EADS Technology Licensing initiative webinar: Featured technologies: - Friction-stir welding using Delta. N tools - Al. Mg. Sc/Scalmalloy® September 30, 2010
Introduction to the EADS Technology Licensing initiative Wulf Höflich EADS Chief Intellectual Property Officer www. technologylicensing. eads. net
Who is EADS? A global leader in aerospace, defense and related services: ° A top-level manufacturer of aircraft, helicopters, combat aircraft, spacecraft and launchers, communications systems ° Main business units are: > Airbus - a world-leading manufacturer of jetliners and military airlifters > Eurocopter - the world's largest helicopter producer > Astrium – the European leader in space programs; > Cassidian - systems-level solutions in electronics, airborne systems, communications, defense electronics and services. ° Total revenues of € 42. 8 billion in 2009, with a workforce of some 118, 000 employees worldwide
EADS Technology Portfolio Patents as a Key Indicator
The EADS Technology Licensing Initiative’s value proposition The EADS Technology Licensing initiative is managed by its Corporate Technology Office, and has the company’s top management support in offering a full range of leading-edge technologies that are proven, mature and available today from all EADS divisions – including Airbus and Eurocopter. For partners, it is an excellent opportunity to gain added value with: Ø Access to new markets that are not yet leveraged Ø Improved performance of existing products by complementary technology Ø Availability of mature technologies, ready for application Ø Enablers for flawless introduction of new technologies Ø Reduction of development time Ø Introduction of innovative products & processes Ø Technologies that meet standards and regulations Ø Superior cost & performance
Status of the EADS Technology Licensing initiative - Formally launched in 2009 as a business activity within EADS - Licensing agreements worth more than € 10 million signed so far in areas that include: ° The production of composite and metallic parts, ° The application of advanced avionics data network, ° New technologies in aircraft cabin interiors & in-flight entertainment systems ° The development of inertial sensors and navigation systems. - Benefits from EADS’ role as one of the world’s most innovative companies: ° A portfolio of more than 7, 200 patents ° Covers state-of-the-art technologies in composites, production & manufacturing, communication infrastructure, security and eco-friendly techniques - More patents were filed by EADS in 2009 than any other aerospace company in the world
Making leading-edge technologies accessible • Smooth access and transfer of EADS Technology is enabled by: – Individual analysis of available technology and partner’s need – Support by the EADS Innovation Works research lab as required for technology transfer and application development – Unique protected IP rights – Access to industrialised technology, including supply chain support – Experienced facilitators for technology transfer – Supplementary know-how – Real-life demonstration – EADS expert team
Friction-stir welding using the EADS-developed Delta. N tool Juergen SILVANUS Expert New Joining Technologies, EADS Innovation Works – Metallic Technologies & Surface Engineering
Improving friction-stir welding with EADS’ Delta. N tool • Innovative friction-stir welding techniques and tools have been in development at EADS for the past 12 years • The new techniques were pursued by EADS to provide high-quality welding on thick welded sections (thicker than 6 mm. ) • The problem with applying friction stir welding on thick sections is the inhomogeneous heat distribution that occurs from the top side to the root side of the welded sheet or plate • The response: EADS’ second-generation Delta. N welding tool, with a stationary shoulder portion and a rotating welding pin. – The heat input introduced by this tool into the welded part is significantly reduced – The tool creates a nearly fully-symmetrical heat input throughout the welded section’s thickness
Advantages of friction-stir welding • Solid state welding process: No issues with liquid phase (pores, hot cracking) • High joint efficiency: Depending on alloy and temper, up to 100% possible also on artificially-aged alloys • High process load level: vertical as well as horizontal forces in KN range EADS’ Delta. N welding tool reduces the contra points and therefore opens new applications for the use of friction-stir welding. Compared to standard friction-stir welding process, the welded alloy’s remaining strength can be significantly higher, and distortion after welding is significantly reduced when the Delta. N welding tool is used.
The EADS Delta. N FSW tool concept: high revs on the pin, zero revs on the shoulder Plug-and-play-version: Individual-machine-mount-version:
Delta. N advantages: surface appearance – standard tool weld crown (side view)
Delta. N advantages: generating a superb smooth weld surface
Delta. N: dissimilar Joints of Al&Al for T-Joint welding of frame structures • T-Joint of Al-Li & 6 xxx and 7 xxx & 6 xxx
Delta. N industrialization: Robo. FSW by Delta. N – A 380 wing flap rib tailored welded blank • Tailored welded plate by part penetration welding t 1=200 mm to t 2=20 mm to reduce amount of milling time and volume mainly of cost intensive alloys Al-Li • An 8 X reduction in welding distortion by using Delta. N!
Delta. N industrialization: Robo. FSW by Delta. N – Aircraft window frame reinforcement • Robotic FSW by using Delta. N tool on similar weld of 2 xxx alloy • Delta. N reduces the vertical downward force by up to 50%
Delta. N industrialization: Robo. FSW by Delta. N –Wing flap track in Al-Li 2050 • Delta. N FSW on hollow box: Material section thickness is 10 mm. • Motivation for the use of Delta. N: Distortion reduction.
