‘zwaarwegende’ voordelen van

Lichtgewicht Ontwerpen

De Fabrique, Constructeursdag: ‘Out of the box’ ontwerpen

Maarssen, 19 november 2013

Adriaan Beukers

het domein voor composiet constructies

verder terug

motivation and introduction:

Durable Lightness dematerialization

vs. miniaturization

lichtgewicht constructies

tall structures and transport systems struggle with gravity

transport: ‘everything what moves or is being moved’

liquid fuel history: ‘a one century history of slash and burn’

SABIC/GEP-DSM

BASF/DSM

Emirates

Delta Airlines

10-20 -->100$/barrel

Cheap Materials become Scarce e.g. cheap oil, easy exploitable wells, new economies, EC2020

Transport and velocity domains

Total (system + payload) weight, so reduce system weight!

Specific drag 2 drag per unit system weight

15kgf PREQ to move

100kg WTOTAL

extreme efficiency

ratios

less system weight, more payload

Reduce (empty)

System Weight

EFFICIENCY improvements since the 50’s, aerodynamics: L/D ≈ 15%

propulsion: SFC ≈ 40 %

structure : 0.50 > OEW/MTOW > 0.60

Major R&D Challenges:

Structures, Materials &

Manufacturing Techniques

A320/B737 - alikes

structure efficiency

used for aircraft

OEW / MTOW =

42 ton / 74 ton = 0.56

Johnston distribution OEW:

50%: 21ton for systems, crew and power-plant(s)

50%: 21ton for structure in total

• 10.5ton for wing , undercarriage (6% ) and movables (6%), (12%=5 ton)

• 10.5ton for fuselage and empennage (13%)

• 16.0ton for wing, fuselage and empennage shell structures (38%)

FOCWA-ColdFeather 1995, 3 ton weight reduction per trailer!!!!

max weight saving with composites for aluminium shell structures

is about 25%, equal to 4ton, for a A320 or B737 alike!

Energy saving: 667 GJ/year.100kg Specific energy content: 35 MJ/litre

So fuel saving per year per 100kg: 19000 litre

Sell tickets priced per kilogram not per seat!

A320/B737 AIRCRAFT mass reduction pays

Minimize Airmiles (point to point)

Amsterdam - Dubai - Bejing: KLM direct flight: -30% airmiles, 2 x ticket price

Emirates policy: ‘sell A380-seats instead of oil’

Aircraft profit breakeven at ≈85%,

KLM profit ≈5$/passenger÷0.05$/kg, Easy Jet profit 1.2$/passenger

Life-time energy savings per 100kg average values for energy

savings by

weight reduction

IFEU 2004, 1GJ is about 30lt kerosine

42,000lt

450,000lt

600,000lt

Life time ENERGY SAVINGS HIGH SPEED FERRIES

33% reduction by weight

- 47 ton/100kg.lifetime (-7%)

E-glass reinforced composite

-7% kerosine

1650GJ//35MJ/lt

steel

aluminium

gfrp

+

added

values

Design and Production of Composite Structures

dematerialisation & miniaturization

optimization

Design and Development Strategy

textiles

plastics composites

integration vs. segregation

novel fibre-polymer composites

downstream manufacturing

reduction of costs & energy

reduction of emissions & waste

multidisciplinary R&D

FIBRE AND WIRE PROPERTIES for lightweight engineering, aerospace and sport equipment

FROM ABSOLUTE (E, σ) TO SPECIFIC PROPERTIES (Ex/ρ, σy/ρ)

FIBRES & RESINS: VOLUME, ARCHITECTURE AND HANDLING

roadmap

material

morphologies

& processes

LOW PRESSURE, LOW COST void free infusion free of autoclaves micro bubles carry entrapped voids

classical markets

aerospace & wind

energy show

highest global

growth now,

be in front

of the big

volume

emerging

composite

markets!

CAGR: compound anual growth rate

size of bubbles: indicating for market size ref. Lucintel

Composites Global Market Opportunity 2012-2017

Concept, materials and manufacturing technique selection

Life cycle cost driven

Composiet in Opmars 1 civil constructions 2013

Concept, materials and manufacturing techniques selection

Fast competition structures, maximum performance driven

Composiet in Opmars 2 America’s Cup 2013

Concept, materials and manufacturing techniques

Performance/price driven

Composiet in Opmars 3

2013 BMWi3

Concept, materials

and manufacturing technique selection

Price/performance driven

Composiet in Opmars 4

Airbus 350, 2013

Taniq

Actiflow

Infinious

ALE

Airborne

K&vE

WMC/CompEx

Bond Laminates

Conform/Hylid

DTC / Mupio

Feltrin Composites

CLC / LS

Euro Enaer (‡)

