AEROPLAS – Desarrollo de componentes para la industria aeronáutica mediante tecnologías de bajo coste

Abstract

The future of the aeronautical sector is oriented towards manufacturing lighter and more profitable structures and components, using more ecological materials and technologies, that allow reducing costs, weight and fuel consumption, with shorter manufacturing cycles, while increasing energy efficiency manufacturing. AEROPLAS project arises in this context, with the aim of contributing to the advanced manufacturing process of thermoplastic composites using low-cost technologies for the aeronautical industry. This study focuses on the replacement of aeronautical parts currently manufactured in thermosetting composite by thermoplastic ones, in two real components: cover panel and access door of the ventral fairing of A350, using two materials of different quality: LM-PAEK/CF semipreg (TenCate Cetex® TC1225) and PC/CF prepreg (ePreg245CHT/PC40). Through design and calculation, the stacking and part thicknesses necessary to cover the structural requirements of both components have been obtained, based on the data acquired from the characterization of the base materials. Two manufacturing processes have been studied and compared to obtain the new parts, selecting thermoforming and stamping as the most promising. Finally, the characterization of the pieces obtained has been carried out by means of non-destructive tests (visual inspection, ultrasonic verification, dimensional inspection using laser tracker) and destructive tests (pull-out strength on riveted joints [AITM1-0066], bearing strength [AITM1-0009], laminate tensile strength [AITM1-0007], fastened joints strength [AITM1-0067]).