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Agency: Cordis | Branch: FP7 | Program: JTI-CS | Phase: JTI-CS-2011-3-GRA-01-039 | Award Amount: 288.48K | Year: 2012

The use of composites materials for aircraft design allows integrating other different materials with non-structural functions thanks to the layered structure. This layered structure offers the opportunity to embed damping interleaves in the CFRP laminate to improve the vibroacoustic damping behavior of the structure. These multifunctional structures will result in hybrid configurations which combine traditional CFRP laminate with other materials such as rubbers or nanoparticles. Therefore hybrid configurations need to be developed and compared with current structural solutions to quantify their improvement in terms of weight savings or functionality improvement. This proposal plans to manufacture curved (hybrid skin) panels stiffened with twisted stringers of different shape section by co-curing in female curing tool in one-shot process. Curved panels manufactured will be representative of the structure that conforms the nose fuselage stiffened skin.

Agency: Cordis | Branch: FP7 | Program: CP-FP | Phase: AAT.2012.4.1-2.;AAT.2012.4.1-5. | Award Amount: 6.62M | Year: 2012

The main challenge of the BOPACS project is to reduce the weight and costs of primary aerospace structures by developing bolt free adhesive bonded joints that comply with the airworthiness requirements. Until today thin walled composite primary aerospace structures are joined by using a large number of fasteners. Bolt free joining would considerably contribute to the weight and cost reduction of aerospace structures. Within BOPACS target applications will be selected that are commonly used in todays aerospace primary structures and where adhesive bonding might advantageously replace conventional riveting / fastening. Based on these target application bolt free adhesive bonded joining methods will be developed that comply with the EASA airworthiness requirements. Contrary to projects focusing on the development of non destructive techniques for the inspection of weak bonds, BOPACS proposes arigorous road map to certification by developing Means of Comply based on: Thorough research, beyond the state of the art, into the crack growth / disbond extension mechanisms in adhesively bonded joints. Design, analysis, testing and assessment of different categories of crack stopping design features, i.e. features that are capable of preventingcracks or disbonds from growing above a predefined acceptable size, with a joint still capable of carrying the limit load. The project results and certification issues will be reviewed on a regular base by EASA representatives through the Airbus certification department.

Agency: Cordis | Branch: FP7 | Program: JTI-CS | Phase: JTI-CS-2011-1-ECO-01-021 | Award Amount: 284.44K | Year: 2011

Thermoplastics (TP) are high molecular weight polymers which, unlike thermosetting (TS) resins, do not form a rigid three-dimensional cross-linked chemical structure after processing. This allows the TP to be readily re-melted and re-formed, not the TS. Additional advantages are: chemical/impact resistance, range of temperatures, low level of moisture uptake then low hot/wet conditions degradation, eco-friendly/reusable properties that can make them a primary selection when the part live cycle is considered. In situ consolidation automated processes with TP (ISC/TP) are currently at a level of development that does not allow efficient series production of complex TP components. More research is still needed to manufacture double curvature panels including strong thickness changes, plies drop-off, etc. Disadvantages for a good industrialization are: difficult process management, high process temperatures and pressures, material handling for an efficient ISC/TP process. The four main drivers of the ISINTHER project are: -To assess an in situ consolidation process for TPM orientated to industrial outcome -To apply the above main guidelines for trials and demonstrators manufacturing - To investigate on repair solutions and process to restore nominal quality of parts - To assess the potential benefit impact of the ISC/TP process in terms of environment, costs and elongated life cycle. The project work plan shall be supported on a strong collaboration of a Technology Center (FIDAMC) with an experimented Automation Manufacturer (MTorres) able to transfer their experience to ISC/TP process. PEEK APC2-AS4 will be the material reference but open to evolution or new materials. Reparability is other aspect to be investigated with a high budget and mechanical tests. Finally, process eco-assessment is a key objective of the ECODESIGN ITD, widened here to the concept of process sustainability (environment plus cost efficiency) to see if ISC/TP could be the preferred selection.

Agency: Cordis | Branch: FP7 | Program: JTI-CS | Phase: JTI-CS-2012-1-SFWA-02-020 | Award Amount: 546.79K | Year: 2013

Natural Laminar Flow (NLF) has been identified as a key technology to contribute to the reduction of emissions in aircraft transport. However, the stringent NLF surface requirements are difficult to be reached with conventional manufacturing processes. The aim of NOGAP project is to develop a fully automated gap filler device that is able to performance in a 3D environment and achieve surface finish within NLF tolerances at high production rates. To achieve its purpose, NOGAP project will integrate different systems in a single multifunction robot: Computer Vision device and 2D laser measurement device integrated in a verification system, for guidance, surface scanning and post-application metrology control Innovative filler injection system with flow software control and variable-geometry nozzles (under patent development) Multiple operation for accelerated curing (thermal, UV) and/or secondary finishing The flexibility and automation of assembly tooling is therefore a step forward to achieve the Aeronautical Factory of the Future based on the concept of Smart Factory.

Agency: Cordis | Branch: FP7 | Program: JTI-CS | Phase: JTI-CS-2012-1-GRA-01-049 | Award Amount: 287.74K | Year: 2012

The general objective of the project is to smartly handle the overall process of the composite integrated parts production reducing costs in two ways. First, by adequately simulating the spring back produced after the curing process and providing solutions in order to reduce the costs of reworking or assembly. Secondly, by simulating the thermal model of the set tooling/compositepart/vacuum bag and auxiliary parts under autoclave conditions to optimize the cure cycle temperatures distribution creating more uniformity in the composite part, lower residual stress, lower energy costs and better environmental friendliness. Given the large number of parts produced and their growth, the importance of the target is large. For that general purpose, the first specific objective of the OPTOCOM project is to carry out all the necessary steps to design and manufacture large tool for a composite complex structural part, typically a double curvature fuselage stiffened panel with co-cured stiffeners of about 2x1sqm. The stiffening elements shall be of both Z type and type cross section. Requirements such as high accuracy and rigidity, typical autoclave conditions, CTE matching, durability, minimal weight, provisions for transport, handling and accessories integration for easy demoulding, shall be imposed Second, is to develop analytical and FEM models which adequately simulate the distortions and spring back occurring in the curing process. This requires to establish the correct hypothesis and to obtain real material performance behavior both along the curing process and when the composite is cured, in order to be introduced into the model. Third, is to set up FEM simulation models to assess the thermal behavior and temperature evolution of the set of elements that get in the autoclave in order to optimize the thermal ramps and maps in the composite part. Finally, an analysis of the design and manufacturing tooling costs to assess benefits and procedures is made

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