

Verification

Full-scale

tests Analysis

Verification

Full-scale

tests

critical structuralcomponent

New material within asystem for which there

Up to 10 years – includestime to define the material’sDesign-value

Component

tests

Sub-component tests Design-value

Component

tests

Sub-component tests

s exper ence compos on an process ngparameters

New material class Up to 20 years or more – includes time required to developdesi n ractices that full ex loit

eve opmen

Material

Structural elements tests

Allowable development

Material specification development

eve opmen

Material

Structural elements tests

Allowable development

Material specification development

SOURCE: R. Schafrik, GE Aircraft Engines, Technology Transition in Aerospace Industry, briefing presented at the Worksop on AcceleratingTechnology Transition, National Research Council, Washington DC, November 24, 2003

the performance of the materialand establish a viable industrialbase

evaluationMaterial screening and selection evaluationMaterial screening and selection


Significant Risk Mitigation is Required to Certify a

New Structural Material


7/15

BOE021711-120

Blocking Block Approach to

1. Basic Material Physical

.

3. Process Feasibility4. Material and Process Scalability - Specifications

5. Design Allowables & Subcomponent ArticleDemonstration

6. Critical Feature/Full Scale Component Testing

A A A A A A


Processing and Process Variabil ity Can Significantly

Impact Structural Performance


8/15

BOE021711-120

Material Processing Can Significantly

Scale and Complexity of DesignMatter …Alot

Processing anomalies

• Surface irregularities

• Splicing

Pristine materials

Reductionof theallowable

Processing Variability ImpactsWeight Reduction Potential

• Waviness

• Inclusions• Voids

Damage

• Visible damage

•

Stress

stress

Materials Development Must IncludeProcessing Needs

• Repair (holes, etc.)

Design

• Environment

designregion

Strain

an Existing Process or Is a NewFabrication Technique Required?

Do the Support Materials Exist – Consumables, Adhesives, etc…


Variabil ity Impacts Both Processing and

Structural Performance


9/15

BOE021711-120

Aerospace Requires Enhanced

Industrial Scale Quantities

and FacilitiesQualit / Verification Control

Capability

Standardization of Testing~Supplier Certification

Expertise/Skill Base

composites, by

weight, in annual

Cost

Regulatory Compliance

u -ra e pro uc onof 787 than F-22


Aerospace Manufacturers Need to Understand a

Materials Impact Beyond Acquisit ion


10/15

BOE021711-120

A New Material System Needs to Be

Fabrication

AssemblySurface Preparation

-Retire

Shop

r l i n

e s &

g e r

s S

E nv

Energy

Efficiency

Energy

Efficiency

Solid

WasteDisposal

Solid

WasteDisposal

& RepairPart/Product

a f e f o r A i

P a s s e nf e

F or

i r onm en t

Hazardous

Waste

Hazardous

Waste

Green

House

Gases

Green

House

Gases

ReduceFootprintRecycle

Copyright © 2006 Boeing. All rights reserved. BOE021711-120EOT_RT_Sub_Template.ppt | 12/16/2009 | Materials & Fabrication Technology 10

NanoComposites Need to Be Safe and Meet Regulatory

Compliance Throughout the LIfecycle


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BOE021711-120

NanoComposites Have Tremendous

Electrical

PropertiesMechanical

Properties

Potential forPotential for

MultifunctionalMultifunctional

Thermal

Properties Manufacturing

Enablers

Acoustic Properties Fire Retardant


Need to Demonstrate the Performance Feasibility of

NanoComposites to Create the Necessary Pull


12/15

BOE021711-120

Emerging Materials Focus

New Material FormsScience

, ,

Analysis will Accelerate the

Adoption

“ En ineered” Materials“ En ineered” Materials

Functionality Improved Structural Properties Novel Processing


Enabling Engineered Materials for System LevelEnabling Engineered Materials for System Level

Performance is KeyPerformance is Key


13/15

BOE021711-120

NanoComposites Transition Opportunities

Horizon 3:Horizon 3:

Exploration for Future GenerationExploration for Future GenerationHorizon 2:Horizon 2:

Horizon 1:Horizon 1:

Current GenerationCurrent Generation

ProgramsPrograms

Next GenerationNext Generation

•• Nano Enhanced, HighNano Enhanced, HighPerformance PrimaryPerformance Primary

• Enhancements to

Secondary Structure i e s

• Coating Technology

•• MultifunctionalMultifunctionalStructural MaterialsStructural Materials

• Payloads and Interior Applications

•

C a p a b i l i

• Sensor Materials &Technology

• Point Solution to

•• Engineered MaterialsEngineered Materials

•• Dynamic self Dynamic self--assembly of materialsassembly of materials

Payoff TechnologyDifficult Problem


Implementation of NanoComposites isImplementation of NanoComposites is

Likely to Be IncrementalLikely to Be Incremental


14/15

BOE021711-120

Summary

NanoCom osites have si nificant otential

Materials must earn their way onto the airplane

development costs

approach and quality control system

Implementation likely to be incremental (builds


con ence an mproves un ers an ng

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