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Aeroplan Composites Repair Monitoring and Validation in Aeronautical Industry

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Copyright © TWI Ltd 2013 AeroPlan “Composites repair monitoring and validation Dissemination of innovations and latest achievements to key players of the aeronautical industry” September 2011 – February 2014 AeroPlan is a collaboration between: TWI Ltd. NATIONAL TECHNICAL UNIVERSITY OF ATHENS, LZH LASERZENTRUM HANNOVER E.V., FUNDACION TECNALIA RESEARCH & INNOVATION, GMI AERO SAS, INASCO - INTEGRATED AEROSPACE SCIENCES CORPORATION O.E. and EADS DEUTSCHLAND GMBH MRO Europe 2013 - Advanced Material Repair Technologies 24 September 2013, London Kamer Tuncbilek TWI www.aeroplanproject.eu
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Page 1: Aeroplan Composites Repair Monitoring and Validation in Aeronautical Industry

Copyright © TWI Ltd 2013

AeroPlan

“Composites repair monitoring and validation

Dissemination of innovations and latest

achievements to key players of the aeronautical

industry”

September 2011 – February 2014

AeroPlan is a collaboration between: TWI Ltd. NATIONAL TECHNICAL UNIVERSITY OF ATHENS, LZH LASERZENTRUM HANNOVER E.V.,

FUNDACION TECNALIA RESEARCH & INNOVATION, GMI AERO SAS, INASCO - INTEGRATED AEROSPACE SCIENCES CORPORATION O.E. and EADS DEUTSCHLAND GMBH

MRO Europe 2013 - Advanced Material Repair Technologies

24 September 2013, London

Kamer Tuncbilek TWI

www.aeroplanproject.eu

Page 2: Aeroplan Composites Repair Monitoring and Validation in Aeronautical Industry

Copyright © TWI Ltd 2013

Agenda

Introduction

AEROPLAN “Background” Projects

Questions & Answers

www.aeroplanproject.eu

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Page 3: Aeroplan Composites Repair Monitoring and Validation in Aeronautical Industry

Copyright © TWI Ltd 2013

• INTRODUCTION

www.aeroplanproject.eu 3

Page 4: Aeroplan Composites Repair Monitoring and Validation in Aeronautical Industry

Copyright © TWI Ltd 2013

The Need

The time from the generation of an innovation until its inclusion into a Structural Repair Manual (SRM)

Need for new technologies – for innovative repair and monitoring solutions to reduce operating costs

www.aeroplanproject.eu

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Page 5: Aeroplan Composites Repair Monitoring and Validation in Aeronautical Industry

Copyright © TWI Ltd 2013

AeroPlan Main Project Goal

The aim is

to introduce the foreground knowledge generated

under 10 EU funded research projects’

in repair and monitoring of metallic and composite

structures

to Aeronautical industry so that both existing aircrafts

and future designs can take benefit of the these

innovations.

www.aeroplanproject.eu

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Page 6: Aeroplan Composites Repair Monitoring and Validation in Aeronautical Industry

Copyright © TWI Ltd 2013

About AeroPlan

Beneficiary name Country Type

1 TWI Ltd (Coordinator) UK RTD

2 NTUA Greece RTD

3 LZH Germany RTD

4 Tecnalia Spain RTD

5 GMI France SME

6 Inasco Greece RTD

7 EADS Germany Industry

Start Date: 1 September 2011

End Date: 28 February 2014

AeroPlan project has received funding from the European Union's Seventh Framework Programme managed by REA

Research Executive Agency [FP7/2007-2013] under grant agreement no 285089.

www.aeroplanproject.eu

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Page 7: Aeroplan Composites Repair Monitoring and Validation in Aeronautical Industry

Copyright © TWI Ltd 2013

Projects

COMPRES - Composite Repair of Metallic Structure for Ageing Commercial Aircraft

SENARIO - Advanced Sensors and Novel Concepts for Intelligent and Reliable

Processing in Bonded Repairs

PLASER - Portable Laser system for the Surface Preparation of Composite Repairs

INDUCER - Induction Heating and Health Monitoring Solutions for Smart Aircraft

Maintenance Using Adapted Composite Patches

COMPAIR - Continuous Health Monitoring and Non-destructive Assessment of

Composites and Composite Repairs on Surface Transport Applications

IAPETUS - Innovative Repair of Aerospace Structures with Curing Optimization and Life

Cycle Monitoring Abilities

EXPECT - Examination of Practical Aspects of Innovative Bonded Composite Repair

Techniques

INDUCTOR - Induction Based Curing Tool for Optimized Heating of Composite Repairs

COMPARE - Comparative Evaluation of NDT techniques for High Quality Bonded

Composite Repairs

ADVANCED - Advanced Heating System and Control Mode for Homogeneous High

Temperature Curing of Large Composite Repairs

www.aeroplanproject.eu

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Page 8: Aeroplan Composites Repair Monitoring and Validation in Aeronautical Industry

Copyright © TWI Ltd 2013

Main Technical Issues

Addressed

Innovations related to bonded composite repairs:

Heating Issues (mode of heat generation [conduction – induction],

homogeneity etc.)

