sqrtm nose landing door : boarding for flight test detaille 19_01_2016.pdfrepresentative of airbus...

© 2016 - Coexpair s.a – This Document is the property of Coexpair s.a. Its content is confidential and cannot be copied or diffused without written autorisation.

Emmanuel Detaille

R&D Program Manager

SQRTM Nose Landing Door : boarding for flight test

EUCIA Seminar • Composite & Sustainability, Bruxelles

19 January 2016

1


Presentation Overview

• Coexpair activities overview

• IMS&CPS project – A350 doors

• Aflonext project – A320 doors

2






3


Coexpair – New location since 2012 (Namur)

BELGIAN AEROSPACE COMPANY DEDICATED TO NET SHAPE COMPOSITE EQUIPMENT &

TECHNOLOGIES (RTM, SQRTM)

CLOSE PARTNERSHIP WITH RADIUS ENGINEERING (SALT LAKE CITY, USA), LEADER OF THIS

MARKET FOR NEARING 30 YEARS

MAIN EXPERTISE

• ENGINEERING SERVICES - DESIGN, ANALYSIS, M&P

• PROCESS SET-UP FROM COUPONS TO FIRST PART QUALIFICATION (NO SERIAL PRODUCTION)

• MOLD DESIGN & FABRICATION

• EQUIPMENT - INJECTION SYSTEM, PRESSES

• TRAINING : 3 DAYS INTRODUCTION TO RTM OR SQRTM


Serial Equipment – Injection system

2,100cc Electric 5,000cc Electric 10,000cc Electric 25,000cc Pneumatic

→ PLC Controlled

→ Locally Controlled (Touchscreen)

→ Remotely Controlled (PC)

→ Complete DAQ Station Remote Control


Serial Equipment – Press


• RADIUS PRESS 1.8 M X 1.3 M - 15 BARS - 80KW HEATING

• RADIUS PRESS 1.0 M X 0.65 M - 15 BARS - 30KW HEATING

• RADIUS INJECTION SYSTEM 2,5 & 10 LITERS

• CALIBRATED DATA ACQUISITION SYSTEM

• CNC CUTTING TABLE

• 10 TONS CRANE

• INFRARED HEATER & VACUUM TABLE

• ADVANCED SENSOR SYSTEMS

Prototyping – Shop equipment


Engineering

DESIGN

ANALYSIS & TEST

MATERIALS & PROCESSES

TECHNOLOGY TRANSFER


RTM & SQRTM Training

3 DAY INTENSIVE INTRODUCTION COURSE OF RTM & SQRTM

FOR AEROSPACE

THE COURSE COVERS THE PROCESS, THE DESIGN, THE MATERIALS AND THE

EQUIPMENT COMMONLY USED

TWO COMPONENTS ARE FABRICATED BY THE PARTICIPANTS TO ILLUSTRATE

THE THEORY AND PROVIDE HANDS-ON LEARNING


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► Traditional composites: many detail parts

molded, then assembled

► Net-Shape composites molded in one piece• Detail parts integrated together

• Molded in matched tooling, out-of-autoclave

• 90% finished, ready for trim and paint

Result – Complex aerospace parts are produced with:

Less labor, less time

Lower materials cost

Lighter weight

(Much assembly required)

► Successful processes:• RTM: resin transfer molding

• SQRTM: same qualified resin transfer molding

Net-Shape Processes

Radius & Coexpair Focus on “Net-Shape” Composites

© 2016 - Coexpair s.a – This Document is the property of Coexpair s.a. Its content is confidential and cannot be copied or diffused without written autorisation.11

• RTM uses dry fabric to make preform

• Tooling is generally steel or Al, on all surfaces

• Fabric has small amount (~5%) of resin to stabilize preform

• Resin is thoroughly degassed and vacuum is drawn on tool

• Low viscosity RTM resin, < 500 cps, infuses entire preform

• Resin pressure maintained at 7 to 8 Bar during cure

Net-Shape Processes

RTM is a robust process


• SQRTM allows use of program-specific prepreg (“same qualified”), including

toughened systems such as Hexply 8552, Hexply M21, Cycom 977, Cycom 5250-4 BMI, and Toray 3900-2 (BMS 8-276) (*)

