Innovative tooling and manufacturing processes for pressure bulkheads of REG IADP Fuselage Demonstrator of Leonardo Aircrafts

Abstract

The current work has been performed in the context of FUSINBUL, an European project framed within CleanSky2 research programme funded by the EU’s Horizon 2020 (Grant Agreement nº 831946). The scope of this project is to accomplish the full barrel demonstrator tests, needed to certify the new conception of fuselage created and manufactured in the Green Regional Aircraft context. Two advanced manufacturing processes for composites materials (prepreg cobonding process in autoclave and LRI infusion process out of autoclave) are developed and validated to achieve full scale innovative pressure bulkheads for Regional Aircraft Fuselage barrel on-ground demonstrators. The design of the tooling has taken into account the main needs of both manufacturing processes to carry out the bulkheads and the industrial requests. In addition to this, innovative tool technologies have been developed and applied, such as cast aluminium by lost foam casting, precise but robust indexing system split and seal system of tool too large to be fabricated one shot, then precisely assembled with no gap or step. For both manufacturing processes, the most advanced techniques of lay-up are used to reduce labor costs and increase the level of industrialization in serial production to achieve bulkheads with a diameter of 3.5m and the required standards in aeronautical industry.