D73

Development and INnovation
for Advanced ManufacturIng

of Thermoplastics
Mid-Term Achievements of work
by
Patrice LEFEBURE _ EADS CCR
(patrice.lefebure@ eads.net)
&
C. QUINQUIS _ A-F, S. KASCHEL _ A-D, R. AVILA DOMINGUEZ _ A-E, M. BUCKLEY _ A-UK, C. COIFFIERCOLAS _ D. Av, H. SIBOIS _ Eurocopter, G. LAMPEAS _ LTSM Patras, B. PEREZ Magallon _ CIDAUT, U. SPELZ _
ACM, H. RUCKDSCHEL LPW Bayreuth, J. LEE _ I.C, R. SCHLEDJEWSKI _ IVW Kaiserslautern.
FP6 DINAMIT Program -P.LEFEBURE

P.LEFEBURE--EADS CCRCCR- Aerodays Vienna 2006
This document is the property of EADS CCR ; no part of it shall be reproduced or transmitted without the express prior written authorisation of EADS CCR,
and its contents shall not be disclosed. - EADS CCR - 2006
FP6 STREP DINAMIT Program

contract :AST3-CT-2003-502831
Duration: 36 month from 2004/02/01
Budget: 3.6 Meuros

Consortium: 13 partners
Co-ordinator
UNIVERSITY
of PATRAS

Content
z Interests
of High Performance Thermoplastic

Composites for aeronautics structure.
z Objectives
z Main
of the DINAMIT program
Achievements of works
z Conclusion

Interests of H.P Thermoplastics

High Performance Thermoplastic Composite materials are soon used
for manufacture of aeronautical structures.
Compared to Thermoset resin Fibres systems, many advantages such as:
Good Impact behaviour.
Fire resistance.
Low moisture absorption.
capabilities of Storage at Room Temperature.
Welding capabilities.
Potential recycling capabilities.
Great interest for potential Fuselage applications !


Today, restrictions for application to design and manufacture
of aerospace structures
Thermoplastics are furthermore generally restricted to simple
geometry parts and limited dimensions, due to the current
technological limitations.
Material costs, and the global production costs remain high
2005 Price/kg
Relative Prices
of
Carbon fibres prepregs
Hexcel M21/T800
100
Hexcel M21/T700
75
Cytec 977-2/HTS
75
Cytec APC2/AS4
300


Temperatures of consolidation > 350C
@Manufacturing costs drastically increase!
Specific Industrial facilities and consolidations costs
Ancillary
products
Relative Prices
of ancillary products
Thermoset
Thermoplastic
Sealant
100
2000
Vessel
100
200
Breather
fabric
100
500
Peel ply
100
200
Release
film
100
200

DINAMIT PROGRAM OBJECTIVES

Main objectives of the project :
Reduction of the prohibitive material costs.
Min . 20% reduction hoped.(/very limited number of references)
Reduction of the associated forming-consolidation costs.

Due to high temperature of processes.
Development of rapid, flexible, low cost processes for structure

assembly .

ACHIEVEMENT OF THE OBJECTIVES

Objectives achieved by:
The development of low cost H.P thermoplastic composites for aeronautical
application:
New TP blend /Carbon prepregs, Carbon/PEKK prepregs evaluation, Evaluation
of new multiaxial Thermoplastic Fabrics, New material for In Situ Consolidation
processes .
The development of enhanced forming-consolidation processes for skins and
substructures
In situ consolidation processes & high speed automatic lay down process for
manufacture of double curvature parts, Continuous Forming and Roll-Forming
technologies for TP contoured profiles, low pressure injection process, enhanced
Diaphragm forming technique coupled with IR heating.
The development of new welding processes :
In-situ welding process , Feasibility study of Laser welding Including laser
treatment of surfaces for preparation to welding.
The development of a cost optimisation tool for innovative materials and
processes
ACHIEVEMENTS OF WORK
Development of TP blends products
(by LPW, AirbusD, Eurocopter)
z
Specifications elaborated from references = PEEK based materials .

