01 TCT-Stress Familiarization

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TM0500291

Transnational Composites TrainingMike StephensESACT

Composite Familiarization

For Training purposes only

Composite Stress - Familiarization - For Training purposes only- Page 2

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Table of contentsTable of contents

1- Introduction2- Fibre Material3- Fibre Form4- Matrix Material5- Composite Form6- Manufacturing Process7- Assembly


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11-- IntroductionIntroduction

General Definition :A complex material, such as wood orfiberglass, in which two or more distinct, structurally complementary substances, especially metals, ceramics, glasses, and polymers, combine to produce structural or functional properties not present in any individual component.

Today, when we speak of composite materials, or just "composites",

we are referring to the highly engineered combinations of polymer

resins and reinforcing materials such as glass/carbon fibers.


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CFRP Floor Beamsfor Upper Deck

CFRP Rear Pressure Bulkhead

CFRP Vertical Tail Plane

CFRP center wing box

CFRP Section 19CFRP Wing Ribs

CFRP J-Nose

CFRP Section 19.1

CFRP Horizontal Tail Plane

GLARE in Upper Fuselage

LBW, Lower Fuselage

CFRP Ailerons

CFRP Outer Flaps

CFRP Spoilers

Radome

Landing Gear Doors

Composites on A380



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VTP and rudder

HTP and elevator

Centre Wing Box

Fairings

Sponsons

Movables

Fairings

Cowlings

Wing box

LG doors

CFRP on A400M



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Metals Vs Composites Fibre Characteristics

Higher Strength Higher Stiffness No plasticity Lower strain levels Lower fracture energy

Resin Characteristics Lower strength Lower Stiffness


Glass fabric

Stre

ss N

/mm

2

500

1000

1500

2000

2500

Aluminium7075-T6

HS Carbon fabric

IM Carbon UD Tape

HS Carbon UD Tape

0.005 0.01 0.015 0.020.0

Strain


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Composites Vs Metals Structural Issues

Interlaminar/Through thickness failures

+Interlaminar shear

Through Thickness


FM

S


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Environmental effects (Heat / Moisture reduce Material Properties)



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Environmental effects (Heat / Moisture reduce Material Properties)


-1- Hole effect in tension after wet ageing

1

0.8

0.6

0.4

0.2

1.2

0

1

0.8

0.6

0.4

0.2

1.2

0

-2- Hole effect in compression after wet ageing

1

0.8

0.6

0.4

0.2

1.2

0

1.4

1

0.8

0.6

0.4

0.2

1.2

0

1.4

1

0.8

0.6

0.4

0.2

1.2

0

1.4


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Impact (Barely Visible Impact Damage - BVID)



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Notch Sensitivity different to metallics

METALLICS

Plastic deformation relives stress peaks

COMPOSITESStress peak behaviour different to metallics

High stress region



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t.GENERIC METHODS

Composite MetalLay -up to shape Machine

Bolt/Bond Bolt

Inspect

Composites Vs Metals Manufacturing

Methods

Defects (e.g Resin rich areas, inclusions, voids, incorrect ply lay-ups etc)

Tolerances > metals (Thickness Variations, springback, warpage)

Cost Material ~ 80-100% > metals

Assembly/Machining ~ 10 -15% > metals

In service (maintenance etc) ~ 30% < metals

Resin Rich Area

Spar flangeSpar flangeSparSpar

CoverCover

Angular variation Angular variation -- spring backspring back



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When deciding what material and structure to use, it is necessary to know/consider;

What are the options?

What are the most important characteristics?

What is the Airbus initial choice and what are the important issues to take into account during decision making?



