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1This document is the property of EADS CCR ; no part of it shall be reproduced or transmitted without the express prior written authorisation of EADS CCR, and its contents shall not be disclosed. - EADS CCR - 2006

FP6 DINAMIT FP6 DINAMIT ProgramProgram -P.LEFEBUREP.LEFEBURE--EADSEADS CCRCCR-- AerodaysAerodays ViennaVienna 20062006

byPatrice LEFEBURE _ EADS CCR

(patrice.lefebure@ eads.net)&

C. QUINQUIS _ A-F, S. KASCHEL _ A-D, R. AVILA DOMINGUEZ _ A-E, M. BUCKLEY _ A-UK, C. COIFFIER-COLAS _ D. Av, H. SIBOIS _ Eurocopter, G. LAMPEAS _ LTSM Patras, B. PEREZ Magallon _ CIDAUT, U. SPELZ _ ACM, H. RUCKDSCHEL LPW Bayreuth, J. LEE _ I.C, R. SCHLEDJEWSKI _ IVW Kaiserslautern.

DDevelopmentevelopment and and ININnovationnovationfor for AAdvanced dvanced MManufacturanufacturIIng ng

of of TThermoplasticshermoplastics

Mid-Term Achievements of work



Duration: 36 month from 2004/02/01Budget: 3.6 Meuros

UNIVERSITY UNIVERSITY of PATRASof PATRAS

Consortium: 13 partners

CoCo--ordinatorordinator

FP6 STREP DINAMITDINAMIT Programcontract :AST3-CT-2003-502831



Content

z Interests of High Performance Thermoplastic Composites for aeronautics structure.

zObjectives of the DINAMIT program

zMain Achievements of works

zConclusion



Interests of H.P ThermoplasticsHigh Performance Thermoplastic Composite materials are soon used

for manufacture of aeronautical structures.

Compared to Thermoset resin Fibres systems, many advantages such as: Good Impact behaviour.

Fire resistance.

Low moisture absorption.

capabilities of Storage at Room Temperature.

Welding capabilities.

Potential recycling capabilities.

Great interest for potential Fuselage applications !



Interests of H.P Thermoplastics

Material costs, and the global production costs remain high

75Cytec 977-2/HTS

75Hexcel M21/T700

300Cytec APC2/AS4

100Hexcel M21/T800

2005 Price/kg

Relative Prices

of

Carbon fibres prepregs

Thermoplastics are furthermore generally restricted to simple geometry parts and limited dimensions, due to the current technological limitations.

Today, restrictions for application to design and manufacture of aerospace structures



Interests of H.P Thermoplastics

200100Release film

200100Peel ply

500100Breatherfabric

200100Vessel

2000100Sealant

ThermoplasticThermosetAncillaryproducts

Temperatures of consolidation > 350C

@Manufacturing costs drastically increase!Specific Industrial facilities and consolidations costs

Relative Prices

of ancillary products



DINAMIT PROGRAM OBJECTIVES

Main objectives of the projectMain objectives of the project :: Reduction of the prohibitive material costs.

Min . 20% reduction hoped.(/very limited number of references)

Reduction of the associated forming-consolidation costs.

Due to high temperature of processes.

Development of rapid, flexible, low cost processes for structure assembly .



ACHIEVEMENT OF THE OBJECTIVESACHIEVEMENT OF THE OBJECTIVESObjectives achieved by:Objectives achieved by:The development of low cost H.P thermoplastic composites for aerThe development of low cost H.P thermoplastic composites for aeronautical onautical application:application:

New TP blend /Carbon prepregs, Carbon/PEKK prepregs evaluation, Evaluation of new multiaxial Thermoplastic Fabrics, New material for In Situ Consolidation processes .

The development of enhanced formingThe development of enhanced forming--consolidation processes for skins and consolidation processes for skins and substructuressubstructures

In situ consolidation processes & high speed automatic lay down process for manufacture of double curvature parts, Continuous Forming and Roll-Forming technologies for TP contoured profiles, low pressure injection process, enhanced Diaphragm forming technique coupled with IR heating.

The development of new welding processesThe development of new welding processes ::

In-situ welding process , Feasibility study of Laser welding Including laser treatment of surfaces for preparation to welding.

The development of a cost optimisation tool for innovative materThe development of a cost optimisation tool for innovative materials and ials and processes processes



ACHIEVEMENTS OF WORKACHIEVEMENTS OF WORK

z Specifications elaborated from references = PEEK based materials .

Development of TP blends products Development of TP blends products (by LPW, Airbus(by LPW, AirbusD, D, EurocopterEurocopter))

PEI

PES

PEEK

decreased mediaresistancecost reduction

brittle behaviour

brittle behaviourcost reductionincreased glass transitionReference: LPW BAYREUTH

Formulation of 4 TP blends from this diagram.

Resin Characterisations set up.

2 blend formulations chosen for UD & Fabric impregnation:Blend 1: best performances.Blend 2: most suitable for forming consolidation processes.

30% resin cost reduction is hoped (Victrex source)

First Carbon Fabrics/ blend are consolidated.