• tape-laid, drape-formed, or hand-laid, then debulked under vacuum

• Tooling is Al, steel or Invar

• Vacuum is drawn on tool

• As tool is heated, small quantity of prepreg resin is injected into tool to fill tool cavity around edges of part

• Resin hydrostatic pressure maintained at 8 - 9 Bar during cure

Net-Shape Processes

(*) Cycom 977-2 and Cycom 5250-4 are registred trademarks of Cytec

Hexply 8552 and Hexply M21E are registred trademarks of Hexcel

Toray 3900-2 is a registred trademark of Toray

SQRTM is a robust alternative to Autoclave


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TIME (minutes)

TE

MP

ER

AT

UR

E (

°C

)

30 60 90 120 150 180 210

95

175

240 270 300 330 360 390

120 minutes

1o/min1 o/min

3o/min

3o/min

3 o/min

SQRTM

AUTOCLAVE

CURE

SQRTM

INJECTION

PART REMOVAL

0.5o/min

Net-Shape Processes

SQRTM Cycle Can Be Shorter Than Autoclave Cure


SQRTM & UD tape

MOLD FOR LARGE PART – UP TO 8 METERS LONG


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• RTM/SQRTM Projects

– JSF Development (Lockheed)

– JASSM Missile (Klune Industries)

– A340 Spoilers Center Hinge Fitting (FACC)

– Boeing 787 (various customers)

• SQRTM Process Gains Industry Acceptance

– Toyota Wing

– Global Hawk Wingtip

– 787 Structures

– Sikorsky SARAP UH-60 Fuselage Roof

– Embraer E2 190 Flap

Public Applications

Net-Shape Applications (Public, Non-confidential)


SQRTM in Production

Embraer E2 190 Flap






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2010-2013 – Coexpair coordinated a large FP7 project

(IMS&CPS)

DEMONSTRATORS

SQRTM A350

NOSE LANDING

GEAR DOOR

CONCEPT

Cambridge

Public Applications


IMS&CPS project overview

• Objective: development & evaluation of innovative

material (CNT) and advanced preforming methods (e.g.

automated stitching)

• Major steps for Coexpair :

1. Demonstrator selection with SLCA

2. Mechanical tests on coupons and sub-elements

3. Manufacturing of demonstrator with SLCA

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Selected Demonstrator

20

Nose Landing Gear Door

selected as demonstrator

made in SQRTM : complex

part with double curvature &

several stiffener geometries


Demonstrator characteristics

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Geometry:

• Double curvated panel with integrated stiffeners

(one-shot manufacturing)

• Aerodynamic profil & space allocation

representative of Airbus A350 nose landing gear

door

• Size: 2m x 1m (2/3 of the actual A350 door)

Material:

• 1st door: full M21/46280 prepreg (twill 2x2) +

bronzemesh on skin

• 2nd door: stiffeners in M21/46280; skin with M21

UD tape filled with CNT + bronzemesh on skin

Manufacturing process:

• SQRTM to allow to use M21 in closed mold & to

allow high integration level

2 m

1 m


Test pyramid

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Validation elements to reflect geometry

and manufacturing feasibility of typical

aera of the demonstrator

Tests on coupons & T junctions

to compare material properties

between M21 twill 2x2 (ref.) vs.

CNT and stitched preforms

T-junctions

Test pyramid for selected demonstrator

Coupons

I beam

Integrated box

(unit cell of demo)

Demonstrator

Bending tests on I beams to

validate FEM prediction methods

Manufacturing of the

full demonstrator


Door manufacturing

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Work performed at Coexpair

• Mold manufacturing management

– 51 inserts machined, adjusted and anodised

– A cavity and a lid of 2.3 x 1.3 m

• Handling equipment

– Solidarise mould parts for assembly

– Conveying of blocks for preforming, considering their weight

(most of them are > 15kgs)

– Conveying of blocks assembled for positioning into the cavity


Shop tuning for LGD

manufacturing

⟹ ergonomic environment

for preforming

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Press adaptation

• Heating panels to be added as

part is longer than Coexpair’s

shop press. Additional heating

elements controlled separately.

