20161027 aqua mandrel presentation la.pptx 1 © 2016 aero … · 2020-01-09 · © 2016 aero...
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© 2016 Aero Consultants AG, LA
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20161027 Aqua Mandrel Presentation_LA.pptx
Lukas AtzProduct Manager
© 2016 Aero Consultants AG, LA20161027 Aqua Mandrel Presentation_LA.pptx
About Hollow parts with closed shape require
mandrel technology
Existing mandrel or bladder techniquesshow disadvantages
New class of lost core / mandrel material
Water soluble
Environmentally friendly
Processing Advantages
Applications: Air- and Cable Ducts
Stiffening Structures
Pressure Vessels
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© 2016 Aero Consultants AG, LA20161027 Aqua Mandrel Presentation_LA.pptx
Highlight Features Water soluble
Leightweight 0.54 gcm-3
Low CTE 4.7 e-6
Temperature resistant 195°C
Pressure resistant 8.5 bar
Autoclave and RTM
Non corrosive
Smooth surface
Automated manufacturing, machinable
Fast wash-out
Environmentally friendly – no wastewater treatment
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P
© 2016 Aero Consultants AG, LA20161027 Aqua Mandrel Presentation_LA.pptx
Materials
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Aquacore™ wet paste
Aquapour powder, castable
Aquafill™ filler for repair
Aquaseal™ water soluble sealant
Fastcore for automatedprocessing
Rapidcore rapid prototypes
© 2016 Aero Consultants AG, LA20161027 Aqua Mandrel Presentation_LA.pptx
Materials
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Aquacore for Honeycomb Stabilisation
© 2016 Aero Consultants AG, LA20161027 Aqua Mandrel Presentation_LA.pptx
Reasons for Mandrel Production Common operator problems with processing
Service to offer ready to use water soluble mandrels
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© 2016 Aero Consultants AG, LA20161027 Aqua Mandrel Presentation_LA.pptx 8
Products AquaBlock for Prototyping
Pressed & Sealed
Machinable
Machined surface must be sealedwith tape or sealer
© 2016 Aero Consultants AG, LA20161027 Aqua Mandrel Presentation_LA.pptx 9
Products RapidCore for Prototyping
Build volume 800 x 400 x 400mm
Silica sand with water-soluble binder
Temperature resistant 120°C
Density 1.3 gcm-3
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RapidCore Mandrel Steering Wheel Mounting
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RapidCore Mandrel for Carbon Rim Rim size Ø 10” x 7”
Weight 1.35kg
Rim profile according DIN 7817
Made of Carbon Prepreg on a Rapidcore Mandrel with outside tool
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Products RapidCore combining with Composites for highly integrated
lightweight structures
Hydraulically actuated Quadruped robot (HyQ)
Developed at Istituto Italiano di Tecnologia IITwww.iit.it Dynamic Legged Systems Lab
Türk et al. Combining Additive Manufacturing with Advanced Composites for Highly Integrated Robotic Structures, 26th CIRP Design Conference 2016, submittedDaniel Türk, dtuerk@ethz.ch, www.pdz.ethz.ch
© 2016 Aero Consultants AG, LA20161027 Aqua Mandrel Presentation_LA.pptx 13
RapidCore Mandrel for ANYmal Robot RapidCore Mandrel used for Carbon legs
=> lightweight, high stiffness and cable integration
www.wysszurich.ch
© 2016 Aero Consultants AG, LA20161027 Aqua Mandrel Presentation_LA.pptx 14
Products Manufactured Mandrels
© 2016 Aero Consultants AG, LA20161027 Aqua Mandrel Presentation_LA.pptx 15
Applications Hollow Door Structures
Door Hinges
Airducts
Stringers
Example: compositesworld.com 201307
© 2016 Aero Consultants AG, LA20161027 Aqua Mandrel Presentation_LA.pptx
Different mandrel shapes
Wash-out station Door assembly
Aircraft Passenger Door Hinge
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© 2016 Aero Consultants AG, LA20161027 Aqua Mandrel Presentation_LA.pptx
Airducts
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Different Airducts Missile Airduct
© 2016 Aero Consultants AG, LA20161027 Aqua Mandrel Presentation_LA.pptx
Landing Flap 1.5m length
RTM Processing
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© 2016 Aero Consultants AG, LA20161027 Aqua Mandrel Presentation_LA.pptx
Reinforced Silicone Sealants
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© 2016 Aero Consultants AG, LA20161027 Aqua Mandrel Presentation_LA.pptx 21
Omega Stringer Up to 7m length
© 2016 Aero Consultants AG, LA20161027 Aqua Mandrel Presentation_LA.pptx
Pressure Vessels Mandrel made from block or with mould
Composite processing by winding or tapelaying
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© 2016 Aero Consultants AG, LA20161027 Aqua Mandrel Presentation_LA.pptx
Automotive Parts
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Rear Crash Structure Front Nose Section
© 2016 Aero Consultants AG, LA20161027 Aqua Mandrel Presentation_LA.pptx
Maintenance Door
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Dimension 600x690mm (24”x 27”)
Volume 8.0 litre
OEM in Germany
Lay-up of the SMC material
Temperature 140°C / 284°F
Pressure 40bar / 580psi
Cycle time each part 8 – 11min
SMC Part
Very accurate in wall thickness
Weight reduction 51%(16.5kg => 8.0kg)
Better acoustic insulation
© 2016 Aero Consultants AG, LA20161027 Aqua Mandrel Presentation_LA.pptx
Production Equipment
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Hot Air Ovens
Microwave Heating
© 2016 Aero Consultants AG, LA20161027 Aqua Mandrel Presentation_LA.pptx
CAD/CAM Design
CNC Milling
Production Equipment
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Logistics / Serial Production
© 2016 Aero Consultants AG, LA20161027 Aqua Mandrel Presentation_LA.pptx
Customers
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© 2016 Aero Consultants AG, LA20161027 Aqua Mandrel Presentation_LA.pptx 31
Aero Consultants
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Your Partner in the
Aerospace
Composites
Industry
Aero Consultants AGP.O.Box 35Grabenstrasse 8CH-8606 Naenikon / SwitzerlandT +41 44 905 28 00 (08)F +41 44 941 31 37l.atz@aero-consultants.chwww.aero-consultants.ch
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