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Fibre Material

Fibre Form

Matrix MaterialThermosetsCarbonGlass

AramidQuartz

Thermoplastics

NCFWoven pre- formUni directional Chopped strand

Manufacturing processes

Pre-Preg RTM RFI

Forming Pre-Preg.Pre impregnatedNCF Non crimped fabric

RTM Resin Transfer moulding

RFI.. Resin Film infusion

PolyesterPhenolicsBismalemidesCyanate EstersPolyimideEpoxies

Composite Form

LaminaLaminateSandwich

Assembly BondedBolted

Design Approach

22-- Fibre materialFibre material


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Carbon

Glass

Fibre Materials - Options



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Characteristics

Low cost

Low Density = 2.6g/cm3,

Moderate stiffness ~60% CF,

Good strength ~60-80% CF,

Fibre Materials - GlassE-Glass - Electronic glass High strength/ weight ratio Outstanding dielectric properties

Good fatigue

Good environmental resistance

Low compressive strength

S-Glass - High strength glass

Higher compressive and tensile strength whilst being less dense than E-Glass



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Characteristics Cost ~10-15 x glass Excellent balance of performance and price High/Very High Stiffness (cf Glass) High/Very High Strength (cf Glass) Very Low Density = 1.6g/cm3

Fibre Materials - Carbon

Examples ~ T800, AS4, HTA



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Fibre Material

Fibre Form


AramidBoron

Thermoplastics




Composite Form



Design Approach

Pre-Preg.Pre impregnated

NCF Non crimped fabric



33-- Fibre FormFibre Form

Pre-Preg RTM RFI

Forming


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UD (Unidirectional)

Woven

Non Crimp Fabric (NCF)

Chopped Strand (Mat)

Fibre Form - Options



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Characteristics High strength & stiffness (1-1) High compression stability Low drape capability Un-crimped fibres

2

2

1

1

Fibre Form - UD



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Characteristics Lower strength & stiffness Lower compression stability High drape capability Complex/double curvatures Crimped Fibres

2

21

1Wea

veWeft

Fibre Form - Woven



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Characteristics High cost (raw material) High deposition rate High tension strength/stiffness (1-1) Lower compression stability Slightly crimped fibres Good drape? Variability?

2

2

1

1

Fibre Form - (NCF)



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Important Issues Thickness (UD-0.1 to 0.25,Woven-0.2 to

0.35, NCF-.866)

Impact Resistance (UD


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Fibre Material

Fibre Form


AramidBoron

Thermoplastics




Composite Form



Design Approach





44-- Matrix MaterialMatrix Material

Pre-Preg RTM RFI

Forming


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Matrix Materials - OptionsThermoset Resins

Epoxies: most widely used, best properties for primary structures, principal resin type in current graphite production use.

Polyester & Phenolics: used in secondary structures, cabin interiors, primary with fibre glass

Bismalemides: good structural properties, high temperature resistance, alternative to epoxy, expensive

Polyimide: specially use for high temperature application

Thermoplastic Resins

Thermoplastics are used for parts with low tolerance range, they have good material health, good stability comparing to possible parameter variations and smooth aspect



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Polyester Low strength / weight ratio (boats/Cars)

Phenolics Low strength / weight ratio (interior dcor & electronics)

Good FST (fire, smoke and toxicity) properties

Bismalemides High temp, expensive, difficult to process (matrix microcracking)

Cyanate Esters Expensive, electrically transparent, low moisture absorb

Polyamide Very high temp, expensive Lower properties than epoxies

EpoxiesEpoxies Good resistance to chemical attack Adequate high temp properties Good secondary bond strength Can be formulated to meet a wide range of processing

Available asRoom temp epoxies (eg Araldite)Elevated temperature curing (pre preg)

Thermoset resins



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Characteristics Tg ~ Glass transition temperature, determines max operating temperature of material (from 100 to 150 degrees) depending on environment

Matrix Materials - Epoxy

Brittle glassy state

Tg

Liquid or rubbery state


340320280240140 300260220120 160 180 20040 60 80 100

Module G (N/mm2)

103

5.102

T300 / BSL 914

X X

12

1DRY

2WET

Temperature (C)95C 120C

0.50

0.30

0.40

0.20

0.10

T300-914 glass transition point graphic


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CharacteristicsTensile Strength 60-80 MPa Tensile Modulus 3000-4000 MPa Performance decrease by moisture pick-up and T Brittle Resistant to aggressive media (Skydrol, de-icing etc) Sensitive to UV => top coat required

Matrix Materials - Epoxy



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Fibre Material

Fibre Form


AramidBoron

Thermoplastics




Composite Form



Design Approach





55-- Composite FormComposite Form

Pre-Preg RTM RFI

Forming


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t.Composite Form - Lamina Characteristics

