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Larnac Guy Madrid 11/14/2018

MATERPLAT – SAMPE IBERICA

Space structure, is metallic a competitive solution toward composite ?

This document is the property of Airbus Safran Launchers. It shall be not communicated to third parties without prior written agreement. Its content shall not be disclosed. Airbus Safran Launchers Holding/SAS/GmbH. All rights reserved.

This document is the property of Airbus Safran Launchers. It shall be not communicated to third parties without prior written agreement. Its content shall not be disclosed. Airbus Safran Launchers Holding/SAS/GmbH. All rights reserved. 2



Space Transport Evolution

From



To Breakthrough concepts


Al/Al-Li 19%

Titane 14%

Acier 6%

Misc. 8%

A350-900 Material Breakdown

(%) Including Landing Gear

Composite

53%

A350XWB ARIANE Family

AIRBUS Civil Aircraft Family



Ariane 6 Configuration



• Automatic Fiber Placement • Out Of Autoclave curing

Incremental Technologies

Cardan Cross

Short and mid term Forced by competitors



A6 Structures

ESR Fairing - CFRP

A6-2 Version CFRP = 55%

A6-4 Version CFRP = 63%



1st Stage Cost

Engine

Structures

Propellant/gaz

Electrical

Tubes, valves…

2nd Stage Cost

Engine

Structure

Electrical/avionic

Tubes, Valves…

Others

1st Stage weight

Engine

Structure

Electrical

Tubes, valves

2nd Stage Weight

Engine

Structure

Electriccal/Avionic

Tubes, Valves

Others

Where to act ?

Figures from Atlas launch vehicle – American Institute of Aeronautics and Astronautics

Futur

% Reusability

Very low cost expandable launchers

Low Cost Upper Stage

Upper stage Recovery

Upper Stage in-orbite operation –

Kickstages

A6 Increment

Low cost tanks & structures

Futur Projects ? Payload Delivery Mission to Lunar

surface



Technologies to consider - Propulsion and Developed

• Propulsion System and tanks

- Stage Structures • Composite • Metallic • Assembly

- Design and sizing Methodologies

- Control and SHM

- Equipment Integration

What ever is the solution : • 50% less costly • Developed 2X faster



2d Stage Weight Engine

Structure

Electriccal/AvionicTubes, Valves

Others

Design with ventilation

system

fluted core Sandwich Panel

Structures A6

Al2050 [kg] CCTD [kg]

1181.0 752.0 (=-33%)

ESR - CFRP



Company Boeing Lockheed-Martin Grumman Aerospace

Design

Dome Between Ellipsoid and Cassini Ellipsoid Ellipsoid

Cylinder Sandwich with „Fluted Core“ Outside hat stiffeners Honeycomb sandwich

Mass -39% -40% -42% Costs -20% / -25% n/a n/a

________________________ Johnson et al.: Structures and Design Phase I Summary for the NASA Composite Cryotank Technology Demonstration Project in 54th AIAA/ASME/ASCE/AHS/ASC Structures, Structural Dynamics, and Materials Conference , 2013.

US Study Composite cryo Tank vs Metallic

NRC mini

20 – 40 M€ for TRL 6



What about metallic technology improvement ?

Additive layer manufacturing • Powder bed • Direct Energy Deposition

Assembly • Friction Stir Welding • High Pulse creeping

Surface treatment • Preparation before bonding • Surface functionalization



Additive Manufacturing

Powder or Wire

EBM Electron Beam Melting

LBM Laser Beam Melting

Powder

LMD Laser Metal Deposition

CGS Cold Gas Spraying

Additive Layer Manufacturing

26 November 2018 16

Powder bed process : Laser or electron beam

• Large network • Reduction of assemblies & functions integration • Topological Optimisation and biomimetism

• Dimensions < 0,5-1m • Lead time reduction

Days/months

• Cost reduction till 50%



Stratégie Introduction sur lanceur

Step 2 Re-Def

Process

simplification

• Integration of functions • Assembly of parts • Mass & Cost

Step 4 New Concepts

Architecture

rupture

• Functional optimization

Step 1 IsoDef

Step 1 IsoDef Casting

Replacement •Same design • Better mech. properties • No tooling

Step 3 New Def

Technology

rupture

• Mass & Cost optim. • Topological optim. • New materials • Biomimics

Introduction Strategy on launchers

THIS DOCUMENT AND ITS CONTENTS ARE PROPERTY OF ARIANEGROUP. IT SHALL NOT BE COMMUNICATED TO ANY THIRD PARTY WITHOUT THE OWNER’S WRITTEN CONSENT | ARIANEGROUP SAS – ALL RIGHTS RESERVED. - -

