Direct energy deposition for propulsion airframe : enabler for more integrated and cost-effective design.
Propulsion primary structures architectures are major structural elements carrying loads from engine to wing. They classically involve assembly of hard metal parts made from forgings and thick plates, through fasteners. The high loads transfer between parts are a key part of the design and drives architecture principles, from parts blanks size to manufacturing assembly processes and lay-out. These structures are experiencing a very constrained environment (temperatures, vibrations, fatigue and damage tolerances aspects).
After successful applications on less complex parts and less critical areas, recent achievements and progress in DED technology have allowed completely new architectures for medium term new developments. These architectures rely on a maximum integration of parts. This is allowing to delete most of the fastener assemblies, and to improve structure stability thanks to better integration of stiffening elements.
This is resulting in more efficient products and open the door to significant savings in terms of lead time reduction, cost and weight, while changing the current approach in several key domains : assembly steps and management of load paths for example.
This presentation will introduce the way the architecture can be adapted to DED ,maximizing the benefits of this technology. These new architectures are bringing new challenges in terms of justification and certification, on top of the design implications of DED. Consequences on the whole value chain, from procurement to manufacturing lines are also analyzed with a particular focus on machine, qualification and inspections, in strong interaction with the product definition.
This presentation will finally identify the remaining gaps to reach the necessary maturity for a serial application.
Stéphane Machado graduated from University of Technology of Compiègne (UTC) as mechanical engineer, specialized in industrial design. He began his career in 1997 as primary structure designer in propulsion area on A340-600 program, and then entered Airbus in 2000 where he occupied different operational positions in propulsion airframe engineering, , as structure and systems installations designer and team leader, head of engineering and airframe architect, both in development programs and in-service programs. In the last years he was acting as design skill leader in propulsion airframe domain, including an innovation catalyst role, and has been strongly involved in the deployment of hard metals additive manufacturing in primary and secondary structures design. He is currently design technical authority in the Airbus airframe center of competence, covering pylons and nacelles area, with a focus on new developments and new technologies introduction.
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