Anders Brødsjø - Airborne


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Anders Brødsjø - Airborne

  1. 1. Thermoplastic composites foraeronautical and automotiveapplicationsA. Brødsjø, Research SpecialistAirborne Technology Centre, The Hague
  2. 2. Contents• Thermoplastics• Continuous winding process• TAPAS project• Discrete fibre placement• Process testing• Continuous Fibre Placement
  3. 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. 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. 5. Current pilot line
  6. 6. First commercial product
  7. 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. 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. 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. 10. TAPAS project• WP 1 Fuselage panel demonstrator – Double curved fuselage nose skin structure of A30x (successor to A320) – Airbus in the lead
  11. 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. 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. 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. 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. 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. 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. 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. 18. Continuous fibre placementPossible uses of profiles: welding or sawing co-consolidation press-forming sawing
  19. 19. Continuous fibre placementPotential markets: Aerospace• Panel stiffeners, floor beams – New generation single aisle will require >100km /year of stringers – Length >10m
  20. 20. Continuous fibre placementPotential markets: Automotive• State of the art in composites – Small/medium series <10/day – Labor intensive => hand made
  21. 21. Continuous fibre placementPotential markets: Automotive• Crash beams, door pillars,… – High volume cars: >100.000/year – Competing with high strength steel and aluminium
  22. 22. Thank you for your attention!