Leading the way with advanced aluminium solutions for aerospace structures AGEFORM: Form Form ing adv adv ance ance d ae ae rospace rospace pane pane ls at reduce reduce d cost F. Eberl, Eberl, Alcan R&D Ce Ce nter, nter, Vorepp Voreppe e , France France S. Gardin Gar diner, er, Airbus irb us UK Ltd, England England G. Campanil Campan ile, e, ALE ALENI NIA A AERON AERONA AUTIC UTICA A - Enginee ring, Itali Italie e G. Sur Surdon, don, Dassault Dassault Av iation, iation, France France M. Venmans, SABCA, Belgium P. Prangnell, Prangne ll, UoM, UoM, Engla ng land nd
[email protected]
Aerodays Aerodays 2006, Vienna, ienna, the the 18.06. 18.06. – 21.0 21.06.06, 6.06, Agefor Ageform, m, F. Eberl Eberl
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Lightweight solutions for metallic airframes
•
Objective – Development of competitive metallic solutions in the fields of • Design • Materials t h g • Manufacture i e – With the target of w % 0 cost 2 • Cost and • Weight reduction 20 %
Aerodays 2006, Vienna, the 18.06. – 21.06.06, Ageform, F. Eberl
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High performance and low cost airframes Laser beam welding technology % 0 2
Integrally machined monolithic structures
t h g i e w cost
20%
Welded monolithic structures Ageforming
Friction stir welding technology
Aerodays 2006, Vienna, the 18.06. – 21.06.06, Ageform, F. Eberl
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Airframe structure performance Advanced alloys
Advanced Design Concepts
Advanced joining and forming techniques
AND Multi-disciplinary & Collaborative approach! Aerodays 2006, Vienna, the 18.06. – 21.06.06, Ageform, F. Eberl
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Alternative routing for assembling
TOP wing skin
Current fuselage skin
7xxx plate TAF temper
6xxx sheet T4 temper
plate machining
forming (stretch forming)
ageforming
3D machining
Damage tolerant structures
Integral machining 2xxx plate (new material) T3 temper
ageforming surface treatment
welding
re-shaping
Laser Beam Welding
special features
Friction stir welding
ageforming
Manhole/overthickness machining
surface treatment pocketing
ageing
surface treatment Aerodays 2006, Vienna, the 18.06. – 21.06.06, Ageform, F. Eberl
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AGEFORM: Forming advanced aerospace panels at reduced cost • • • •
Process principles Metallurgical principles and mechanical properties Ageform process for Aerospace applications Summary and outlook
Aerodays 2006, Vienna, the 18.06. – 21.06.06, Ageform, F. Eberl
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AGEFORM process room temperature
aging temperature
Aerodays 2006, Vienna, the 18.06. – 21.06.06, Ageform, F. Eberl
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Metallurgical principles •
Physical phenomenon: creep – Stress relaxation during the artificial ageing cycle Application of specific ageing treatment Relaxation
200
a
150
6h@175°C+13h@190°C
s s 100 e r t
4h@108°C+24h@160°C 24h@173°C Constant strain tensile test: Highest stress relaxation for 2022
50
AlCuMg
IS237 2022 6056 7475
AlMgSiCu AlZnMgCu
0 0
4
8
12
16
20
24
Time (hrs) Aerodays 2006, Vienna, the 18.06. – 21.06.06, Ageform, F. Eberl
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Metallurgical principles •
Precipitation alignment in the 2022 alloy – No impact on static properties – No impact on anisotropy 400 2022 static
2022 dynamic
a 390 P M ( s 380 s e r t S 370 d l e i Y 360 % 2 . 0 350 340 0
10
20
30
40
50
60
70
80
90
Angle w ith longitudinal axis (° )
Aerodays 2006, Vienna, the 18.06. – 21.06.06, Ageform, F. Eberl
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Metallurgical principles •
Precipitation alignment in the 2022 alloy – No impact on damage tolerance properties
