philip grainger senior technical director and chief ... · philip grainger senior technical...
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Introduction
No shortage of passengers –steady population growth
Plenty of need for more commercial aircraft
Commercial market is in boom
Approx 8,000 aircraft forecast to 2015
Source: Rolls-Royce (Oct 2006)
Environmental IssuesAdvisory Council for Aeronautical Research in Europe (ACARE) has set targets, endorsed by all major aerospace companies, to be met by 2020
Reduce fuel consumption and CO2 emissions by 50 per cent
Reduce external noise by 50 per cent
To reduce the emission of nitrous oxides by 80 per cent
To make substantial progress to reduce the environmental impact of the manufacture, maintenance and disposal of aircraft and related products
Targets not stringent enough – 30%
But prepared to pay to make a better aircraft
Source: Rolls-Royce (Oct 2006)
Why???
Weight, weight and weightCompared to aluminium structure Carbon can save between 20% to 30%
LifeCarbon fibre components are relatively insensitive to fatigue damage
Design FreedomBecause CFRP is a moulded product extravagant high performance shapes are possible for the same cost as traditional solutions
Future Trends
Lighter engines delivering the same power provide:
A lower weight propulsion system installation
Lighter wing attachments leading to a lighter wing
A more efficient aircraftLess fuel burn and lower emissions
Engines of the future will incorporate:
Lower speed, larger diameter fans and perhaps open rotors
Higher bypass ratios
Better fuel efficiencies
Lower CO2, NOX and noise emissions than engines of today
Future Trends
Lightweight structures are an equally important part of the equation
They will be self sensing for damage through life
They will be highly automated in manufacture to compete on cost and drive up quality
End of life disposal will become ever more important
A400M Carbon Spar
Stiffeners co-cured with skins
Fasteners used to attach ribs to skin
Tape-layed and diaphragm formed
assemblies
Expanding Composite Usage
Main composite parts
Boeing B787250 passengers
EIS 2010
Main composite parts
Airbus A380550 Passengers
EIS2008
0%
10%
20%
30%
40%
50%
60%
1970 1975 1980 1985 1990 1995 2000 2005 2010 2015
Com
posi
tes
ratio
in s
truc
tura
l airc
faft
wei
ght
AIRBUS BOEING Military
A300
A320A340-600
A380
B747-400
B777
A400M
B787
A350F-35(JSF)
F-22
F/A-18E
A330
A310
AV-8B
F/A-18A
F-16 B767
B737-300
Aerospace Application Aerospace Application –– Expanding Composite UsageExpanding Composite Usage
A320X
Carbon Fibre Demand
Worldwide CF Demand vs SuppliabilityWorldwide CF Demand vs Suppliability
PROPRIETARY
20,000
25,000
30,000
35,000
40,000
2004 2005 2006 2007 2008 2009 2010
Unit: Ton
Total Demand
Supply total
Supply not forecast to meet demand until 2008; by 2010 supply equals demand
Carbon fibre not confined to aircraft applications
Industrial applications
Sports applications
GKN Aerospace Composite Differentiators
World leading expert on Resin Transfer moulded assemblies
JSF Front Fan Frame
F22 spars
World first with out of autoclave processesA380 Fixed Trailing edge Panels
GE GenX fan case
First Tape layed and formed Primary Spars for Large Aircraft
A400M Wing Spars
VITAL (EnVIronmenTALly Friendly Aero Engines)
Development and manufacture of engine composite fan blades.
Lay-up trials commenced June 2007.
First blades manufactured at Cowes
Programme is on track for manufacture of 45 test blades by December 2007.
Birdstrike test by RR Q1 2008.
Trials began on production tooling in June 2007
Fan Blade Opportunities
Wide body aircraft blades. (e.g.A350)- £50M turnover
Single Aisle blades. (A320/Boeing 737) - £120M turnover
Bonding fixturing
Automated manufacture
General Electric GenX Fan Case
Contracted for the Boeing 787
Uses Resin Film Infusion
Automated lay-up
Turnover £80M
Second Engine to Test
First Engine to Test
JSF Resin Transfer Moulded Fan Frame
F-135 Fan Frame
Highly complex structure
Manufactured in one shot
No machining prior to engine parts assembly
Contract Value of £200M
Integrated Wing
Automated manufacture of closed box type structures
Demonstrator components now fully defined
Staged manufacture now in progress, leading to a wing box demonstrator.
Closed cell wing box
Out side surface
In side waffle surface
Out side surface
In side waffle surface
Waffle skin structure
ALCAS (Advanced Low Cost Aircraft Structures)
Out-of-autoclave manufacture of large scale spar component.
Trials at 3.0m scale successful.
Trials at 7.0m scale underway.
Full scale 11.5m component scheduled for completion and delivery by April 2008.
7.0m tool - First DDF trial June 2007
Next Generation Composite Wing
Underpinning technologies for next generation 150 seateraircraft.
Deposition of carbon pre-pregsat higher rate.
Advances in composite tooling, especially when combined with Out-of-autoclave self heated tools with embedded thermometers and local cure detection.
Higher Rate ATL
Wing Structure Opportunities
A400M Spars program born out of Framework 4 and 5 work
£10M turnover
Success on a wide body program (A350)£200M turnover
Whole wing technology for Single Aisle£500M turnover
Ice Protection
Spraymat™ - plasma sprayed metal on composite materialsSelected for Boeing 787 wing ice protection system
Design drivers: WeightNon-metallic structureNo engine bleed airField replaceable
Design concept (composite heater mat structure behind a thin aluminum erosion shield, on the movable slats)
Potential Business on Single Aisle £50M
Single Aisle Solution
Spar Bracket Assembly showing alternative
mounting of the TWB to the Fixed Wing Forward Spar
TWB
Airframe Electrical Connections
Slat Deployment Mechanism
Demountable Composite Solution (c/w integrated heater elements)
‘Breakaway’ at Telescopic Tube Termination (not shown)
Mounting Flange to Fixed Wing Rib
JSF F-135 Engine Inlet Ice Protection
StartDefineDevelop contract with Pratt & Whitney
JSF F-135 engine inlet struts, vane and hub require electro-thermal ice protection
Metal plasma spray on dry composite cloth
Wrap/drape to shape
Process via resin transfer moulding with the engine case already won
Business for JSF £250M
Summary
Technology Programs in GKN Aerospace have been directed towards and led to significant new business
Work in Framework 4 and 5 directly led to Composite spars product for A400m
Work in Framework 5 led to winglet design and build for APB
RTM Fan frame development led to JSF
Fan blades could be a great product
Anti ice, already on 787, has enormous potential
All programs are focussed on product and partnerships that will generate significant future revenues