Senz/Protension

MOCS/CTC

proof of the

structure is

in the testing

Structure efficiency

slender beams and plates

dominated by bending

or compression buckling

material specific efficiencies determine:

fig.4.3.3: Compression panel efficiency

for different types of stringers

fig.4.3.1: Z-section stringer, pitch b, length L, As cross sectional area

fig.4.3.2: Minimize equivalent thickness t ≥ p / versus yield strength, plate buckling L, t, and b and local and global stringer buckling (L and r = I / As)

4.3 STIFFENED SKIN STRUCTURE EFFICIENCY

1932- Buckling or compression critical wing panels

Source: A. Rothwell

cfrp gfrp alu

Structure Design Efficiency (factored for environment)

global material efficiency, load intensity

structures free of discontinuities

final structure efficiency, integrity and durability depend

on ‘smart’ design of joints, cut outs and load trajectories

Good material, Poor structure the inconvenient true of a C141 Starlifter

compression

efficiency

comparison,

stiffened panel

configuration, ref. Prof. Rothwell

machined monolithic wing panels:

poor splices, poor radii, poor drain holes for a fatigue and

(fungus, fuel tank) corrosion sensitive environment

FLOPPY AND FROZEN TEXTILES

Ultimate Lightness textile

structures

in aerospace

George Cayley ’s

paradigm ca.1799

Frozen textile = composite structure

Segregate functions to solve ‘design’problems

27 CompEx for BOSAL & SKODA | 27

Design, prototype & test a lightweight,

durable exhaust system

• Mass reduction at least 20% (60%)

• Cost penalty per saved kg : < € 10 (same for hybrid cars)

• Dynamic & acoustic properties: comparable

Composite redesign, example 1

CompEx Concept

Ferrari California exhaust system

Pyrogel

Mesh

Carbon skin

Superwool

28 | 29

CompEx technology

How it works

Insulation layer1

Insulation layer 2

Mesh

Carbon skin

Carbon Composite skin 200˚C resistant

Exhaust exterior <200˚C

Exhaust gases up to 950˚C

Mesh

Insulation layer 1 1100˚C

resistant

Insulation layer 2 650˚C

resistant

29 | 29

Concept

Adapter

• Inner tube conveys exhaust gases into composite exhaust

• Outer tube is connected to the composite exhaust outer shells

30 | 29

1. CompEx Heat Tests Heat testing is done on prototype 1

• Thermocouples on 10 different locations

• Temperature measures as function of time at 6000 rpm/ 690 Nm torque

• No adhesive, only clamping rings

31 | 29

1. CompEx Heat Tests

32 | 29

2. CompEx Acoustic Testing Testing of prototype 3 vs. steel pipe

Speaker Inlet microphone Outlet microphone

33 CompEx for BOSAL & SKODA | 27

2. CompEx Acoustic Testing

CompEx Technology A light weight, durable and high performance exhaust system concept Sotiris Koussios & Adriaan Beukers

Faculty of Aerospace Engineering Delft University of Technology

packaging on the move, from technology push to market pull 1

Impertinate design: new materials and processes,traditional morphology

oak barrel mimics, Eugene Kelly ‘37 mimics, B787 metal mimicked

composite AC; from refillable to disposable lightweight packaging

LIGHTER TRANSPORT COUNTS Adriaan Beukers, TUDelft

packaging on the move, from technology push to market pull 2

Exchangeable bag-in-box light weight packaging, low cost,

collapsable:‘flexy-fust’: beer, wine, chemicals

30lt: from 11 to 3.75kg, no CO2 for beer

LIGHTER TRANSPORT COUNTS

packaging on the move, from technology push to market pull 3

from refillable to disposable lightweight packaging:

via ‘flexy-fust’ to ‘key-keg for beer, wine, chemicals, et cetera

30lt: from 11 to 1.5kg’, no CO2 for beer, better taste

LIGHTER TRANSPORT COUNTS

Jan

Veenendaal

Bert

Hanssen

THE END

-KEYKEG DISPOSABLES (pet) - -2010: ca 300.000 units 30lt (-10kg)

no 10kgCO2 bottle per 50 beer kegs

no NaOH cleaning & final water flushing

(chemical disposal)

reduced transport mass ca 3000ton

saves transport equivalent to 150 trailers

huge improvement of used raw material

(from 7/1 to 3/1) and energy balance!?

