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Performance Readiness

Wing to Fuselage Sub-Demonstrator TRL3 _ VISION OF IMPLEMENTATION. Performance Readiness.

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Performance Readiness

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  1. Wing to Fuselage Sub-DemonstratorTRL3 _ VISION OF IMPLEMENTATION Performance Readiness Perf_3.1: Identification of options (concept, functionalities, material…) to fullfill expected functionality from Product and related criteria to select or reject with respect to application and environment.Identification of options (concept, functionalities, technology : material & process). Identification of Top level requirements and major assumptions to define the concept (e.g. interface clash…). Preliminary assessment of weight impact A350-900 Baseline concept: The baseline is actually a SKF product realized with RTM process. The current section is composed of 3 materials (reference from 16 different item of A380 qualification): - G1157 : unidirectional fabric (96% warp and 4% weft) / El = 105000 MPa - GB201 : fabric (50% warp and 50% weft) / El = 60000 MPa - Glass (not in all the item) : El = 29000 Mpa In average, the theoretical longitudinal modulus is equal to 90500 MPa. But, the real measurement that takes into account the fork end and the axis clearance shows a drop of 9% to the value of 82000 MPa (average tension / compression). Example, A380 strut technology: 48580 = 2 * G1157(UD 280 g/m²) GB500 = 1* GB201 + 1 * G1157 48400 = 2 * GB201(taffetas 200g/m²) G1158 = 1* G1157 (Version 12 K CORAC - Wing to Fuselage Demo - TRL2 Review - V53PR1015504 08/10/2010

  2. Wing to Fuselage Sub-DemonstratorTRL3_CWB Far Field Area : CFRP Strut & Fitting Performance Readiness Perf_3.1 : Initial evidence of concept (incl. new certification issues, if any) at component level with respects to environment and targeted application Present concepts versus analysis results (based on pre-sizing, or other preliminary studies…) LEADING TO DOWN SELECTION Identification of 3 solutions: As a partner in CORAC project, SKF proposes some improvements of its actual technology. The aim is to : - Decrease impact damage by using damping skin - Decrease buckling phenomena by using Unidirectional Braid (A350-900: braid ±45°) - Increase allowable stress by using polar patch. 1 2 3 1 3 2 2 removable half shells

  3. Wing to Fuselage Sub-DemonstratorTRL3_CWB Far Field Area : CFRP Strut & Fitting Performance Readiness Perf_3.1 : Initial evidence of concept (incl. new certification issues, if any) at component level with respects to environment and targeted application Present concepts versus analysis results (based on pre-sizing, or other preliminary studies…) LEADING TO DOWN SELECTION Damping skin details: 1 Benefits: Protection of composite parts avoiding delamination Visualization of impacts => ease of maintenance Can be easily removed => ease of maintenance Position vs. Competition:New patented product for Airbus to protect composite parts against impact. • General concept of the Technology Product • External skin with high plastic deformation • Hollow spheres as energy absorber system External skin (aramid) Hollow spheres Composite Rod

  4. Wing to Fuselage Sub-DemonstratorTRL3_CWB Far Field Area : CFRP Strut & Fitting Performance Readiness Perf_3.1 : Initial evidence of concept (incl. new certification issues, if any) at component level with respects to environment and targeted application Present concepts versus analysis results (based on pre-sizing, or other preliminary studies…) LEADING TO DOWN SELECTION Unidirectional braid details: 2 • UD braid is localized like the red line • Reduce thickness / radius of the lug • Reduce weight • increase allowable stress on fork end/ tube connection • decrease local buckling phenomena • Increase stiffness

  5. Wing to Fuselage Sub-DemonstratorTRL3_CWB Far Field Area : CFRP Strut & Fitting • Reduce thickness / radius of the lug • Reduce weight • increase cleaving / bearing allowable stress • In line with specification • Increase stiffness Performance Readiness Perf_3.1 : Initial evidence of concept (incl. new certification issues, if any) at component level with respects to environment and targeted application Present concepts versus analysis results (based on pre-sizing, or other preliminary studies…) LEADING TO DOWN SELECTION Polar patch details: 3

