JEC COMPOSITES MAGAZINE - Issue #122 - July 2018 - 28

FEATURE AEROSPACE thermoplastic

Multifunctional over-molded access
door by Sintex NP

adapted to the high-volume production
rates of future programs.
A collaborative project
The demonstrator skin was produced
using the fully-automated deposition of
materials by automated fibre placement
(AFP) of new slit PEKK carbon tape
and slit copper foil (innovative lightning strike protection material). Stelia
Aerospace optimized the key parameters
of the AFP process for slit carbon tape
and slit copper foil (heating laws, speed,
compaction pressure) to ensure an
efficient out-of-autoclave thermal consolidation cycle (no major investment)
and good material quality.
The omega stringers and frames were
produced by a fast stamp forming
process using a robotic loading system
well-suited for automated high-volume
production. A process simulation
software was used to define the best
stamping design tools to quickly achieve
accurate sizing tolerance for the parts.
This method eliminated many expensive
tooling adjustments. This collaborative
work was conducted by French sub-

contractors (CETIM in Nantes for the
frames, Aviacomp in Toulouse for the
stringers and Compose for the tooling).
New 12K (vs. 3K) woven carbon/PEKK
laminates were specifically developed for
the stamp forming process to achieve a
cost-effective solution.
An induction welding process on carbon
UD tape with a metallic surface protection and skin thickness variations was
developed for the automated assembly of
stringers by dynamic robotic induction
welding. A test campaign was performed
on a high number of specimens to set up
the key parameters of the induction welding process and achieve good healing.
A multi-functional single-part access door
was then produced using the overmoulding process. By combining two processes
- injection (short fibres) and stamping
(continuous fibres) - additional features
were included in the access door: inserts,
ribs and a hinge to produce a lightweight
part.
Value and market
This innovative dynamic robotic induction welding demonstration highlights a
new cost-effective assembly process (no
drilling or titanium fasteners) for the
assembly of very long stringers (+10 m)
for future TP fuselage panels.
Due to the capabilities of the out-of-autoclave consolidation process on TP skins,
TP carbon composites can be considered
for the high-volume production of fuselage primary structures thanks to the
reasonable investment (positive impact
on workshop hourly rates).

Multi partner project team

28

jec composites magazine / N°122 July 2018

This development shows innovative
(lightweight and cost-efficient) design
capabilities with TP composites using the
overmoulding process. Overmoulding
technology allows the integration of
functions and hence reduces the number
of parts as a C/PEKK laminate can be
overmoulded with a C/PEKK compound. With this technology, designs
can be improved and three functions that
initially required three different parts
manufactured using traditional metal
technology can now be embedded in a
single part.
This development also demonstrated
the feasibility of the stamp forming
process with a cost-effective 12k fabric/
PEKK consolidated plate (new weaving
process).
This typical demonstrator showed the
capability of TP technology bricks
well-suited for a low-cost, high-production volume airframe targeting the
market of future commercial aircraft
(single-aisle and middle-market) or
future self-flying taxis (CityAirbus).
Recyclability and
reduced emissions
One of the advantages of thermoplastic
composites is their inherent recyclability.
The full-thermoplastic airframe structure
used in this project demonstrates the
potential use of PEKK carbon tape in
primary airframe structures such as fuselage panels for high-volume production
applications. The future aircraft embedding this technology will offer better
recyclability at their end of life.

Automated Fiber Placement of slit tape TP at SteliaLab



Table of Contents for the Digital Edition of JEC COMPOSITES MAGAZINE - Issue #122 - July 2018