PES
Formulation of 4 TP blends from this diagram.
decreased media
resistance
cost reduction
brittle behaviour
Resin Characterisations set up.
2 blend formulations chosen for UD & Fabric impregnation:PEEK

Blend 1: best performances.
Blend 2: most suitable for forming consolidation processes.
30% resin cost reduction is hoped (Victrex source)
brittle behaviour PEI

cost reduction
increased glass transition
Reference: LPW
BAYREUTH
First Carbon Fabrics/ blend are

consolidated.
Mechanical tests on UD and Fabrics tapes to be set up

Evaluation of New multiaxial TP products (A-F, LTSM)
Main interests: lay up time saving, formability at room temperature
Formability tests performed on 4 PEEK based NCF products
Carbon/peek
commingled
fibres
Peek between
each dry ply
SUPPLIER
Drape-ability
PORCHER
(NCF from SAERTEX)
tbd
SAERTEX
(fibres from COMFIL)
excellent
HEXCEL
(fibres from SCHAPPES)
excellent
HEXCEL (fleece)
excellent
HEXCEL (towflex)
possible
SAERTEX plate
Consolidation of plates
Mechanical tests in progress for comparison of the TP NCF to
APC2/AS4 (reference)
10
Processing evaluation of UD PEKK/C tapes (IC, A-UK)

Major results
PEKK/C tapes seem available for aeronautical application.
No major effect of the processing method.
But no real cost reduction on the manufacturing cost today.

11
New technology developments for first ply lay-up on
complex geometry (by Dassault Aviation and EADS CCR)
DAv developments:
Adhesive technology
Glass fabric + adhesive on tooling
Specific first ply: PEEK/Carbon tape + adhesive
EADS CCR Developments

Vacuum technology
Specific double
First ply maintained with
curvature
tooling
vacuumof EADS CCR,
This document is the property of EADS CCR ; no part of it shall be reproduced or transmitted without the express prior written authorisation
12
Automated cost effective Technology for TPs d.c. panel

manufacture (by EADS/CCR)
Consolidation
into oven
Automatic lay down of 1 inch width APC2/AS4 tape

With max speed of the head displacement
Determination of the
Process window completed:
Max head speed.
Pressure.
Temperature
consolidated
APC2/AS4
Panel

13
Benchmarking on ISC Process (IVW)
Influence of process parameters :
heating source, velocity, consolidation force, material nature (CYTEC PEEK/Carbon tapes)
Main results:
material nature and heating method seems to have the most influence for ISC
process (validation with peel tests)
Infrared heating system for the diaphragm process (LTSM)

Temp. Vs Time
350
Temperature [^C]
300
250
200
5 mm Thick
150
100
50
0
0
1000
2000
3000
4000
5000
Time [s]
Process simulation
Thermal analysis for optimisation
(strain distribution)
of the Infra red heating

14
Continuous forming of contoured profiles (ACM)
Process parameters optimised for

C/PEEK Z stiffeners manufacture
TP roll forming developments (Airbus UK)

Thermoset roll forming machine
upgraded with a specific Infrared preheating system
Development a TP RTM process (EADS CCR)

Materials: TICONA PPS pellets
and PORCHER Carbon fabrics
Drastic Problems of PPS oxidation

at high temperature
15
Laser developments for TPs assembly (CIDAUT, Airbus-E, Eurocopter)
LASER WELDING Feasibility

Welding tests performed with a YAG laser source (transmission mode)
on PEI, PPS, PEEK, PEKK Carbon or Glass fibre parts.
laser welded Pei/GF with PEKK/CF
CF/PPS Welded joint
Weldability of TP GF
components demonstrated,
but critical process for TP
CF tapes:
limitation to thin components
Laser
treatment of surfaces before welding

9Compared Processes by measurements of surface
energy and mechanical shear properties after
treatments
o Manual sanding ( standard industrial process)
oYag laser source (tripled 355 nm)
oDiode laser
(810 nm) P.LEFEBURE--EADS CCRFP6 DINAMIT Program -P.LEFEBURE
CCR- Aerodays Vienna 2006
Tests in progress,
but Laser Treatments
seem soon more
adapted to TP parts
than for TD
16
Cost effective Analysis (LTSM Patras)
Sub
Process 1
Sub
Process 2
Sub
Process 3
COST
DRIVERS
COST
DRIVERS
COST
DRIVERS
CER
CER
Sub
Process 4
Sub
Process 5
COST
DRIVERS
COST
DRIVERS
CER
CER
Cost Estimation Tool main Characteristics

