1This document is the property of EADS CCR ; no part of it shall be reproduced or transmitted without the express prior written authorisation of EADS CCR, and its contents shall not be disclosed. © - EADS CCR - 2006
FP6 DINAMIT FP6 DINAMIT ProgramProgram -P.LEFEBUREP.LEFEBURE--EADSEADS CCRCCR-- AerodaysAerodays ViennaVienna 20062006
by
Patrice LEFEBURE _ EADS CCR(patrice.lefebure@ eads.net)
&
C. QUINQUIS _ A-F, S. KASCHEL _ A-D, R. AVILA DOMINGUEZ _ A-E, M. BUCKLEY _ A-UK, C. COIFFIER-COLAS _ D. Av, H. SIBOIS _ Eurocopter, G. LAMPEAS _ LTSM Patras, B. PEREZ Magallon _ CIDAUT, U. SPELZ _ ACM, H. RUCKDÄSCHEL LPW Bayreuth, J. LEE _ I.C, R. SCHLEDJEWSKI _ IVW Kaiserslautern.
DDevelopmentevelopment and and ININnovationnovationfor for AAdvanced dvanced MManufacturanufacturIIng ng
of of TThermoplasticshermoplastics
Mid-Term Achievements of work
2This document is the property of EADS CCR ; no part of it shall be reproduced or transmitted without the express prior written authorisation of EADS CCR, and its contents shall not be disclosed. © - EADS CCR - 2006
FP6 DINAMIT FP6 DINAMIT ProgramProgram -P.LEFEBUREP.LEFEBURE--EADSEADS CCRCCR-- AerodaysAerodays ViennaVienna 20062006
Duration: 36 month from 2004/02/01Budget: 3.6 Meuros
UNIVERSITY UNIVERSITY of PATRASof PATRAS
Consortium: 13 partners
CoCo--ordinatorordinator
FP6 STREP DINAMITDINAMIT Programcontract :AST3-CT-2003-502831
3This document is the property of EADS CCR ; no part of it shall be reproduced or transmitted without the express prior written authorisation of EADS CCR, and its contents shall not be disclosed. © - EADS CCR - 2006
FP6 DINAMIT FP6 DINAMIT ProgramProgram -P.LEFEBUREP.LEFEBURE--EADSEADS CCRCCR-- AerodaysAerodays ViennaVienna 20062006
Content
Interests of High Performance Thermoplastic Composites for aeronautics structure.
Objectives of the DINAMIT program
Main Achievements of works
Conclusion
4This document is the property of EADS CCR ; no part of it shall be reproduced or transmitted without the express prior written authorisation of EADS CCR, and its contents shall not be disclosed. © - EADS CCR - 2006
FP6 DINAMIT FP6 DINAMIT ProgramProgram -P.LEFEBUREP.LEFEBURE--EADSEADS CCRCCR-- AerodaysAerodays ViennaVienna 20062006
Interests of H.P ThermoplasticsHigh Performance Thermoplastic Composite materials are soon used
for manufacture of aeronautical structures.
• Compared to Thermoset resin Fibres systems, many advantages such as:• Good Impact behaviour.
• Fire resistance.
• Low moisture absorption.
• capabilities of Storage at Room Temperature.
• Welding capabilities.
• Potential recycling capabilities.
Great interest for potential Fuselage applications !
5This document is the property of EADS CCR ; no part of it shall be reproduced or transmitted without the express prior written authorisation of EADS CCR, and its contents shall not be disclosed. © - EADS CCR - 2006
FP6 DINAMIT FP6 DINAMIT ProgramProgram -P.LEFEBUREP.LEFEBURE--EADSEADS CCRCCR-- AerodaysAerodays ViennaVienna 20062006
Interests of H.P Thermoplastics
• Material costs, and the global production costs remain high
75Cytec 977-2/HTS
75Hexcel M21/T700
300Cytec APC2/AS4
100Hexcel M21/T800
2005 Price/kg
Relative Prices
of
Carbon fibres prepregs
•Thermoplastics are furthermore generally restricted to simple geometry parts and limited dimensions, due to the current technological limitations.
Today, restrictions for application to design and manufacture of aerospace structures
6This document is the property of EADS CCR ; no part of it shall be reproduced or transmitted without the express prior written authorisation of EADS CCR, and its contents shall not be disclosed. © - EADS CCR - 2006
FP6 DINAMIT FP6 DINAMIT ProgramProgram -P.LEFEBUREP.LEFEBURE--EADSEADS CCRCCR-- AerodaysAerodays ViennaVienna 20062006
Interests of H.P Thermoplastics
200100Release film
200100Peel ply
500100Breatherfabric
200100Vessel
2000100Sealant
ThermoplasticThermosetAncillaryproducts
Temperatures of consolidation > 350°C
Manufacturing costs drastically increase!
