Composites R&D challenges for EMBRAER aerostructures SAMPE BRAZIL CONGRESS 2017
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1 Composites R&D challenges for EMBRAER aerostructures SAMPE BRAZIL CONGRESS 2017 Luciana Selmi Marques October 5 th, 2017
2 AGENDA 1. EMBRAER OVERVIEW 2. EMBRAER PORTUGAL ESTRUTURAS EM COMPÓSITOS, S.A. 3. COMPOSITES TODAY 4. EMBRAER R&D 5. R&D CHALLENGES
3 AGENDA 1. EMBRAER OVERVIEW 2. EMBRAER PORTUGAL ESTRUTURAS EM COMPÓSITOS, S.A. 3. COMPOSITES TODAY 4. EMBRAER R&D 5. R&D CHALLENGES
4 1994 Embraer is privatized, fusing technological and industry expertise with an entrepreneurial approach Brazil launches a national strategic aerospace initiative via the Aeronautics Technical Center (CTA) and the Technological Institute of Aeronautics (ITA) Today Embraer is the market leader in commercial jets with up to 130 seats Embraer is one of the world s leading manufacturers of commercial and executive jets, with substantial and growing operations in defense and security Federal Government creates Embraer to develop aeronautical engineering and manufacture aircraft in Brazil.
5 We have developed our business in the areas of COMMERCIAL AVIATION EXECUTIVE AVIATION EMBRAER DEFENSE & SECURITY
6 We have developed our business in the areas of - 70 s: Bandeirante - 80 s: Brasília - 90 s: 145 Family s: E-Jets : E2 EXECUTIVE AVIATION EMBRAER DEFENSE & SECURITY
7 We have developed our business in the areas of COMMERCIAL AVIATION 2000 to Legacy Phenom 100/300 - Lineage Legacy Legacy 500/450 EMBRAER DEFENSE & SECURITY
8 We have developed our business in the areas of COMMERCIAL AVIATION EXECUTIVE AVIATION - Bandeirante - Tucano & Super Tucano - AMX - ISR: Intelligence, Surveillance & Reconnaissance - KC390
9 This information is property of Embraer and cannot be used or reproduced without written permission. GLOBAL PRESENCE DIVERSITY IS WEALTH
10 This information is property of Embraer and cannot be used or reproduced without written permission. WHERE WE OPERATE USA Nashville Fort Lauderdale Melbourne Mesa Windsor Locks Jacksonville Irwindale NETHERLANDS Amsterdam IRELAND Dublin PORTUGAL Évora Alverca - OGMA UNITED KINGDOM Farnborough FRANCE Le Bourget UAE Dubai SINGAPORE Singapore CHINA Beijing BRAZIL São José dos Campos Gavião Peixoto Botucatu Taubaté Brasília Belo Horizonte São Paulo Rio de Janeiro Sorocaba Campinas
11 AGENDA 1. EMBRAER OVERVIEW 2. EMBRAER PORTUGAL ESTRUTURAS EM COMPÓSITOS, S.A. 3. COMPOSITES TODAY 4. EMBRAER R&D CASE 5. R&D CHALLENGES
12 EMBRAER Portugal Évora Composite Excellence Center Metallic Excellence Center Industrial area m m2
13 The plant Hot Drape Ultrasonic inspection CNC Water Jet RTM Autoclave Assembling AFP ATL Painting Packing
14 Production in Portugal at Embraer Composites, S.A. Legacy 500/450 Horizontal, Vertical Stabilizer & Tailcone KC-390 Horizontal Stabilizer E175-E2 Horizontal Stabilizer & Outboard Flaps
15 AGENDA 1. EMBRAER OVERVIEW 2. EMBRAER PORTUGAL ESTRUTURAS EM COMPÓSITOS, S.A. 3. COMPOSITES TODAY 4. EMBRAER R&D CASE 5. R&D CHALLENGES
16 This information is property of Embraer and cannot be used or reproduced without written permission. Phenom 300 & Phenom 100E Radome Fiberglass/Epoxy Fairings Wing to fuselage fairing Fiber Glass/Epoxy Hand Layup Dorsal Fin Fiberglass/Epoxy Hand Layup Empennages Carbon/Epoxy Hand Layup ATL Ribs Thermoplastics Control Surfaces Flap, Aileron, Rudder, Elevator, Spoilers Carbon/Epoxy Hand Layup Aft Pressure Bulkhead Carbon/Epoxy, Sandwich Hand Layup Landing gear doors Carbon/Epoxy Hand Layup ,971 nm 5-7 1,178 nm