Door manufacturing


SLCA & Coexpair teams draped the part at Coexpair plant

Door manufacturing


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Door manufacturing

The mold is then placed in the press for resin injection and curing

Injection steps:

1. Mold closure (press clamping)

2. Mold heating (± 100°C)

3. Injection of hot resin (±100°C)

4. Curing @ 180°C for several hours

5. Demolding






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2013-2017 – Coexpair participating to large FP7 project

AFLoNext (Active Flow Loads & Noise Control on Next

Generation Wing) led by Airbus

COEXPAIR CONTRIBUTION : SQRTM A320 NOSE LANDING GEAR

DOOR FOR FLIGHT TEST IN CLOSE PARTNERSHIP WITH SLCA

Public Applications

40 partners including:


AFLoNext project overview

• Objective for Coexpair & SLCA: replace current

sandwich nose landing gear door by monolithic structure

for flight test

• Major steps:

1. Door concept selection

2. Detailed design of the door

3. Design of the mold

4. Manufacturing of the door

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Concept generation & selection

1. Requirement review (e.g. list of load cases, same shape envelope, same

connections as current ones,…)

2. Brainstorming on concept possibilities

3. Classification of all generated concepts

4. Trade-off with several criteria: Technical: inspectable, withstand load cases,…

Production: suitable for potential serial production

Criteria oriented to Aflonext project: time schedule respect for flight test

=> Selection of the most relevant concept

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• Composite structure:

– Material: full M21/46280 (as for IMS&CPS)

– FEM models performed with Nastran for design load cases

(ultimate & failure) provided by Airbus

• Current auxiliary parts kept identical to ease door

installation on the aircraft

Detailed design

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Detailed design

• Additional coupon tests performed to show composite by

SQRTM process fulfill Airbus material requirements

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Ratio SQRTM process / Airbus requirements (in %) SQRTM adim SQRTM adim

Glass transition Temperature Tg-onset AITM 1.0003 °C 127%

Tension Allowable 0° EN 2597 B Xmin MPa 135% 140%

0° EN 2597 B ‾X‾ Gpa 124% 115%

Tension Allowable 90° EN 2597 B Xmin MPa 152%

90° EN 2597 B ‾X‾ Gpa 118%

Compression Allowable 0° EN 2850 B Xmin MPa 125%

0° EN 2850 B GPa 115%

Compression Allowable 90° EN 2850 B Xmin MPa

90° EN 2850 B GPa

In-plane Shear Stress Allowable +/- 45° AITM 1.0003 Xmin MPa 113%

+/- 45° AITM 1.0002 GPa 155%

Interlaminar Shear Stress Allowable 0° EN 2563 Xmin MPa 133%

Properties AR/-55°C AR/RT

Tension Modulus

Tension Modulus

Compression Modulus

Compression Modulus

In-plane Shear Modulus


Next steps

2016 :

Complete detailed door design

Design door mold

Manufacture door (2 articles)

2017 :

Deliver door to Airbus for flight test

The work described in this presentation on Aflonext project & the research leading to these results has

received funding from the European Community's Seventh Framework Programme FP7/2007-2013,

under grant agreement n° 604013, AFLONEXT project

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General conclusions & Long-term perspectives

Sandwich structures such as nose landing gear door replacable by

monolithic structures

SQRTM process, serial production proven, suitable to manufacture

highly integrated structures including doors

Composite with SQRTM process meets Airbus material

requirements

In the future, more and more sandwich structures, complex to

manufacture, to be replaced by highly integrated monolithic

structures with simpler preforming and curing cycles

SQRTM already qualified by Boeing and Embraer

34


Thank you for your attention

Contacts:

– [email protected] (IMS&CPS project)

– [email protected] (AFLoNext project)

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mailto:[email protected]

mailto:[email protected]

sqrtm nose landing door : boarding for flight test detaille 19_01_2016.pdfrepresentative of airbus...

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