LAMINA = PLY OR LAYERFibre Matrix

Mechanical: High stiffness Low stiffness Thermal: Small (-ve ) Larger (+ve) Moisture: No change Swelling & shrinkage

Terminology Fibre Weight Fraction fwf = Wf /(Wf + Wm ) Fibre Volume Fraction fvf = Vf /(Vf + Vm) ~60% 5% Porosity Vp = 1 - (fv + fvm)Note: Vp < 1-2% required for a/c structural application

Vf altered during manufacturing by bleeding resin (improves Mechanical properties)

NomenclatureV = volume

W = weight

f=fraction

Subscripts

f = fibre

m = matrix

p = pores/voids



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0.2 0.4 0.6 Vf

E1 GN/m2

Em10

40

30

20

50

0.3 0.50.1

E.g. GF/PE

0.7

2

1

Assume compatibility of strains:

f = m = 1 E1 = Ef Vf + Em Vm

c = f vf + m vm

Composite Form - LaminaRule of Mixtures

Ef-Em



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Axis Orientation Lamina has material Axes 1 2 3 Laminate has axes x y z Orientate and define 1 2 3 with respect to x y z

x

y

z

312

2 1

21

21

Composite Form - Laminate DefinitionsLAMINATE = COMBINATION OF LAMINA

x

y

z

x

y

z

Individual Response Apparent Response (Black Metal Approach)

Analysis Approaches Individual fibre and matrix response Apparent homogeneous/orthotropic response (Average individual fibre/matrix response in laminate directions)



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Individual Lamina properties obtained from Material Qualification Data Sheets

f11,22,33T,C E11,22,33T,C f12 G12 etc

Apparent Material Properties approximated using

10% Rule

fxxT,C = P0 x f11T,C + P45 x 0.1 x f11T,C + P90 x 0.1 x f11T,C

Carpet Plots

Classical Laminate theory

Composite Form - Laminate Properties

NomenclatureP0 ~ % 0o fibres / 100

P45 ~ % 45o fibres / 100

P90 ~ % 90o fibres / 100



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Isotropic Material - Metals

Anisotropic Material - Composite

Composite Form - Laminate Properties Analysis Fundamentals

Failure defined by yielding

Constant stress across thickness

Failure defined by first ply failure

Variable stress across thickness



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Composite Form - Laminate Lay-up/Stacking Ply Guidelines % any one orientation ~ 10% 60 % max same orientation 4 plies max adjacent same orientation (depending on thickness) 45 degree angle change + - 45 on surface Balanced Symmetric

Tailoring as Required

0o DIRECTION PLIES IN SKIN TO REACT BENDING / DIRECT LOAD

45o / 135o DIRECTION IN SKIN TO REACT SHEAR

90o DIRECTION TO REACT BOLT BEARING, FUEL PRESSURE AND AERODYNAMIC SUCTION.



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Joint Guidelines Staggered Joints

Ply Drop Guidelines

P L YW I D T H

S T A R T P O I N T

FIBR

E D

IREC

TIO

N

STAG

GER

IND

EX 2

1 5 m m( N o m ' )

STAG

GER

IND

EX 1

STAG

GER

IND

EX 0

Composite Form - Laminate Lay-up/Stacking

Arrow Diamond

NA NA

11mmRamp16mmSkin: 1:20 Spanwise

1:10 Chordwise

Spar: as skin but may go up to 1:5

Rib: 1:20 but may go up to 1:5



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Composite Form - Laminate Lay-up/Stacking See example drawing

Layer No

Fibre orientation

Roll Orientation

Line No (Parts List)

Material

Stagger Index



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t.Composite Form SandwichSandwich concept provides very stiff and strong structures

They have high flexural stiffness and buckling strength.