Surface preparation

NDT & Health monitoring of structures / repairs

Degree of cure monitoring

Design of composite to metal repairs

www.aeroplanproject.eu

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Page 9: Aeroplan Composites Repair Monitoring and Validation in Aeronautical Industry

Copyright © TWI Ltd 2013

• AEROPLAN

“BACKGROUND” PROJECTS

www.aeroplanproject.eu 9

Page 10: Aeroplan Composites Repair Monitoring and Validation in Aeronautical Industry

Copyright © TWI Ltd 2013

COMPRES

Project Acronym: COMPRES Period of Implementation: 1999 - 2002

Project Title: Composite Repair of Metallic Structure for Ageing Commercial Aircraft

Research Framework: FP5

Research Project Partners: HAI, IAI, ALENIA, OGMA, CYTEC, GMI, NTUA, DUT, DERA

Partners participating to AeroPlan: GMI, NTUA

Contribution of COMPRES innovations to AeroPlan: -Simulation, design, application and certification of bonded composite repairs to metallic aircraft structures -Surface preparation for metal to metal or metal to composite bonding -Heat transfer issues in composite repairs -Equipment and tooling for composite to composite and composite to metal repairs

www.aeroplanproject.eu

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Page 11: Aeroplan Composites Repair Monitoring and Validation in Aeronautical Industry

Copyright © TWI Ltd 2013

SENARIO

Project Acronym: SENARIO Period of Implementation: 2007-2010

Project Title: Advanced Sensors and Novel Concepts for Intelligent and Reliable Processing in Bonded Repairs

Research Framework: FP6

Research Project Partners: Inasco, GMI, NTUA, IAI, TAU, LZH, Inasmet, SENER BOMBARDIER, University of KHARKIV

Partners participating to AeroPlan: Inasco, GMI, NTUA, LZH, Inasmet

Contribution of innovations to AeroPlan: - Optical fibre development for repair monitoring - Dielectric sensors for monitoring of repair curing process

www.aeroplanproject.eu

aluminium substrate

M20 pre-preg

sensing mat21

heating blanket

vacuum bag

vacuum bag

perforated sheet

glass fibre breather

T/CT/C

wirewire

powerpower

control

T/C

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Page 12: Aeroplan Composites Repair Monitoring and Validation in Aeronautical Industry

Copyright © TWI Ltd 2013

Project Acronym: PLASER Period of Implementation: 2009-2012

Project Title: Portable Laser system for the Surface preparation of composite Repairs

Research Framework: EUROSTARS E!

Research Project Partners: GMI, LZH, CleanLaserSystems GmbH, NTUA

Partners participating to AeroPlan: GMI, LZH, NTUA

Contribution of innovations to AeroPlan: -Surface preparation of composite repair areas to be repaired using laser. -General composite surface treatment, drilling and processing issues.

PLASER

www.aeroplanproject.eu

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Page 13: Aeroplan Composites Repair Monitoring and Validation in Aeronautical Industry

Copyright © TWI Ltd 2013

Project Acronym: INDUCER Period of Implementation: 2009-2011

Project Title: Induction Heating and Health Monitoring Solutions for Smart Aircraft Maintenance Using Adapted Composite Patches

Research Framework: FP7

Research Project Partners: GMI, TWI, NTUA – ALENIA (Topic Manager)

Partners participating to AeroPlan: GMI, TWI, NTUA, ALENIA

Contribution of innovations to AeroPlan: -Induction heating solutions for curing composite repairs. -Thermal transfer and temperature homogeneity across repair issues. -Use of magnetostrictive sensors for health monitoring.

INDUCER

www.aeroplanproject.eu

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Page 14: Aeroplan Composites Repair Monitoring and Validation in Aeronautical Industry

Copyright © TWI Ltd 2013

Project Acronym: INDUCER Period of Implementation: 2009-2011

Project Title: Induction Heating and Health Monitoring Solutions for Smart Aircraft Maintenance Using Adapted Composite Patches

Research Framework: FP7

Research Project Partners: GMI, TWI, NTUA – ALENIA (Topic Manager)

Partners participating to AeroPlan: GMI, TWI, NTUA, ALENIA

Contribution of innovations to AeroPlan: -Induction heating solutions for curing composite repairs. -Thermal transfer and temperature homogeneity across repair issues. -Use of magnetostrictive sensors for health monitoring.

INDUCER

www.aeroplanproject.eu

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Page 15: Aeroplan Composites Repair Monitoring and Validation in Aeronautical Industry

Copyright © TWI Ltd 2013

Project Acronym: COMPAIR Period of Implementation: 2009 - 2011

Project Title: Continuous Health Monitoring and Non-Destructive Assessment of Composites and Composite Repairs on Surface Transport Applications.