Roll forming Sample loading Ageforming in autoclave
190
R-Curve s CCT760 (L-T) Ageforming effect
170 150
no impact on R-curve
Ageformed
panels can be characterised in the flat shape
) m √ √ a130 P M ( r K110
2022clad T8 th 3.2 ref 2022clad T8 ageformed 3.2 mm (R 1 m)
90
2022clad T8 th 6 mm ref 2022clad T8 ageformed 6 mm (R 2 m)
70 50 0
20
40
ae ff (mm) Aerodays 2006,∆Vienna, the
60 18.06. – 21.06.06, Ageform, F. Eberl
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AGEFORM: Forming advanced aerospace panels at reduced cost • • • •
Process principles Metallurgical principles and mechanical properties Ageform process for Aerospace applications Summary and outlook
Aerodays 2006, Vienna, the 18.06. – 21.06.06, Ageform, F. Eberl
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Ageform process for Aerospace applications •
Example of a commercial aircraft fuselage panel – Including modern assembling features as • Laser Beam Welded (LBW) stringers on the skin • Longitudinal Friction Stir Welded joints • Machining of fuselage skin: pocketing, …
Aerodays 2006, Vienna, the 18.06. – 21.06.06, Ageform, F. Eberl
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Ageform process for Aerospace applications •
Manufacturing of a commercial aircraft fuselage panel (1/2)
Skin Trimming
FSW Skin Panels
Pocket Mechanical/Chemical Milling
Cleaning / Pickling
Laser Beam Welding of Stringers Aerodays 2006, Vienna, the 18.06. – 21.06.06, Ageform, F. Eberl
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Ageform process for Aerospace applications •
Manufacturing of a commercial aircraft fuselage panel (2/2)
Creep / Age Forming
Dimension Checks
NDE
Cleaning / Painting Aerodays 2006, Vienna, the 18.06. – 21.06.06, Ageform, F. Eberl
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Ageform process for Aerospace applications Evaluation of result obtained
•
Quality increase
Weight reduction
m m n i t n e m e c a l p s i d
- 500
Cost reduction
baseline: 2024/7175
0% 5
after welding 4
6056 T6 welded
after ageforming 3
-5%
2 1 0 -1 -2
- 300
- 100
100
w idth in mm
300
500
n i a g t h-10% g i e w e v -15% i t a l e r
high str ength 2xxx, riveted high strength 2xxx, welded
-20%
-25% 2.65
Al-Li, welded Al-Li, welded 2. 70
2.75
2. 80
average density in g/cm
2.85
3
Aerodays 2006, Vienna, the 18.06. – 21.06.06, Ageform, F. Eberl
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Summary and outlook Bottom wing skin
• • • • • •
Complex fuselage structures
Aerospace structures
Process demonstrated Final properties evaluated Micro-structural mechanisms well understood Process demonstrated on LBW and FSW containing structures Representative bottom wing structure demonstrated Representative fuselage panel demonstrated
Ageform process can be applied to damage tolerant structures Aerodays 2006, Vienna, the 18.06. – 21.06.06, Ageform, F. Eberl
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Summary and outlook 180
Property Improvement of Al alloys: 170 Fuselage skin & stringers 2139 T851 180 ) 160 % ( n o i t 140 a i r a v e v 120 i t a l e R
2198 T851
160 Skin - Kapp T-L ) m Stringer - TYS L s √ √
s a150 e P n M h ( 140 g ) L u o T ( t p130 p
2022 T8512139
6156 T651
2198 6156 2524 7475 T7651
a
K 2024 120
100
7075
110
?
2024 T351
7349
Al-Li PA766
7150
80 1950
1970 100 230
1990
2010
330Year of AA registrat 430 ion CYS(LT) (MPa)
530
Still a lot of 2030 improvement anticipated !
strength Aerodays 2006, Vienna, the 18.06. – 21.06.06, Ageform, F. Eberl
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Aerodays exposition: Ageform, stand nr. 51 rib 42
rib 49
rear spar
stringers m 5 . 0 ~
~1.5 m
f ront spar
~500 mm
~1500 mm
Aerodays 2006, Vienna, the 18.06. – 21.06.06, Ageform, F. Eberl
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