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Composite Form - Sandwich Options & Characteristics



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t.Composite Form - AIRBUS most common choice

Important issues: Strength/Stiffness (Sandwich, Lamina) Cost (Sandwich, Lamina) Moisture Ingress (Sandwich) Availability (Sandwich, Lamina) Is it approved ? (Sandwich, Lamina) Definition of axes relative to laminate plate (Lay-up) Follow Lay-up/Stacking/Terminology rules (Lay-up/Stacking)

Lamina: UD Epoxy pre preg

Lay-up: Tailored to suit load direction

Sandwich: Nomex



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Fibre Material

Fibre Form


AramidBoron

Thermoplastics




Composite Form



Design Approach





66-- Manufacturing ProcessManufacturing Process

Pre-Preg RTM RFI

Forming


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Manufactured Component

Pre-preg Technology(e.g. HTP, VTP)

Resin film Technology Resin Film Infusion (RFI)

(e.g. Pressure Bulkhead)

Liquid resin Technology Resin Transfer Moulding (RTM)

(e.g. CWB Stiffeners, VTP Ribs)

Liquid Resin Infusion (LRI)(e.g Shorts TANGO Front Spar)

Manufacturing Process - Options



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Generic Method Cut Plies and Lay-up

By Hand (Cheap but time consuming) Automatic cutting and tape lay (ATL)

Forming Pre - forming over mould tool Hot Rolled

Curing (Autoclave) Inspection, Machining, Cleaning, Painting

Characteristics Material cost high Fair quality and accuracy

Manufacturing Process - Pre Preg Technology

Pre-heated Flat composite sheet

Final roll controlling finished profile

Second set of rollers establishing blade

First set of rollers to initiate profile



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Generic Method Semi-Preg and Cut Plies

Semi-preg to hold dry fibres together Lay-up and Forming

Hand Lay-up semi-preg plies onto forming tool Transfer pre-form to cure tool

Curing and Infusion (Autoclave) Full infusion during curing (Heat and Pressure)

Inspection, Machining, Cleaning, Painting

Characteristics Fair quality Low Material Cost Time efficient

Manufacturing Process - RFI



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Manufacturing Process - RTMGeneric Method Cut Plies (Dry fibres + binder) Lay-up and Forming

Hand Lay-up onto forming tool (multi-surface) Hot de-bulk creating pre-form Transfer to cure tool

Injection and curing Liquid resin injection into pre-form Integrally heated tool for curing


Characteristics High tooling cost (High Volume Process) Low Material Cost Very good Tolerance on all faces



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Generic Method Cut Plies (dry fibres + binder) Lay-up and Forming

Hand Lay-up onto forming tool (single surface) Hot de-bulk creating pre-formTransfer to cure tool

Infusion and curing Vacuum Liquid resin into pre-form Ensure flow distribution media for resin


Characteristics Lowest quality Lowest cost

Manufacturing Process - LRI



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edge bars

vacuum bagbreather blanket

caul plate

Rubber mandrels

component

release film

Inflatable mandrels

Solid mandrels

Issues Fundamental in achieving high accuracy parts Component scale and complexity Manufacturing process technology Balance between cost, accuracy, thermal massOptions Steel - high accuracy for small part Aluminum - high CTE, low cost Invar - highest accuracy, cost and durability Composite - lower thermal mass, shorter life

Manufacturing Process - Tooling Concept66-- Manufacturing ProcessManufacturing Process


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t.Manufacturing Process - Defects/Inspection

Manufacturing DefectsDelaminations Broken or cut fibres Inclusions (razor blades, release film etc) Incorrect ply lay-up Variations in Vf (resin rich areas, dry patches etc) Voids/porosity Handling/machining damageInspection - Non-Destructive Test (NDT) 100% inspection for CFRP parts after manufacture Ultrasonic Radiography, X ray Acoustography (coin tap also) Shearography



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Manufacturing Process: AIRBUS most common choice

Important issues: Strength/Stiffness properties (material)

Increase Vf of material (process) ?

