FACILITIES

“ The duality of composites:

from aeronautics to space ”

Brokerage Event:

Defense and Dual-Use Technologies 2018

Almudena del Teso

October 3rd-4th 2018. Seville

Synergies “are used to name the action of two or

more causes that generate an effect superior to the one that will be achieved

with the sum of the individual effects”

Dual techologies “technologies that, developed for sectors such as defense, security and space, have a relevant role in tasks of daily life, which has resulted in an improvement of society as a whole “

Composites “ those materials that are formed by the

union of two or more materials to achieve the combination of properties

that can not be obtained in the materials separately”

”

50% 25%

25%

Enhance and consolidate the Spanish leading position in the composite field.

Set up an excellence composite centre providing services to the Spanish aeronautical industry and opened to other industries.

Promote contact with Universities, Scientific Institutions and others Research & Development Centres.

Test campaign to obtain the design Manufacturing test Lighting protection studies Structural tests Specimen manufacturing: LE , wing

Manufacturing upper skin in thermoplastic for C295 plane with AFP-ISC Manufacturing leadind edge in thermoplastic

Dimenssion

4160 x 853 mm 2,120 K€ 60000 HOURS IN 4 YEARS (2015-2019) CS2 FUNDING

Manufacturing test stringers

Lightning protection

Anti-ice system

Bird strike protection

Rotation Mechanism

Lighting protection studies

Test preparation MULTI-TOW

RESULT ANALYSIS DEMOS RESULTS

AIRBUS D&S

Manufacturing a sandwich tail cone demo for a helicopter.

Material definition. Manufacturing process. Tooling definition. First specimen manufacturing

AIRBUS HELICOPTER

FRAME 9 FRAME 8

COMPOFUEL purpose development of fuel pipes in composite material, comprising from the duct concept up to the industrialization support. Project is divided in different phases.

Composite pipes SoA Feasibility analysis Material functionalization & characterization

Manufacturing process Industrialization support Pipes validation

AIRGRUP

CoMposite pipes SoA

Design Requirements.

Pipes Design

Matrix and reinforcement

selection

Matrix functionalization

Manufacturing process

Pipes validation

SUPERSUB project objective is to compare naval & aeronautical stress methods, and obtain the stress allowable of the super structure components

Stress methods comparison. Proposals to optimize methods used in NAVANTIA with aeronautical processes. Analysis of allowable used. Testing processes and values Complete the allowable test campaign, manufacturing and testing coupons. Joint allowable test

NAVANTIA

Methods comparison

Tests definition and coupons

manufacturing

Testing and allowable

calculation

FIDAMC contribution to the project:

WP1&2: Carbody Study& Carbody components design

Coordinator: Talgo

Length: 24 months

Man-month WP1&2: 11.2+13.0

Total WP1&2: 315K€ (requested140k€)

WP6: Entrance systems

Coordinator: Faiveley Transport Tours (FTT)

Length: 24 months

Man-month WP6: 18.3

Total WP6: 237k€ (requested105k€)

FIDAMC/AIRBUS

The aim of this project is to acquire the know-how and abilities in 3D printing technology, specially in FDM (Fused Deposition Modeling) processes. Definition of applications and development of machines and processes according with application requirements.

Knowledge base of the 3D printing technology Analyze and study the characteristics and limitations of current printers Material characterization. Physico-chemical and mechanical testing

Definition of applications Brainstorming Identification of potential projects

Development of 3D printers Requirement definition FDM 3D printer with continuous fiber filament FDM 3D printer with plastic filament

Technology evaluation and lessons learnt

Material characterization

Potential applications

FIDAMC FDM printer

ELASTIC POLYMERS

ATL TOOLING

ASSY TOOLING

FLYING PARTS

HIGH PERFORMANCE POLYMERS: PEEK and PEI

CFRP: continuous and short fibre

Not all composites works: ultraviolet radiation, ionizing

radiation, etc.

However CFRP are used in space (limited by matrixes and

protection layers)

Aeronautic materials are not exactly the same used in

aerospace. Material selection is an important part of the

process

However, composites can be processed in the same way

for both aerospace and aeronautic components

What is a lattice or grid structure?

In aerospace applications nowadays mainly two basic structural

concepts are widely used :

• Stringer & frame stiffened shell structures

• Sandwich structures

• A third concept, the lattice or grid structure, has been

followed and further developed in the last 30 years in the

US and more predominantly in Russia.

SPACE PROJECTS: ISOGRID

Where do CFRP Grid Structures make Sense?

In application where structures have to

- Reduce thermal gradients

- Improve damage tolerance ( multiple load paths)

- Reduce mass while provide bending strength

- Improve manufacturing cost efficiency

- Improve dimensional stability

- Provide extra space for the integration of other elements

Made at FIDAMC

Project led by Astrium Cassidian

process of manufacturing stiffened structures with nerves by means of Fiber placement machine

MATERIALS SCIENCE

MATERIALS AND

PROCESSES

INDUSTRY SUPPORT

PROCESSES AND

INDUSTRIALIZATIONATION

• Research develop & innovate materials with new or enhanced functionalities.

• To fit Material Supplier/ Universities investigation lines with Industry needs, proposing new investigation lines.

• Establishment of specific design principles & simulation methods

• To investigate and share tasks with other institutions.

• Propose and contribute to new investigation lines with processing equipment suppliers. • Evaluate new structural architectures/

Element Integration/ New manufacturing techniques in terms of process ability, cost, lead time and weight

• Collaborate to establish design principles associated with new technologies

• Asses and improve knowledge and

performance on already known technologies, materials and processes (Effect of Defect, Quality or Cost improvement...) •Propose and develop solutions for

specific Industry needs in terms of new application of existing technologies

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Thanks for your attention!

Almudena.delteso@fidamc.es