Boeing CLEEN II Briefing

Boeing CLEEN II program update

Consortium Public Session Craig Wilsey, Jennifer Kolden May 5, 2021

Boeing Overview, Sustainability

Recap of Boeing’s CLEEN program transitions

Boeing CLEEN II Technologies

Aft Fan Acoustics Project

Sustainability Strategy CLEEN and ecoDemonstrator programs are Key Elements in Boeing’s Sustainability Portfolio

Boeing Overview, Sustainability

Recap of Boeing’s CLEEN program transitions

Boeing CLEEN II Technologies

Aft Fan Acoustics Project

ATE CMC Nozzle Short Inlet (RR Contract) Flight Test Flight Test Ground Test Support to Short Inlet Flight Test

2010 2011 2012 2013 2014 2015 2016 2017 2018 2019 2020 2021 2022 2023 2024 2025

Alt Fuels CMC Nozzle SEW SEW Fan Duct Test Report* Ground Test NIAR Rig Large Acoustics Test Notch Flight Test Test

* Supported 2012 ASTM D7566 Specification

for “drop-in” blends up to 50% 8

Tested on 2012 ecoDemonstrator

Boeing developed and demonstrated a prototype Wing Adaptive Trailing Edge (ATE) system capable of tailoring SMA System Design 777X Baseline Adv Manufacturing and Supply Chain Architecture Smart Shims and wing performance to reduce noise and fuel burn at Standard design Static Trailing Edge related design different flight regimes. tools and actuators processes, tools In 2012, Boeing demonstrated that the ATE system Environmental Cost Reduction Future Product provides up to a 2 percent reduction in aircraft fuel Control Systems EE Low / High Speed Smart VGs, burn and reduces aircraft noise levels by 1.7 decibels Cooling Shut Off Wind Tunnel Models H/L Noise reduction, (dBs). Valve Advanced wing

When used fleet-wide in the United States, a 2 percent Defense and Space Applications reduction relative to 2009 fuel usage could save 340 Adaptive Rotor blades Satellite Thermal Switches million gallons of fuel with operating cost savings of V-22 replacement actuators, valves Proprietary programs $1.2 billion. ECS valves Folding wings Tech Forward Applications Forward Tech

Tested on 2014 ecoDemonstrator

Boeing designed, fabricated and demonstrated an acoustic 787, 777X Programs Propulsion System ceramic matrix composite (CMC) primary exhaust system. Trades Future Products Propulsion System & Heat The advanced material system enables lighter, quieter, Shield trade studies more efficient engines, flight tested on the Boeing 787 ecoDemonstrator. Engine Company Learnings Collaboration for engine applications: This technology can withstand higher temperatures, is Analysis, inspection and repair made of lighter weight material, and lowers fuel consumption and can also accommodate acoustic treatments that reduce community noise. Defense and Space Applications

The CMC nozzle reduces fuel burn by up to 1 percent and • High Mach Vehicles –Hot structural components provides up to a 2.3 dB noise reduction relative to a • Rotorcraft exhaust systems • Space Plane Control Surface Structure comparable twin-aisle baseline aircraft equipped with Applications Forward Tech • Chinook metallic nozzle. 10

Boeing Overview, Sustainability

Recap of Boeing’s CLEEN program transitions

Boeing CLEEN II Technologies

Aft Fan Acoustics Project

Structurally Efficient Wing (SEW) • Upper Skin - BMS8-276 13” - Non -traditional laminates - Co-bonded Stringers 50” • Vent Stringers - Braided carbon fiber - Resin infused - Co-bonded to upper skin Objective • Blade Stringers • Lower Skin - Stitched - Advanced IM+ - Resin infused - Non-traditional laminates Demonstrate 14 wing structure - Co-bonded to upper skin • Spars - Integral Stringers technologies that improve structural - Advanced IM+ • Ribs (fuel and dry bay) 5” - Al-Cu-Li efficiency and reduce weight • Ribs (dry bay) through a structural ground test - Stamped thermoplastic CFRP 29” • Rib (dry bay) - Sine -wave - Braided - Resin infused

SEW Technologies Goal Impact Benefits and Application

• Advancing manufacturing technologies • Advanced pre-preg composites • Resin-infused stitched blade stringers • Resin-infused hat stringers Reduce Block Fuel up to 3.5% by saving • Advanced alloy metallic ribs Fuel Burn reduction up to 28% [wing] structural weight • Resin-infused sine wave rib relative to 777-200 baseline. • Stamped thermoplastic ribs • Non-Traditional Laminates • Co-Bonded Stringers 12

Objective Demonstrate aerodynamic performance of a short inlet in crosswind through ground testing

Compact Nacelle Technologies Goal Impact Benefits and Application

Reduce Block Fuel up to 1.0% through weight and Drag reductions relative to a Short Inlet Fuel Burn Reduction conventional length inlet. Enable next generation engines for Boeing’s next new product