•Specific Industrial facilities and consolidations costs
Relative Prices
of ancillary products
7This document is the property of EADS CCR ; no part of it shall be reproduced or transmitted without the express prior written authorisation of EADS CCR, and its contents shall not be disclosed. © - EADS CCR - 2006
FP6 DINAMIT FP6 DINAMIT ProgramProgram -P.LEFEBUREP.LEFEBURE--EADSEADS CCRCCR-- AerodaysAerodays ViennaVienna 20062006
DINAMIT PROGRAM OBJECTIVES
Main objectives of the projectMain objectives of the project ::• Reduction of the prohibitive material costs.
•Min . 20% reduction hoped.(/very limited number of references)
• Reduction of the associated forming-consolidation costs.
•Due to high temperature of processes.
• Development of rapid, flexible, low cost processes for structure assembly .
8This document is the property of EADS CCR ; no part of it shall be reproduced or transmitted without the express prior written authorisation of EADS CCR, and its contents shall not be disclosed. © - EADS CCR - 2006
FP6 DINAMIT FP6 DINAMIT ProgramProgram -P.LEFEBUREP.LEFEBURE--EADSEADS CCRCCR-- AerodaysAerodays ViennaVienna 20062006
ACHIEVEMENT OF THE OBJECTIVESACHIEVEMENT OF THE OBJECTIVESObjectives achieved by:Objectives achieved by:The development of low cost H.P thermoplastic composites for aerThe development of low cost H.P thermoplastic composites for aeronautical onautical application:application:
•New TP blend /Carbon prepregs, Carbon/PEKK prepregs evaluation, Evaluation of new multiaxial Thermoplastic Fabrics, New material for In Situ Consolidation processes .
The development of enhanced formingThe development of enhanced forming--consolidation processes for skins and consolidation processes for skins and substructuressubstructures
•In situ consolidation processes & high speed automatic lay down process for manufacture of double curvature parts, Continuous Forming and Roll-Forming technologies for TP contoured profiles, low pressure injection process, enhanced Diaphragm forming technique coupled with IR heating.
The development of new welding processesThe development of new welding processes ::
• In-situ welding process , Feasibility study of Laser welding Including laser treatment of surfaces for preparation to welding.
The development of a cost optimisation tool for innovative materThe development of a cost optimisation tool for innovative materials and ials and processes processes
9This document is the property of EADS CCR ; no part of it shall be reproduced or transmitted without the express prior written authorisation of EADS CCR, and its contents shall not be disclosed. © - EADS CCR - 2006
FP6 DINAMIT FP6 DINAMIT ProgramProgram -P.LEFEBUREP.LEFEBURE--EADSEADS CCRCCR-- AerodaysAerodays ViennaVienna 20062006
ACHIEVEMENTS OF WORKACHIEVEMENTS OF WORK
Specifications elaborated from references = PEEK based materials .
Development of TP blends products Development of TP blends products (by LPW, Airbus(by LPW, Airbus––D, D, EurocopterEurocopter))
PEI
PES
PEEK
decreased mediaresistancecost reduction
brittle behaviour
brittle behaviourcost reductionincreased glass transitionReference: LPW BAYREUTH
•Formulation of 4 TP blends from this diagram.
•Resin Characterisations set up.
•2 blend formulations chosen for UD & Fabric impregnation:•Blend 1: best performances.•Blend 2: most suitable for forming consolidation processes.
•30% resin cost reduction is hoped (Victrex source)
First Carbon Fabrics/ blend are consolidated.
Mechanical tests on UD and Fabrics tapes to be set up
10This document is the property of EADS CCR ; no part of it shall be reproduced or transmitted without the express prior written authorisation of EADS CCR, and its contents shall not be disclosed. © - EADS CCR - 2006
FP6 DINAMIT FP6 DINAMIT ProgramProgram -P.LEFEBUREP.LEFEBURE--EADSEADS CCRCCR-- AerodaysAerodays ViennaVienna 20062006
possibleHEXCEL (towflex)
excellentHEXCEL (fleece)
excellentHEXCEL (fibres from SCHAPPES)
excellentSAERTEX (fibres from COMFIL)
tbdPORCHER (NCF from SAERTEX)
Drape-abilitySUPPLIER
possibleHEXCEL (towflex)
excellentHEXCEL (fleece)
excellentHEXCEL (fibres from SCHAPPES)
excellentSAERTEX (fibres from COMFIL)
tbdPORCHER (NCF from SAERTEX)
Drape-abilitySUPPLIER
Formability tests performed on 4 PEEK based NCF productsMain interests: lay up time saving, formability at room temperature
Consolidation of plates
SAERTEX plate
ACHIEVEMENTS OF WORKACHIEVEMENTS OF WORKEvaluation of New multiaxial TP products (A-F, LTSM)
Mechanical tests in progress for comparison of the TP NCF to APC2/AS4 (reference)
Carbon/peekcommingledfibres
Peek betweeneach dry ply
11This document is the property of EADS CCR ; no part of it shall be reproduced or transmitted without the express prior written authorisation of EADS CCR, and its contents shall not be disclosed. © - EADS CCR - 2006
FP6 DINAMIT FP6 DINAMIT ProgramProgram -P.LEFEBUREP.LEFEBURE--EADSEADS CCRCCR-- AerodaysAerodays ViennaVienna 20062006
ACHIEVEMENTS OF WORKACHIEVEMENTS OF WORK
Processing evaluation of UD PEKK/C tapes (IC, AProcessing evaluation of UD PEKK/C tapes (IC, A--UK)UK)
•Major results
•PEKK/C tapes seem available for aeronautical application.