  6. Wing to Fuselage Sub-DemonstratorTRL3_CWB Far Field Area : CFRP Strut & Fitting Performance Readiness Perf_3.2 Compatibility/integrability Perf_3.2 Initial assessment of compatibility/integrability of component and cross technology issues (PDR) (incl. Systems installation and ramp-up requirements) Present product integration with respect to its environment highlighting major interface issue if any (tolerance, clash, corrosion, …) No interface modification: mettre photo du process/ ou schéma du cône 1 Aramid Plies Bonding (Hysol 9321) Clamping (x3) Mettre Photo après ébavurage 2 3

  7. Wing to Fuselage Sub-DemonstratorTRL3 _ VISION OF IMPLEMENTATION • Impact tests on composite part protected by a damping skin (configuration c1) Clamping system Carbon plate Damping skin Carbon Plate  C-San control : After 30 J impact, no internal delamination of composite parts after impact. After 50 J impact, defects appear (no visible).  Definition of the baseline configuration c1 : AITM 1-0010 Standard 1.4 mm Aramid 5.8 mm hollow spheres Performance Readiness Perf_3.3 Initial technology trials addressing key features of component Present product technical test results addressing sizing/selection criteria 1 09 June 2008

  8. Wing to Fuselage Sub-DemonstratorTRL3 _ VISION OF IMPLEMENTATION • Real Scale Manufacturing : • Impact on shells (in-shape damping skin) Al plate Higher Maximum effort Indentation Al Edge Displacement [mm] Performance Readiness Perf_3.3 Initial technology trials addressing key features of component Present product technical test results addressing sizing/selection criteria 1 Damping skin Rod 16000-08(real part) 09 June 2008

  9. Wing to Fuselage Sub-DemonstratorTRL3 _ VISION OF IMPLEMENTATION Performance Readiness Perf_3.3 Initial technology trials addressing key features of component Present product technical test results addressing sizing/selection criteria 2 3 09 June 2008

  10. Wing to Fuselage Sub-DemonstratorTRL3 _ VISION OF IMPLEMENTATION Performance Readiness Perf_3.3 Initial technology trials addressing key features of component Present product technical test results addressing sizing/selection criteria Test results analysis: 2 3 Cleaving section lug failure Rq: More flexibility on design capability to reach the combinaison of low stiffness and high load level F = ESε 09 June 2008

  11. Wing to Fuselage Sub-DemonstratorTRL3 _ VISION OF IMPLEMENTATION Performance Readiness Perf_3.3 Initial technology trials addressing key features of component Present product technical test results addressing sizing/selection criteria 2 • Datas obtain on full scale rods permit us to: • Analyse failure load from test results → calculate rods failure load • Analyse σ cleaving and bearing of fork end → made optimized design with these values • Take stiffness results → defined stiffness in line with specification 3 *New design based only on tube modification 09 June 2008

  12. Wing to Fuselage Sub-DemonstratorTRL3 _ VISION OF IMPLEMENTATION Performance Readiness Perf_3.4 Limitations for the technology Perf_3.4 Identification of basic design rules or limitations for the technology Rod stiffness: like serial spring (fork end/ cone/ tube) 1 2 3 • Keep same stiffness • Decrease tube thickness Decrease global ES (N) • Increase stiffness of : • Fork end by polar patch • Cone by using Unidirectional Braid instead of ± 45° • No other Limitations of the Technology • but increase of the damping layer weight and thickness with the absorption capacity needs (7.2 mm for 35 J and 13.4 mm for 50 J)

