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Materials Day
“WERKSTOFFE FÜR TRANSPORT UND VERKEHR ”, 18th of May 2001, ETH Zürich, Switzerland

NEW ALUMINIUM ALLOYS AND FUSELAGE STRUCTURES IN AIRCRAFT DESIGN
Gerhard Tempus

EADS Airbus GmbH Bremen

Outline Outline
New Fuselage Structures:
→ Laser Beam Welding (LBW) → Friction Stir Welding (FSW) → Extruding

New Aluminium Aerospace Alloys:
→ Al-Mg-Si-Cu Alloy (AA6013) → Al-Mg-Sc-Alloy → Al-Mg-Li-Alloy (1424)

Dr. Tempus

Zurich_5

Blatt: 1

NEW FUSELAGE STRUCTURES NEW FUSELAGE STRUCTURES
Frame

Today
Differential Structures
STRINGER PROFILE VARNISH (Primer and Top Coat) EDGE SEALING SURFACE SEALING SKIN SHEET

Clip

Stringer Skin Sheet

Riveted

Tomorrow
Integral Fuselage Design

T-joint (Clip/Sheet)

Welded
(T-joint, Sheet/Stringer)
Dr. Tempus

Extruded
Zurich_5

T-joint (Stringer/Sheet)

Butt joint (Sheet/Sheet)
Blatt: 2

INTEGRAL STRUCTURES - Goals
Cost reduction max. 15 % Cost reduction max. 15 %

• High grade of automation • Reduced mass of material (joining elements, sealing) • Saving of manufacturing steps
Weight reduction max. 10 % Weight reduction max. 10 %

• Reduced mass of sealing • More freedom for design • Aluminium alloys with lower density
Corrosion-resistance improvement Corrosion-resistance improvement

• Free of gaps and crevices • No rivet holes
Dr. Tempus Zurich_5 Blatt: 3

LASER BEAM WELDING (LBW) Advantages Advantages

• • • • •

Narrow welding seam Low energy input per seam length affected zone Very high welding speed reduced distortion, reduced heat

Dr. Tempus

Zurich_5

Blatt: 4

LASER BEAM WELDING (LBW) – Cross-Section of T-joint

• Extruded stringer • Chemically milled sheet • Simultaneous welding from both sides

• Skin itself is not influenced by the laser beam welding process (HAZ)

Dr. Tempus

Zurich_5

Blatt: 5

LBW Pilot Equipment

max. welding speed 10 m/min.

X-axis Y-axis z-axis A-axis B-axis C-axis

6m 3m 0,9 m +/- 90° +/-

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