SAMPE Journal - January/February 2021 - 33
INTRODUCTION
Using an automation process developed by Evonik
and its partners CTC and DLR, CFRP composites
with a structural foam core can be produced automatically and in aviation quality1. The aircraft industry expects an annual production rate of up to 1000
aircraft for some programs (e.g. single aisle aircraft
such as A320 and B737), thus has an economical
production process at its disposal.
Motivation
Over the mid-term, the aviation industry expects
an annual production rate of up to 1000 aircraft in
selected programs. Because some components are
produced in multiple quantities, 40 to 50 pieces may
be required per day. While automated serial production of fiber composite parts is state-of-the-art in
the automotive industry, in aviation, the question
arises: How can components be cost-effectively produced in large quantities so as to comply with the
quality and documentation requirements for aviation? Large components, such as the wing shells
of the Airbus A350, are already being produced by
Automated Fiber Placement (AFP) and Automated
Tape Placement (ATP).
Sandwich Design with Honeycomb as Core
Material
Sandwich design has established itself over decades
in components with high stiffness requirements,
such as spoilers, flaps, rudders and paneling. The
material used was, and still is today, usually Nomex
honeycomb. Due to the manual processes required,
the complicated handling of the honeycomb and the
processing of the components continue to be timeand cost-intensive, with the following cost drivers:
o Honeycomb stabilization: chamfering
and force application, for example, by core
filling or potting
o Complex layup processes due to
insufficient inherent stiffness
o Smoothing and polishing after curing,
to produce aerodynamically acceptable
surfaces and impermeability of the
component.
A further problem with the honeycomb sandwich became evident after only a few years of use in
flight: In some components, water accumulated in
the honeycomb cells and then structural problems
Complete Ultrasonic Systems Integration
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Matec Instrument Companies, Inc. | Northborough, MA | 1-508-393-0155 | sales@matec.com | matec.com
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SAMPE Journal - January/February 2021
Table of Contents for the Digital Edition of SAMPE Journal - January/February 2021
Table of Contents
SAMPE Journal - January/February 2021 - Cover1
SAMPE Journal - January/February 2021 - Cover2
SAMPE Journal - January/February 2021 - Table of Contents
SAMPE Journal - January/February 2021 - 2
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SAMPE Journal - January/February 2021 - Cover3
SAMPE Journal - January/February 2021 - Cover4
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