•No major effect of the processing method.
•But no real cost reduction on the manufacturing cost today.
12This document is the property of EADS CCR ; no part of it shall be reproduced or transmitted without the express prior written authorisation of EADS CCR, and its contents shall not be disclosed. © - EADS CCR - 2006
FP6 DINAMIT FP6 DINAMIT ProgramProgram -P.LEFEBUREP.LEFEBURE--EADSEADS CCRCCR-- AerodaysAerodays ViennaVienna 20062006
ACHIEVEMENTS OF WORKACHIEVEMENTS OF WORKNew technology developments for first ply layNew technology developments for first ply lay--up on up on complex geometry (by Dassault Aviation and EADS CCR)complex geometry (by Dassault Aviation and EADS CCR)
Specific double curvature tooling First ply maintained with
vacuum
DAv developments:
Adhesive technology
EADS CCR Developments
Vacuum technology
Glass fabric + adhesive on tooling Specific first ply: PEEK/Carbon tape + adhesive
13This document is the property of EADS CCR ; no part of it shall be reproduced or transmitted without the express prior written authorisation of EADS CCR, and its contents shall not be disclosed. © - EADS CCR - 2006
FP6 DINAMIT FP6 DINAMIT ProgramProgram -P.LEFEBUREP.LEFEBURE--EADSEADS CCRCCR-- AerodaysAerodays ViennaVienna 20062006
ACHIEVEMENTS OF WORKACHIEVEMENTS OF WORK
Automatic lay down of 1 inch width APC2/AS4 tape
With max speed of the head displacement
Consolidation into oven
consolidated APC2/AS4 Panel
Automated cost effective Technology for TPs d.c. panel Automated cost effective Technology for TPs d.c. panel manufacture (by EADS/CCR)manufacture (by EADS/CCR)
Determination of the Process window completed:
•Max head speed.
•Pressure.
•Temperature
14This document is the property of EADS CCR ; no part of it shall be reproduced or transmitted without the express prior written authorisation of EADS CCR, and its contents shall not be disclosed. © - EADS CCR - 2006
FP6 DINAMIT FP6 DINAMIT ProgramProgram -P.LEFEBUREP.LEFEBURE--EADSEADS CCRCCR-- AerodaysAerodays ViennaVienna 20062006
Benchmarking on ISC Process (IVW)Benchmarking on ISC Process (IVW)Influence of process parameters :•heating source, velocity, consolidation force, material nature (CYTEC PEEK/Carbon tapes)
Main results:•material nature and heating method seems to have the most influence for ISC process (validation with peel tests)
Infrared heating system for the diaphragm process (LTSM)Infrared heating system for the diaphragm process (LTSM)
ACHIEVEMENTS OF WORKACHIEVEMENTS OF WORK
Temp. Vs Time
0
50
100
150
200
250
300
350
0 1000 2000 3000 4000 5000
Time [s]
Tem
pera
ture
[^C
]
5 mm Thick
Process simulation
(strain distribution)
Thermal analysis for optimisation
of the Infra red heating
15This document is the property of EADS CCR ; no part of it shall be reproduced or transmitted without the express prior written authorisation of EADS CCR, and its contents shall not be disclosed. © - EADS CCR - 2006
FP6 DINAMIT FP6 DINAMIT ProgramProgram -P.LEFEBUREP.LEFEBURE--EADSEADS CCRCCR-- AerodaysAerodays ViennaVienna 20062006
ACHIEVEMENTS OF WORKACHIEVEMENTS OF WORK
Development a TP RTM process (EADS CCR)Development a TP RTM process (EADS CCR)
Materials: TICONA PPS pellets and PORCHER Carbon fabrics
Drastic Problems of PPS oxidation at high temperature
Process parameters optimised for
C/PEEK Z stiffeners manufacture
TP roll forming developments (Airbus UK)TP roll forming developments (Airbus UK)Thermoset roll forming machine
upgraded with a specific Infrared preheating system
Continuous forming of contoured profiles (ACM)Continuous forming of contoured profiles (ACM)
16This document is the property of EADS CCR ; no part of it shall be reproduced or transmitted without the express prior written authorisation of EADS CCR, and its contents shall not be disclosed. © - EADS CCR - 2006
FP6 DINAMIT FP6 DINAMIT ProgramProgram -P.LEFEBUREP.LEFEBURE--EADSEADS CCRCCR-- AerodaysAerodays ViennaVienna 20062006
ACHIEVEMENTS OF WORKACHIEVEMENTS OF WORK
LASER WELDING FeasibilityWelding tests performed with a YAG laser source (transmission mode) on PEI, PPS, PEEK, PEKK Carbon or Glass fibre parts.