Cover
Edito
Opinion: Bringing expertise on board
Contents
NEWS
In brief
Announcement at OC
Agenda
BUSINESS
Trends - Overview of the global carbon composites market Simulation
Market - Attractive growth opportunities for composites in the transportation market
MANUFACTURING
Fibre placement - Fibre placement on-line monitoring and solutions for quality optimisation
Fibre placement - Repurposing residual AFP tape for complex aerospace parts
Monitoring - Overcoming the complexities of RTM
Joining process - Filament winding for automated joining of lightweight profiles
Aerospace - Are thermoplastics essential to the future of composites in aeronautics?
Thermoplastic - Full out-of-autoclave thermoplastic welded airframe
Thermoplastic - Thermoplastic composites are vital to drive aerospace build rates
UAV - The Dash X unmanned aerial vehicle
Nano-satellite - Successful mission of TuPOD, a TubeSats deployer manufactured via additive manufacturing
Manufacturing - Orbital ATK and Lockheed Martin celebrate F-35 programme milestone
Light aviation - A “one shot” aircraft to revolutionize the light aviation sector
Research - An aeronautics and space-oriented research group
SOLUTIONS
Sustainability - Agricultural waste for thermal and acoustic insulation in construction
Recycling - Natural fibres and recycled rubber: new alternative solutions for composite panels
Artistic vases - Art FRP, an innovation based on the Japanese traditional sense of beauty
In the world
TECHNOLOGY
Nanotubes - Conductive glass fibre products using single-wall carbon nanotubes
Simulation - Optimizing the key manufacturing parameters of the AFP process
Index
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JEC COMPOSITES MAGAZINE - Issue #122 - July 2018 - 68
JEC COMPOSITES MAGAZINE - Issue #122 - July 2018 - Cover
JEC COMPOSITES MAGAZINE - Issue #122 - July 2018 - 2
JEC COMPOSITES MAGAZINE - Issue #122 - July 2018 - Edito
JEC COMPOSITES MAGAZINE - Issue #122 - July 2018 - Opinion: Bringing expertise on board
JEC COMPOSITES MAGAZINE - Issue #122 - July 2018 - 5
JEC COMPOSITES MAGAZINE - Issue #122 - July 2018 - Contents
JEC COMPOSITES MAGAZINE - Issue #122 - July 2018 - 7
JEC COMPOSITES MAGAZINE - Issue #122 - July 2018 - In brief
JEC COMPOSITES MAGAZINE - Issue #122 - July 2018 - 9
JEC COMPOSITES MAGAZINE - Issue #122 - July 2018 - Announcement at OC
JEC COMPOSITES MAGAZINE - Issue #122 - July 2018 - 11
JEC COMPOSITES MAGAZINE - Issue #122 - July 2018 - 12
JEC COMPOSITES MAGAZINE - Issue #122 - July 2018 - Agenda
JEC COMPOSITES MAGAZINE - Issue #122 - July 2018 - Trends - Overview of the global carbon composites market Simulation
JEC COMPOSITES MAGAZINE - Issue #122 - July 2018 - 15
JEC COMPOSITES MAGAZINE - Issue #122 - July 2018 - Market - Attractive growth opportunities for composites in the transportation market
JEC COMPOSITES MAGAZINE - Issue #122 - July 2018 - 17
JEC COMPOSITES MAGAZINE - Issue #122 - July 2018 - Fibre placement - Fibre placement on-line monitoring and solutions for quality optimisation
JEC COMPOSITES MAGAZINE - Issue #122 - July 2018 - 19
JEC COMPOSITES MAGAZINE - Issue #122 - July 2018 - 20
JEC COMPOSITES MAGAZINE - Issue #122 - July 2018 - Fibre placement - Repurposing residual AFP tape for complex aerospace parts
JEC COMPOSITES MAGAZINE - Issue #122 - July 2018 - 22
JEC COMPOSITES MAGAZINE - Issue #122 - July 2018 - Monitoring - Overcoming the complexities of RTM
