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May 5, 2021 at 5:53 PMLufthansa Cargo will equip all Boeing 777 freighters with ‘AeroSHARK’ starting in 2022. This innovative surface technology, a joint project of Lufthansa Technik and BASF, improves fuel efficiency and helps achieve sustainability goals. The technology is inspired by the fine structure of shark skin.
(Frankfurt) The lower the drag resistance of an aircraft in the air, the lower the fuel consumption. Following nature’s example, the aviation industry has long been researching ways to reduce air resistance. In a joint project, Lufthansa Technik and BASF have made a breakthrough. ‘AeroSHARK’, a surface film modeled after the fine structure of shark skin, is set to be used across the entire freighter fleet of Lufthansa Cargo starting in early 2022, making the aircraft even more economical and environmentally friendly.
The surface structure, consisting of approximately 50-micrometer riblets, mimics the properties of shark skin and optimizes aerodynamics at flow-relevant points on the aircraft. This results in overall lower fuel consumption. For the ten freighter aircraft of the Boeing 777F type in the Lufthansa Cargo fleet, Lufthansa Technik expects a drag reduction of more than one percent. This could lead to annual savings of around 3,700 tons of kerosene and nearly 11,700 tons of CO2 emissions. When extrapolated to the entire Lufthansa Cargo fleet, the annual CO2 savings correspond to 48 individual freighter flights from Frankfurt to Shanghai.
Strong Partners with Great Innovative Power
“Responsibility for the environment and society is a central strategic issue for us,” says Christina Foerster, board member of Deutsche Lufthansa AG and responsible for sustainability. “We have always played a leading role in the introduction of environmentally friendly technologies. The new sharkskin technology for aircraft demonstrates what strong partners with great innovative power can achieve together for the environment. This supports us in our goal of becoming climate-neutral by 2050.”
“The aviation industry faces similar challenges as the chemical industry: despite a high energy demand, continuous progress must be made in climate protection. Our close collaboration and successful combination of our expertise in surface design and aerodynamics has now brought us a significant step forward. This is an outstanding example of lived sustainability, achieved through collaborative efforts and innovative technologies,” says Dr. Markus Kamieth, board member of BASF.
Investments Reinforce Commitment to Sustainability
“We are proud to be able to operate our entire freighter fleet even more efficiently in the future thanks to sharkskin technology and to further reduce the CO2 footprint of our modern fleet. Our investments in the introduction of ‘AeroSHARK’ at Lufthansa Cargo reaffirm our commitment to the United Nations sustainability goal ‘Climate Action’,” explains Dorothea von Boxberg, CEO of Lufthansa Cargo.
Lufthansa Technik is responsible for the specification of the material, the aviation regulatory approval, and the implementation of the aircraft modifications in cooperation with BASF, which will take place during regular maintenance downtime. With decades of expertise as an approved aviation development company, the firm will obtain a necessary Supplemental Type Certificate (STC) for the B777F from the European Union Aviation Safety Agency (EASA).
“We have always utilized our extensive expertise as a global leader in aircraft technical services to contribute to reducing the ecological footprint of our industry. We can extract significant savings potential from all generations of aircraft,” explains Dr. Johannes Bußmann, CEO of Lufthansa Technik AG. “Therefore, I am very proud that we will soon be able to transfer the positive findings from the practical test into series production with Lufthansa Cargo. The exceptionally constructive collaboration with BASF is also the best example of cross-industry cooperation in the service of aviation sustainability.”
Focus on Durability
The Coatings division of BASF develops innovative, functional films in its ‘Beyond Paint Solutions’ unit – such as riblet surfaces. Together with Lufthansa Technik, a solution has been realized that meets the strict requirements of aviation. In aviation applications, exterior surfaces are exposed to strong UV radiation as well as temperature and pressure fluctuations at high altitudes. Therefore, BASF has focused on extreme durability and weather resistance in its development. Key criteria for application in aviation operations include easy application and handling, as well as uncomplicated repairability, for which a tailored concept has been developed.
“As surface experts, we implement customized solutions for our customers. With the innovative sharkskin technology, we support Lufthansa in achieving its sustainability goals and making aviation a bit more environmentally friendly,” says Dirk Bremm, head of the BASF Coatings division and responsible for functional films in this position.
Photo: © Lufthansa Cargo