Laser developments for TPs assembly (Laser developments for TPs assembly (CIDAUT, AirbusCIDAUT, Airbus--E, E, EurocopterEurocopter))
Laser treatment of surfaces before welding
laser welded Pei/GF with PEKK/CF
•Weldability of TP GFcomponents demonstrated,• but critical process for TP CF tapes:
limitation to thin componentsCF/PPS Welded joint
Compared Processes by measurements of surface energy and mechanical shear properties after treatments
o Manual sanding ( standard industrial process)oYag laser source (tripled 355 nm)oDiode laser (810 nm)
Tests in progress,
but Laser Treatments seem soon more adapted to TP parts than for TD
17This document is the property of EADS CCR ; no part of it shall be reproduced or transmitted without the express prior written authorisation of EADS CCR, and its contents shall not be disclosed. © - EADS CCR - 2006
FP6 DINAMIT FP6 DINAMIT ProgramProgram -P.LEFEBUREP.LEFEBURE--EADSEADS CCRCCR-- AerodaysAerodays ViennaVienna 20062006
ACHIEVEMENTS OF WORKACHIEVEMENTS OF WORK
Cost effective Analysis (LTSM Cost effective Analysis (LTSM PatrasPatras))Cost Estimation Tool main Characteristics• Easy accessibility by the user• Friendly interface• Fully parametric• Divides the process into sub-processes• Extracting graphs • It can be modified any time
TTOOTTAALL CCOOSSTT KKttoottaall
SSuubb PPrroocceessss 11
SSuubb PPrroocceessss 22
CCEERR CCEERR CCEERR CCEERR CCEERR
CCOOSSTT DDRRIIVVEERRSS
OOPPTTIIMMIIZZAATTIIOONN
CCOOSSTT DDRRIIVVEERRSS
CCOOSSTT DDRRIIVVEERRSS
CCOOSSTT DDRRIIVVEERRSS
CCOOSSTT DDRRIIVVEERRSS
K1K5K3K2 K4
SSuubb PPrroocceessss 33
SSuubb PPrroocceessss 44
SSuubb PPrroocceessss 55
IInnppuutt
OOuuttppuuttHeating Material supply
Preparation of the material and
closingPreparation of the tool
Opening, Demolding, rework, inspection and
storage
Final Part Forming –consolidation
– cooling
Diaphragm forming Process chain
Cost analysis flow chart
18This document is the property of EADS CCR ; no part of it shall be reproduced or transmitted without the express prior written authorisation of EADS CCR, and its contents shall not be disclosed. © - EADS CCR - 2006
FP6 DINAMIT FP6 DINAMIT ProgramProgram -P.LEFEBUREP.LEFEBURE--EADSEADS CCRCCR-- AerodaysAerodays ViennaVienna 20062006
CONCLUSIONCONCLUSIONIndustrial ApplicationsIndustrial Applications
To Increase the level of HP Thermoplastic Composites on Aerospace structures.Impact on civil or military projects.
– Applications on the next generation of Aircrafts or Helicopters Fuselageswith new materials and enhanced technologies.
Today it is hoped a minimum 20% Materials cost reductions in the 2 or 5 years after the end of the programme.
New TPs technologies could induce 20% to 30% manufacture cost reduction with:
Automation of the TPs processes.
Increase of the importance of high Performance Thermoplastics in aerospace structures.
Flexible welding technologies .
Efficient Cost effective tool needed for help to the design of aerospace composite structural parts
Costs ImpactsCosts Impacts
19This document is the property of EADS CCR ; no part of it shall be reproduced or transmitted without the express prior written authorisation of EADS CCR, and its contents shall not be disclosed. © - EADS CCR - 2006
FP6 DINAMIT FP6 DINAMIT ProgramProgram -P.LEFEBUREP.LEFEBURE--EADSEADS CCRCCR-- AerodaysAerodays ViennaVienna 20062006
ACKNOWLEDGMENTSACKNOWLEDGMENTS
The DINAMIT consortium acknowledges the grant of the European Community
for the FP6 DINAMIT STREP Project (Contract No. AST3-CT-2003-502831).