Cost (material/process/tooling) Accuracy/Tolerance/Quality (process/tooling) Temperature (Tg of resin) Thermal Mass (Tooling) Non Recurring Costs (Autoclave/Facilities etc)



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Fibre Material

Fibre Form


AramidBoron

Thermoplastics




Composite Form



Design Approach





77-- AssemblyAssembly

Pre-Preg RTM RFI

Forming


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Assembly - Joint IssuesBonded vs Bolted Stiffness (bonded > bolted) Aerodynamic profile (bonded > bolted) Assembly (bolted > bonded) Weight (bonded > bolted) Inspection (bolted > bonded)

Bolted Joints Galvanic corrosion (Titanium Bolt/Glass) Thermal coefficient mismatch Failure issues around holes SealingFailure mode sensitive to out of plane loadingBonded Joints Surface preparation Operating Temperature Failure issues at bond joint Lightening strike considerationHighly sensitive to out of plane loading G. Peel/Disbond



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2.5d

* For Fuel Seal

5d4d-6d typ

4d-6d (typ)Primary

Load

Direction

3d5d*

d = next nominal/first oversize(depending on repair philosophy)

Bolted Joints GuidelinesAssembly - Bolting

8 Fasteners

6 Fasteners7 Fasteners

5 Fasteners4 Fasteners

2 Fasteners

3 Fasteners

0.0

0.1

0.2

0.3

0.4

0.5

Fastener LoadApplied Load

Bolted Joints Loading Distributions - Double Row



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Overlap length (for bonded repair)

maybe lamina37.5o

Assembly - BondingBonded Joints Options

1

2

CO CURE

CO BONDComponent 1 curedComponent 2 un-curedBonded together during cure of cure cycle of component 2

Component 1 un-curedComponent 2 un-curedCured together effectively creating a single part

Component 1 curedComponent 2 curedBonded together with separate bonding operation

SECONDARY BOND

1

2

12

Adhesive

Adhesive

Bonded Joints GuidelinesFor Secondary bonds only



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Issues Shimming required to fill gaps between interface surfaces, restore smoothness and avoid assembly stresses

Liquid shim : between 0.4mm and 0.7mm upper limit (harmonization ongoing-depends on design)Solid Shim > 0.5mm (validated by tests :static, fatigue)

Carbon dust extraction essential during drilling procedure In-jig access to be considered for additional jig features

Shimming tooling Bonding tooling

Thermal mismatch between metallic jig and composite components

Assembly - Tolerances/Heat and Safety/Jigs

A340-600 Horizontal Tail Plane



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Assembly: AIRBUS most common choice

Important issues: Strength/Stiffness (Joints) Weight (Joints) Cost (Joints/Jig/Shimming) Repair/Inspection (Joints) Tolerance (Jig/Shimming) Thermal Mass (Jig) Health and Safety (Joints/Jig) Access (Jig)



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t.Summary: AIRBUS most common choice

Important issues: Strength/Stiffness Weight Cost Certification

Fibre: Carbon HS or IM

Resin: Epoxy, phenolics

Form: UD Pre-preg

Manufacturing Process: Pre-preg ATL

Joints: Bolted (Bonded if co-cured)

Shim: aim for no shim, liquid then solid/liquid if needed



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Approval & Authoring TeamApproval & Authoring Team

Mike StephensA-F

NameNatCosFunction

AUTHORS

Signed electronically 27/06/2006Chantal FualdesHead of ESAC

SignatureName Domain

APPROVAL


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Record of RevisionsRecord of Revisions

For general queries or information contact:

Airbus Documentation OfficeAirbus SAS

31707 Blagnac CEDEXFrance

Tel: +33 [0] 561 93 49 93Fax: +33 [0] 561 93 27 44

General update2

General update3

4

1

Issue

RECORD OF REVISIONS

General update

Creation

Summary and reasons for changesDate


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AIRBUS S.A.S. 2006. All rights reserved. Confidential and proprietary document.

This document and all information contained herein is the sole property of AIRBUS S.A.S.. No intellectual property rights are granted by the delivery of this document or the disclosure of its content. This document shall not be reproduced or disclosed to a third party without the express written consent of AIRBUS S.A.S. This document and its content shall not be used for any purpose other than that for which it is supplied.

The statements made herein do not constitute an offer. They are based on the mentioned assumptions and are expressed in good faith. Where the supporting grounds for these statements are not shown, AIRBUS S.A.S. will be pleased to explain the basis thereof.

AIRBUS, its logo, A300, A310, A318, A319, A320, A321, A330, A340, A350, A380, A400M are registered trademarks.

01 TCT-Stress Familiarization

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Transcript of 01 TCT-Stress Familiarization