TANGO Overview Presentation

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Kristian Booth
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1 TANGO Overview Presentation Presenter: Glenn Watson Date: June 20, 2006 Event: Aerodays,, Vienna

2 Industry Needs Ensure that the next generation of products significantly reduce the direct operating costs of the airlines. Airframe Maintenance 6% Navigation & Landing Fees 9% Flight & Cabin Crew 13% Fuel 23% Engine Maintenance 5% Acquisition Cost 44% Improve Structural Efficiency to; Typical DOC s for Long Range Aircraft - reduce acquisition cost, through improved material utilisation, design and manufacturing processes - reduce airframe weight, leading to lower fuel consumption and reduced environmental impact

3 Aims and Objectives Quantitative Product Improvement Targets; - 20% weight reduction in comparison to current structures - 20% cost reduction in comparison to both current manufacturing processes and state of the art design This will require new, high potential, materials, design methods manufacturing techniques and assembly processes to be employed on key primary airframe elements.

4 Airframe Elements Most Likely to Generate Significant Weight and Cost Reductions Chosen. Advanced Metallic Fuselage Composite Fuselage Composite Wing (Including Metal to Composite Joint) Composite Centre Box

5 THE TANGO PARTNERSHIP Finland Patria Finavicomp Ireland Uni of Galway UK Airbus, GKN, Shorts, ACG, INBIS, HYDE, LEICA, QINETIQ Belgium SONACA, SABCA France Airbus, CEAT, Hurel Dubois Italy Alenia, CIRA, CSM, FIAT, RTM, Uni of Napoli Sweden SAAB Netherlands NLR, FCS Control Systems Germany Airbus, Uni of Braunsweg Spain Airbus, INTA, CADTECH Greece INASCO, ISTRAM, HAI Israel IAI TANGO program is partially funded by the European Union

6 The TANGO Approach On key elements most likely to bring large advantage Selected most promising innovative technologies Validate at a large scale the most promising technologies Design and manufacture large elements Involving the supply chain extensively Using Integrated Product Teams in a Quasi-Industrial distributed environment Test large scale elements

7 Role: Cost / Weight Trade Management The Cost / Weight workpackage ensures the progress towards the challenging TANGO objectives of 20% cost and 20% weight saving.

8 Overall Design, analysis & Integration Panels - thick prepreg technology (up to 52mm) with integral stringers Advanced manufacturing processes - LRI or RFI spars with co-injection of stiffeners Composite Centre Wing Box Industrialised assembly & large scale integration Large scale testing and structural validation

9 Composite Centre Wing Box Steel dummy wing (12600 kg) Aluminium dummy wing (4350 kg) Composite box Steel dummy box (4700 kg) (13770 kg)

10 Composite Centre Wing Box Output Knowledge gained in: o Manufacture and assembly of thick composites o Material forming automation o Use of advanced dry-fibre materials (NC2) o Understanding structural behaviour

11 Composite Lateral Wing Multidisciplinary Analysis and Optimisation Advanced Simulation Design for Manufacture & Assembly Advanced Materials Advanced Processes Resin Transfer Moulding RFI / LRI Drilling of Hybrid Metal/Composite Structures Joining Techniques Adhesive Bonding (Covers) Industrialised Assembly

12 Spar landing for front spar which tapers slowly to ease assembly Lateral Wing - Upper Panel, ALA MSI region increased thickness, complex for manufacture at front spar region Tension Test specimen Alenia 12M Large Scale Demonstrator, Dry Stringer Preparation

13 Wing Ribs, IAI, PATFIN, HAI, ALA IAI rib in RTM PATFIN Fuel Pressure Load Test

14 Composite Lateral Wing Assembled Wing Ultimate Load Test

15 Advanced Metallic Wing Panel: SAAB Stringer / Skin Test Skin laminates Forming Trials

16 Lateral Wing Output Knowledge gained in the design and manufacture of composite wing structures The Lateral Wing had significantly more contributing Partners than the other platforms (20 inc. AUS), this caused some headaches initially. However, the group were able to develop a cross-cultural, cultural, cross-national way of working and management style that has resulted in both technical success and the development of organisational practices that will be indispensable in future large-scale, multi-partner composites projects.

17 TANGO AMF Barrel: Panel Layout Structure based on Long Range Fuselage 17 frames, representing 2 Section 16 s

18 Large Shell Test Programme C 1 C 2 C 3 C 4 C 5 C 6 C 7 FML 3(7475) 3/2-0.4mm P 10 Drawing No. V533B0332 P 9 P 8 P 7 L2 C1 Internal Splice P 6 P 5 Lap Joint P 4 P 3 P 2 P 1 C2 L1 Damage Location Large Test panels were tested at IMA in Dresden using different materials and configurations

19 Metallic Fuselage Panels ALA: FSW & LBW SAAB: Bonded Fully Panel Al/Li FSW & LBW (Russian 1424)

20 Barrel Test Status: -Flight by flight loading, with full test load spectra applied, with internal pressure -Fatigue phase completed -Artificial damages applied -Testing now successfully completed TANGO AMF test in Hamburg

21 Metallic Fuselage Output Experience gained in using in technologies giving low cost and light weight which are compatible with today s assembly processes: Al/Mg/Sc and Al/Li (RUS) both laser and friction-stir welded Fully bonded metallic panel (SAAB) Advanced GLARE & GLARE stringers Offers an attractive alternative to carbon in the pressurised fuselage in terms of weight as well as cost.

EXPERIMENTAL/NUMERICAL TECHNIQUES FOR AIRCRAFT FUSELAGE STRUCTURES CONTAINING DAMAGE

EXPERIMENTAL/NUMERICAL TECHNIQUES FOR AIRCRAFT FUSELAGE STRUCTURES CONTAINING DAMAGE Abstract Padraic E. O Donoghue, Jinsan Ju Dept. Civil Engineering National University of Ireland Galway, Ireland padraic.odonoghue@nuigalway.ie,