JEC COMPOSITES MAGAZINE - Issue #36 - October 2007 - 21

patented process developed by Augsburg. Based on an infusion process, VAP uses vacuum to suck liquid resin into preformed semi-finished parts made of high-performance fibre. This process makes it possible to reduce material and direct production costs by 30-35%, compared to conventional production processes. The latest AN INTERVIEW WITH MR. LONSINGER, VICE PRESIDENT AUGSBURG SITE & AEROSTRUCTURE PROGRAMS MILITARY AIR SYSTEMS product made using the proprietary VAP process is the cargo door for the new A400M military transport aircraft. At approximately 7 m x 4 m, it is the world’s largest aircraft component manufactured using VAP technology. The advantages of VAP include: - processing of dry textile fibre, - easy handling of textile fibre, maiden flight, it will contain more than 50% of carbon fibre materials. Composites are on an upward trend. JCM: To what extent do you use composites in your business? Is your utilization increasing? M. LONSINGER: The motto “Aerostructures made in Augsburg” looks back on nearly 30 years of experience in the development and production of high-quality aerostructures using CFRP materials. In the seventies, the use of carbon fibre composites in the MRCA Tornado multipurpose combat aircraft and the production of a complete model front fuselage section from CFRP represented a major innovative leap forward. Since then, the Augsburg plant has continuously expanded its areas of competence. This includes the production of all CFRP centre fuselage shells for the Eurofighter prototypes and the air brake for the complete EF-series production. The use of CFRPs has been extended to civil programmes to include, for example, flap tracks for the A380, rear pressure bulkheads for the B787, and the cargo door for the new A400M military - curing in convection oven, - vacuum infusion of liquid resin, - no cold storage, - fast ply arrangement for part, - no autoclave required, - ideal process for manufacturing big CFC structures like fuselage and wing frames. More information: www.eads.com transport aircraft. In total, our capacities in the composite field are increasing by about 100% per year. We have adapted the professional training of our staff members and extended our apprenticeship programme in the field of CFRP to keep up with today’s requirements. JCM: You have expertise in several different technologies, but you depend heavily on the vacuum-assisted process (VAP) technology. Can we expect more progress in that area? M. LONSINGER: The portfolio of aerostructures produced in Augsburg contains all of the trend-setting CFRP technologies for infusion and prepreg applications. As a leading aerostructure plant, Augsburg not only has exceptional capabilities in the processing of all raw materials, but also in the development and assembly of integrated hybrid constructions. Our design skills enable us to select the ideal combination of materials right from the design phase. The focus here is on cost and weight reduction. Our customers thus have a wide choice of materials, from classic aluminium through to titanium JCM: More than ever, composites are crucial for aircraft. In your opinion, why is this so? M. LONSINGER: The aircraft of the future must be efficient, economical and environmentally-friendly. These are objectives that are impossible to realise without CFRP materials. The use of lightweight construction materials leads to reductions in weight and fuel consumption, thus contributing significantly to climate protection. I am therefore absolutely convinced that CFRP materials will become increasingly relevant. The success of composite materials is mainly due to their outstanding characteristics. More specifically, the ability to select the fibre and matrix, as well as the enhancement geometry, allows for optimal design in compliance with structural and functional requirements. However, the main motivation behind using CFRP materials is still their great weight reduction potential, good fatigue characteristics, design flexibility and corrosion resistance. The importance of fibre composite materials is particularly welldemonstrated by the aviation industry. For example, the share of carbon fibres both in Airbus and Boeing aircraft has increased considerably in recent years. In 1983, the A310 had a CFRP material share of less than 5%, whereas this share has already increased to 25% for the A380. When the A350 embarks on its Airbus structures No36 October - November 2007 / JEC Composites Magazine

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JEC COMPOSITES MAGAZINE - Issue #36 - October 2007

Table of Contents for the Digital Edition of JEC COMPOSITES MAGAZINE - Issue #36 - October 2007