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    AMP1

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    Anmol Kumar
    The Boeing 787 Dreamliner uses composite materials extensively to reduce weight. The fuselage is made of carbon fiber reinforced plastic composites, which are 20% lighter than aluminum. Other composite materials like HexPly carbon fiber are used for the fuselage skins and stringers. The landing gear uses composites for braces to reduce weight and titanium for the inner cylinder. The wings use carbon fiber reinforced epoxy prepregs. The engines, Trent 1000 and GEnx-1B, feature composite fan blades and cases to reduce weight through advanced materials.

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    AMP1

    Uploaded by

    Anmol Kumar
    143 views42 pages
    The Boeing 787 Dreamliner uses composite materials extensively to reduce weight. The fuselage is made of carbon fiber reinforced plastic composites, which are 20% lighter than aluminum. Other composite materials like HexPly carbon fiber are used for the fuselage skins and stringers. The landing gear uses composites for braces to reduce weight and titanium for the inner cylinder. The wings use carbon fiber reinforced epoxy prepregs. The engines, Trent 1000 and GEnx-1B, feature composite fan blades and cases to reduce weight through advanced materials.

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    Material of boieng 787

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    The Boeing 787 Dreamliner uses composite materials extensively to reduce weight. The fuselage is made of carbon fiber reinforced plastic composites, which are 20% lighter than aluminum. Other composite materials like HexPly carbon fiber are used for the fuselage skins and stringers. The landing gear uses composites for braces to reduce weight and titanium for the inner cylinder. The wings use carbon fiber reinforced epoxy prepregs. The engines, Trent 1000 and GEnx-1B, feature composite fan blades and cases to reduce weight through advanced materials.

    Copyright:

    © All Rights Reserved
    Download as PPTX, PDF, TXT or read online from Scribd
    Download as pptx, pdf, or txt
    143 views42 pages

    AMP1

    Uploaded by

    Anmol Kumar
    The Boeing 787 Dreamliner uses composite materials extensively to reduce weight. The fuselage is made of carbon fiber reinforced plastic composites, which are 20% lighter than aluminum. Other composite materials like HexPly carbon fiber are used for the fuselage skins and stringers. The landing gear uses composites for braces to reduce weight and titanium for the inner cylinder. The wings use carbon fiber reinforced epoxy prepregs. The engines, Trent 1000 and GEnx-1B, feature composite fan blades and cases to reduce weight through advanced materials.

    Copyright:

    © All Rights Reserved
    Download as PPTX, PDF, TXT or read online from Scribd
    Download as pptx, pdf, or txt
    of 42
    At a glance
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    The key takeaways are that Boeing 787 makes extensive use of composite materials like carbon fiber reinforced plastic in its construction for weight savings and fuel efficiency. It also provides specifications and details of the 3 models - 787-8, 787-9, 787-10

    The fuselage of Boeing 787 is constructed using carbon fiber reinforced plastic (CFRP) and materials like HexPly AS4 carbon fiber prepreg for the skins and stringers. The nose cone uses fiberglass.

    Some advantages of using composite materials are weight savings of around 20% compared to aluminum, higher strength to weight ratio, reduction in maintenance due to fatigue resistance, and excellent tensile strength handling.

    SELECTION OF MATERIALS

    Boeing -787

    Submitted by: Shubhra Mandal, Sanjay Mahesh, Anmol Kumar, Shubham Agarwal, Krishna Maheta, Manish Raghuwanshi,
    Kashish Vaid, Arslan Rafi
    CONTENTS
    1. Introduction
    2. Specifications
    3. Fuselage
    4. Landing gear
    5. Tail wing
    6. Main wing
    7. Engine
    8. Drawbacks
    9. Conclusion
    Introduction
     The Boeing 787 Dreamliner is a
    long-range, mid-size wide-
    body, twin-engine jet
    airliner developed by Boeing
    Commercial Airplanes.
     It is Boeing's most fuel-efficient
    airliner and the world's first major
    airliner to use composite
    materials as the primary material in
    the construction of its airframe.
     The aircraft's initial designation was
    the 7E7.
    Specifications

