A380 Fuel Connectorunter Anwendung

generativerFertigungsverfahren

7. Lübecker-Werkstofftag

Prepared by Christian Grützmann

Airbus Operations GmbH

© AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document.

Agenda

Airbus Operations GmbH / Innovation Cell

Introduction and Current Fuel Connector Design

Development of Integrated Design for Additive Manufacturing

Results and Outlook

© AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document.

“ALM Innovation Cell” within Airbus

Plateau FILTON - to be Ti Power Bed eBM Technology Reference

Plastic SLS Technology Reference

SDW for Wing

GETAFE

SDW for RFE

Plateau TOULOUSE ALM Platform management

SDW for Pylon, FTI

Procurement

Plastic FDM printer Reference

St ELOI Inconel Powder Bed Laser Technology Reference

Ti64technology reference

Reference Shop for Metallic Printing Technologies

SAINT NAZAIRE Plastic FDM Speedshop

Plateau BREMEN

Development & qualification of ALM M&P

Plateau HAMBURG Plastic FDM Technology Reference

Ti Power Bed Laser Technology Reference

SDW for Fuselage FAF, NCF

Cabin; Systems

Plastic FDM & Ti64 Speed Shop

Customer Service / SATAIR

Engineering Speed Line

Innovative design / Bionic design

© AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document.

“Father” of Innovation Cell

Dipl. Ing. Peter Sander

© AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document.

Agenda

Airbus Operations GmbH / Innovation Cell and Laser Zentrum Nord GmbH

Introduction and Current Fuel Connector Design

Development of Integrated Design for Additive Manufacturing

Results and Outlook

© AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document.

A380 Fuel Trimmtank-System

A

View A

© AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document.

Today’s manufacturing process

Assembly Manufacturing

1. Side

Plate (2x)

Welding

Bending

2. Face

Plate

3. Base

Plate

Milling Drilling

4. End

Fitting (2x)

Welding

5. Inner

Pipe

6. Milling

Ring

Welding

Turning Bending Milling

8. Shroud

(2x)

Milling

Coating

7. Ground

Connector (4x)

Bending

CuttingBendingCutting

Welding

Assembly

Assembly

Waterjet Cutting

Welding

© AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document.

A380 Fuel Connector Approach

AS-IS

TO-BE

© AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document.

First Integrated Design

© AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document.

Agenda

Airbus Operations GmbH / Innovation Cell

Introduction and Current Fuel Connector Design

Development of Integrated Design for Additive Manufacturing

Results and Outlook

© AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document.

Support Structures

© AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document.

1. Verzug von Supportstrukturen

2. Abriss von Supportstrukturen

3. Ausbeulen der Rohre

Results from 1st Version

1.

2.

3.

1.

3.

2.

3.

1.

2.

© AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document.

Internal Stresses

Disconnection from Supports

Mechanical Failure

[Source: Mercelis 2006]

© AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document.

Problem solving

1.

2.

3.

© AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document.

Lessons Learned – Definition of new Design

© AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document.

Results from Fuel Connector Workshop

Side-View Top-View

© AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document.

Results from Fuel Connector Workshop

Side-View Top-View

© AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document.

Results from Fuel Connector Workshop – Final Design

© AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document.

Agenda

Airbus Operations GmbH / Innovation Cell

Introduction and Current Fuel Connector Design

Development of Integrated Design for Additive Manufacturing

Results and Outlook Fuel Connector

Airbus Road Map

© AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document.

New Manufacturing Steps

31Process steps versus 5

Additive

Manufacturing

Laser Melting

Heat Treatment

Milling

Microfinishing

Remove support

structure

14 single parts versus 1

new ALM Part

© AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document.

Integration of fatigue oriented design

© AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document.

Integration of proper support structure

© AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document.

Clamping concept for milling

old fashion vs. new clamping

methods

© AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document.

Airbus Outlook & Roadmap

2015

Titanium ALM: Powder bed Technology TRL6

First Version of integrated toolset (automated data transfer) testing phase and skill development

1st set of design concepts enabled by ALM and 1st set of Ti demonstrator / pilot parts defined

2016

Plastic Laser Sintering (PA/PEK) TRL6

Nickel / INCONEL Powder Bed TRL6

Ti Powder Bed full process qualification

20182017

Aluminum ALM: Powder Bed TRL6

Enhanced / reinforced plastic ALM TRL6

2nd version of Development Toolset(incl. material properties, process parameters, manufacturing simulation, use of microstructures)

1st Bionic components in the aircraft

2020 Fully Integrated Stress/ Design Toolset rolled out.

2025 Bionic component inegration

2030+ Bionic aircraft

Page 24

Christian Grützmann

Airbus Operations GmbH

Vielen Dank für Ihre Aufmerksamkeit

A380 Fuel Connectorunter Anwendung

generativerFertigungsverfahren

7. Lübecker-Werkstofftag

© AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document.

A380 Fuel Connector – Comparison of ALM and Casting

Key Characteristic ALM

powder bed

Investment Casting

Freedom of Design ++ +

Max. Size - ++

Mechanical properties static ++ +

Mechanical properties fatigue +* +

Surface Roughness (blank) -(Ra12) + (Ra3)

Cost RC (fabrication cost) - +

Cost NRC + -

Process qualification - +

Remove “micro static” material defects - +

With friendly support of TITAL GmbH*after shot peening

© AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document.

X-RAY results