JEC COMPOSITES MAGAZINE - Issue #56 - April 2010 - 34

SPECIAL jec composites show 2010
PROCESS
Winner: S.A.B.C.A. (Belgium)
Partnership network: Biteam AB (Sweden); Cooperative Research Centre for Advanced Composite Structures (CRC-ACS) (Australia), Dassault Aviation (France), Deutsches Zentrum für Luftund Raumfahrt (DLR) (Germany), EADS Deutschland GmbH (Germany), EADS Innovation Works (France), Eurocopter Deutschland GmbH (Germany), KTH - Royal Institute of Technology (Sweden), Premium AEROTEC GmbH (Germany), Secar Technologie GmbH (Austria), the University of Patras (Greece), Výzkumný a zkusební letecký ústav a.s. (VZLU a.s.) (Czech Republic). Name: The MOJO demonstrator (Modular Joints for composite aircraft components) is one of the very first representative aeronautical structures designed for assembly by structural adhesive bonding, which provides damage tolerance characteristics. Description: The composite innovation is a full-size aerospace structure designed to gather all the features developed in the MOJO project. The innovation brings together various developed elements. These will ultimately find use in different domains by different end users, including SABCA, Dassault-Aviation, Premium AEROTEC, EADS Military Air Systems and Eurocopter. The innovations will combine tailored preformed profiles for modular joints with structural bonding processes, including out-of-plane reinforcements. Applications will include stiffened wing-skin panels, vertical and horizontal tail planes, flap-track beams, cargo and pax doors, cargoand pax-door surroundings, as well as unmanned air vehicles. The main components of this closed beam were manufactured with out-of autoclave infusion processes such as Resin Transfer Moulding (RTM) for the top and side panels, and Vacuum Assisted Resin Infusion (VARI) process for the lower panel. Non-crimp carbon fabrics (from SAERTEX and CYTEC) and tailored preformed profiles made of high-performance textiles (developed by the partners) were used. Considering that structural bonding is the most compatible joining method for composite parts, adhesive processes with both film and paste adhesive were developed and successfully used for the assembly. Advantages or salient features: Structural bonding is still not a widely accepted alternative to riveting. Therefore, demonstration projects like MOJO, leading to the cost and performance benefits described, will help change minds and gain a wider acceptance, opening the way to “rivetless” CFRP structures. Around 25% overall cost savings and 50% weight savings. Up to 60% assembly cost savings as compared with “black metal” concepts. State of development: The project started in 2006 and was completed in 39 months. The launching of the innovation started with the selection of the MOJO project under the 6th European Framework Program. This enabled the development and demonstration of the different technologies and processes. The development phases followed the different steps needed for composite manufacturing, i.e. definition of requirements, preformed components preparation, infusion (including tooling), assembly rigs and testing. The market potential lies in aeronautical structures made from competitive CFRP materials. More information: www.sabca.com Description: The use of efficient, highly automated sequential processes, including prepreg unidirectional tape laying, automatic tape laying, hot forming, SQRTM (RTM process adapted to prepreg technology), and phased-array ultrasonic inspection for rapid manufacturing of highly integrated structures in one shot (no cobonding or assembly operations).

Finalist: Dr. Ing. h.c. F Porsche AG (Germany)
Partnership network: GKN-Aerospace GmbH (Germany); Karlsruhe Institute of Technology KIT (Germany) Name of product or process: Microwave curing of composite components. A HEPHAISTOS modular microwave system line with very homogeneous field distributions has been developed. HEPHAISTOS means High Electromagnetic Power Heating Autoclaveless Injected STructures Oven System. Description: The oven system uses microwave energy to cure the composite materials. This specific heating method generates heat within the material, thus allowing a fast temperature increase and shortening the whole production process.

Finalist: Acrolab Ltd. (Canada)
Partnership network: McClean-Anderson (USA); Ameritherm Inc. (USA); TCR Composites (USA) Name of product or process: Isomandrel™ Description: A new and unique super thermal conductive mandrel technology developed by Acrolab Ltd. can now cure filament-wound pipe and tube sections without cure ovens. This is done by heating the mandrel uniformly while rotating, using induction heating. By providing high thermal energy uniformly over the entire mandrel surface outward through the filament winding, the cure is completed in much shorter time with less energy while providing a significantly more uniform cure and resin rich inner diameter.

Finalist: S.A.B.C.A. (Belgium)
Partnership network: SABCA Limburg (Belgium); COEXPAIR (Belgium); DGO6/SKYWIN Aerospace cluster of Wallonia (R&D financial support) Name of product or process: SQRTM processes combine the advantages of RTM with the mechanical properties of prepreg unidirectional tapes.

jec composites magazine / No56 April 2010

http://www.sabca.com

JEC COMPOSITES MAGAZINE - Issue #56 - April 2010

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