2008

Impact of Aircraft operations

on carbon brake condition

Prepared By :

Jean-Baptiste BRILLAUD
Engineer Braking and Steering Systems
Customer Services Engineering

Ref: SEEL2-2008-256067

Introduction
Feed back from field:

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

Adaptation of Operational procedures:

- Fuel savings,
- wear saving (brake, engine, reversers)
- airport regulations,
-
Potential detrimental effect to the brakes

Ref: SEEL2-2008-256067

2008

Page 2

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

Introduction

Ref: SEEL2-2008-256067
2008
Page 3

Agenda
Introduction

1. Main in-service issues:

Carbon brake wear
2. Carbon brake oxidation
3. Dragging brake
1.

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

2. Airbus recommendations
Conclusion

Ref: SEEL2-2008-256067

2008

Page 4

Agenda
Introduction

1. Main in-service issues:

Carbon brake wear
2. Carbon brake oxidation
3. Dragging brake
1.

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

2. Airbus recommendations
Conclusion

Ref: SEEL2-2008-256067

2008

Page 5

1. Main In-service issues

1.1. Carbon brake wear:

Complex physical process

In-service experience and tests identified two main
factors:
4

Number of brake applications

Less applications = less wear

Brake temperature

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

No linear relation between brake temperature and brake wear.

Ref: SEEL2-2008-256067

2008

Page 6

1. Main In-service issues contd

1.1. Carbon brake wear contd:
Impact of brake temperature on carbon brake wear
Messier - Bugatti
Honeywell-ALS
Goodrich

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

Wear
rate

80
Ref: SEEL2-2008-256067

150

250

315

Indicated temperature C
2008

500

Page 7

Agenda
Introduction

1. Main in-service issues:

Carbon brake wear
2. Carbon brake oxidation
3. Dragging brake
1.

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

2. Airbus recommendations
Conclusion

Ref: SEEL2-2008-256067

2008

Page 8

1. Main In-service issues contd

1.2. Carbon Oxidation:
General information on oxidation:
4

Degradation of carbon material

Carbon fiber delamination
Carbon discoloration
Loss of carbon mass

5% loss of mass = 25% loss of strength

Disc rupture
AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.

Causes:
High temperature: thermal oxidation
Chemical pollution (runway de-icing products): catalytic
oxidation

Ref: SEEL2-2008-256067

2008

Page 9

1. Main In-service issues contd

1.2. Carbon Oxidation - thermal
oxidation:
4

Due to elevated temperatures

Magnitude
Time of exposure / frequency

Homogeneously distributed
around the discs
4 More likely on center discs
AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.

NOTE: In case of high temperature,

possibility to definitely degrade
the anti-oxidation protection.

Ref: SEEL2-2008-256067

2008

Page 10

1. Main In-service issues contd

1.2. Carbon Oxidation - thermal
oxidation contd:
Operational practices potentially
leading to thermal oxidation:

No use of Thrust reversers

Airbus recommend MAX thrust

reversers

Landing in flap CONF 3

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

Airbus recommend CONF FULL

Autobrake overridden to take 1st
exit

Airbus recommend not to

override the autobrake

Continuous elevated temperatures = Oxidation

Ref: SEEL2-2008-256067

2008

Page 11

1. Main In-service issues contd

1.2. Carbon Oxidation - thermal oxidation contd:

Reverse
max
Flap Full
Reverse
Idle

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

Flap 3

Ref: SEEL2-2008-256067

Reverse
Max
Reverse
Idle

Auto-Brake Low

Auto-Brake Med

No Risk

Low risk

Low risk

Risk

No Risk

Low risk

Risk

High risk

2008

Page 12

1. Main In-service issues contd

1.2. Carbon Oxidation - catalytic oxidation:
Due to alkali elements (Potassium, Sodium)
4 Located mainly on stators
4 Localized on specific areas of the disc

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

Ref: SEEL2-2008-256067

2008

Page 13

1. Main In-service issues contd

1.2. Carbon Oxidation - catalytic oxidation contd:
4

Main reasons for catalytic oxidation:

Pollution ingested by carbon brakes during rolling phases
Ice/slush trapped in the brakes

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

Airbus recommendations:

Cover Wheels / brakes (as per AMM)

Ref: SEEL2-2008-256067

Remove ice from brake (as per AMM)

2008

Page 14

1. Main In-service issues contd

1.2. Carbon Oxidation - catalytic oxidation contd:
Phenomenon existing on all carbon brakes:
All brake manufacturers
4 All airframers
4 Increasing across the fleet
4

Recognized as an industry issue:

4

Society of Automotive Engineering (SAE) working group:

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

Co-chaired by Airbus, Boeing and KLM

Particpants include:

Brake manufacturers,
Operators,
De-icing products manufacturers

Refer to SAE presentation.

Ref: SEEL2-2008-256067

2008

Page 15

Agenda
Introduction

1. Main in-service issues:

Carbon brake wear
2. Carbon brake oxidation
3. Dragging brake
1.