EADS’ Delta. N tool has fulfilled all of the expectations The Delta. N tool concept’s potential has been validated: o Reduction of the welding distortion by a factor of 8 (compared with a typical standard tool) o Reduction in vertical down force by a factor 2 (compared with a typical standard tool) o Simple – and therefore robust – design o Simplifies tool design optimization work by avoiding shoulder influences o Higher level of revolutions increases lifetime of the pin by reducing the lateral pin loads o Next to butt-joints of thickness from 0. 3 to 15 mm also suitable for T-Joints
Al. Mg. Sc sheet & Scalmalloy® New solutions for carefree and long-lasting high-performance structures and components for use in transportation, defense, aerospace & leisure products Frank Palm Senior Expert, Welded Structures & Processes, EADS Innovation Works
Motivation/Market Driver/ Environmental Needs of Scmodified Al. Mg-Alloys o Reduce weight & improved durability “Greener” performance o Improve protection against corrosion fatigue & stress corrosion cracking – a show-stopper for all high performance (aerospace) Al-alloy applications o Minimize VOCs and other hazardous agents for surface conditioning & protection, as currently mandatory for all high strength ( 415 MPa / 60 ksi) Al -alloys Al. Mg. Sc/Scalmalloy® is the solution (our answer) for: o High (specific) strength + exceptional high corrosion resistance o Robust manufacturing chains + low-cost production schemes o Highest material (micro structure) stability for “low carbon footprint” applications
Technology description for Al. Mg. Sc sheet material technology o Developed for any kind of sheet metal application (here Sc 0. 3 wt%) o Principal replacement of 2024 (but lower density 2, 66 2, 78 g/cm³, better HCF & fatigue crack growth (comparable to 2524) + high fracture toughness o No knock-down factor for application in corrosive environments - sea water suitable (AIMg. Sc sheet offers a reduction of 30 -50 percent in stress corrosion cracking when compared to 2 xxx, 2 xxx. Li and 7 xxx alloys!) o Easy to weld by arc or laser beam (no filler required !) o Enhanced thermal stability (no RT property degradation after temperature exposures 550 F/287°C)
Technology Status
Scalmalloy®: EADS’ second-generation Al. Mg. Sc material o Developed for high & very high strength extrusions (Sc 0. 3 x 1. 5 wt%) o Strength & density adaptable (> 100 ksi (690 MPa)/2. 68 – 2. 62 g/cm³) o Exceptional high fatigue properties (Kt 2. 3) (better than 2524) (no SCC) o Same positive manufacturing propensities like Al. Mg. Sc sheet material o Rapid solidification (powder) metallurgy o Maximum profile cross-section depends on billet size ( 10 inch (~ 250 mm) 3 inch² (~ 2000 mm²) secured, up to 15 – 18 inch possible) Scalmalloy® is a registered trademark of EADS
Scalmalloy® profile materials corrosion resistance Alternate immersion test (ASTM G 44) Scalmalloy® is a registered trademark of EADS
Technology Status/What is available ? • Al. Mg. Sc sheet technology – as well the related integrated creep forming manufacturing technology – is an EADS in-house development (with external partner), and is protected by a comprehensive patent portfolio • Scalmalloy® is an EADS in-house 2 nd generation Al. Mg. Sc profile material technology (with external partner), whose development started in 2002 • Al. Sc master alloy prices impairs more or less final (semi) product prices • Sheets and profiles can be manufactured on industrial scales on demand (no material on stock!) • Wrought material costs life cycle costs of Al. Mg. Sc high competitiveness due to exceptional durability and new high performance design options
Opportunities offered by EADS: partnering, licensing, franchising and/or collaboration o Licensing of technology on patent(s) and know-how o Manufacturing of material (or bonded, welded or riveted test components) on request (Structural components by Premium AEROTECH) o Al. Mg. Sc sheet material industrial scale o Scalmalloy® profiles semi industrial scale o Exploration and expanding of the Scalmalloy® material concept up to its limits (Engineering strength > 110 - 120 ksi 800 – 850 MPa, density < 2. 60 g/cm³) o Aleris Aluminum Koblenz Gmb. H is strategic partner as plate material supplier Furthermore, Al. Mg. Sc is an ongoing part of EADS/Airbus technology scenarios for future high performance and “green” aircraft structures
For additional information: See the feature story on Al. Mg. Sc Sheet & Scalmalloy® and friction-stir-welding using EADS-developed Delta. N Tools at: www. technologylicensing. eads. net …in the “Latest Technology Licensing News” section
Your contacts for the EADS Technology Licensing initiative: EADS - Dr. Peter Westphal, Senior Manager, Intellectual Property Strategy e-mail: Peter. Westphal@eads. net EADS Technology Licensing initiative marketing consultants - Dr. Michael Beyer, Chief Operating Officer, PATEV Consulting Group Gmb. H e-mail: Michael. Beyer@patev. de Tel: +49 (0) 162 2 90 18 09 - Philippe Fornies, Business Dev. & Licensing Manager, Avenium Consulting e-mail: philippe. fornies@avenium-consulting. com Tel: +33 (0) 4 38 78 98 82
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