  13. Wing to Fuselage Sub-DemonstratorTRL3 _ VISION OF IMPLEMENTATION • See Perf. 3.1 • C-san control for 3 tested composites plates (Résultats St Vallier !!!!) Ok for 30 J Ok for 50 J Performance Readiness Perf_3.5 Material characterisation Perf_3.5 Initial evidence of material characterisation through coupon testing on reference loads to prove key characteristics (TRL4 for dimensioning new material) Present material candidates screening results in the format of a spider diagram to compare with standard material. 1 09 June 2008

  14. Wing to Fuselage Sub-DemonstratorTRL3 _ VISION OF IMPLEMENTATION Performance Readiness Perf_3.6 Scale-up issues Perf_3.6 Scale-up issues addressed through design of scaled components to include specific features targeted in the demonstration Present scale-up issue mitigation plan progress and demonstrate risk management & reduction. 1 Flat specimens 150 x 150 mm² Cylindrical specimens (F 89 mm - Real part) Non - Flat specimens ( l = 180 mm)  First tests on flat damping layers have been successfully extrapolated to landing gear rods. Same approach is used for the composite rods (A350 Application). 09 June 2008

  15. Wing to Fuselage Sub-DemonstratorTRL3_CWB Far Field Area : CFRP Strut & Fitting Engineering Readiness • Eng_3.1 Confirmation of a sponsor acceptance • For the A350-1000 and potential retrofit on other Airbus program • Eng_3.2 Appropriate multidisciplinary team • Eng_3.2 Identification of appropriate multidisciplinary team to review and/or develop the new technology (i.e. M&P, EDS, CoC...) • Airbus Team, NDT expert for non destructive test, SKF for manufacturing and design, Ateca for the damping skin • Eng_3.3 Material preliminary specification • Eng_3.3 Identification or production of an appropriate material preliminary specification • UD Braid: same fiber than already qualified tube material • Polar patch: AS4 fiber for Hexcel (standard list materials) 1 2 3 1 2 3 2 3 Wing box rods specification n° V00030001 curent version

  16. Wing to Fuselage Sub-DemonstratorTRL3_CWB Far Field Area : CFRP Strut & Fitting Engineering Readiness • Eng_3.3 Material preliminary specification • Eng_3.3 Identification or production of an appropriate material preliminary specification • Damping skin materials: 1 • Aramid Fabric K336 (Sicomin) • Epoxy Resin Araldite LY5052/ Aradur 5052 (Airbus database) • FAR 25 certified hollow spheres (ATECA), used by EADS Eurocopter since 2002 ( for vibroacoustic application) • Adekit 211 (Axson) • Work in progress : • Environmental condition tests (fuel, wet ageing). PHOTOS ST vallier!!! • Research of new Airbus certified adhesives

  17. Wing to Fuselage Sub-DemonstratorTRL3_CWB Far Field Area : CFRP Strut & Fitting Engineering Readiness Eng_3.4 Validation of pre-sizing methods Eng_3.4 Validation of pre-sizing methods with respects to lessons-learnt from material and manufacturing screening 1 • Low energy Impact Tests performed by Conseil & Technique on week 15 … • See Perf. 3.3 and :

  18. Wing to Fuselage Sub-DemonstratorTRL3_CWB Far Field Area : CFRP Strut & Fitting Engineering Readiness • Eng_3.4 Validation of pre-sizing methods • Eng_3.4 Validation of pre-sizing methods with respects to lessons-learnt from material and manufacturing screening • Present pre-sizing methods used and show its reliability with respects to lessons-learnt from material, manufacturing screening, etc… • SKF High knowledge for rods design • Using first results from sample for lug section • Using damping skin result for tubular section design • Test on complete rod will be done on week 15 to validate first design 2 3 Datas establish from sample

  19. Wing to Fuselage Sub-DemonstratorTRL3_CWB Far Field Area : CFRP Strut & Fitting Engineering Readiness Eng_3.5 Preliminary Certification Plan Eng_3.5 Preliminary Certification Plan incl. Showstoppers • Witch A350-900 rod reference must be tested? • A Jonhson/Euler or mixte failure mode reference • High fork end thickness due to high cleaving/bearing stress

