Innovation for a Sustainable Aviation in a Global Environment · Innovation for a Sustainable...
Transcript of Innovation for a Sustainable Aviation in a Global Environment · Innovation for a Sustainable...
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Innovation for a Sustainable Aviation in a Global Environment
30th March - 1st April 2011Madrid (Spain), Palacio Municipal de Congresoshttp://www.aerodays2011.org/
Sixth European Aeronautics Days
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MOJO ‐ Dr. Llorenç Llopart Prieto, Premium AEROTEC GmbH March the 31st 2011, Madrid 2
Modular Joints for Aircraft Composite Structures
Development EngineerDr. Llorenç LLOPART P.
March 31st 2011, Madrid
Materials & Processes at
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MOJO ‐ Dr. Llorenç Llopart Prieto, Premium AEROTEC GmbH March the 31st 2011, Madrid 3
OverviewMOJO: Partners
MOJO: Objectives
MOJO: Strategy
Task 1: Preforming
Task 2: Infusion & Assembly
Task 3: Quality assurance & Effect‐of‐Defects
Task 4: Simulation
Task 5: Demonstrators
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MOJO ‐ Dr. Llorenç Llopart Prieto, Premium AEROTEC GmbH March the 31st 2011, Madrid 4
MOJO: Partners1.‐ EADS Deutschland GmbH
2.‐ Biteam AB
3.‐ SECAR Technology GmbH
4.‐ Kungliga Tekniska högskolan Stockholm (Royal Institute of Technology)
5.‐ University of Patras UP
6.‐ Vyzkumny a Zkusebni Letecky Ustav a.s. (Aeronautical Research and Test Institute, Plc.)
Germany: Ottobrunn, Manching and Augsburg
Sweden: Bromma
Austria: Mürzzuschlag‐Hönigsberg
Sweden: Stockholm
Greece: Patras
Check Republic: Prag
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MOJO ‐ Dr. Llorenç Llopart Prieto, Premium AEROTEC GmbH March the 31st 2011, Madrid 5
12.‐ Co‐operative Research Center for Advanced Composite Structures Limited
8.‐ Eurocopter Deutschland GmbH
9.‐ EADS ‐ Innovation Works France
10.‐ Societe Anonyme Belge de Constructions Aeronautiques
11.‐ Deutsches Zentrum für Luft und Raumfahrt (German Aerospace Center)
France: Saint Cloud
Germany: Ottobrunn
France: Suresnes
Belgium: Brussels
Germany: Braunschweig and Stuttgart
Australia:Melbourne
MOJO: Partners7.‐ Dassault Aviation
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MOJO ‐ Dr. Llorenç Llopart Prieto, Premium AEROTEC GmbH March the 31st 2011, Madrid 6
Technical objective was to develop a material driven composite design philosophy, new structural design principles, in order to fully utilise fibre related advantages, thus resulting in weight savings.
Scope of MOJO was to provide synergy between:
‐ preform technology
‐ low cost resin infusion, and
‐ structural adhesive bonding for a specialised composite material design without fasteners
MOJO: Objectives
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MOJO ‐ Dr. Llorenç Llopart Prieto, Premium AEROTEC GmbH March the 31st 2011, Madrid 7
‐ Introduction of a modular design concept using advanced preforms and textile methods for 3D reinforcement in combination with bonding by means of a demonstrator structure.
‐ The activities were complimented with an effects‐of‐defect research task in order to assess structural consequences of most common manufacturing faults and in‐service damages.
‐ The principle of MOJO laid in the design of CFRP joining elements for pure shear load transfer.
MOJO: Strategy
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MOJO ‐ Dr. Llorenç Llopart Prieto, Premium AEROTEC GmbH March the 31st 2011, Madrid 8
- The mechanical performance of Modular Joints were determined with an extensive testing program according to the Rouchon pyramid (building block approach).
Representative structure testing definition
Sub element testing definition
Assembled panel testing definition
Individual join element testing definition
Basic material properties testing definition to produce basic materials properties of adhesives and composite and evaluate process parameters
to test a structural assembly displaying all the isolated features characterised separately earlier in the test program
to test an article focused on joint fittings onto other reinforcement elements including bonding methods and profiles tested previously
to produce assembled panels properties with the studied configuration profiles
to produce join element properties with woven profiles
MOJO: Strategy
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Task 1: PreformingTask 1: Preforming
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MOJO ‐ Dr. Llorenç Llopart Prieto, Premium AEROTEC GmbH March the 31st 2011, Madrid 10
‐ Preforming using compacting techniques
Redirection of NCF tapes &
Positioning
Compacting Fixed Preform
MOJO: Preforming
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‐ Analysis for different types of connections, 3D‐reinforced joints, and design concepts, altering the failure mode ‐ hence improving the mechanical performance.
MOJO: Preforming & 3D‐ Reinforcements
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MOJO ‐ Dr. Llorenç Llopart Prieto, Premium AEROTEC GmbH March the 31st 2011, Madrid 12
- From the scientific point of view the focus is laid on the application of especially 3D-Woven preforms in order to alter the failure mechanism in favourof higher limit loads and overall improved mechanical performance.
MOJO: 3D‐Woven profiles
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Task 2: Infusion Task 2: Infusion & Assembly& Assembly
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MOJO ‐ Dr. Llorenç Llopart Prieto, Premium AEROTEC GmbH March the 31st 2011, Madrid 14
‐ RTM, VAP and VARI‐process (Vacuum assisted resin infusion)
Pi‐profile
Cross section of Pi‐profile
L‐Profiles
MOJO: Infiltration
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MOJO: Infiltration‐ by means of pultrusion
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MOJO: Adhesive bonding- Structures bonded with film adhesive
- Structures bonded with paste adhesive
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Task 3: Quality assurance & Task 3: Quality assurance & EffectEffect‐‐ofof‐‐DefectsDefects
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MOJO ‐ Dr. Llorenç Llopart Prieto, Premium AEROTEC GmbH March the 31st 2011, Madrid 18
‐ Basically by means of NDT and Tolerance/ Assembly management
MOJO: Quality Assurance
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‐ NDT, mechanical behaviour and simulations
2%
2%
MOJO: Effect of Defects
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Task 4: SimulationTask 4: Simulation
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‐ Insertion Squeeze flow process optimisation
Tapered 1 Tapered 2 Rounded
‐ 3D‐Woven structures
MOJO: Support adhesive bonding process & on Woven structures
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MOJO: Failure analysis on different structure level testing
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Task 5: DemonstratorsTask 5: Demonstrators
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‐ One‐shot PAX‐Door Demonstrator(Fubacomp); 2004
‐ Reference Structurefor MOJO: Quarter Element forPreform‐Studies
ALCAS / MOJO Shear concentration profile
MOJO: Demonstrator
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MOJO: Industrial Applications and Demonstrator choice
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MOJO: Industrial Applications and Demonstrator choice
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Damage tolerant and structural bonded demonstrator
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1
2
3
Disbonding at 7‐8mm at many locations
MOJO: Damage tolerant and structural bonded demonstrator
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MOJO: Damage tolerant and structural bonded demonstrator
‐ The disbonding area in the Pi has propagated and stopped during fatigue testing.
‐ The demonstrator passed successfully the sequence of tests dealing with limit load, fatigue test until 200000 Cycles, limit load and ultimate load
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See the Flap Track See the Flap Track demonstrator at Booth 18demonstrator at Booth 18
Thank you for your attention
Thank you for your attention
Thank to all partenrs and the European CommissionThank to all partenrs and the European Commission