JEC COMPOSITES MAGAZINE - Issue #122 - July 2018 - 24
JEC COMPOSITES MAGAZINE - Issue #122 - July 2018 - Joining process - Filament winding for automated joining of lightweight profiles
JEC COMPOSITES MAGAZINE - Issue #122 - July 2018 - 26
JEC COMPOSITES MAGAZINE - Issue #122 - July 2018 - Thermoplastic - Full out-of-autoclave thermoplastic welded airframe
JEC COMPOSITES MAGAZINE - Issue #122 - July 2018 - 28
JEC COMPOSITES MAGAZINE - Issue #122 - July 2018 - 29
JEC COMPOSITES MAGAZINE - Issue #122 - July 2018 - Thermoplastic - Thermoplastic composites are vital to drive aerospace build rates
JEC COMPOSITES MAGAZINE - Issue #122 - July 2018 - 31
JEC COMPOSITES MAGAZINE - Issue #122 - July 2018 - UAV - The Dash X unmanned aerial vehicle
JEC COMPOSITES MAGAZINE - Issue #122 - July 2018 - 33
JEC COMPOSITES MAGAZINE - Issue #122 - July 2018 - Nano-satellite - Successful mission of TuPOD, a TubeSats deployer manufactured via additive manufacturing
JEC COMPOSITES MAGAZINE - Issue #122 - July 2018 - 35
JEC COMPOSITES MAGAZINE - Issue #122 - July 2018 - 36
JEC COMPOSITES MAGAZINE - Issue #122 - July 2018 - 37
JEC COMPOSITES MAGAZINE - Issue #122 - July 2018 - Manufacturing - Orbital ATK and Lockheed Martin celebrate F-35 programme milestone
JEC COMPOSITES MAGAZINE - Issue #122 - July 2018 - Light aviation - A “one shot” aircraft to revolutionize the light aviation sector
JEC COMPOSITES MAGAZINE - Issue #122 - July 2018 - 40
JEC COMPOSITES MAGAZINE - Issue #122 - July 2018 - Research - An aeronautics and space-oriented research group
JEC COMPOSITES MAGAZINE - Issue #122 - July 2018 - 42
JEC COMPOSITES MAGAZINE - Issue #122 - July 2018 - 43
JEC COMPOSITES MAGAZINE - Issue #122 - July 2018 - 44
JEC COMPOSITES MAGAZINE - Issue #122 - July 2018 - 45
JEC COMPOSITES MAGAZINE - Issue #122 - July 2018 - 46
JEC COMPOSITES MAGAZINE - Issue #122 - July 2018 - 47
JEC COMPOSITES MAGAZINE - Issue #122 - July 2018 - Sustainability - Agricultural waste for thermal and acoustic insulation in construction
JEC COMPOSITES MAGAZINE - Issue #122 - July 2018 - 49
JEC COMPOSITES MAGAZINE - Issue #122 - July 2018 - 50
JEC COMPOSITES MAGAZINE - Issue #122 - July 2018 - 51
JEC COMPOSITES MAGAZINE - Issue #122 - July 2018 - 52
JEC COMPOSITES MAGAZINE - Issue #122 - July 2018 - Recycling - Natural fibres and recycled rubber: new alternative solutions for composite panels
JEC COMPOSITES MAGAZINE - Issue #122 - July 2018 - 54
JEC COMPOSITES MAGAZINE - Issue #122 - July 2018 - 55
JEC COMPOSITES MAGAZINE - Issue #122 - July 2018 - Artistic vases - Art FRP, an innovation based on the Japanese traditional sense of beauty
JEC COMPOSITES MAGAZINE - Issue #122 - July 2018 - 57
JEC COMPOSITES MAGAZINE - Issue #122 - July 2018 - 58
JEC COMPOSITES MAGAZINE - Issue #122 - July 2018 - In the world
JEC COMPOSITES MAGAZINE - Issue #122 - July 2018 - Nanotubes - Conductive glass fibre products using single-wall carbon nanotubes
JEC COMPOSITES MAGAZINE - Issue #122 - July 2018 - 61
JEC COMPOSITES MAGAZINE - Issue #122 - July 2018 - 62
JEC COMPOSITES MAGAZINE - Issue #122 - July 2018 - Simulation - Optimizing the key manufacturing parameters of the AFP process
JEC COMPOSITES MAGAZINE - Issue #122 - July 2018 - 64
JEC COMPOSITES MAGAZINE - Issue #122 - July 2018 - 65
JEC COMPOSITES MAGAZINE - Issue #122 - July 2018 - Advertisers
JEC COMPOSITES MAGAZINE - Issue #122 - July 2018 - 67
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