  20. Wing to Fuselage Sub-DemonstratorTRL3_CWB Far Field Area : CFRP Strut & Fitting TRL 3 damping skin TRL 6 TRL 5 TRL 4 TRL 3 Engineering Readiness Eng_3.5 Preliminary Certification Plan Eng_3.5 Preliminary Certification Plan incl. Showstoppers Damping skin: 1

  21. Wing to Fuselage Sub-DemonstratorTRL3_CWB Far Field Area : CFRP Strut & Fitting TRL 3 UD braid/ polar patch TRL 6 TRL 5 TRL 4 TRL 3 Engineering Readiness Eng_3.5 Preliminary Certification Plan Eng_3.5 Preliminary Certification Plan incl. Showstoppers Polar patch and UD braid: 2 3

  22. Wing to Fuselage Sub-DemonstratorTRL3_CWB Far Field Area : CFRP Strut & Fitting Engineering Readiness Eng_3.6 Compatibility with environmental and H&S legislation Eng_3.6 Initial assessment of compatibility (benefit/risk) of material, manufacturing process… with environmental and H&S legislation, identification of mitigation opportunities For this assessment, you can ask for a dedicated Enviromental Life Cycle Analysis (ELCA) 1 2 3

  23. Wing to Fuselage Sub-DemonstratorTRL3_CWB Far Field Area : CFRP Strut & Fitting Manufacturing Readiness Manuf_3.1 Manufacturing trials to produce small-scale shaped test components Manuf_3.1 Initial assessment through manufacturing trials to produce small-scale shaped test components with respects to key characteristics See Perf_3.3for ud braid and polar patch. 2 3 ±45° braid UD braid • Damping layers successfully manufactured to protect real scale rods for aircraft landing gear. • Manufacturing of demonstrator subparts in March 2011 (Protection of rod 16000-08). 1 89 mm

  24. Wing to Fuselage Sub-DemonstratorTRL3_CWB Far Field Area : CFRP Strut & Fitting Manufacturing Readiness • Manuf_3.2 Potential manufacturing hot spots • Manuf_3.2 Identification of potential manufacturing hot spots and high risk areas with respect to robust manufacturing and (inner) quality, manufacturing defects and related inspection methods • No risk for UD braid, exactly the same process than standard A350-900. • For polar patch, the positionning must be in line with drilling localization • For damping skin : • Porosity of the aramid skin has to be controlled. • Standard NDT Inspection not applicable • New procedures should be defined to check the damping layers after manufacturing (In Progress with NDT Expert). 2 possibilities: • shearography os US inspection • or • Y To increase the trust in the manufacturing process – use of aramid prepreg (In Progress). 2 3 1

  25. Wing to Fuselage Sub-DemonstratorTRL3_CWB Far Field Area : CFRP Strut & Fitting Manufacturing Hollow spheres manufacturing Same process as for EADS-Eurocopter Hollow spheres assembly (bonding) Curing NDT Hollow spheres bonded on to the external skin -Machining- External Skin cutting (laser , same procedures than SAFRAN) Damping layer clamped to the rod Manufacturing Readiness Manuf_3.3 Suitable model for the manufacturing method and component performance Manuf_3.3 Development of a suitable model for the manufacturing method and the component performance Present the serial manufacturing process that complies with product performance 1 Manufacturing vacuum bag Processing for eternal skin

