BOE021711-120

Aerospace Structural Aerospace StructuralMaterial Certification Material Certification

Dave Furdek Dave FurdekMgr – Next Generation Composite MaterialsBoeing Research and Technology28 February 2011

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BOE021711-120

Boeing Products 

767 717 

F-18

BBJ

JTRS 

ISS 

Ad 

787 747

Adva

UnmannedSystems

777 737

Rotorcraft

Tankers

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Boeing Commercial 

Aircraft

Boeing Defense

and Secur
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Material Selection Drivers

225 SEATS 275 SEATS

per seat

300 SEATS

225 SEATS

250 SEATS

275 SEATS

350 SEATS 400 SEATS

450 SEATS

500 

SEATS

200 SEATS

pCurrent Quadser seat

300 SEATS

225 SEATS

250 SEATS

275 SEATS

350 SEATS 400 SEATS

450 SEATS

500 

SEATS

200 SEATS

per seat

300 SEATS

225 SEATS

250 SEATS

275 SEATS

350 SEATS 400 SEATS

450 SEATS

500 

SEATS

200 SEATS

per seat

300 SEATS

225 SEATS

250 SEATS

275 SEATS

350 SEATS 400 SEATS

450 SEATS

500 

SEATS

200 SEATS 300 SEATS

225 SEATS

250 SEATS

275 SEATS

350 SEATS 400 SEATS

450 SEATS

500 

SEATS

200 SEATS

Current Quads

Fuel consumption p

550 

Current Twins SEATS

Current Quads

20% Better

Fuel consumption p

550 

Current Twins SEATS

Current Quads

20% Better

Fuel Efficiency is Driving

Fuel consumption per trip

F

787

Fuel Efficiency is Driving Payload, Performan

Commercial Focus on 

Structural Materials 

y, 

are Driving the Boe

Focus on Structur

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Performance Gains from Weight Reductions 

Driving the Increased Usage of Composite Ma
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Commercial Production DrivingIncreased Usage of Composite MateIncreased Usage of Composite Mate

sites 

n

 50% of the 787 Is Composite 

Structure

 Compos

oduction

 787’s Primary Structural 

Composite Material System was 

developed in the 1990’s

tructural

space Prodeveloped in the 1990 s

ume of St

in Aeros

Volu

Time

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Material Development Must Begin Well in Adva

Conceptual Design
BOE021711-120

A New Material System Must EarnIts Way p onto the Airplane

Targeted ApplicationBreakthrough Perform

Design loads

Static strength

Environment & discrete events

Breakthrough Perform

Improvements

 Material Substitution

Stiffness and 

Durability

• Fatigue

C i

Producibility

Maintainability

• Repairability• Inspectability Structures Design

Criteria

Stiffness and

flutter

Durability

• Fatigue

C i

Producibility

Maintainability

• Repairability• Inspectability Structures Design

Criteria

 Reduced Minimum Gaug System Level Functional

Value / Affordability A

• Corrosion

Fail safety

Crashworthiness

Damage tolerance

or safe -life

• Corrosion

Fail safety

Crashworthiness

Damage tolerance

or safe -life

Value / Affordability A

the Life Cycle

 Material Cost

Systems

Materials

Engines

 Fabrication  Service

Aerodynamics

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Significant Improvements Must Be Realized to 

the Development and Certification Costs
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Certification of New Material System

Development Phase Develo

 Modification of an 2-3 years

existing material for a non-critical component

 Modification of an 

existing material for a 

Up to 4 ye

Analysis Verification

Fullscale

tests

critical structural component

 New material within a 

system for which there i i

Up to 10 y

time to define 

iti 

Design-value

dl t

Component

tests

Sub-component tests Design-value

dl t

Component

tests

Sub-component tests

is experience composition a

parameters

 New material class Up to 20 y

includes time design practic

development

Material 

property

Structural elements tests

Allowable development

Material specification development

development

Material 

property

Structural elements tests

Allowable development

Material specification development

SOURCE: R. Schafrik, GE Aircraft Engines, Technology Transition in Aerospace Industry, brTechnology Transition, National Research Council, Washington DC, November 24, 2003

gp 

the performaand establish base

property

evaluation Material screening and selection

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Significant Risk Mitigation is Required to Cer

New Structural Material 
BOE021711-120

Blocking Block Approach to Materials Maturity and Risk ReductioMaterials Maturity and Risk Reductio

