High-Performance Composites

NOV 2014

High-Performance Composites is read by qualified composites industry professionals in the fields of continuous carbon fiber and other high-performance composites as well as the associated end-markets of aerospace, military, and automotive.

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N O V E M B E R 2 0 1 4 | 3 3 posite parts via lean manufacturing ap- proaches. The facility features automated capabilities including fber placement and automated tape laying machines. The key to Embraer's regional jet aspi- rations, however, is its E -jet family. Its frst- generation E -jets featured doors and other nonstructural parts made from compos- ite materials. Embraer announced the launch of its new E-Jets E2 commercial aircraft at the 2013 Paris Air Show. These second-generation jets reportedly will of- fer airlines a family of "leading-edge re- gional jets" with a capacity for 70 to 130 seats. Embraer foresees a demand for 6,400 jets of this size in the next 20 years. The family will comprise the E175-E2, E190-E2 , an d E195-E2 — updated and upgraded versions of its original E -jet trio. Although advanced technologies will be applied to engines, wings and avionics, the E-Jets E2 planes will provide airlines commonality with current E- Jets, yet are expected to yield double-digit reductions in fuel consumption, emissions, noise and maintenance costs. According to Em- braer, parts made with composite materi- als will include fight-control components (faps, ailerons, elevators, rudder, spoil- ers), landing gear doors, wing-fuselage fairings and radomes. However, Embraer decided not to use composites on the wing primary structure, after trade studies reportedly indicated that aluminum was the most cost-effective, low-risk choice. FACC AG (Ried im Innkreis, Switzer- land) is designing, building and will pro- vide support for the wing spoilers and ailerons for the E-Jets E2 . FACC estimates that revenue from the contract, said to extend for the lifetime of the program, could exceed $120 million (USD), de- pending on the sales of the aircraft. Struck in August of 2013, the contract marked a signifcant expansion of FACC's relationship with Embraer: Previously limited to the supply of products for air- craft interiors, FACC gained entry into Embraer's aerostructures (take HPC's FACC Plant Tour, beginning on p. 38). Installed in the wing trailing edge, above the faps, the spoilers number six per aircraft side. The aileron is attached to each wing's trailing edge. Both sys- tems are in design phase and will be tested and manufactured by the FACC Aerostructures division in Austria. The engineering Joint Defnition Phase (JDP) began in June 2013. Delivery of the frst parts is expected in frst quarter 2015. These moveable fight-control sur- faces will incorporate "innovative con- necting elements" and the fundamental spoiler and aileron functions will be in- tegrated into one ready-for-delivery unit. According to FACC, the result will be a vital element in Embraer's effort to give these next-generation aircraft an aero- dynamically advanced wing, reduce fuel burn and limit emissions. In June of this year, Embraer an- nounced that it had concluded the pre- liminary design review, and thus the Joint Defnition Phase (JDP), as well as the wind tunnel tests, on the E190-E2 jet. The next step in its development is the critical design review, when the prod- uct's maturity will be validated, opening the way for prototype production. Sched- uled to begin revenue service in 2019, the E195-E2 entered its Joint Defnition Phase in May this year. Concurrently, Embraer concluded concept studies for the E175-E2, which is expected to en- ter service in 2020, and commenced the preliminary studies as well as the aero- dynamic wind tunnel tests. The E175-E2 will have wings and engines that are op- timized for the aircraft's size, distinctly different from the confguration that was adopted for the other models. Although Embraer and Bombardier dominate this segment, they are no lon- ger alone in regional air space. The fol- lowing OEMs are vying for market share: ATR, an Alenia Aermacchi SpA (Vene- gono Superiore, Italy) and Airbus Group joint venture based in Toulouse, is rapidly gaining market share in the 50- to 70-seat range with its regional turboprops and claimed 61 percent of the sub-90 seat market at the end of 2012 (Figs. 4 and 5, p. 32). Filippo Bagnato, ATR CEO, foresees growth in the regional market due mainly to the development of new regional net- works in Southeast Asia and Latin Amer- ica. Growth will be augmented as aging turboprop feets are replaced in Europe and the U.S. "We estimate a global de- mand for some 3,300 turboprops within the next two decades," Bagnato says. ATR began using composites in the 1980s for wing faps, ailerons and some fairing panels on its original ATR42 , and designed and produced a full composite outer wingbox for its 1980s-version of the ATR72 . Typically, the company uses Kevlar aramid fbers for secondary North Coast Composites delivers the complete parts solution. For 35 years North Coast Tool & Mold has been an industry leader in the manufacture of molds for high performance composites. Y ISO9001-2000 AS9100B C o m p o s i t e s The Companies of North Coast North Coast Tool & Mold Corp. North Coast Composites, Inc. www.northcoastcomposites.com 216.398.8550

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