TAI MATERIAL AND PROCESS TECHNOLOGIES

Transcription

1 TAI MATERIAL AND PROCESS TECHNOLOGIES 26 September

2 CONTENT General Information About TAI Composites Applications Trends, Innovation, Challenges Travel Trends 2

3 Merger of TAI and TUSAŞ Procurement of Lockheed Martin / General Electric shares (%49) by TUSAŞ Establishment of TAI as a joint venture to manufacture F-16 aircraft in Turkey Establishment of TUSAŞ 3

4 TAFF 54.49% SSM 45.45% Aerostructures Aerospace Integrated Systems Aeroengines TAI-GE Joint Venture 4

5 5 DIŞI TASNİF

6 Business Units Support Departments TAI BOARD CEO&President Muharrem DÖRTKAŞLI Strategy & Corporate Governance Bekir Ata YILMAZ Facilites and Asset Management İsmail ULUBAYRAM Enterprise Management Systems Orhan Veli KAYA Industralization and Procurement İlhami TANYOLU Strategy and Technology Management Bekir Ata YILMAZ (a) Quality and Certification Murat TAŞPINAR (a) Logistics Muammer AKPINAR Flight and Flight Tests Cemal Nadir SAYIN Human Resources Oya TANSU Finance and Subsidiaries Saadet KORKEM Aerostructures Aerospace Integrated Systems AeroEngine Aerostructures Naki POLAT Aircraft Özcan ERTEM Helicopter Metin SANCAR UAV Systems Sinan ŞENOL Space Systems Sinan ŞENOL JV with GE 6

7 (budget) ENGINEER DESIGN ENGINEER

8 BOEING BOMBARDIER LOCKHEED MARTIN LMMFC MARVIN ENGINEERING NORTHROP GRUMMAN SIKORSKY SPIRIT AEROSYSTEMS AGUSTA WESTLAND AIRBUS AIRBUS D&S AIRBUS HELICOPTERS ALENIA AERMACCHI FOKKER IAMCO PAG TELESPAZIO THALES TAI is accredited to the stringest quality standards in the aerospace business 8

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11 Airbus A400M Airbus Helicopter MK1 Fuselage, Tail Boom and Canopy Airbus - CN-235 Center Fuselage INDUSTRIAL PARTNER SOLE SOURCE SUPPLIER SOLE SOURCE SUPPLIER Sikorsky - S-70, MH-60, UH-60, S-76 Components F35 Joint Strike Fighter (JSF) Tail Rotor Pylon Tailcone Stabilator S- 76 SOLE SOURCE OUTSIDE USA 11 SOLE SOURCE SUPPLIER

12 Airbus - A320 Series Section 18 Airbus - A330 Rudder SOLE SOURCE SUPPLIER Airbus - A350 XWB Aileron SOLE SOURCE SUPPLIER AgustaWestland - AW139 Fuselage SOLE SOURCE - RISK SHARING PARTNER Boeing - B787 Elevator Cargo Barrier Body Seal (Mnfg.) (Design+Mnfg.) (Design+Mnfg.) MAIN SUPPLIER 12 SOLE SOURCE SUPPLIER

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14 Cruise Speed G Limits Climb Seating Configuration > 250 kts +7g/-3.5g 15000ft in 5 min Stepped tandem 0/0 Ejection Seat Yes First Flight 29 Aug 2013 EASA CS 23 Certification

15 Day & Night, High & Hot Performance Precision Strike Multi-Role Combat Helicopter New Avionics Hardware and Weapon Systems Generation Engine (LHTEC CTS 800-4A) Power Transmission Tail Rotor Several Fuselage Modifications TAI has T129 s global marketing and sales rights. 15

16 Service Ceiling Endurance MTOW Payload Powerplant Autonomous Take-Off & Landing Range 30,000 ft 24 Hours 1750 kg 200 kg EO/IR Camera SAR/ISAR 155 HP HEAVY FUEL Integrated 200 km LOS (BLOS Optional) 16

17 Definition of a new aircraft to substitute the existing Turkish Air Forces T-38 Trainer Aircraft and F-16 Fighter Aircraft. TAI is assigned as the Prime Contractor. F-16 HIGHER SPEED SUPERIOR LETHALITY GREATER AGILITY WIDER COMBAT RADIUS 17

18 Prime responsibility to design, develop and manufacture a civil certified light utility (5 ton) helicopter for military and commercial use. Program contract was signed in June First flight is expected to take place in 5 years. 18

19 Göktürk-1 High Resolution Earth Observation and Reconnaissance Satellite TAI: Manufacturing of Mission Model Structure Panels, AI&T Göktürk-2 Earth Observation and Reconnaissance Satellite Launched from China in December Göktürk-3 SAR Earth Observation Satellite Preliminary-Design Phase initiated in November

20 Capable to support Assembly, Integration and Test (AI&T) activities at least one LEO satellite up to minimum two tons and one GEO satellite up to minimum five ton simultaneously. AI&T Center will be fully operational in All final tests of GÖKTÜRK-1 Satellite will be performed at AI&T Center. AI&T Center will be able to serve national and international space programs. Closed Area :9.850 m² Clean Room Area:3.880 m² 20

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22 A composite materials is one which is composed of at least two elements working together to produce materials properties that are different to the properties of those elements on their own Typically reinforcing fibres in a matrix The ultimate «designer material» 22

