SAMPE Journal - July/August 2020 - 15
The design of the flap with the spars, nose and
trailing edge integrated into the lower skin was
based on the geometry of a serial part production. It was representative of the outboard flap of a
business jet (4,3 m). The general thicknesses were
derived from the existing design but some design
adaptations were performed to allow for the integration of the spars, nose and trailing edge. Mainly,
the plies drop-off in the nose and trailing edge were
adapted to allow for the demolding of the mandrels
after curing. The CFRP material used was UD tape
8552/AS4.
All preforms were draped by ATL, hot-formed
and then inserted in the SQRTM mould. The mandrels inside the nose and trailing edge are metallic
and single parts. The demolding had been checked
by analysis on the 3D models. The manufacturing sequence is illustrated in the Figure 16.
After demolding, the lower skin was controlled
by visual and ultrasonic inspections, thickness
measurements and micrography analysis. The
overall quality was good; a few local defects (porosities) were detected by ultrasonic inspection.
These were due to insufficient compaction, mainly
due to misplacement of some local CFRP patches
at rib stations. These CFRP patches were placed
manually. The thickness measurements also ex-
Figure 15. Design of the full scale flap lower skin with cocured spars, nose
and trailing edge.
hibited a few control points out-of- the tolerance
(over-thickness), which shall be related to previous
compaction issues. These issues were not related to
the SQRTM process. A second demonstrator will be
manufactured with few process adjustments. Some
micrography analyses were performed on coupons
extracted in the overlength of the part. The internal
quality was good. There were no plies wrinkles and
the noodle fillers were positioned correctly.
The concept of the spars cocured to the lower
skin has been validated through a series of tests:
low energy impacts, pull-off tests and a bird impact
test. For that purpose, two components (1,2 m)
with spars cocured to the lower skin were assembled with metallic ribs and composite upper cover
and nose.
Figure 16. Manufacturing of the flap lower skin with cocured spars, nose and trailing edge.
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SAMPE Journal - July/August 2020
Table of Contents for the Digital Edition of SAMPE Journal - July/August 2020
Table of contents
SAMPE Journal - July/August 2020 - Cover1
SAMPE Journal - July/August 2020 - Cover2
SAMPE Journal - July/August 2020 - Table of contents
SAMPE Journal - July/August 2020 - 2
SAMPE Journal - July/August 2020 - 3
SAMPE Journal - July/August 2020 - 4
SAMPE Journal - July/August 2020 - 5
SAMPE Journal - July/August 2020 - 6
SAMPE Journal - July/August 2020 - 7
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SAMPE Journal - July/August 2020 - 11
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SAMPE Journal - July/August 2020 - 14
SAMPE Journal - July/August 2020 - 15
SAMPE Journal - July/August 2020 - 16
SAMPE Journal - July/August 2020 - 17
SAMPE Journal - July/August 2020 - 18
SAMPE Journal - July/August 2020 - 19
SAMPE Journal - July/August 2020 - 20
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SAMPE Journal - July/August 2020 - Cover3
SAMPE Journal - July/August 2020 - Cover4
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