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Improving competitiveness of Additive Manufacturing Aerospace serial parts

LISI AEROSPACE Additive Manufacturing-Maxime gas, Alexis RENE-CORAIL, Sebastien EYRIGNOUX, Guillaume IKER, Stephane SUDRE
  • Technical Paper
  • 2019-01-1900
To be published on 2019-09-16 by SAE International in United States
The interest of selective laser melting technology for aerospace parts is very high due to their high complexity and their freedom of design which allow functions integration. However, the competitiveness of Laser Beam Melting (LBM) machines for aerospace industry is limited by two major road blocks. On the one hand, basic parametric set sold with LBM machines are more oriented to historical qualification than productivity rates. For instance, the ongoing qualification on EOS M290 by AIRBUS COMMERCIAL AIRCRAFT only enables us to produce a hundred pieces per machine per year. On the other hand, wasted times between two consecutive manufacturing batches are significant and are impacting the yearly output of the machines. The present project focuses on two activities, focusing on the largest available machines, XLINE2000R and M400, in order to maximize the amount of pieces per build. The first one was the improvement of parametric set productivity, to reduce production time, while keeping material and mechanical properties. We focused on main aerospace materials: titanium alloys, aluminum alloys (Scalmalloy®) and nickel-chromium-based superalloys. The second one…
 

Development Of Multi-Material Overhead Stowage Systems For Commercial Aircrafts By Using New Design and Production Methods

3D Systems GmbH-Gunnar Fick
Composite Technology Center / CTC GmbH-Marc Fette
  • Technical Paper
  • 2019-01-1858
To be published on 2019-09-16 by SAE International in United States
The relevance of innovative and functional lightweight components for aircrafts has risen significantly during the recent years. In this context, modern lightweight materials as well as cost-efficient and time-saving manufacturing technologies are required for a future aircraft production. The so called Hybrid SMC Technology and the SMC-Foam-Sandwich Technology are promising approaches for the cost-efficient and time-saving manufacturing of lightweight, geometrically complex and functional aircraft components. Both technologies have been used for the development of a new generation overhead stowage system. It is realized by sidewalls made out of enhanced SMC technologies with directly implemented metallic load introduction elements and regular sandwich structures that can be assembled by a quick-assembly principle. Due to the glass fibers in the shape of chopped long fibers with no predominant direction in SMC material, continuous carbon fiber tailored fiber placement (TFP) fabrics were integrated to increase mechanical properties. Because of several load introduction points in the demonstration part, carbon fiber loops are a good and efficient possibility to transfer these loads. The challenge in the virtual design process of SMC…
 
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NRC Particle Detection Probe: Results and Analysis from Ground and Flight Tests

National Research Council Canada-Craig Davison, Jennifer Chalmers, Dan Fuleki
Published 2019-06-10 by SAE International in United States
High altitude ice crystals are causing in-service events in excess of one per month for commercial aircraft. The effects include air data probes malfunctioning (pitot pressure and total air temperature in particular), and uncommanded engine power loss or flameout events. The National Research Council Canada (NRC) has developed a particle detection probe (PDP) that mounts on the fuselage of aircraft to sense and quantify the ice crystals in the environment. The probe is low-power and non-intrusive. This paper presents the results of ground and flight testing of this probe. Results are presented for ground testing in a sea level ice crystal wind tunnel and an altitude icing tunnel capable of generating both ice crystal and super-cooled liquid. The PDP was operated on several flight campaigns and the results of two will be presented. The first was on board a NRC Convair 580 aircraft in French Guiana (FG) and the second was on an Airbus operated A340 research aircraft in Darwin and Reunion Island. The flight campaigns included fully glaciated, mixed phase and fully liquid conditions.…
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How Dual Polarization Technique May Improve Weather Radar on Commercial Aircraft

NOVIMET-Jacques Victor Testud, Emmanuel Moreau, Erwan Le Bouar
Published 2019-06-10 by SAE International in United States
The airborne weather radar on a commercial aircraft is essential to ensure flight safety. It is able to detect severe weather, probable areas where presence of hail may be suspected, and thanks to its Doppler capability, the wind shears that may be dangerous when taking-off or landing. However, because it operates at X-band, the picture that it offers to the pilot may be seriously biased in situation of severe weather, in reason of the attenuation of the radar wave.The adoption of the dual pol technique in this weather radar would be most beneficial for the quality of the information delivered to the pilot for the following reasons:1Dual pol technique allows to operate a classification of the precipitation: distinguishing rain, melting layer, snow, hail, small ice particles.2Dual pol technique allows correcting the return signal for attenuation in rain.The paper aims reporting recent advances in the exploitation of dual pol radar data, based on the concept of normalisation of the particle size distribution (PSD) and on ZPHI® algorithm for precipitation retrieval. Their combination helps retrieving parameter N0*…
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The World of Civil Aerospace

