Michael Grese Michael Hawley Michael Lyrenmann Timothy Smith

Dreamliner 787
Boeings latest aircraft, the Dreamliner 787, is pushing the barriers of aircraft construction and component technologies. The biggest departure from previous aircraft is the use of composite structures in its design, about 50% by weight. The highest amounts of composites used before the Dreamliner were about 12% in Boeings own 777.

Material make-up of the 787

Carbon Fiber Composites

Making Carbon Fiber

Figures courtesy of The Macrogalleria

Making Carbon Fiber (contd)

Carbon Fiber woven ribbons

The lay-up process

Thermally Conductive Plastics

Thermally conductive plastics are becoming viable solutions for handling heat in some specific, high-tech applications. Some modified plastics can approach the thermal conductivity of die-cast aluminum, one of the most widely used heat sink materials today. Considerations: lightweight, moldable, cost, etc.

Traditional Aircraft Interior Applications

Figure courtesy of SABIC Innovative Plastics

Typical Airplane Composites

Ultem 9085 resin
Polyetherimide Decompression grilles, window revels, bezels Extruded, thermoformed, injection molded

Noryl LS6010 resin

Polyphenylene ether + Polystyrene Rub strips and seat track covers Injection molding, profile extrusion, sheet extrusion

Examples
(Left) Vacuum-formed panel (Ultem), overhead bin (Noryl) (Below) Cabin seat on the 787

Typical Airplane Composites

Lexan FST9705 resin
Polycarbonate copolymer Personal service units, window revels, and bezels Injection molding

Bismaleimide (BMI) resins

External structural applications Autoclaving process

PR Domain: GE Plastics Launches Three New High-performance Materials for Aircraft Industry.

Assembly - A Global Undertaking

Reprocessing Techniques
Thermoplastics can be repaired using a number of different techniques: Fusion Bonding
Heat, molecule diffusion, cooling Frictional, thermal, electromagnetic welding

Patch Repair
Wide variety of techniques Mechanical fastening, adhesive bonding, focused infrared

Reprocessing Techniques
Thermo-reforming
Heated to create viscous polymer Use same technique as when originally formed

Vodicka, Roger. Thermoplastics for Airframe Applications: A Review of the Properties and Repair Methods for Thermoplastic Composites

Advantages over Metals

Lightweight
Density of composites: about 1.4 g/cm3 Density of aluminum: 2.7 g/cm3 Density of titanium: 4.5 g/cm3

Large single-piece construction

80% reduction in number of fasteners

Resistant to corrosion and fatigue Lower maintenance cost

Disadvantages
High material cost Difficult repairs (composites) Specialized tools needed

Figure courtesy www.compositecarbonfiberprop.com

Cost of Boeing 787

767 Family 767-200ER 767-300ER 767-400ER 787 Family 787-3 787-8 787-9 $127.5 -- 139.0 Million $144.5 -- 161.5 Million $158.0 -- 173.0 Million $150.0 -- 155.5 Million $161.0 -- 171.5 Million $194.0 -- 205.5 Million 255 passengers 350 passengers 375 passengers 290-330 passengers 210-215 passengers 250-290 passengers 6,385 nmi 5,990 nmi 5,625 nmi. 2,500 to 3,050 nmi. 7,650 to 8,200 nmi. 8,000 to 8,500 nmi.

Source: www.boeing.com

Weight/ Maintenance Costs

Boeing: Dreamliner 787 will be 20% more efficient Light weight also affects landing taxes Boeing: 30% reduction in maintenance costs over aluminum fuselage airplane

Electrical Improvements
8% efficiency improvement from engine design: GE GENX and
Rolls Royce Trent 1000 Electrical Reconfigurations: more reliance on electrical starters Bleed air-hot compressed air from engines used in de-icing, cabin pressurization 787 will use pneumatic compressors

Problems with Cost Estimates

Cost estimates released by Boeing: incentive to make the plane sound better Boeing 787 has yet to actually be released So many new innovations

Questions?