Composites R&D challenges for EMBRAER aerostructures SAMPE BRAZIL CONGRESS 2017 Luciana Selmi Marques October 5 th, 2017
AGENDA 1. EMBRAER OVERVIEW 2. EMBRAER PORTUGAL ESTRUTURAS EM COMPÓSITOS, S.A. 3. COMPOSITES TODAY 4. EMBRAER R&D 5. R&D CHALLENGES
AGENDA 1. EMBRAER OVERVIEW 2. EMBRAER PORTUGAL ESTRUTURAS EM COMPÓSITOS, S.A. 3. COMPOSITES TODAY 4. EMBRAER R&D 5. R&D CHALLENGES
1994 Embraer is privatized, fusing technological and industry expertise with an entrepreneurial approach. 1949 Brazil launches a national strategic aerospace initiative via the Aeronautics Technical Center (CTA) and the Technological Institute of Aeronautics (ITA). 2014 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. 1969 Federal Government creates Embraer to develop aeronautical engineering and manufacture aircraft in Brazil.
We have developed our business in the areas of COMMERCIAL AVIATION EXECUTIVE AVIATION EMBRAER DEFENSE & SECURITY
We have developed our business in the areas of - 70 s: Bandeirante - 80 s: Brasília - 90 s: 145 Family - 2000 s: E-Jets - 2018: E2 EXECUTIVE AVIATION EMBRAER DEFENSE & SECURITY
We have developed our business in the areas of COMMERCIAL AVIATION 2000 to 2015 - Legacy 600 - Phenom 100/300 - Lineage 1000 - Legacy 650 - Legacy 500/450 EMBRAER DEFENSE & SECURITY
We have developed our business in the areas of COMMERCIAL AVIATION EXECUTIVE AVIATION - Bandeirante - Tucano & Super Tucano - AMX - ISR: Intelligence, Surveillance & Reconnaissance - KC390
This information is property of Embraer and cannot be used or reproduced without written permission. GLOBAL PRESENCE DIVERSITY IS WEALTH
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
AGENDA 1. EMBRAER OVERVIEW 2. EMBRAER PORTUGAL ESTRUTURAS EM COMPÓSITOS, S.A. 3. COMPOSITES TODAY 4. EMBRAER R&D CASE 5. R&D CHALLENGES
EMBRAER Portugal Évora Composite Excellence Center Metallic Excellence Center Industrial area 32.000m 2 37.000m2
The plant Hot Drape Ultrasonic inspection CNC Water Jet RTM Autoclave Assembling AFP ATL Painting Packing
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
AGENDA 1. EMBRAER OVERVIEW 2. EMBRAER PORTUGAL ESTRUTURAS EM COMPÓSITOS, S.A. 3. COMPOSITES TODAY 4. EMBRAER R&D CASE 5. R&D CHALLENGES
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 7-10 1,971 nm 5-7 1,178 nm
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 8-12 3,125 nm Pylon Fairing Carbon/epoxy RTM Aft Pressure Bulkhead Carbon/Epoxy RFI
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 97-106 2,800 nm
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 1970 1980 1990 2000 2010 2020
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 1970 1980 1990 2000 2010 2020
AGENDA 1. EMBRAER OVERVIEW 2. EMBRAER PORTUGAL ESTRUTURAS EM COMPÓSITOS, S.A. 3. COMPOSITES TODAY 4. EMBRAER R&D CASE 5. R&D CHALLENGES
Wing, Empennage & Fuselages Demonstrators
WING DEMO R&D CASE TECHNOLOGY VALIDATION
Wing Demo Project Ref. E190
Wing Demo Project Ref. E190
Wing Demo Project Ref. E190 CMH-17: Test sequence recommendations
Wing Demo Project Ref. E190
AGENDA 1. EMBRAER OVERVIEW 2. EMBRAER PORTUGAL ESTRUTURAS EM COMPÓSITOS, S.A. 3. COMPOSITES TODAY 4. EMBRAER R&D CASE 5. R&D CHALLENGES
Why should % of composites be increased? NEEDS Performance DMC Weight Special Application
Why should % of composites be increased? CONCERNS Costs Inspections Environment Specific Requirements
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
R&D Challenges Special Application New Materials Erosion protection Damage tolerance Conductive materials Preform/3D fabric
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
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 1970 1980 1990 2000 2010 2020
Make the best decision! Biggest Challenge? Strategy Supply chain Composites technologies Non-recurring costs Aircraft mission Partnership
THIS INFORMATION IS THE PROPERT OF EMBRAER AND CANNOT BE USED OR REPRODUCED WITHOUT AUTHORIZATION IN WRITING.