JEC COMPOSITES MAGAZINE - Issue #106 - July 2016 - 31

thermoplastics

New aircraft spoiler concept
using thermoplastic composites
In the aerospace industry, there is a strong need for cost-effective lightweight solutions based on innovative materials and
processes. A simple aircraft spoiler design has been developed
utilizing the low-cost processing features of thermoplastics.

By
ARNT OFFRINGA
DIRECTOR R&D
FOKKER

S

poilers (Figures 1 and 2) are a control
surface on the top of an aircraft wing
that serve to "spoil" the airflow to
either lower a wing during flight or to
brake during landing. Spoilers are made of
metal and composite materials, sometimes

Fig. 2: Aircraft wing with spoilers extended
upward

The design of the new spoiler is basically a
box with a triangular cross-section. The box
consists of a top skin, a bottom skin and a
spar (Figure 3). The three parts are welded
together all around at the seams. Metal hinge
brackets are then attached. The span of the
demonstrator is roughly 2.5 metres.

Co-consolidation is a proven technology used for the A340-500/600 wings'
leading-edge access panels and for the
torsion box of the award-winning AgustaWestland AW169 horizontal tail. During
co-consolidation, the part is heated up to
its melt temperature under pressure or
vacuum, after which the final quality is
attained. Removable tooling blocks are used
to locally support the part during the melt
cycle. Figure 5 shows the bottom skin after
processing.
The spar (Figure 6) is made by forming a
pre-laminated blank in a press in a single
step.

Skins and spar

Welding

The skins are monolithic, i.e. solid laminate
parts. As a first step, the skin laminate is laid
up by either a 2D laminator (for the flat top
skin) or by 3D fibre placement (for the complex shaped bottom skin, see Figure 4).
The skins are integrally stiffened with omega
stringers. These are first pre-formed roughly
into shape in a press and then co-consolidated with the skin.

Welding together the spoiler parts is key
to having an attractive cost. Thermoplastic
composites welding is becoming an established technology, as illustrated by the new

Fig. 3: Spoiler design

No106 July 2016 / jec

composites magazine

FEATURE AERONAUTICS

Fig. 1: Welded thermoplastic spoiler at JEC World
2016 (photo CompositesWorld)

stiffened with core materials. A new thermoplastic spoiler has been developed with
simplicity of design and low-cost processing
in mind. The new concept exploits the processing capabilities of thermoplastic composites, such as rapid fibre placement, press
forming, co-consolidation and welding.

31



Table of Contents for the Digital Edition of JEC COMPOSITES MAGAZINE - Issue #106 - July 2016

