Aerospace Materials

1. Aerospace Materials

2. Why Advance Materials? … to the airline … to the factory … to the designer Reduced Fuel Consumption New Production Possibilities Reduced Weight Fewer & Easier Inspections Fatigue & Corrosion Resistant Fewer Parts Reduced Maintenance Cost Lower Amortization Cost New Design Possibilities Reduced Production Cost Longer Life

3. Why Advance Materials? Materials, Processes, & Design Improvements Future Technology Levels MOSTLY UNCHARTED Weight & Cost Improvements 2002 - 2006 Technology Level KNOWN TECHNOLOGIES 777 Technology Level 757/767 Technology Level 737 Technology Level 747 Technology Level Time

4. Composite Steel Titanium Aluminum Miscellaneous History of Composite Materials (Boeing) 787 777 757/767 747 Increased composite usage over time Materials

5. History of Composite Materials (Boeing) • 747 Program – 1960’s • Extensive use of fiberglass/honeycomb components • Control surfaces • Fairings • Trailing edge panels

6. History of Composite Materials (Boeing) • Carbon fiber concepts development – early 1970’s • NASA-ACEE program—reaction to 1973/74 OPEC oil price increase • Boeing designed, fabricated, and certified • 727 elevators • 737 horizontal stabilizers

7. Graphite Aramid Hybrid History of Composite Materials (Boeing) • Increased Production Implementation – early 1980’s • 757/767 introduced expanded use of composites • Material and process specifications in place • Experienced design, fabrication, and certification personnel • Technology jointly developed with suppliers Wing tips Fixed trailing edge panels Fin Fixed Trailing Edge Panels Fin tip Nose gear doors graphite/fiberglass Rudder Wing-to-body fairing Inboard spoilers Main landing gear doors graphite/Kevlar Elevators Stabilizer fixed trailing edge panels Inboard ailerons Strut forward and aft fairings Enginecowlings Stabilizer tips Outboard flap Trailing edge wedge Trailing edge flap support fairings Kevlar Outboard ailerons Outboard spoilers

8. Increased Production Implementation – early 1990’s • 777 applied introduced expanded use of composites Toughened graphite Graphite Hybrid Fiberglass History of Composite Materials (Boeing) Outboard aileron Fin torque box Stabilizer torque box Rudder Outboard flap Elevator Flaperon Inboard flap Wing fixed leading edge Floor beams Trailing edge panels Leading and trailing edge panels Strut forward and aft fairings Wing-to-body fairing Inboard and outboard spoilers Flap track fairing Nose radome Main landing gear doors Engine cowlings Nose gear doors

9. Carbon laminate Carbon sandwich Fiberglass Aluminum Aluminum/steel/titanium pylon History of Composite Materials (Boeing) 787 Material Overview – 2000’s

10. Where Do Materials Matter? • Answer – Everywhere! • Airframe: • Wing, Fuselage, Empennage, Landing Gear, Control Surfaces • Interiors/Payloads: • Seats, Overhead Bins, Linings, Bulkheads, Cargo Restraints, Floors • Systems: • Electrical transmission (wiring), Insulation/Isolation, Mech/Hyd systems • Propulsion: • Fairings, Cowlings, Exhaust, Acoustics, Fuel Systems, Pylon/Strut • Other: • Windows, Doors, Seals, Electromagnetic Effects (EME) Materials Enable Design and Performance Across the Airplane

11. Now What? • More, newer, tougher Composites • Lighter weight • Better Damage Resistance • Better Damage Tolerance • Improved Manufacturability • Higher temperature Materials • Composites Ceramics Polymers • Metals • Conductive Materials • Electrical Systems • EME/Lightning Strike • Improved Processing • Drilling/fastening EME issues • Layup • Joining/Bonding/Welding