1. Basic Material Physical 2. Mechanical Properties Mechanical Properties3. Process Feasibility 4. Material and Process Scalability - Specif5. Design Allowables & Subcomponent Arti

Demonstration

6. Critical Feature/Full Scale Component T

A

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Processing and Process Variability Can Signif

Impact Structural Performance 
BOE021711-120

Material Processing Can SignificantImpact Structural Performance Impact Structural Performance

 Scale and Complexity of 

Matter ...Alot

Processing anomalies• Surface irregularities• Splicing

Pristine materials

Reduction of the allowable 

 Processing Variability Im

Weight Reduction Poten

• Waviness• Inclusions• Voids

Damage• Visible damage 

Allowable • BVID (For Ultimate)

Stress

stress

 Materials Development M

Processing Needs 

 Can the New Materials B

BVID (For Ultimate)

• Repair (holes, etc.)

Design• Environment

Allowable

design 

region

Strain

 Can the New Materials B

an Existing Process or Is Fabrication Technique R

 Do the Support Materials 

Consumables, Adhesive

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Variability Impacts Both Processing and 

Structural Performance
BOE021711-120

Aerospace Requires Enhanced Quality Control in the Supply Base Quality Control in the Supply Base

Industrial Scale QuantitProduction Ready Equip

Production Ready Equip

and Facilities

Quality / Verification Co

Capability

Standardization of Test

~80X more

Supplier CertificationExpertise/Skill Base

~80X more

composites, by 

weight, in annual 

f ll t d ti Cost

Regulatory Compliance

full-rate production 

of 787 than F-22

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Aerospace Manufacturers Need to Understa

Materials Impact Beyond Acquisition 
BOE021711-120

A New Material System Needs to Be Understood Throughout Its Life CycUnderstood Throughout Its Life Cyc

Fabrication

Assembly

Surface P

for Fifor Fi

Safe for

In-service M

Retire 

Safe for

Shop

rlines & 

gersSa

Env Energy Efficiency Energy Efficiency Solid Waste Disposal Solid Waste Disposal In service M

& R

Part/Product

Safe for Air

Passen afe For 

ironment Hazardous Waste Hazardous Waste Green House Gases Green House Gases

Reduce 

Footprint

S

Recycle

Copyright © 2006 Boeing. All rights reserved. BOE021711-120 EOT_RT_Sub_Template.ppt | 12/16/2009 

NanoComposites Need to Be Safe and Meet Reg

Compliance Throughout the LIfecycle
BOE021711-120

NanoComposites Have Tremendous Potential To Improve Our Systems Potential To Improve Our Systems

Electrical 

Properties

MechPrope

Potential for 

Multifunctional 

Composites

Thermal 

Properties Ma

Acoustic Properties Fire Retardant

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Need to Demonstrate the Performance Feasib

NanoComposites to Create the Necessary P
BOE021711-120

Emerging Materials Focus

Understand the Investigate and Mature Investigate and Mature Modeling S

New Material Forms 

Understand the

Science

Modeling, S

Analysis will 

Ado

“Engineered” Materials

Functionality Improved Structural Properties Novel 

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Enabling Engineered Materials for System L

Performance is Key 
BOE021711-120

NanoComposites Transition OpportuAcross Time Horizons Across Time Horizons

Horiz

Exploration for F

Horizon 2: 

Horizon 1: 

Current Generation 

Programs

• Multifunctional Coatings

Next Generation

• Nano Enha

Performan

• Multifunctional Coatings Structure

• Enhancements to 

Secondary Structure

ties

• Coating Technology

Structure

• Multifunct

Structural 

• Payloads and Interior 

Applications

• Very High Cost/Weight

Capabilit

• Sensor Materials & 

Technology

• Point Solution to 

• Engineere• Dynamic s

Dynamic s

assembly 

• Very High Cost/Weight Difficult Problem Payoff Technology

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Implementation of NanoComposites is 

Likely to Be Incremental 
BOE021711-120

Summary

 Na oCo pos tes a e s g ca t pote t a noComposites have significant potential  Materials must earn their way onto the airp

 Significant Performance improvements required 

Significant Performance improvements required 

development costs

 Aerospace use requires rigorous building b

Aerospace use requires rigorous building b

approach and quality control system

 Safety and Environmental issues are critica

Safety and Environmental issues are critica

 Implementation likely to be incremental (bu

fid d i d t di )

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confidence and improves understanding)
BOE021711-120

Thank You

BOEING is a trademark of Boeing Management Company.Copyright © 2006 Boeing. All rights reserved. BOE021711-120