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Anders Brødsjø - Airborne
Anders Brødsjø - Airborne
Anders Brødsjø - Airborne
Anders Brødsjø - Airborne
Anders Brødsjø - Airborne
Anders Brødsjø - Airborne
Anders Brødsjø - Airborne
Anders Brødsjø - Airborne
Anders Brødsjø - Airborne
Anders Brødsjø - Airborne
Anders Brødsjø - Airborne
Anders Brødsjø - Airborne
Anders Brødsjø - Airborne
Anders Brødsjø - Airborne
Anders Brødsjø - Airborne
Anders Brødsjø - Airborne
Anders Brødsjø - Airborne
Anders Brødsjø - Airborne
Anders Brødsjø - Airborne
Anders Brødsjø - Airborne
Anders Brødsjø - Airborne
Anders Brødsjø - Airborne
Anders Brødsjø - Airborne
Anders Brødsjø - Airborne
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Anders Brødsjø - Airborne

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  • 1. Thermoplastic composites foraeronautical and automotiveapplicationsA. Brødsjø, Research SpecialistAirborne Technology Centre, The Hague
  • 2. Contents• Thermoplastics• Continuous winding process• TAPAS project• Discrete fibre placement• Process testing• Continuous Fibre Placement
  • 3. Thermoplastics• Group of materials from PE, PP, PA up to PEEK and PEKK• Thermal process, no chemical reaction (in theory)  Fast process• Low cost (PE,PP)• High performance (PEEK, PEKK)• High toughness, high strain• Good chemical performance (semicrystalline)
  • 4. Continuous winding processDevelopment:• Shell: “Develop ideal pipe for oil & gas down hole tubing”• Development started in 2000• Concept study showed thermoplastic pipe is ideal• However, production technology not available at the time• First production line operational 2008
  • 5. Current pilot line
  • 6. First commercial product
  • 7. Continuous winding processNew factory:• Two production lines with multiple lay-up stations• Finished product can be loaded onto ship for transport over water• Located in IJmuiden sea harbour• Building started, opening 2012
  • 8. TAPAS project• TAPAS = Thermoplastic Affordable Primary Aircraft Structure• Airbus + NL cluster: – Stork Fokker, Ten Cate, Airborne, DTC, KVE, – TU Delft, Universiteit Twente, Technobis, (NLR)
  • 9. TAPAS project• Target: Raise the TRL of thermoplastics composites in order to use it for structural aircraft components• Driver thermoplastics: cost & cycle time – A30x = 1 tot 2 per day! – High level of integration possible – Secondary: toughness, impact resistance, FST properties
  • 10. TAPAS project• WP 1 Fuselage panel demonstrator – Double curved fuselage nose skin structure of A30x (successor to A320) – Airbus in the lead
  • 11. TAPAS project• WP 2: Torsion box demonstrator – Torsion box of Gulfstream G650 horizontal stabilizer – Fokker in the lead TP Skins 6m TP stringers
  • 12. TAPAS projectAirborne’s role in within TAPAS:• Deliver flat stringer preforms• Manufactured with fiber placement• “consolidated”• Material Carbon/PEEK or Carbon/PEKK• Length up to 3 m.
  • 13. Fibre placement setupSetup:• Fibre placement head designed and developed at Airborne• Features: – 1” tape – Cut & restart mechanism – Suitable up to PEEK• Head placed on existing 5-axis milling machine• Set-up used to manufacture blanks for TAPAS torsion box demonstrator
  • 14. Fibre placement setupRobot platform:• Large industrial robot (range 3 m, payload 360 kg, high accuracy)• To be used as general platform for research on automation• Fibre placement head will be modified for use on the robot in 2011-Q4• Will be used to manufacture blanks for TAPAS fuselage demonstrator
  • 15. Process testingApproach:• Material PEKK/AS4D tape by Cytec• Temperature measured inside laminate with thermocouples• Parameters (temperature, pressure, speed) varied to optimize settings per layer• Laminate quality checked using microscope
  • 16. Process testing C-scan result: • C-scan of first laminate shows large amount of porosity • After autoclave consolidation porosity reduced to acceptable levelBefore autoclave consolidation After autoclave consolidation
  • 17. Continuous fibre placementConcept:• Continuous process to produce discrete rectangular profiles• Based on continuous winding technology• Use of connected mandrels Mandrel Mandrel joining separation CFP CFP CFP saw station station station
  • 18. Continuous fibre placementPossible uses of profiles: welding or sawing co-consolidation press-forming sawing
  • 19. Continuous fibre placementPotential markets: Aerospace• Panel stiffeners, floor beams – New generation single aisle will require >100km /year of stringers – Length >10m
  • 20. Continuous fibre placementPotential markets: Automotive• State of the art in composites – Small/medium series <10/day – Labor intensive => hand made
  • 21. Continuous fibre placementPotential markets: Automotive• Crash beams, door pillars,… – High volume cars: >100.000/year – Competing with high strength steel and aluminium
  • 22. Thank you for your attention!

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