MHI composite technology - Status and Future - Toshio Abe
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1 Composite Safety Meeting and Workshop [CAANZ, Wellington, New Zealand] MHI composite technology - Status and Future - Toshio Abe Fixed Wing Aircraft Engineering Department, Integrated Defense & Space Systems 2016 MITSUBISHI HEAVY INDUSTRIES, LTD. All Rights Reserved.
2 Achievement and Challenge MHI Composite Application History MHI Composite Application History and Achievement Since early 1980 s, Started Composite application in aircraft structure. Aggressive development activities led by Japan s self-defense force has borne much fruit, such as co-cured wing-box in F-2 Support Fighter. Turning into 21 st Century, composite application has been spread out into commercial airplane. MHI has been contributing to develop / produce wing-box on Boeing 787 and now making composite empennage on next coming MRJ. Achievement To realize co-cured and co-bonded composite structure Spar / Stringer Skin Challenge = Low Cost Volume Production Cost Contributor * Material / Fabrication Process - Too expensive compared to Metal * Parts Fabrication - Bunch of elaboration compared to Metal counterparts * Assembly - Bunch of Fasteners needed Co-cured Joint 2016 MITSUBISHI HEAVY INDUSTRIES, LTD. All Rights Reserved. 1
3 Today - Composite Structure Production Parts Fabrication & Assembly are two major cost drivers, even though all process hold high cost issues. High Cost & Low Produce-ability compared to Metallic structure. <Material> Too Expensive <Parts> Gigantic Jigs for realizing geometrical accuracy Energy Complicated Fablication <Sub Assy> Skin-Stringer Panel High Cost <Assembly> Hole Prep. Fastening, EME Protection Material Cost Cost Distribution High Cost Bunch of Bolts Shimming <Shimming> Time & Cost Issue Measure Shim Prep. Shim Operation due to poor geometry Crack Delam. Prevention Feature High- Cost Hole Prep. Fastening Weight Up High Cost Inside of the Tank Sealant Coverage Strength Down High Cost 2016 MITSUBISHI HEAVY INDUSTRIES, LTD. All Rights Reserved. 2
4 Cost Contributor - Parts Fabrication Hand Craft Products Hand Lay-up SKIN Old Days ~2000 Industrial Products Automated Lay-Down Today 2003~ After Boeing787 Ref : G. Hasko, An Introduction to Aerospace Composite Manufacturing Technology Ref : Ref : M-Torres HP Stringer and other Skeletal Parts In-efficient and Low Produce-ability Hot Drape Forming Lay-down up to more than 100plies Vacuuming Even in similar geometrical Parts, Needed parts-by-parts procedures. Half Day Curing At last, One parts finished!! Multi-Parts Assemble & Co-cure 出典 : 三菱重工技報 Vol.51 No.4 (2014) Bagging Curing Demolding Machine & Finish Part 2015 MITSUBISHI HEAVY INDUSTRIES, LTD. All Rights Reserved. 3
5 Cost Contributor Parts Fabrication Compared to Metal counterparts, Bunch of elaboration = Cost Needed in Today s Composite Fabrication. Stringer and other Skeletal Parts In-efficient and Low Produce-ability Lay-down up to more than 100plies Vacuuming Even in similar geometrical Parts, Needed parts-by-parts procedures. Half Day Curing Hot Drape Forming Multi-Parts Assemble & Co-cure 出典 : 三菱重工技報 Vol.51 No.4 (2014) Bagging Curing Demolding Machine & Finish Part Standard Parts & Finishing Metal Stringer Fabrication (Example) Extrusion (Ex.) Standard Parts Rolled & Tapred Forming Part Machine Finish Finish!! 2015 MITSUBISHI HEAVY INDUSTRIES, LTD. All Rights Reserved. 4
6 Cost Reduction Challenge Composite application on aircraft have becoming popular. But Need pursue more aggressive cost target for meeting fierce market challenge. Thus, Future Target on Composite is To realize head-to-head competitive production cost against traditional metallic structure Material DOWN Assembly DOWN Parts Fab. DOWN Dramativcally Cost Down!! Less Usage DOWN << Opportunity >> Innovation on Parts Fabrication To realize Bonded Structure Today Future 2015 MITSUBISHI HEAVY INDUSTRIES, LTD. All Rights Reserved. 5
7 How to achieve the Goal Innovation on Parts Fab. Standardization Today Every single part has unique geometry. Thus, Need independent fabrication tool / process even in very similar parts. Quality Concerns, such as fiber wrinkles, due to aggressive contour, joggle Long process time is also concern. Future Standardization needed for realizing Metal-equivalent fabrication cost. Drape-ability suited for contour and joggle. To realize short process time Candidate Technology Textile and Thermo-Plastic contour Textile & CFRTP Joggle Future Aircraft CFRTP = Carbon Fiber Reinforced Thermo-Plastic 2016 MITSUBISHI HEAVY INDUSTRIES, LTD. All Rights Reserved. 6
8 How to achieve the Goal Bonded Structure To realize Bonded Structure Today Panel-level unified structure realized utilizing co-cure / co-bond technology. Still, Need far trek toward realizing bonded construction due to less-reliable process and lack in prevalent quality assurance procedures. Future To realize Bonded Structure and fully utilize composite advantage w/less Fastener counts. Expected Technology Stable Bond w/robust Process Quality Assurance for Weak/Kissing Bond Strength Degradation due to Hole Prep. CFRP 370MPa Al-Alloy (7050) 950MPa To eliminate / decrease Fastener counts using bonded technology Non-Hole Open-Hole 2016 MITSUBISHI HEAVY INDUSTRIES, LTD. All Rights Reserved. 7
9 How to achieve the Goal Bonded Structure Bunch of parameters affects Quality and Strength on Bonded Joints Assembly & Curing Process Time Parts Gap Pressure Curing Temperature Trapped Air Multiple Cure Cycles Adhesive Thickness Bond Strength Toughness & Failure Mode Void / Porosity Shear & Flat-wise Strength Surface preparation on Composite Wettability Surface Energy Surface Roughness Contamination Pre-Bond Humidity 2016 MITSUBISHI HEAVY INDUSTRIES, LTD. All Rights Reserved. 8
10 How to achieve the Goal Bonded Structure Statistics Based Strength Prediction from Process Record Clarification of the Missing Link Crack/Delam. Propagation Prevention Feature Process Chemical/Physical State of Bond Surface Certification on Bonded Structure Process Parameters Contamination Humidity Pressure Temperature Surface Preparation Exposure Time after Surface Prep. etc. Bonding Process to Enable Chemical Cross-link Minimizing Variability by Process Automation Non-Destructive Inspection Method for Weak & Kissing Bond Several Routs leading to the goal, or Certification. Discuss & Find the Solution for future Aircraft!! Proof Test Hard to Achieve 2016 MITSUBISHI HEAVY INDUSTRIES, LTD. All Rights Reserved. 9
11 Thank you for your attention! 2016 MITSUBISHI HEAVY INDUSTRIES, LTD. All Rights Reserved. 10
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