  26. Wing to Fuselage Sub-DemonstratorTRL3_CWB Far Field Area : CFRP Strut & Fitting Manufacturing Readiness • Manuf_3.4 Manufacturing process repeatability • Manuf_3.4 Preliminary assessment of manufacturing process repeatability • For Ud braid and polar patch: same process than standard rods, with robust concept. For damping skin, Industrial Process at small scale: • Hollow spheres manufacturing already exists to answer to small scale industrial needs (EADS- Eurocopter) • but some discrepancies appeared in the external skin porosity. • YThis would be improved using aramid Prepreg (In Progress). • Manuf_3.5 Tolerance management philosophy for component & manufacturing tooling • Manuf_3.5 Assessment of tolerance management philosophy for the component and manufacturing tooling • Similar tooling than existing qualified part. • Manuf_3.6 Concepts for new tooling • Manuf_3.6 Identification of concepts for new tooling capabilities (TRL1 for new tooling capabilities) to go to next levels of demonstration (incl. Plan for demonstrator if required) • The prototype tooling is the same concept than serial tooling. Only material (Aluminium versus Steel) is different. • Manuf_3.7 Assembly issues • Manuf_3.7 Identification of assembly issues (i.e. bonding drilling, fastening methods etc…) and mitigation plan defined • No issue concerning this point : damping layers clamped on the struts.

  27. Wing to Fuselage Sub-DemonstratorTRL3_CWB Far Field Area : CFRP Strut & Fitting 15 J 30 J Operational Readiness Op_3.1 Repair solution for both manufacturing defect and in-service requirements Op_3.1 Preliminary assessment of repair solution for both manufacturing defect and in-service requirements No repair on this CFRP part. Part replacement necessary. Feed back from Airbus EIOI assessment showing no issues in the past years Op_3.2 Impact on support services Op_3.2 Assessment of impact on support services (acceptability by A/L ie maintenance processes, tools, skills, DOC/DMC…) 1 2 3 • During maintenance process, damping layers should be controlled. • Inspection needed to check the rod integrity after impact • Criteria to change the damping layer : indentation value (in progress) 1 20 mm Indentations on a damping layer after 15 J and 30 J impact

  28. Wing to Fuselage Sub-DemonstratorTRL3_CWB Far Field Area : CFRP Strut & Fitting Value & Risk V&R_3.1 & 3.2 Benefits and risk analysis V&R_3.1 Update of benefits and risk analysis with respects to environment of application and feasibility results (material, component, scale-up and production constraints, preliminary manufacturing time cycle analysis, new certification issues if any…). Present weight & cost analysis and exchange rate. 1 2 3 • Hypothesis: • Move from visibility criteria to cut off (35J) • Stiffness calculation based on 008 rods test results • Damping sking protection of 50g/dm² maximum to get weight saving • Fork end thickness based on 008 rods test results

  29. Wing to Fuselage Sub-DemonstratorTRL3_CWB Far Field Area : CFRP Strut & Fitting Value & Risk V&R_3.1 & 3.2 Benefits and risk analysis V&R_3.1 Update of benefits and risk analysis with respects to environment of application and feasibility results (material, component, scale-up and production constraints, preliminary manufacturing time cycle analysis, new certification issues if any…). Present weight & cost analysis and exchange rate.

  30. Wing to Fuselage Sub-DemonstratorTRL3_CWB Far Field Area : CFRP Strut & Fitting Value & Risk Route to TRL4 • Confirm sample result on full scale rods • Redesign and optimized the part with the TRL3 test result • Potential other failure modes identification (braid lenght, polar patch number) • Test, @ temperature and fatigue/ageed condition • Damage and defect tolerance tests and associated destructive and Non Destructive Test reports • Variability assessement • Test with A350 baseline rods for global stiffness measurement on dedicated test bench TRL3 TRL4

  31. Wing to Fuselage Sub-DemonstratorTRL3_CWB Far Field Area : CFRP Strut & Fitting Route to TRL6 • Damping skin industrialization parameter to be fixed • Confirm sample result on complete rods • UD braid • Polar patch • Damping skin • Obtain optimized design based on test realized on full scale rods • adjust the stiffness in line with specification • Manufacturing rods parameters to be fixed • Obtain polar patch localization effect • Obtain optimized damping skin length protection and material fixed • Obtain allowble material necessary for design part • NDT parameters to be fixed TRL5 TRL6 TRL3 TRL4 Value & Risk

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