17 This information is property of Embraer and cannot be used or reproduced without written permission. Legacy 500/450 Radome Fiberglass/Epoxy Empennages Carbon/Epoxy Hand Layup ATL Ribs Thermoplastics HS Tip Carbon/Epoxy VARTM Wing Fus. Fairing Fiberglass/epoxy Hand Layup Control Surfaces Flap, Aileron, Rudder, Elevator, Spoilers Carbon/Epoxy Hand Layup ,125 nm Pylon Fairing Carbon/epoxy RTM Aft Pressure Bulkhead Carbon/Epoxy RFI
18 This information is property of Embraer and cannot be used or reproduced without written permission. E175 E2 Control Surfaces Flap, Aileron, Rudder, Elevator, Spoilers Carbon/Epoxy Hand Layup AFP Hot forming Floor panel Carbon or Fiberglass Sandwich panels Outboard Flap Carbon/Epoxy ATL Hot forming Thermoplastic Thermophorming Radome Fiberglass/Epoxy Empennage Horizontal Tail Carbon/Epoxy ATL AFP Hot forming Landing Gear Doors NLG door, MLG doors Carbon/Epoxy Hand Layup Wing Fus. Fairing Fiberglass/epoxy Hand Layup ,800 nm
19 Composites % - airframe weight Fairings & Radome + Control Surfaces 15% Fairings & Radome 25% + Empennage & Pressure Bulkhead + Control Surfaces + Rear Fuselage 20% 50% + Wing box & Fuselage + Empennage & Pressure Bulkhead Larger Aircraft Embraer
20 Composites % - airframe weight Fairings & Radome + Control Surfaces 15% Fairings & Radome 25% + Empennage & Bulkhead + Control Surfaces + Rear Fuselage 50% Why should % of composites be increased? 20% + Wing box & Fuselage + Empennage & Bulkhead Larger Aircraft Embraer
21 AGENDA 1. EMBRAER OVERVIEW 2. EMBRAER PORTUGAL ESTRUTURAS EM COMPÓSITOS, S.A. 3. COMPOSITES TODAY 4. EMBRAER R&D CASE 5. R&D CHALLENGES
22 Wing, Empennage & Fuselages Demonstrators
23 WING DEMO R&D CASE TECHNOLOGY VALIDATION
24 Wing Demo Project Ref. E190
25 Wing Demo Project Ref. E190
26 Wing Demo Project Ref. E190 CMH-17: Test sequence recommendations
27 Wing Demo Project Ref. E190
28 AGENDA 1. EMBRAER OVERVIEW 2. EMBRAER PORTUGAL ESTRUTURAS EM COMPÓSITOS, S.A. 3. COMPOSITES TODAY 4. EMBRAER R&D CASE 5. R&D CHALLENGES
29 Why should % of composites be increased? NEEDS Performance DMC Weight Special Application
30 Why should % of composites be increased? CONCERNS Costs Inspections Environment Specific Requirements
31 R&D Challenges Specific Requirement Lightning Small aircrafts have higher current density Flammability Small aircrafts have thinner skins less fire resistant Bigger composite components, as wing, require more tests no historical data
32 R&D Challenges Special Application New Materials Erosion protection Damage tolerance Conductive materials Preform/3D fabric
33 R&D Challenges Costs Maintenance DMC material properties (fatigue, corrosion); SHM Manufacturing Process Special process: bonding quality control; inspection Production rate automation; integration OOA process Scraps new technologies recycling Certification Process Extensive testing and time consuming virtual testing
34 This is not the right question! Fairings & Radome + Control Surfaces 15% Fairings & Radome 25% + Empennage & Bulkhead + Control Surfaces + Rear Fuselage 50% Why should % of composites be increased? 20% + Wing box & Fuselage + Empennage & Bulkhead Larger Aircraft Embraer
35 Make the best decision! Biggest Challenge? Strategy Supply chain Composites technologies Non-recurring costs Aircraft mission Partnership
36 THIS INFORMATION IS THE PROPERT OF EMBRAER AND CANNOT BE USED OR REPRODUCED WITHOUT AUTHORIZATION IN WRITING.
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