IVHM Centre Cranfield University-Ian K. Jennions
  • Book
  • R-468
Published 2019-05-28 by SAE International in United States
Collaboratively written by eleven experts with extensive experience in the field of commercial aviation, The World of Civil Aerospace is a unique book that defines its own category. Covering the beginnings of commercial aviation, aircraft design and certification, manufacturing and testing, airline operation, maintenance and safety, among other topics, The World of Civil Aerospace shows the reader the fundamental (yet almost invisible) aspects of how the planes and airports we use every day actually function. The title, edited by Prof. Ian Jennions, from Cranfield University in the UK, came about from the desire to share the inner workings of what it takes to create, test, approve, certify and launch a new aircraft. Not mention how to maintain it and make the user experience of flying it positive. With the commercial aviation industry expected to continue to grow for decades to come, the challenges of keeping aircraft in the air safely, reliably and economically are enormous. Thousands of engineers, support personnel, maintainers and crews go to work every day with one goal in mind: to make…
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Damage and Repair of Aerospace Composite Materials

Charles Lu
  • Progress In Technology (PT)
  • PT-200
Published 2019-04-30 by SAE International in United States
Damage and Repair of Aerospace Composite Materials reports the latest developments on the detection and repair of composite structures from the perspective of ten SAE technical papers, especially chosen for this book. This micro-collection of papers offers an overview of composite utilization on large-scale commercial aircraft as well as an outline of general damage inspection and repair of composite structures. On the damage detection side, really important techniques are explained, including: • Porosity inspection of large composite panels. • Damage detection of large composites using acoustic ultrasonic and radio frequency methods. • Discrimination of damaged and undamaged composite panels using acoustic emission sensors. • Automated defect inspection system integrated in the production line by utilizing laser sensors and cameras. The latest studies in damage repair of composite structures are also presented, including: • the design of a bonded repair technique for multilayer laminate composite panels. • the analysis on the performance of bolted repair vs. bonded repair. • the method for economically repairing the holes on composites. • the development of a novel cutting tool…
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Materials and Process Modeling of Aerospace Composites

Charles Lu
  • Progress In Technology (PT)
  • PT-202
Published 2019-04-30 by SAE International in United States
Since the successful production of carbon fibers in early 1960s, composite materials have emerged as the materials of choice for general aviation aircraft, military aircraft, space launch vehicles, and unmanned air vehicles. This has revolutionized the aerospace industry due to their excellent mechanical and physical properties, as well as weight-reducing ability. The next- generation material development model should operate in an integrated computational environment, where new material development, manufacturability, and product design practice are seamlessly interconnected. Materials and Process Modeling of Aerospace Composites reports recent developments on materials and processes of aerospace composites by using computational modeling, covering the following aspects: • The historical uses of composites in aerospace industry, documenting in detail the early usage of composite materials on Premier I by Raytheon to recent full-scale applications of composites on large commercial aircraft by Boeing and Airbus. • An overview on the classifications of composites used in aerospace industry, ranging from conventional glass- fiber reinforced composites to advanced graphene nanocomposites. • The recent work on computational material engineering on aerospace composite materials, including fundamental…
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Recommended Practice Regarding Commercial Aircraft Hydraulic System External Leakage

A-6A1 Commercial Aircraft Committee
  • Aerospace Standard
  • ARP6175
  • Current
Published 2019-04-29 by SAE International in United States
This Aerospace Recommended Practice (ARP) provides a comprehensive and consistent set of guidelines for the definition, recognition, troubleshooting and repair of hydraulic components and systems on in-service commercial aircraft affected by external leakage.
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Aircraft Nosewheel Steering/Centering Systems

A-5B Gears, Struts and Couplings Committee
  • Aerospace Standard
  • AIR1752A
  • Current
Published 2019-04-17 by SAE International in United States
The intent of this AIR is twofold: (1) to present descriptive summary of aircraft nosewheel steering and centering systems, and (2) to provide a discussion of problems encountered and “lessons learned” by various airplane manufacturers and users. This document covers both military aircraft (land-based and ship-based) and commercial aircraft. It is intended that the document be continually updated as new aircraft and/or new “lessons learned” become available.
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Oxygen Cylinder Installation Guide

A-10 Aircraft Oxygen Equipment Committee
  • Aerospace Standard
  • ARP5021B
  • Current
Published 2019-04-11 by SAE International in United States
This document provides guidance for oxygen cylinder installation on commerical aircraft based on airworthiness requirements, and methods practiced within aerospace industry. It covers considerations for oxygen systems from beginning of project phase up to production, maintenance, and servicing. The document is related to requirements of DOT-approved oxygen cylinders, as well to those designed and manufactured to standards of ISO 11119. However, its basic rules may also be applicable to new development pertaining to use of such equipment in an oxygen environment. For information regarding oxygen cylinders itself, also refer to AIR825/12.
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