23 The first composite primary structure was built in Duxford, UK in 1940, due to shortage of Aluminium during II. World War. Flax linen rovings impregnated with phenolic resin. Tests showed that this first FRP structure was as strong as Al. 23

24 Prepregs are mainly two-dimensional fabrics made from high quality fibers and impregnated with resins. Prepregs are the base materials for the manufacture of fiber composite materials Fiber Carbon Glass Aramide Fabric Woven UD NCF Resin TS Epoxy Phenolic BMI TP PPS PEI PEEK 24

25 filaments (until in large tows) Single filament from 5-7 microns 92-99% carbon content Low density : 1/4 of steel High mechanical performance : 10 times stronger than steel High resistance to fatigue Excellent corrosion performance Resistant to chemicals X ray transparency Electrically conductive 25

26 High specific modulus and strength Weigth reduction High fiber and low voids content Optimum laminate design Good environmental resistance Excellent corrosion resistance Very low CTE Good fatigue resistance Repairibility of damaged structures Ability to manufacture complex shapes Clean process 26

27 Machine Suppliers Pan Suppliers Fiber Suppliers Fabrics END USERS Release Liners Silicone Suppliers PREPREG Resin Suppliers Aerospace Automative Wind Sports. 27 Paper & Film Suppliers Machine Suppliers Machine Suppliers Machine Suppliers

28 Termosets vs Thermoplastics Industry Applications Breakdown products (% volume) 100% 90% 80% 70% 60% 50% 40% 30% 20% 10% 0% 30% 70% 37% 38% 40% 63% 62% 60% Thermosets 100% 90% 80% 70% 60% 50% 40% 30% 20% 10% 0% 15% 16% 15% 15% 9% 9% 8% 8% 3% 1% 3% 7% 9% 6% 4% 6% 6% 7% 5% 4% 26% 28% 26% 26% 10% 7% 7% 7% 30% 27% 26% 24% Building Pipe&Tank Thermoplastics Transport Marine Aerospace Wind 28 Source: Lucintel, Estin&Co interviews, analysis and estimates Consumer Goods Electrical

29 Metric tons Estimates

30 TONS Total estimated at t

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32 TONS CF USAGE Wind Aerospace Sports Automotive

33 Composites for aerospace are the highest added value products Others Pipe - Tank Construction Transortation Marine Consumer Goods Wind Aerospace Average Prices Euro/kg 33

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36 36 For all segments UD prepregs are dominant

37 FABRICS vs UD TAPES More and more UD tapes, less fabrics Weight optimization, water tight structures UD TAPES One single grade FAW 135 gsm or 194 gsm Depending on the plant 3 grades FAW 134 gsm FAW 194 gsm FAW 268 gsm One single width 300 mm Several width 300 mm 150 mm 1200 mm, etc. Manufacturing cycle/weight optimization balance 1980 s

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45 Fast curing resins (especially for automotive) Materials stored in room temperature, with longer shelf life Better damage tolerance properties Better electrical properties Out of autoclave prepregs Thin plies for tailoring Wider selection of reinforcements and polymer matrix Automation techniques for less fabric use 45

46 Aircraft Design Weight reduction, excellent fatigue properties. Improved film weight control with world class continues mixing and filming capability / Tighter control of fibre weight Need to control tightly cured ply thickness control for thick part UD tapes / slit tape manufactured to tightest tolerances (on line slitting and precision winding) Need to control CPT to avoid shimming operation for assembly of composite parts 46

47 Weight saving is very important, however no more the only key driver!! Long range aircraft 1 kg weight saving = 3500 (over the full life of A/C) Short range aircraft 1 kg weight saving = 1500 (over the full life of A/C) Composite parts have to be cheaper: Improvement of composite materials costs Continuous production with short cycle times Lower amount of waste Composite parts have to integrate functions Conductivity Acousting damping Thermal resistance New assembly concepts SHM 47

48 Eco effiency Composite materials must get recyclable Low weight >> Lower fuel burn, lower CO 2 emission Customer satisfaction to improve Cabin noise improvement by acoustic materials development Operations cost improvements Composites/Surfaces must support walk around inspection The detection of damages and the repair must be robust to ensure short turn-around time 48

49 Challenge on Release Paper Perfect roll quality No paper debris Perfect alignment Silicon paper choice for ATL tailoring Tight weight tolerance Future trends for large volume Eliminate silicon transfer to prepreg Reduce cost vs. paperless technology (Infusion / Solvent route) Paper technology improvement is key for future composite penetration 49

50 tonnes CFRP scrap produced annually, commercial planes expected to reach end of life by 2030 There is currently no real market for the recycled product that is produced. Work needs to be done to demostrate the properties of the recyclate, create a market and give it a value.

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54 Fleet in servise evolution Source: Airbus 54

55 To produce in time, cost and quality Source: Airbus 55

56 Annual growth of %13-%17 of CFRP market (prepreg could account for %55-%60) Aerospace and wind will be the significant drivers. Automotive is expected to be the largest growth, if CRFP cost decreases. Mass production, automation, optimal design for better price-performance ratio, hybrid solutions, will support the growth of this very dynamic market. CFRP is the most important growing field, followed by GFRP and hybrid materials. Prepregs are the material of choice for its high performance characteristics and have a brigtht future. 56

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