Abstract

This work resumes the results achieved until today in the European project AirGreen 2 of Clean Sky 2 programme, deriving from the application of two different dry preforming processes for the manufacturing of a composite outer wing box of the next generation turboprop aircrafts. Liquid Resin Infusion and Out of Autoclave techniques, by Hand-Layup and Automated Fiber Placement, are considered. The optimisation and validation of the manufacturing processes have been done according to key performance indexes: weight and cost reduction, lower energy consumption, high productivity and minimal reworking time, less intensive labour, minimal scrap and less waste of materials. The work has been performed through manufacturing tests and optimisation of the process parameters, implementation of several bagging techniques, numerical simulations of the infusion process and material characterization tests in operative conditions, from coupons level up to details and elements level (flat stiffened panels). Pro and cons, suggestions and technical considerations useful for the next step of the project (final manufacturing of large parts and components) are assessed.

Highlights

  • This work resumes the results achieved until today in the European project AirGreen 2 of Clean Sky 2 programme, deriving from the application of two different dry preforming processes for the manufacturing of a composite outer wing box of the generation turboprop aircrafts

  • The optimisation and validation of the manufacturing processes have been done according to key performance indexes: weight and cost reduction, lower energy consumption, high productivity and minimal reworking time, less intensive labour, minimal scrap and less waste of materials

  • The Liquid Resin Infusion (LRI) and Out of Autoclave (OoA) manufacturing process is the focus of the activity, starting from some validations already reached at laboratory level in the previous project AirGreen of Clean Sky (CS1), [1]

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Summary

Introduction

The Liquid Resin Infusion (LRI) and Out of Autoclave (OoA) manufacturing process is the focus of the activity, starting from some validations already reached at laboratory level in the previous project AirGreen of Clean Sky (CS1), [1]. Layup (HLU) and Automated Fiber Placement (AFP) dry preforming processes are applied, by improving weight and cost reduction, lower energy consumption, high productivity and minimal (manual) reworking time, less intensive labour, minimal scrap and lower buy/fly ratio. NOVOTECH has validated and verified the great potential of the liquid resin infusion process based on preforms laydown with the AFP technology [2]. Technical considerations useful for the manufacturing of large parts and components, are assessed

Manufacturing improvement and development
Vulnerability in operative conditions
Findings
Conclusions
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