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

2. Airbus recommendations
Conclusion

Ref: SEEL2-2008-256067

2008

Page 16

1. Main In-service issues contd

1.3. Dragging brake:
4

Permanent discs friction without pedal deflection.

Causes:
Loss of running clearance,
Seized piston(s)

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

Consequences:

Brakes elevated temperature

Brake unit damage (broken discs, cracked torque tube)
Thermal oxidation
Pistons on parking brake circuit cannot retract.

Ref: SEEL2-2008-256067

2008

Page 17

1. Main In-service issues contd

4

Investigations:
Loss of pistons running clearance:

Piston adjusters over extension further to thermal expansion of

the brake structure

Caused by prolonged parking brake application on hot brakes

Seized piston(s)

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

Loss of mechanical clearance

Caused by baked hydraulic fluid in the piston
4 Airbus recommendations:
Follow FCOM recommendations regarding parking brake
application.

Ref: SEEL2-2008-256067

2008

Page 18

1. Main In-service issues contd

BRAKE CONDITION ALTERED

BRAKE DRAGGING

THERMAL OXIDATION

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

ELEVATED
TEMPERATURES

OPERATIONAL
PROCEDURES

Ref: SEEL2-2008-256067

2008

Page 19

Agenda
Introduction

1. Main in-service issues:

Carbon brake wear
2. Carbon brake oxidation
3. Dragging brake
1.

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

2. Airbus recommendations
Conclusion

Ref: SEEL2-2008-256067

2008

Page 20

2. Airbus recommendations
Standard Operating Procedures (FCOM 3.03.XX)
4

At landing :
Ensure Safety:

SAFETY

Max Thrust reversers recommended

4 If airport restrictions, select Idle

Optimize carbon brake wear:

WEAR

OXIDATION

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

Autobrake,
Brake Cooling fans,
Parking brake
4

During Taxi:

WEAR

OPERATIONS

Do not ride the brakes,

Firm applications.

Ref: SEEL2-2008-256067

2008

Page 21

2. Airbus recommendations contd

Autobrake settings:
4

At landing:

WEAR

OXIDATION

When brake application is deemed necessary,

On short / unevenly contaminated R/W : LO or MED

On long and dry R/W : LO
Equivalent to one brake application
Brings brake temperature to appropriate range for taxi in.

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

!! Do not over-ride the autobrake !!

4

SAFETY

At take off:
Select MAX for safety reasons.

Ref: SEEL2-2008-256067

2008

Page 22

2. Airbus recommendations contd

Brake Cooling fans:
4

OPERATIONS

Taxi out:
Fans ON if temperature > 100C

Before Take Off:

If temperature >150C with fans ON, delay T/O
Fans OFF when temperature <150C

Taxi in:

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

Normal operations: Fans ON 5 minutes after landing or at gate

Short TAT, or temperature likely to exceed 500C: Fans ON
4

Parking:
Fans OFF if temperature < 100C

If installed: use them !

Ref: SEEL2-2008-256067

2008

Page 23

2. Airbus recommendations contd

Parking brake:

DRAG

OXIDATION

Prolonged parking brake application on hot brakes can be

detrimental to brakes
4 Brake temperature >300C (150C fans ON)
Release parking brake once shocks are in place
4

Brake temperature >500C (350C fans ON)

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

Avoid parking brake application, unless operationally

necessary.

Ref: SEEL2-2008-256067

2008

Page 24

2. Airbus recommendations contd

NOTE: BRAKES HOT ECAM Warning

to prevent fire in the Landing Gear bay in case of

hydraulic leakage when L/G are retracted.
4

Brake temperature = 300C (at the probe)

400C in the hottest region of the brake
< 480C (auto ignition temperature of hydraulic fluid).

FCOM : Delay take-off until warning extinguishes

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

Different criteria if brake fans are on

BRAKES HOT warning after landing is not abnormal

Ref: SEEL2-2008-256067

2008

Page 25

Agenda
Introduction

1. Main in-service issues:

Carbon brake wear
2. Carbon brake oxidation
3. Dragging brake
1.

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

2. Airbus recommendations
Conclusion

Ref: SEEL2-2008-256067

2008

Page 26

Conclusion
Airbus Standard Operating Procedures (SOP):
Ensure Safety
4 Best compromise between:
4

Operations
Cost

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

Airbus SOP adaptation may have detrimental impact on

brake condition.

BRAKING HAS A COST

Ref: SEEL2-2008-256067

2008

Page 27

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

Thank you

for your attention

Ref: SEEL2-2008-256067
2008
Page 28

Appendix
References:
4
4
4
4
4

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

FCOM 3.03.XX (SOP)

AMM 12-31-12 Ice and Snow Removal
SIL 32-123 (Carbon brake thermal oxidation)
SIL 32-124 (Carbon brake catalytic oxidation)
Airbus operational presentation: Airbus recommendations
for a proper operation of carbon brakes
SAE engineering report.

Ref: SEEL2-2008-256067

2008

Page 29

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

AIRBUS, its logo, A300, A310, A318, A319, A320, A321,

A330, A340, A350, A380, A400M are registered trademarks.

Ref: SEEL2-2008-256067

2008

Page 30