    Model 787-8 787-9 787-10

    Length 186 ft (56.7 m) 206 ft (62.8 m) 224 ft (68.3 m)

    Wingspan 197 ft 3 in (60.1 m)

    Wing area 3,501 sq ft (325 m2)

    Height 55 ft 6 in (16.9 m)

    Fuselage dimensions Width: 18 ft 11 in (5.77 m) / Height: 19 ft 7 in (5.97 m)


    Maximum takeoff weight 502,500 lb (228,000 kg) 557,000 lb (253,000 kg)

    Maximum landing weight 380,000 lb (172,000 kg) 425,000 lb (193,000 kg) 445,000 lb (202,000 kg)

    Cruising speed Mach 0.85 (567 mph, 490 knots, 913 km/h at 35,000 ft/10,700 m)

    Maximum speed Mach 0.90 (593 mph, 515 knots, 954 km/h at 35,000 ft/10,700 m)

    Range, fully loaded 7,850 nmi (14,500 km; 8,300 nmi (15,400 km; 7,020 nmi (13,000 km;
    9,030 mi) 9,550 mi) 8,080 mi)

    Maximum fuel capacity 33,340 US gal (126,210 L) 36,641 US gal (138,700 L)

    Engines (×2) General Electric GEnx-1B or Rolls-Royce Trent 1000

    Thrust (×2) 64,000 lbf (280 kN) 71,000 lbf (320 kN) 76,000 lbf (340 kN)
    Fuselage
    Exterior section:
     The material used on fuselage is a redevelopment of the Toray composites America.
     Composites used: carbon fiber reinforced plastic (long strands of carbon fiber coated with an epoxy
    resin).
     Fuselage is assembled with 1- piece composites barrel section.

    Materials used:
     Nose cone: Fiber glass.
     Nose: Carbon laminate composites.
     Center fuselage, mid-fuselage, forward fuselage section: HexPly AS4 carbon fiber prepreg.
     fuselage skins, stringers, aft wheel well bulkhead: HexPly AS4 carbon fiber prepreg.
     Cargo and access doors: Torayca prepreg; Polyacrylonitrile based Carbon Fibers prepreg.
    Interior Section:
     WINDOWS: electrochromism-based smart glass
     ADVANTAGES: helps to adjust five levels of sunlight and visibility to the liking.

     WINDOW FRAMES: HexPly AS4 carbon fiber prepreg.

     FUSELAGE FRAMES (supports the passenger floor cabin) : Resin film


    infusion(RFI).
    ADVANTAGES:

     Larger strength and stiffness than the conventional aluminum.


     Weight saving on average of 20% compared to more conventional aluminium
    designs.
     Excellent in handling tension.
     Reduction in maintenance due to fatigue.
     Higher strength to weight ratio making the a/c lighter.
     Electrochromism-based smart glass: reduces cabin glare while maintaining a
    view to the outside world , but the most opaque setting still has some
    transparency.
     HexPly AS4 carbon fiber prepreg : good structural properties, net shape
    molding, better fatigue performance, lower weight.
    LANDING GEAR – B787
    Technology Innovations

