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Materials Day“WERKSTOFFE FÜR TRANSPORT UND VERKEHR ”, 18th of May 2001, ETH Zürich, Switzerland
NEW ALUMINIUM ALLOYS AND FUSELAGE STRUCTURES IN AIRCRAFT DESIGN
Gerhard Tempus
EADS Airbus GmbH Bremen
Outline Outline
New Fuselage Structures:
→ Laser Beam Welding (LBW) → Friction Stir Welding (FSW) → Extruding
New Aluminium Aerospace Alloys:
→ Al-Mg-Si-Cu Alloy (AA6013) → Al-Mg-Sc-Alloy → Al-Mg-Li-Alloy (1424)
Dr. Tempus
Zurich_5
Blatt: 1
NEW FUSELAGE STRUCTURES NEW FUSELAGE STRUCTURES
Frame
Today
Differential Structures
STRINGER PROFILE VARNISH (Primer and Top Coat) EDGE SEALING SURFACE SEALING SKIN SHEET
Clip
Stringer Skin Sheet
Riveted
Tomorrow
Integral Fuselage Design
T-joint (Clip/Sheet)
Welded
(T-joint, Sheet/Stringer)
Dr. Tempus
Extruded
Zurich_5
T-joint (Stringer/Sheet)
Butt joint (Sheet/Sheet)
Blatt: 2
INTEGRAL STRUCTURES - Goals
Cost reduction max. 15 % Cost reduction max. 15 %
• High grade of automation • Reduced mass of material (joining elements, sealing) • Saving of manufacturing steps
Weight reduction max. 10 % Weight reduction max. 10 %
• Reduced mass of sealing • More freedom for design • Aluminium alloys with lower density
Corrosion-resistance improvement Corrosion-resistance improvement
• Free of gaps and crevices • No rivet holes
Dr. Tempus Zurich_5 Blatt: 3
LASER BEAM WELDING (LBW) Advantages Advantages
• • • • •
Narrow welding seam Low energy input per seam length affected zone Very high welding speed reduced distortion, reduced heat
Dr. Tempus
Zurich_5
Blatt: 4
LASER BEAM WELDING (LBW) – Cross-Section of T-joint
• Extruded stringer • Chemically milled sheet • Simultaneous welding from both sides
• Skin itself is not influenced by the laser beam welding process (HAZ)
Dr. Tempus
Zurich_5
Blatt: 5
LBW Pilot Equipment
max. welding speed 10 m/min.
X-axis Y-axis z-axis A-axis B-axis C-axis
6m 3m 0,9 m +/- 90° +/-