packaging on the move, from technology push to market pull 4

LIGHTER TRANSPORT COUNTS

‘zwaarwegende’ voordelen van

Lichtgewicht Ontwerpen

De Fabrique, Constructeursdag: ‘Out of the box’ ontwerpen

Maarssen, 19 november 2013

THE END

het domein voorcomposiet constructies

From Liquid To Gaseous Energy Carriers 2013

Shale gas, deep well an-organic chemistry from global to local resources

equal to liquid fuel history: ‘a new century of slash and burn’

Shell 2013: US, China, Brazil,

‘very disappointing return

on investments’

CEO Peter Vosscher

Periodic System of Elements

Composites, engineering polymers and fibers versus metals

Ice, mud and concrete are implicit light materials too

polymer

composites

light

metals

heavy metals

minimum mass and energy

a strategy for design

the building blocks for materials

INDUSTRIAL MANUFACTURING, THE FASTER THE BETTER reduce mass of rotating mandrels reduce mass of head place dry fibres keep them straight, simple artificial geodetics

Life-time energy savings per 100kg

average values for energy

savings by weight reduction

IFEU 2004

1GJ is about 30lt kerosine

Energy carriers, energy transformers

Energy carrier

Transformer

Transport system

Structure materials

Carrier follows transformer

PERI OD ENERGY CARRIER/TRANSFORM ER

TRANSPORT SYSTEM MATERI ALS

up to 1830

direct: wood, wind, water,

animals, man

walking, horses, barges, coaches

wood, linen, copper, brass and iron

1830-1900 Coal steam engines coaches, ships, trains wood, linen,

iron, steel

1900-1940 Coal electric dynamo trains, cars, buses wood, linen, plywood,

iron, steel

1903-2003 Oi l internal combustion

engines,

piston and

turbine engines

cars, buses, flying machines,

all aluminium aircraft with

pressurised fuselages

wood, plywood, linen,

iron, steel, aluminium,

polymers

1960-2025? Oi l high efficient by-pass

turbine engines supersonic aircraft (2001†)

classical subsonic aircraft iron, steel, aluminium,

polymers, titanium,

composites

1970-1990 Nuclear centralised electricity

distribution

high velocity trains, steel, aluminium,

composites

1990-2025? G a s clean and efficient

energy supply,

CH4 and H2

city transport steel, aluminium, titanium, advanced composites, advanced alloys, ceramics

2025 – future? Hydrogen?

Nuclear?

Wind/Solar?

Oil

fuel cell?

gas?

bio-fuels?

direct electricity

direct elektrocutie

highest caloric value

per unit volume and

mass

sustainable transport: smart cars, busses, new train concepts, high velocity trains composite aircraft/BWB

new polymers, ceramics, fibres, new reinforcing materials and improved metals.

transport and storage

Gaseous energy carriers

lightweight gascontainer, from liquid

to gaseous energy carriers

lpg, cng, H2, metaan

ref. S. Koussios & L. Zu

Design and Development Strategy

Design and Production of Composite Structures cooled trailer system weight

reduced from ca. 9300

to 6500 kgf

1995, Focwa/Cintec 30% weight reduction challenge

Design and Production of Composite Structures

The end

‘COMPOSITES’

STADE composite waste management: reduction potential of 40%

waste equals per year: 14600kg/€19.4 million = 1328€/kg

(53/47% un/planned)

DISSEMINATION

UTILIZATION

DEVELOPMENT

KNOWLEDGE

• Airbus • Stade • Nantes • Illescas

carbon fibre

pre-preg waste and rejection

cost

Assembly Single Parts, AutoCLave, Ties(links)

∑ €19,4million

Structures

Processes

Materials

composites

Thermal properties

of polymers

glass transition

melt

process

amorphous

semi-crystalline

textile

structures

in aerospace

Textile Morphologies

the flatter the better

down stream manufacturing

fig. 2.1:

Typical commercial aircraft weight distribution

Source: R.W Johnson NASA

fig. 2.2:

Part count distribution

43 % Shell: skin, stiffeners, frames

16 % keel: wheel wells etc.

12 % floor assemblies

11 % door assemblies

10 % bulkheads

8 % windows

Aircraft Structures in Fractions

1985

Fractions of weight, parts and cost

Metal mimics:

Function integration?

Industrial manufacturing?

Composite Fuselages

Design and Production of Composite Structures

6 seat aircraft

pressurized cabin empty weight 1300 kg

cruise speed 400 km/h

range 1100 km

1997, Extra 400/500: conceptual, aerodynamic and

structural design (integration of parts, mechanics and physics)

Lighter transport counts

design of pressure cabins:

frame

pitches

Combine Physics & Mechanics

Frame pitches

A look beneath the surface