Overview of Titanium applications in Dassault Aviation ...
Transcript of Overview of Titanium applications in Dassault Aviation ...
DASSAULT AVIATION Proprietary Data.
Overview of Titanium applications in Dassault Aviation Airframes
Matthieu Pachoutinsky 1 October 7-10, 2012- Atlanta, Georgia, USA
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Overview of Titanium applications in Dassault Aviation Airframes
• Dassault Aviation • Part applications and processes
• Parts machined from plates • Forged parts • Casting • SPF-DB
• Example of canard surface assembly • Others: Tubing / Fasteners / Direct Manufacturing • Titanium distribution on Rafale and Falcon • Challenges • Conclusion
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Agenda
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Dassault Aviation
Aircrafts in production : Rafale, Falcon, nEUROn
A world leader in top-of-the-range executive jets.
Approx 11,500 employees; Based in France and United States and 8 other international locations.
Aircrafts in more than 77 countries across 5 continents.
More than 8,000 aircrafts delivered, representing 25 million hours of flight time.
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Parts machined from plates : Rafale’s leading edge slat tracks
• Advantages : High mechanical properties, non specific supply • Drawbacks : High buy to fly ratio (5.5), geometrical limitations
Leading edge slat tracks machined from Ti-6-4 plates
Size: 310x90x45mm Thickness range: 4mm
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Rib 1
Investment casting Ti-6-4 Rafale rib 1
Size: 1250x300x250mm Thickness: 2 to 25mm
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Investment casting Ti-6-4: Titanium central box for Horizontal Stabilizer
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Horizontal stabilizerFalcon 50, 900, 2000, re-engineering : composite + titanium box • Casting used for functional integration reducing fasteners and parts • Titanium used for high specific strength
Before After Number of parts 240 36
Fastening elements 12000 3500
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Catia model
Stereolithography
Casting
Horizontal stabilizer: titanium casting central box
Vacuum investment casting Ti-6-4
Final part
Shell mould
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Size: 990x520x330mm Thickness range: 2-5 mm Buy to fly : 2 to 3
Investment casting Ti-6-4 • Advantages : Delivers complex parts, functional integration, thin walls, low buy to fly ratio • Drawbacks : Casting factor, long development time, frozen geometry, specific design for each supplier
Size: 1250x300x250mm Thickness range: 2-25mm Buy to fly : 2
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Wing fittings
Size: 270x300x180mm
Forged parts Ti-6-4: Rafale Wing fittings
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Machined Die forged
Forged parts: Rafale under wing fittings • Advantages : high mechanical properties, intermediate buy to fly ratio (4) • Drawbacks : Long development time, frozen geometry, geometrical limitations
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SPFDB : Rafale’s leading edge slats and canard surfaces
SPFDB: Super Plastic Forming Diffusion Bonding
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Canard surface
Leading edge slats
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SPFDB : Rafale Leading edge slat and canard surfaces • Advantages : Very low buy to fly ratio, fully integrated parts • Drawbacks : Complex process, frozen geometry, high quality thin sheets requirements, chemical milling
Leading edge Ti-6-4
Canard surface Ti-6-4
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Size: 2000x1000x200mm
Example of canard surface assembly
Number of parts : 5 Pin is electron beam welded on fitting SPF-BD No fastener
Pin
Fitting
Box
Trailing edge box
Trailing edge
fairing
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Others: Tubings / Fasteners / Direct Manufacturing Tubings : Ti-3-2.5 and CPTi • 600m of hydraulics tubing for F7X • 150m for a Rafale
Fasteners : Ti-6-4 • 110000 titanium fasteners for F7X • 60000 titanium fasteners for Rafale
Direct Manufacturing Ti-6-4 • Ventilation system • Prototyping
15 Tubing parts on prototype
Titanium fasterners
CPTi air conditioning pipe
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105
85
Composite
Titanium
Others
20
10
70
Composite
Titanium
Others
Titanium distribution on Rafale and Falcon airframes
Why Titanium used : -1- benefits of high specific strength (highly loaded parts in small volume) more opportunity in a combat aircraft -2- for thermal expansion compatibility with composite -3- for galvanic compatibility during direct assembly
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Rafale airframes Falcon airframes
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Challenges
Supply chain Dassault Aviation: small player in titanium market
• Develop a strategic supply plan • Critical parts : complex qualification process
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Environmental • Eliminate fluonitric acid for chemical milling and etching • Recycling of scrap material • Friendly surface treatments
Very few suppliers Technical Downsizing qualification test plan
• Microstructure/properties correlation • Identify impact of process steps on properties • Identify scatter in properties
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Conclusion
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Next step Improve performances and competitiveness
• Implement new processes (ex. Machining improvement) • Optimized design • Secure supply chain •
Dassault’s signature Ti-6-4 only
• Well known, homogeneous in term of mechanical properties • Easy supply • Minimization of qualification cost
Processes optimization • Cost driver: buy to fly ratio • Wide range of technology
Environmental • Focus of current research • Chemical milling replacement by mechanical machining
Casting
Die Forging
SPFDB
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Back-up
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Ce document est la propriété intellectuelle de DASSAULT AVIATION. Il ne peut être utilisé, reproduit, modifié ou communiqué sans son autorisation. DASSAULT AVIATION Proprietary Data. Direction Générale Technique
What is SPF-DB? SPF-DB = Super Plastic Forming & Diffusion Bonding
⇒ Thin structures
SPF = Superplasticity Gas presure
sheet mould
T °
⇒ deep hole possibility DB = Welding by atomic diffusion in solid phase
DB zones
⇒Perfect bonding without fasteners
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Direct Metal Deposition Argon
part
substrate
Coaxial
Nozzle
CAD/CAD
Motion Table XY
LASER
∆Z (Nozzle)
Argon
part
CAD/CAM LASER
Laser wipering
Feeding system
Manufacturing Chamber
Feeding chamber
Optomec LENS® 850R Trumph DMD 505 Inss Tek Inc. MetalWorks 350
Phenix PM 250, TRUMPF LF250, EOS M270, MCP Realizer II
Direct Manufacturing Selective Laser Melting
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0
100
200
300
400
500
600
700
800
900
1000
1100
2,5mm < e < 4,76mm 1,6mm < e < 2,5mm 1,27mm < e < 1,6mm 0,8mm < e < 1,27mm 0,5mm < e < 0,8mm
Moy R0,2 LMoyRm LMoy R0,2TLMoy RmTL
mini R0,2
Mini Rm
Maxi Rm
Static properties on Ti-6-4 sheets Variability with thickness between 0.5 to 5mm
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1,E-04
1,E-03
1,E-02
1,E-01
10 100
ΔK (MPa.√m1/2)
da/d
N e
n m
m/c
ycle
VSMPO - 90mm
VSMPO-45mm
RMI-100mm
Timet-100mm
VSMPO 2mm
Fatigue crack growth rate on Ti-6-4 plates Variability between suppliers
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Typical Microstructure on Ti-6-4 sheets
0.5mm gage
4mm gage
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Typical Microstructure on Ti-6-4 casting
0,2mm