Puget Sound BCW - Winnipeg, CAN •BCA - Tech Insertion and •CN - Face sheet processing transition to Products PLC (Derby, UK) •SEW Structural Analysis •T1000 Integration •Fan Aerodynamics •SEW Fab, Assembly, repair Janicki Industries • CN Propulsion Integration •SEW Composite Tooling •CN Aerodynamics CFM/Safran •CN Acoustic Design & Analysis •CN - Fan case liner • CN Test Planning & Safe to Fly Analysis St. Louis, MO •CN Flight Test •Finance, Contracts •SEW Technical Oversight •SEW Test Planning •SEW Stamped Thermoplastics FAA CLEEN Program Office Wichita State University •SEW Element & •NIAR Structural Testing Subcomponent fab NASA LaRC •SEW Structural Analysis •CDTR Coupon Testing •CN Acoustic Analysis • Inlet w/MDOF Liner •CN Metal Machining Charleston, SC Huntington Beach •SEW Stitched RFI, Stringer Fab •Program Leadership Huntsville, AL •CN - Short Inlet Design, Build •CN Structural Analysis •Finance • CN – TR modifications - Design •SEW Stitched RFI •CN Metal Finishing • CN – Composite Face sheet fabrication • CN - TR Integration & Assembly Georgia Tech - ASDL •System Level Modeling

NASA Stennis Facility BR&T Australia Short Inlet Ground Test • •Resin Infusion Tech Support Boeing Sites, Team • External Collaborations & Suppliers Copyright © 2021 Boeing. All rights reserved. 14 CLEEN II Technology Demonstrations Agenda

Boeing Overview, Sustainability

Recap of Boeing’s CLEEN program transitions

Boeing CLEEN II Technologies

Aft Fan Acoustics Project

Acoustic Objective Gloves Demonstrate noise reduction improvements to a thrust reverser duct through flight demonstration Treated Blocker Doors Thrust Reverser Inner Wall

Compact Nacelle Technologies Goal Impact Benefits and Application

Acoustic improvements to Thrust 0.4 to 1.2 EPNdB for new aircraft Reverser Aft Fan Duct: Community Noise applications • Increased acoustically treated area Reduction 0.2 to 0.6 EPNdB as retrofit potential for • Advanced acoustic liner some existing models.

Upper Bifurcation (2) (1x per side)

FWD

Blocker Doors Lower Bifurcation (10) (5x per side) (2) (1x per side)

Silhouette of Nacelle shown for reference 17

Region Improvement

Increased acoustic yield Bifurcations Maximized full-depth treatment

Increased acoustic yield Blocker Doors Advanced treatment concept

Experimental TR incorporates advanced acoustic treatment concepts

Region Production Experimental

Bifurcations 5% 60%

Inner Wall 60% 70% CLEEN II Experimental

Blocker Doors 0% 70%

TOTAL 50% 70%

Experimental TR has significantly more acoustic area than Production

Pre-Test Prediction Exceeds CLEEN II Objectives on Current Aircraft

. Leverage existing hardware . An existing Thrust Reverser from original test program is being modified for ecoDemonstrator flight test . TR locked out for ease of manufacture . All hardware modifications designed and built by Boeing . Collect community noise acoustic flyover data at Moses Lake, WA Grant County Airport. . Ground based acoustic instrumentation . Ground based microphones and 4-ft microphones to be distributed under the flight path . Ground based phased array . Aircraft level attenuation measurements to be projected to 2025+ EIS engine technologies using analytical predictions

Since last Consortium:  Hardware fabrication complete  Acoustic Impedance testing complete  Flight test installation engineering released  Flight test requirements and planning complete  Completed Safe-to-Fly assessments, analyses, and documentation

Fairing Body w/machined cells

Fairing Facesheet Fairing Assembly

Lower Fairing Body Back side of Blocker Door

Lower Fairing Assembly

Last bolt being torqued…

And on their way to Seattle…

. Hardware on Dock @ Boeing Field – May . ecoDemonstrator 737 Max 9 Flight Test – June-July . Final Reports – Q4 ‘21

. Company transforming after COVID, expanded drive for sustainability

. Strong, continued partnership with ecoDemonstrator program

. Successful crosswind ground test of Short Inlet in 2018, achieving TRL6

. Successful rig tests of SEW technologies in 2019 - 2020, achieving TRL6

. Program replanned and on track after delay

. T he T/R Duct Acoustics flight demonstration in June/July will achieve TRL7

Photo: Bob Ferguson

Copyright © 2021 Boeing. All rights reserved. 28 Acronyms ATE Adaptive Trailing Edge BCA Boeing Commercial Airplanes BCW Boeing Canada Winnipeg CDTR Curved Duct Test Rig CFRP Composite Fiber Reinforced Plastic CMC Ceramic Matrix Composite CN Compact Nacelle dB Decibel DDR Detailed Design Review ECS Environmental Control System EIS Entry Into Service EPNdB Effective Perceived Noise, Decibels H/L High Lift H/W Hardware MDOF Multiple Degree of Freedom NAMS Nautical Air Miles Survey NIAR National Institute for Aviation Research PDR Preliminary Design Review PoP Period of Performance RR Rolls-Royce RFI Resin Film Infusion S2F Safe to Fly SEW Structurally Efficient Wing T/R, TR Thrust Reverser VG Vortex Generator