This TMC Brake project reviews the market opportunity and technology needs for silicon carbide fibre reinforced titanium matrix composite aircraft brake drive keys.
Brake drive keys are installed in aircraft wheels to transfer loads between the carbon-carbon brake disks and the wheel. Drive keys are currently made from steel or nickel alloys as they operate at temperatures of 500oC to 600oC in normal landings and a 1000oC if an aircraft aborts a take off.
TISICS develops and produces silicon carbide (SiC) monofilament metal composite technology for titanium and aluminium matrix components. SiC reinforced titanium (TMC) increases tensile strength by up to 50% and stiffness by 100%. Compression strength >2.5GPa which is higher than landing gear steel. The fibre also provides an increase in operating temperature which allows the parts to operate above 500oC.
TISICS has international patents for TMC splines for drive keys. The patent relates to work carried out using older versions of the technology. This project aims to update the performance information and the processing knowledge in order to determine a development route to an economic high volume production process.
The project focuses on a relatively simple component to initiate a new material into civil aerospace use. Reducing aircraft weight has a direct impact on fuel consumption and hence aircraft emissions. Carbon fibre has demonstrated a higher value material can displace common materials where the benefit is shown. CFRP was used in simple fairings before large structures. On average weight reduction leads to a 4% reduction in fuel burn over a year, and 1kg less fuel results in 3.15kg less CO2 emissions.
This project has demonstrated the potential for weight reduction through the use of TMC in brake drive keys. Weight reductions in the region of 100kg-110kg per Airbus A380 is possible with SiC-TMC Drive keys
This brake component technology is applicable to all large long haul aircraft. The technology will need further development to achieve high volume production rates to meet demand and the necessary production economics. This work would form a case for a Horizon 2020 Phase 2 development programme to achieve product ready technology. Once a supply chain and industry qualification is established on relatively simple brake components, titanium composite use will extend to landing gear, engines and structural parts leading to higher efficiency aircraft and a robust European titanium composite industry.
The overall objective was to assess the viability of titanium matrix composites for aircraft brake drive keys. The potential has been demonstrated to TISICS. The Commercial case is based around the Airbus A380 due to the high number of brakes. Weight reduction will lead to reductions in fuel burn and hence CO2 emissions. Growth of the titanium composite technology will lead to job creation and further opportunities for light weight materials for higher efficiency systems.