ALM FOR GAS GENERATOR - ALM AGILITY MASS & COST

18


INTRODUCTION - Prometheus rocket engine

Ambitious Targets

• Ultra-low-cost Engine • Reusable • Versatile • Smart electrical command

19

20

WAAM : Wired and arc/laser additive manufacturing • Different means

available internally and externally • Software development

• Capability of large dimensions > 1m

• High deposition rate >> LBM

• Cost Reduction



Large optimized Structures with reduced cost

26 November 2018 22

• FSW : Friction Stir Welding • Welding on solid phase

TFSW ≈ 0,8 x Tfusion

• 1991 : Patented by The Welding Institute (TWI, GB)

• 1996 : First Industrial application : Scandinavia naval industry

• 1999 : First Space application : Delta Launcher tanks (Boeing)

Assembly by welding • Magnetic Pulse creeping

• Dissimilar materials • No adhesive • Quick • No spring back • Limited size <1m • Conductive materials

THIS DOCUMENT AND ITS CONTENTS ARE PROPERTY OF ARIANEGROUP. IT SHALL NOT BE COMMUNICATED TO ANY THIRD PARTY WITHOUT THE OWNER’S WRITTEN CONSENT | ARIANEGROUP SAS – ALL RIGHTS RESERVED. - - 23

Anticipation of obsolescence

No Cr-based (CrIII including) surface treatment including conversion coating

No Ni or Cd cadmium plating

Laser surface preparation, texturing and finishing

Modelling and virtual testing of laser material impact.

Flexible laser source to simulate and optimize laser parameter effects

Lean repair and protection solutions

Sol-Gel solution as single-layer protection Smartcoating (corrosion inhibitor leakage and

conductivity) Strippable varnish for temporary protection Touch-up repair on stainless steel

Challenge our corrosion requirements

Outdoor exposure test with test panels and corrosion sensor

New representative cycle to ease justification

In-situ corrosion monitoring

Main challenges Surface Engineering

-

Laser Surface Treatment

24

Surface preparation of aluminum alloy before bonding

– Energy absorption by upper layer – Removal of contaminants – Structuration of substrate

– At macro scale – At sub micro scale

– Less than 10µm depth impact


LASER SURFACE PREPARATION ON ARIANE 6

ULPM Cryo Tank & ITS • AA 2195, 2219 & 7175 • Cylinder, Bulkhead • LST before external thermal

insulation • LST before APLIX bonding

ESR Nozzle

DLS – SYLDA6 • Metallic ring • Structural bonding

LLPM Cryo Tank & ITS • AA 2195, 2219 & 7175 • Cylinder, Bulkhead • LST before external thermal

insulation • LST before APLIX bonding

-

Laser Machine for Ariane 6 Upper Stage and main stage

26

Biological examples for surface engineering

5 μm

colour adhesion

wetting toughness

Federle, et al., Journal of The Royal Society Interface (2006)

Galusha, et al., Physical Review E (2008)

Image: Fabian Heinemann, http://de.wikipedia.org

Matthias Geh, www.flickr.com

Surface Texturation / functionalization


ANTI ICING FUNCTIONALIZATION

Ice forming on external parts (atmospheric air French Guyana) and launch pad (cryogenic feeding lines)

Aluminium parts & composite w/o paint

Ice under atmospheric or nitrogen environment on internal parts (cryogenic equipments and internal lines)

Risk of sublimation and runoff humidity on surface

28



Solid Rocket Motor Cases • A5 Metallic • A6 Carbon Thermoset Wound Composite + thermal • Future launchers

Is the next launcher generation 100% metallic ?

curing



Stiffened primary structures

(frame)

Innovative Architectures and composite capabilities


This document is the property of Airbus Safran Launchers. It shall be not communicated to third parties without prior written agreement. Its content shall not be disclosed. Airbus Safran Launchers Holding/SAS/GmbH. All rights reserved. 31 Page 31

Material functionality Interest

Transmit • Data • Environmental conditions

Detect • Damage • Temperature, pressure

Activate

• Morphing • De-icing

Repair

• Diagnostic • Implement

Damping • Chocks • Noise / Vibrations

Electrical continuity • Electrostatic charges • Lightning Strike

Protection

Protect

• Fire resistance • Harsh environtal

resistance

Perfor-mance

Cost Reduction Robustness



Multifunctional Structures Volume improvement : Utilization of non functional volume Mass Reduction: 30% on external raceway Increase robustness : Non-corrosive electrolyte AIT reduction : 50%

Structural Batteries & super capacitors 2d stage mass Engine

Structure

Electriccal/AvionicTubes,Valves



to revolutionary concepts

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