AMIF2014 – [Aerospazio] Ronald Klomp, Sviluppi recenti nella lavorazione “out-of-autoclave” di...
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Transcript of AMIF2014 – [Aerospazio] Ronald Klomp, Sviluppi recenti nella lavorazione “out-of-autoclave” di...
Nationaal Lucht- en Ruimtevaartlaboratorium – National Aerospace Laboratory NLR
Advanced Materials International Forum – Bari - Italy September 18th – 19th, 2014
Recent developments in out-of-autoclave processing of fibre reinforced plastics Session 3 “Advanced Materials: a key driver for business competitiveness” Business Sector Focus: Aerospace
Ronald Klomp – de Boer - R&D Engineer Composites @ NLR
Out-Of-Autoclave: in general
Autoclave
(pressure-cooker)
AMIF – Bari - Italy Sept. 18–19, 2014 2
Oven
Aerospace standard and grade
Autoclave great, but unaffordable for rest of industry:
Automotive
Maritime
Tooling, Etc.
Infusion (RTM, VARTM, etc.)
Press (Compression Molding, SMC, BMC, etc.)
Out-Of-Autoclave; why?
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Oven Infusion Press
Investment oven of equivalent size & temp. Lower than autoclave
Resin & fibres separate “cheaper”
Attractive for large series
Enabling very large, integral composite structures
Preform has no outlife Complex geometries
Increased production flexibility
Large integral structures with VARTM
Integration of inserts
Reduced core crush/stabilsation problems
Complex, close tolerance parts with RTM
Close tolerance
Repairs of same quality as original
Repairs of same quality as original
Possible lower tool costs
Out-Of-Autoclave; examples Industry
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Out-Of-Autoclave; examples Aerospace
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Out-Of-Autoclave; why not?
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Laminate quality
Process control
Process duration
Performance
Out-life
Fibre volume content
Etc.
All of the above processes are just not as well established yet in aerospace as autoclave...but we’re getting there.
OOA: Oven Vacuum Bag only
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Examples of work at NLR:
IM7-BMI OOA prepreg for AFP
5320 slit tape AFP
Glass MTM45-1 fabric for engine nacelle
Challenges:
OOA: Oven Vacuum Bag only
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Work done and required
Contact with material supplier essential
Quality and material specifics (e.g. resin %)
Processing; from lay-up to bagging and curing really different from autoclave
OOA process simulation tools: air evacuation similar as already partly available for infusion
OOA: Infusion
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Examples of work at NLR:
BMI vacuum infusion
Landing gear component DFP preform & RTM
Vacuum infusion DFP preforms
Challenges: e.g. dry spots
OOA: Infusion
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OOA: Infusion
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Work required:
Adequate manufacturing simulation tools: infusion process from A to Z improvements
(constant) improvement of infusion resin mechanical properties compete with prepregs
Especially with RTM and complex, thick geometries; quality control - NDI
OOA: Compression moulding
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Examples of work at NLR:
TS caps
TP window frame
Ongoing research TS and TP materials
OOA: Compression Moulding
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Work required
Process control guarantee minimally required properties
Linked: reduce scatter in mechanical properties
Engineering: how to model random fibre properties acurately, corresponding with observed fibre distribution on moulded parts
Quality control: NDI of complex shaped parts CT scan offers promising results, however, how to relate observations to quality (mechanical properties)?
Conclusions
The field of composites is increasing rapidly: A wide range of materials are available and
continuously being developed And same for the processes and increasing level of
automation Especially now that composites outside Aerospace
are getting at a same level
Plenty of opportunity and possibility of using composites
This makes it a real challenge for companies to select the right Materials & Processes...but also very interesting!
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AMIF – Bari - Italy Sept. 18–19, 2014