Thomas Körwien

Material-related Challenges for Maintaining and Developing Airframes for Sustainable Airpower

Abstract:

Materials, in particular material systems, are the very foundation of each aircraft. In military applications, performance and durability are key drivers. E.g. the C160 Transall transport aircraft has been in service since 1967 while being replaced by A400M now. This translates to roughly 50+ years of service life. For fighter aircraft the service life is similar. The material systems are subjected to multiple stresses during their lifetime ranging from environmental stresses to actual damages, e.g. ground operations or in-flight incidents like bird strikes or other ballistic threats. Maintenance and repair technology is a must to keep the fleet airborne. At the same time, the running production of aircraft is heavily impacted by legislation. The eradication of hazardous substances imposed by REACH such as CrIV poses a major challenge since multiple materials, in particular surface protection systems, are affected. Other substances are emerging, ranging from BPA, affecting composites, to PFAS, affecting e.g. sealants and lubricants. The substance replacements are also impacting new emerging programs and airpower capabilities such as Eurodrone and Future Combat Air System (FCAS) with its 6th generation fighter (New generation weapon system – NGWS) and drone systems. In particular, for NGWS durable low observability material systems of the airframe are key along with composite materials sustaining higher temperatures. Potential introduction into service is foreseen in the 204x, while prototypes are foreseen within this decade. With the war theatres raging in Ukraine and the Middle East conflicts are inching closer to Europe. This is driving scalability and affordability in building aircraft at the same time.
The challenges, in particular for military air systems are common for maintenance, operation, and development of new platforms. Even though the defense market is perceived as a relatively big industrial player the material demand is very specific in requirements, low in volume, long duration of programs and commitments, and long time to market. This makes the defense business for suppliers a potential niche rather than a mass market. While the supplier landscape poses challenges, so do the national defense budgets which put a certain strain also on the R&T as well as R&T efforts. Smart spending is key to wisely developing technologies while building up a strategic network with established and evolving / non-traditional suppliers. A vital key to this approach is funding schemes on the national as well as European levels like the European Defense Fund (EDF).
An overview will be given for the development of repair solutions for metallic as well as composite parts using additive and bonding technology. Examples will be presented to ensure continuous production of platforms such as e.g. Eurofighter and C295 in the wake of Reach-imposed substance replacements. Furthermore, challenges in the development of materials for low observability applications will be presented together with structural concepts and technology aiming for scalability.

Biography:

Thomas Körwien completed his undergraduate studies in Mechanical Engineering at TU Dresden from 1990 to 1996. He pursued his doctoral studies at Uni Bremen, focusing on Preform Technology for Infusion Processes, earning his PhD in 2002. Before this, he also completed a PhD program at Deutschen Zentrum für Luft- und Raumfahrt and EADS Deutschland GmbH, specializing in the same field, from 1998 to 2001.

Thomas Körwien commenced his professional journey as a Development Engineer at EADS Deutschland GmbH (now Airbus DS) in the Military Air Systems division, with a focus on Materials and Processes for Composites from 2001 to 2007. He then transitioned to General Electric Global Research, assuming the role of Lead Scientist at the Composite Manufacturing Lab from 2007 to 2010.

In 2010, Körwien joined Airbus Defence and Space, where he held various roles of increasing responsibility. He served as the Team Leader for the Polymer and Composite team and acted as an Expert in Composite Bonding until 2022. Concurrently, he took on the role of R&T Airbus Group Roadmap Leader for Bonding and Surface Technology from 2014 to the present.

Thomas Körwien’s commitment to advancing aerospace technologies led him to his current position as Senior Expert in Advanced Materials and Process Developments at Airbus Defence and Space’s Materials & Processes Department, a role he assumed in 2023.

With a robust background in engineering, coupled with extensive experience in composite materials and processes, Thomas Körwien continues to drive innovation in aerospace manufacturing, contributing significantly to the advancement of the industry.