Cover
Edito
Point of view: Europe
Contents
COMPANY & BUSINESS
Development
Agenda of Events
APPLICATIONS
Thermoplastics
Automotive
MARKET
Aircraft engine
FEATURE AERONAUTICS
Aerostructures
Characterisation
Thermoplastics
Aero-engines
Process
CFRP
Semi-product
RESEARCH & DEVELOPMENT
Review
Core material
TECHNOLOGY & INNOVATIONS
NDT
Marine
Index
In the world
JEC COMPOSITES MAGAZINE - Issue #106 - July 2016 - Ad1
JEC COMPOSITES MAGAZINE - Issue #106 - July 2016 - Cover
JEC COMPOSITES MAGAZINE - Issue #106 - July 2016 - 2
JEC COMPOSITES MAGAZINE - Issue #106 - July 2016 - Edito
JEC COMPOSITES MAGAZINE - Issue #106 - July 2016 - Point of view: Europe
JEC COMPOSITES MAGAZINE - Issue #106 - July 2016 - 5
JEC COMPOSITES MAGAZINE - Issue #106 - July 2016 - Contents
JEC COMPOSITES MAGAZINE - Issue #106 - July 2016 - 7
JEC COMPOSITES MAGAZINE - Issue #106 - July 2016 - COMPANY & BUSINESS
JEC COMPOSITES MAGAZINE - Issue #106 - July 2016 - 9
JEC COMPOSITES MAGAZINE - Issue #106 - July 2016 - Development
JEC COMPOSITES MAGAZINE - Issue #106 - July 2016 - 11
JEC COMPOSITES MAGAZINE - Issue #106 - July 2016 - Agenda of Events
JEC COMPOSITES MAGAZINE - Issue #106 - July 2016 - 13
JEC COMPOSITES MAGAZINE - Issue #106 - July 2016 - AdHEC
JEC COMPOSITES MAGAZINE - Issue #106 - July 2016 - AdCro
JEC COMPOSITES MAGAZINE - Issue #106 - July 2016 - Thermoplastics
JEC COMPOSITES MAGAZINE - Issue #106 - July 2016 - 15
JEC COMPOSITES MAGAZINE - Issue #106 - July 2016 - 16
JEC COMPOSITES MAGAZINE - Issue #106 - July 2016 - Automotive
JEC COMPOSITES MAGAZINE - Issue #106 - July 2016 - Aircraft engine
JEC COMPOSITES MAGAZINE - Issue #106 - July 2016 - 19
JEC COMPOSITES MAGAZINE - Issue #106 - July 2016 - 20
JEC COMPOSITES MAGAZINE - Issue #106 - July 2016 - 21
JEC COMPOSITES MAGAZINE - Issue #106 - July 2016 - 22
JEC COMPOSITES MAGAZINE - Issue #106 - July 2016 - Aerostructures
JEC COMPOSITES MAGAZINE - Issue #106 - July 2016 - 24
JEC COMPOSITES MAGAZINE - Issue #106 - July 2016 - 25
JEC COMPOSITES MAGAZINE - Issue #106 - July 2016 - Characterisation
JEC COMPOSITES MAGAZINE - Issue #106 - July 2016 - 27
JEC COMPOSITES MAGAZINE - Issue #106 - July 2016 - 28
JEC COMPOSITES MAGAZINE - Issue #106 - July 2016 - 29
JEC COMPOSITES MAGAZINE - Issue #106 - July 2016 - 30
JEC COMPOSITES MAGAZINE - Issue #106 - July 2016 - Thermoplastics
JEC COMPOSITES MAGAZINE - Issue #106 - July 2016 - 32
JEC COMPOSITES MAGAZINE - Issue #106 - July 2016 - Aero-engines
JEC COMPOSITES MAGAZINE - Issue #106 - July 2016 - 34
JEC COMPOSITES MAGAZINE - Issue #106 - July 2016 - 35
JEC COMPOSITES MAGAZINE - Issue #106 - July 2016 - 36
JEC COMPOSITES MAGAZINE - Issue #106 - July 2016 - Process
JEC COMPOSITES MAGAZINE - Issue #106 - July 2016 - 38
JEC COMPOSITES MAGAZINE - Issue #106 - July 2016 - 39
JEC COMPOSITES MAGAZINE - Issue #106 - July 2016 - CFRP
JEC COMPOSITES MAGAZINE - Issue #106 - July 2016 - 41
JEC COMPOSITES MAGAZINE - Issue #106 - July 2016 - 42
JEC COMPOSITES MAGAZINE - Issue #106 - July 2016 - Semi-product
JEC COMPOSITES MAGAZINE - Issue #106 - July 2016 - 44
JEC COMPOSITES MAGAZINE - Issue #106 - July 2016 - 45
JEC COMPOSITES MAGAZINE - Issue #106 - July 2016 - Review
JEC COMPOSITES MAGAZINE - Issue #106 - July 2016 - 47
JEC COMPOSITES MAGAZINE - Issue #106 - July 2016 - 48
JEC COMPOSITES MAGAZINE - Issue #106 - July 2016 - 49
JEC COMPOSITES MAGAZINE - Issue #106 - July 2016 - Core material
JEC COMPOSITES MAGAZINE - Issue #106 - July 2016 - 51
JEC COMPOSITES MAGAZINE - Issue #106 - July 2016 - 52
JEC COMPOSITES MAGAZINE - Issue #106 - July 2016 - NDT
JEC COMPOSITES MAGAZINE - Issue #106 - July 2016 - 54
JEC COMPOSITES MAGAZINE - Issue #106 - July 2016 - Marine
JEC COMPOSITES MAGAZINE - Issue #106 - July 2016 - 56
JEC COMPOSITES MAGAZINE - Issue #106 - July 2016 - Index
JEC COMPOSITES MAGAZINE - Issue #106 - July 2016 - In the world
JEC COMPOSITES MAGAZINE - Issue #106 - July 2016 - 59
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