Mechanical tests on UD and Fabrics tapes to be set up



possibleHEXCEL (towflex)

excellentHEXCEL (fleece)

excellentHEXCEL (fibres from SCHAPPES)

excellentSAERTEX (fibres from COMFIL)

tbdPORCHER (NCF from SAERTEX)

Drape-abilitySUPPLIER

possibleHEXCEL (towflex)

excellentHEXCEL (fleece)

excellentHEXCEL (fibres from SCHAPPES)

excellentSAERTEX (fibres from COMFIL)

tbdPORCHER (NCF from SAERTEX)

Drape-abilitySUPPLIER

Formability tests performed on 4 PEEK based NCF productsMain interests: lay up time saving, formability at room temperature

Consolidation of plates

SAERTEX plate

ACHIEVEMENTS OF WORKACHIEVEMENTS OF WORKEvaluation of New multiaxial TP products (A-F, LTSM)

Mechanical tests in progress for comparison of the TP NCF to APC2/AS4 (reference)

Carbon/peekcommingledfibres

Peek betweeneach dry ply




Processing evaluation of UD PEKK/C tapes (IC, AProcessing evaluation of UD PEKK/C tapes (IC, A--UK)UK)

Major results

PEKK/C tapes seem available for aeronautical application.

No major effect of the processing method.

But no real cost reduction on the manufacturing cost today.



ACHIEVEMENTS OF WORKACHIEVEMENTS OF WORKNew technology developments for first ply layNew technology developments for first ply lay--up on up on complex geometry (by Dassault Aviation and EADS CCR)complex geometry (by Dassault Aviation and EADS CCR)

Specific double curvature tooling First ply maintained with vacuum

DAv developments:

Adhesive technology

EADS CCR Developments

Vacuum technology

Glass fabric + adhesive on tooling Specific first ply: PEEK/Carbon tape + adhesive




Automatic lay down of 1 inch width APC2/AS4 tape

With max speed of the head displacement

Consolidation into oven

consolidated APC2/AS4 Panel

Automated cost effective Technology for TPs d.c. panel Automated cost effective Technology for TPs d.c. panel manufacture (by EADS/CCR)manufacture (by EADS/CCR)

Determination of the Process window completed:

Max head speed.

Pressure.

Temperature



Benchmarking on ISC Process (IVW)Benchmarking on ISC Process (IVW)Influence of process parameters :heating source, velocity, consolidation force, material nature (CYTEC PEEK/Carbon tapes)

Main results:material nature and heating method seems to have the most influence for ISC process (validation with peel tests)

Infrared heating system for the diaphragm process (LTSM)Infrared heating system for the diaphragm process (LTSM)


Temp. Vs Time

0

50

100

150

200

250

300

350

0 1000 2000 3000 4000 5000

Time [s]

T

e

m

p

e

r

a

t

u

r

e

[

^

C

]

5 mm Thick

Process simulation

(strain distribution)

Thermal analysis for optimisation

of the Infra red heating




Development a TP RTM process (EADS CCR)Development a TP RTM process (EADS CCR)

Materials: TICONA PPS pellets and PORCHER Carbon fabrics

Drastic Problems of PPS oxidation at high temperature

Process parameters optimised for

C/PEEK Z stiffeners manufacture

TP roll forming developments (Airbus UK)TP roll forming developments (Airbus UK)Thermoset roll forming machine

upgraded with a specific Infrared preheating system

Continuous forming of contoured profiles (ACM)Continuous forming of contoured profiles (ACM)




LASER WELDING Feasibility Welding tests performed with a YAG laser source (transmission mode)

on PEI, PPS, PEEK, PEKK Carbon or Glass fibre parts.

Laser developments for TPs assembly (Laser developments for TPs assembly (CIDAUT, AirbusCIDAUT, Airbus--E, E, EurocopterEurocopter))

Laser treatment of surfaces before welding

laser welded Pei/GF with PEKK/CF

Weldability of TP GFcomponents demonstrated, but critical process for TP CF tapes:limitation to thin components

CF/PPS Welded joint

9Compared Processes by measurements of surface energy and mechanical shear properties after treatments

o Manual sanding ( standard industrial process)oYag laser source (tripled 355 nm)oDiode laser (810 nm)

Tests in progress,

but Laser Treatments seem soon more adapted to TP parts than for TD




Cost effective Analysis (LTSM Cost effective Analysis (LTSM PatrasPatras))Cost Estimation Tool main Characteristics Easy accessibility by the user Friendly interface Fully parametric Divides the process into sub-processes Extracting graphs It can be modified any time

TTOOTTAALL CCOOSSTT KKttoottaall

SSuubb PPrroocceessss 11


CCEERR CCEERR CCEERR CCEERR CCEERR

CCOOSSTT DDRRIIVVEERRSS

OOPPTTIIMMIIZZAATTIIOONN





K1K5K3K2 K4




IInnppuutt

OOuuttppuuttHeating Material supply

Preparation of the material and

closingPreparation of the tool

Opening, Demolding, rework, inspection and

storage

Final Part Forming consolidation

cooling

Diaphragm forming Process chain

Cost analysis flow chart



CONCLUSIONCONCLUSIONIndustrial ApplicationsIndustrial Applicationsz To Increase the level of HP Thermoplastic Composites on Aerospace structures.

Impact on civil or military projects. Applications on the next generation of Aircrafts or Helicopters Fuselages

with new materials and enhanced technologies.

9Today it is hoped a minimum 20% Materials cost reductions in the 2 or 5 years after the end of the programme.

9New TPs technologies could induce 20% to 30% manufacture cost reduction with:Automation of the TPs processes.Increase of the importance of high Performance Thermoplastics in aerospace structures.

Flexible welding technologies .Efficient Cost effective tool needed for help to the design of aerospace composite structural parts

Costs ImpactsCosts Impacts



ACKNOWLEDGMENTSACKNOWLEDGMENTS

The DINAMIT consortium acknowledges the grant of the European Community

for the FP6 DINAMIT STREP Project (Contract No. AST3-CT-2003-502831).

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capabilities of storage

welding capabilities

global production costs