SAMPE Journal - January/February 2016 - 7
FEATURE ARTICLE
Evolution in Composite Injection Moulding Processes
for Wing Control Surfaces
D. Gueuning and F. Mathieu
Sonaca S.A., Gosselies, Belgium
Abstract
Since 2010, Sonaca is engaged in R&D projects, with the support of Radius Engineering and Coexpair, aiming
to design, develop, manufacture and test monolithic CFRP flap structures made from the conventional 8552 resin
prepreg system and the newest SQRTM process ('Same Qualified Resin Transfer Moulding') in order to assess several
additional benefits of this process over the conventional RTM process, amongst which the use of already qualified
tough prepreg materials and the ease combination with automatic deposition and preforming techniques of UDtapes. Following advantages were also considered during the initial trade-off analysis for the technology selection
of such wing control surface structure having very stringent requirements in terms of structural performance,
weight optimisation, aerodynamic quality and cost:
* Strong control on thicknesses,
* Strong control on the geometry (radii, plies conformity),
* High surface and internal laminate qualities,
* Robust process generating less scraps and non-conformities,
* High level of part integration possible.
Introduction
Sonaca is producing today, in serial production, hybrid
slat structures on the A350 program. The concept
resulted from an important R&D project ('Newslat')
running from 2003 till 2010 and consisting finally in the
assembly of a metallic nose skin with a composite rear
structure produced from a closed mould RTM process
based upon the RTM6 epoxy resin and carbon fabric/
carbon non-crimp fabric reinforcements, allowing very
high product dimensional characteristics together with
very good internal and surface quality. This concept
demonstrates now in serial production to be very
SAMPE Journal, Volume 52, No. 1, January/February 2016
efficient in terms of part quality and robustness but the
use of the dry fabrics and dry non-crimp fabrics do not
allow automation of the lay-up deposition.
In 2010, Sonaca decided to launch an extensive
research and development programme ('Ecotac') to
develop the newest SQRTM (Same Qualified Resin
Transfer Molding) process for application on wing
control surface components and, followed in 2013,
by another programme with the final aim to bring the
technology up to TRL9 for use on flaps of an actual
regional aircraft project (Figure 1). Today, Sonaca can
be considered as the first European company having
introduced this advanced technology in production.
Figure 1. SQRTM TRL Road Map at Sonaca.
7
Table of Contents for the Digital Edition of SAMPE Journal - January/February 2016
Contents
SAMPE Journal - January/February 2016 - Cover1
SAMPE Journal - January/February 2016 - Cover2
SAMPE Journal - January/February 2016 - Contents
SAMPE Journal - January/February 2016 - 2
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