    The 787 landing gears include a number of technology


    innovations, specifically in the area of new materials :
    1. Reducing landing gear weight.
    2. Reducing corrosion and providing higher resistance to
    fatigue versus steel parts.
     Main gear inner cylinder and a number of components: made
    from Titanium.
    Materials used
    • Fiber reinforced composite main landing gear braces.
    • From the start, the landing gear design efforts focused on three primary areas:
    1. New materials to minimize landing gear weight.
    2. Use of environmentally acceptable alternatives to chromium and cadmium, and the
    increased use of corrosion resistant materials.
    Advantages:
    Composite braces offered significant weight savings compared to previous steel
    components.
    capable of handling the brace’s complex axial and shear loading conditions or resist
    bird impact or runway flying debris.
    High resistance to corrosion and improved fatigue life in comparison to metals.
    Improved reliability increasing the service time interval between overhauls of the
    main landing gear braces.
    BENEFITS
    • Lighter weight than steel or titanium alternatives
    • 3D weaving technology allows the production of near net
    shape preforms, minimizing touch labor and saving cost
    • Through thickness reinforcement in 3D woven products,
    provides inherent damage tolerance and resistance to high
    magnitude axial and shear loads in the finished composite
    structure
    • Automated 3D weaving provides consistent quality and
    reproducibility from one part to another while minimizing
    the touch labor involved in manufacture
    • Composite products improve corrosion resistance,
    reliability and maximizes the interval between servicing
    times
    TAIL SECTION
    TAIL SECTION
    MATERIALS USED:
     Tail wing leading edge: Aluminium
     Horizontal and vertical control surfaces: Carbon sandwich
    composite.
     Hinges: Fiberglass
     Horizontal and vertical stabilizer: Carbon Laminate composite.
    WING
    WING
    Movable leading edge structures:
     Aluminium.
     Carbon prepreg combines of: 1. Cytec Engineered materials (Tempe, Ariz).
    2. High temperature bis-maleimide (BMI)
    resin.
    3. Cytec carbon fiber reinforcement.
    Advantage: This allows Boeing to remove some insulation because the wing
    De-icing system(the source of high heat) is integrated into these
    components.
    Fixed Leading Edge structure:
     Boeing BMS legacy glass and
     Carbon fabric reinforced epoxy prepregs
     Cured at 250 degree F/121 degree C.

     Movable Trailing Edge surfaces:


    Includes: 1. Ailerons,
    2. flaperons and
    3. The inboard and outboard flaps,
    4. Spoilers and all
    Are made up of structural carbon fabrics.
     Farings: structural carbon fabrics.
    B-787 engine
    Boeing 787 – Dreamliner Engine
    1.Materials especially those that
    would allow for hotter
    combustion.
    2.Powered By two types of Engine
    • Rolls- Royce Trent 1000
    • General Electric nx
    3.Exhaust Duct cover – Chevron
    toothed pattern
    4.Air Inlet as-
    • Sound Absorbing Materials
    Engine Specification
    • Lighter Weight Composite Materials & advanced systems.
    • Mainly Titanium based alloys are used in engines & fasteners..
    • Improved thrust to weight ratio through the application of advanced
    materials.
    • Compatible with 787 use a standard electrical interface to allow an aircraft
    to be fitted with given engines : -
    • General Electric nx
    • Rolls – Royce Trent 1000
    GEnx- 1B
    • Composite (Carbon Fiber) Fan
    Blades with latest swept
    aerodynamic shape
    • Composite (Carbon Fiber) Fan
    case
    • Steel Alloy leading edges.
    • Ti – Al Blades in last two stages of
    low pressure turbine.
    • As Ti – Al achieves significant
    weight savings over traditional
    Nickel Alloy.
    • Lightweight, durable, composite
    materials & specialized coatings.
    Rolls- Royce Trent 1000
    • Second largest manufacturer of
    turbofans.
    • Bleed less design.
    • Hollow-fan-Blade (Swept) of titanium
    • Surface coolers.
    • Titanium is the material that has the
    right combination of low density & high
    strength.
    • Fan produces 85% of the engine’s
    thrust.
    Trent 1000 Vs GenX-1B