Research Framework: FP7

Research Project Partners: TWI, KTU,VTT, Atoutville, G-Tronix, ENEA, Envirocoustics, Hexcel, KCC, CERETETH

Partners participating to AeroPlan: TWI

Contribution of innovations to AeroPlan: - Development of inspection and monitoring sensors (thermal, ultrasonic, mechanical) for the examination of aircraft structure composite materials.

Development of multi-axis robotic scanner for in-service

inspection of composite components

• Capability of carrying thermographic, U/S and AE equipment.

• Ability to place and orientate the NDT equipment with 6

degrees of freedom

• Ability to inspect curved samples

ComPair

www.aeroplanproject.eu

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Page 16: Aeroplan Composites Repair Monitoring and Validation in Aeronautical Industry

Copyright © TWI Ltd 2013

Project Acronym: IAPETUS Period of Implementation: 2009-2012

Project Title: Innovative Repair of Aerospace Structures with Curing Optimisation and Life Cycle Monitoring abilities

Research Framework: FP7

Research Project Partners: Tecnalia, PZL, HUNTSMAN, UoP, Inasco, DAHER, GMI, USFD, HAI, UoI

Partners participating to AeroPlan: TECNALIA, Inasco, GMI

Contribution of innovations to AeroPlan: -Induction heating solutions for curing of composite repairs -Thermal transfer and temperature homogeneity across repair issues -Application of CNT doped resin heating and health monitoring of repairs.

Aluminium

Composite

Induction Coil

Susceptor

IAPETUS

www.aeroplanproject.eu

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Page 17: Aeroplan Composites Repair Monitoring and Validation in Aeronautical Industry

Copyright © TWI Ltd 2013

Project Acronym: EXPECT Period of Implementation: 2010-2012

Project Title: Examination of Practical Aspects of Innovative Bonded Composite Repair Techniques

Research Framework: FP7

Research Project Partners: GMI, NTUA – Fraunhofer IFAM(Topic Manager)

Partners participating to AeroPlan: GMI, NTUA

Contribution of innovations to AeroPlan: -Innovations concerning surface treatment of composite repairs. -Practical issues concerning processing of composite repairs.

EXPECT

www.aeroplanproject.eu

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Page 18: Aeroplan Composites Repair Monitoring and Validation in Aeronautical Industry

Copyright © TWI Ltd 2013

Project Acronym: INDUCTOR Period of Implementation: 2010-2012

Project Title: Induction based Curing Tool for Optimised Heating of Composite Repairs

Research Framework: FP7

Research Project Partners: GMI, NTUA – Fraunhofer IFAM (Topic Manager)

Partners participating to AeroPlan: GMI, NTUA

Contribution of innovations to AeroPlan: -Induction heating solutions for curing of large composite repairs. -Thermal transfer and temperature homogeneity across repair issues.

INDUCTOR

www.aeroplanproject.eu

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Page 19: Aeroplan Composites Repair Monitoring and Validation in Aeronautical Industry

Copyright © TWI Ltd 2013

Project Acronym: COMPARE Period of Implementation: 2010-2012

Project Title: Comparative evaluation of NDT techniques for high-quality bonded composite repairs

Research Framework: FP7

Research Project Partners: TWI, GMI, NTUA – Fraunhofer IFAM(Topic Manager)

Partners participating to AeroPlan: TWI, GMI, NTUA

Contribution of innovations to AeroPlan: -Inspection and Quality Assurance of composite repairs -Non Destructive Testing of bonded composite repairs.

COMPARE

www.aeroplanproject.eu

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Page 20: Aeroplan Composites Repair Monitoring and Validation in Aeronautical Industry

Copyright © TWI Ltd 2013

ADVANCED

Project Acronym: ADVANCED Period of Implementation: 2011-2012

Project Title: Advanced heating system and control mode for homogeneous high temperature curing of large composite repairs

Research Framework: FP7

Research Project Partners: GMI, NTUA, Tecnalia – Aircelle (Topic Manager)

Partners participating to AeroPlan: GMI, NTUA, Tecnalia (subcontractor)

Contribution of innovations to AeroPlan: -18-zone, 48kW, 80 thermocouples heating device for very large composite repairs -Advanced thermal simulation of repair area to retrieve thermal signature and optimize thermal blankets design.

www.aeroplanproject.eu

• Development of Power Supply and Control unit for heating up to 18 heating zones for homogeneous heating of very large composite repairs (e.g. reversers) at 225oC +/-5oC

• Complete 48 KW prototype delivered and tested at industrial environment .

• Simultaneous data acquisition from eighty control & monitoring thermocouples.

• User MMI.

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Page 21: Aeroplan Composites Repair Monitoring and Validation in Aeronautical Industry

Copyright © TWI Ltd 2013

Thank you for your attention

www.aeroplanproject.eu

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