Easy accessibility by the user
Friendly interface
Fully parametric
Divides the process into sub-processes
Extracting graphs
It can be modified any time
Material
supply
Preparation
of the tool
K1
K2
CER
K3
K4
K5
Input
TOTAL
COST Ktotal
Preparation of
the material and
closing
Heating
OPTIMIZATION
Output
Cost analysis flow chart

Final Part
Opening, Demolding,
rework, inspection and
storage
Forming
consolidation
cooling
Diaphragm forming Process chain

17
CONCLUSION
Industrial Applications
z
To Increase the level of HP Thermoplastic Composites on Aerospace structures.

Impact on civil or military projects.
Applications on the next generation of Aircrafts or Helicopters Fuselages
with new materials and enhanced technologies.
Costs Impacts
9Today it is hoped a minimum 20% Materials cost reductions in the 2 or 5 years
after the end of the programme.
9New TPs technologies could induce 20% to 30% manufacture cost reduction with:
Automation of the TPs processes.
Increase of the importance of high Performance Thermoplastics in aerospace
structures.
Flexible welding technologies .
Efficient Cost effective tool needed for help to the design of aerospace composite
structural
parts
18
ACKNOWLEDGMENTS
The DINAMIT consortium acknowledges the grant

of the European Community
for the FP6 DINAMIT STREP Project
(Contract No. AST3-CT-2003-502831).

19

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Development and INnovation

for Advanced ManufacturIng

FP6 DINAMIT Program -P.LEFEBURE

FP6 STREP DINAMIT Program

Budget: 3.6 Meuros

FP6 DINAMIT Program -P.LEFEBURE

of High Performance Thermoplastic

of the DINAMIT program

FP6 DINAMIT Program -P.LEFEBURE

Interests of H.P Thermoplastics

Great interest for potential Fuselage applications !

Interests of H.P Thermoplastics

FP6 DINAMIT Program -P.LEFEBURE

Interests of H.P Thermoplastics

FP6 DINAMIT Program -P.LEFEBURE

DINAMIT PROGRAM OBJECTIVES

Reduction of the associated forming-consolidation costs.

Development of rapid, flexible, low cost processes for structure

FP6 DINAMIT Program -P.LEFEBURE

ACHIEVEMENT OF THE OBJECTIVES

Specifications elaborated from references = PEEK based materials .

Formulation of 4 TP blends from this diagram.

Resin Characterisations set up.

2 blend formulations chosen for UD & Fabric impregnation:PEEK

brittle behaviour PEI

First Carbon Fabrics/ blend are

Mechanical tests on UD and Fabrics tapes to be set up

Processing evaluation of UD PEKK/C tapes (IC, A-UK)

FP6 DINAMIT Program -P.LEFEBURE

Glass fabric + adhesive on tooling

Specific first ply: PEEK/Carbon tape + adhesive

EADS CCR Developments

Automated cost effective Technology for TPs d.c. panel

Automatic lay down of 1 inch width APC2/AS4 tape

FP6 DINAMIT Program -P.LEFEBURE

Infrared heating system for the diaphragm process (LTSM)

Thermal analysis for optimisation

of the Infra red heating

FP6 DINAMIT Program -P.LEFEBURE

Continuous forming of contoured profiles (ACM)

Process parameters optimised for

TP roll forming developments (Airbus UK)

Development a TP RTM process (EADS CCR)

Drastic Problems of PPS oxidation

LASER WELDING Feasibility

laser welded Pei/GF with PEKK/CF

CF/PPS Welded joint

treatment of surfaces before welding

Cost Estimation Tool main Characteristics

Cost analysis flow chart

Diaphragm forming Process chain

To Increase the level of HP Thermoplastic Composites on Aerospace structures.

The DINAMIT consortium acknowledges the grant

FP6 DINAMIT Program -P.LEFEBURE

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