    Trent 1000 GenX-1B


    • Gear box corrosion • No such problem
    • Major problem of all GenEx’s
    • NO Ice crystal icing
    • Requires Lead coating to prevent
    • Doesn't requires lead coating corrosion of various parts
    • 20% more fuel efficient then 767 • 1-2% less fuel efficient then
    Trent 1000
    R-R is ready for another round
    ”Trent 1000-TEN upgrade in mid-2016”
    Future Analysis
    • Future blades of Rolls-Royce still needed to develop two novel manufacturing
    techniques.
    1. At an atomic level, three sheets of titanium material, are fused. It has to be
    done in an ultra-clean production facility through a process of diffusion
    bonding.
    2. Then the process of superplastic forming creates a hollow within the blade.
    Argon gas is used to inflate the titanium in a furnace operating at almost
    1000°C. Two outer titanium panels are expanded, while the middle sheet is
    stretched into a zig-zag shape, creating the final hollow 3D aerodynamic shape
    of the blade and giving extraordinary rigidity to the structure.
    TRENT 1000 specs
    FAN:
    At takeoff each blade caries a load of 90 tons equivalent to 9 London buses
    Material used:
     Ti-6-Al-4V.
     Made from single piece of Ti-alloy.
     To make it stiff and string, made with process called
    Superplastic forming and Diffusion bonding.
    Properties:
    1. Density: 4.5g/cm^3
    2. Specific heat: 0.5263 J/g degree C.
    3. Electrical Resistivity: 0.000178 ohm-cm.
    4. Melting point: 1604-1660 degree C.
    5. Thermal conductivity: 3.9.
    6. Young’s modulus: 110 Gpa.
    7. Tensile strength: 1000 Mpa.
    Compressor
    Material used:
     Ni based alloy.
     Forging and grinding are use to make compressor blades.
     Compressor blades are corrosion resistant.
    Blade info.
     The blades have an internal warren-girder structure to achieve strength , stiffness and
    robustness at low weight.
    Properties:
    1. Density: 8.2g/cm^3
    2. Specific heat: 0.42 J/g degree C.
    3. Electrical Resistivity: 0.00011 ohm-cm.
    4. Melting point: 1260-1340 degree C.
    5. Thermal conductivity: 11.4.
    6. Young’s modulus: 207 Gpa.
    7. Tensile strength: 1441 Mpa.
    COMBUSTOR:
    Material used:
     Partially Yttria Stabilized Zirconia.
     Interior of combustor is coated with ceramic layer.
     This thermo barrier coating is around 250 micrometer thick
    Properties:
    1. Density: 5.1g/cm^3
    2. Specific heat: 0.6 J/g degree C.
    3. Electrical Resistivity: 0 ohm-cm (ceramic).
    4. Melting point: 2700-2850 degree C.
    5. Thermal conductivity: 0.7 W/mK
    6. Young’s modulus: 20 Gpa.
    7. Tensile strength: 25 Mpa.
     TURBINE:

    Material used:
     Nickel Super Alloy.
     The turbine blades are made up of single crystal nickel alloy
     Nickel-based alloys can withstand the heat.
     But there's been a problem with Nickel based alloys; their
    thermodynamic limit, is around 1,150°C; so if the
    temperatures increases beyond this limit then the blades will
    start to melt.
     So Coated in an advanced ceramic material to insulate it
    from extreme temperatures.
     Ceramics are brittle.
    Properties:
    1. Density: 8.2g/cm^3
    2. Melting point: 1350 degree C.
    3. Young’s modulus: 110 Gpa.
    4. Tensile strength: 1000 Mpa.
    Ceramics
    • Ceramics are Brittle
    • Engine parts including Turbine blades have ceramic coatings.
    • Allow Engines to run hotter by several hundred degree Celsius.
    Nacelle
    • Light weight composite fan cowls.
    • Advance Ti Alloy exhaust system components.
    • Composite diagonal brace
    • Advanced titanium alloy strut.
    Drawbacks
    • Difficulty in: structural health monitoring and non destructive inspection of composites (in
    comparison to metals).

    • Delamination i.e debonding of one layer from another.

    • Weight reduction potential at higher cost(use of carbon fibre and titanium).

    • Carbon fibres react very differently to lightning strikes.

    Solution: thin copper mesh beneath the outer skin ( in the lightning prone areas).
    Conclusion
    Thank you

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