AERO CONSULTANTS (UK) LTD

AERO CONSULTANTS (UK) LTD

© 2014 Aero Consultants UK 1


© 2014 Aero Consultants UK

2



About Hollow parts with closed shape require

mandrel technology

Existing mandrel or bladder techniques show disadvantages

New class of lost core / mandrel material

Water soluble

Environmentally friendly

Processing Advantages

Applications: Air- and Cable Ducts

Stiffening Structures

Pressure Vessels

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Highlight Features Water soluble

Leightweight 0.54 gcm-3

Low CTE 4.7 e-6

Temperature resistant 195°C

Pressure resistant 8.5 bar

Autoclave and RTM

Non corrosive

Smooth surface

Automated manufacturing, machinable

Fast wash-out

Environmentally friendly – no wastewater treatment

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P



Materials

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Aquacore™ wet paste

Aquapour powder, castable

Aquafill™ filler for repair

Aquaseal™ water soluble sealant

Fastcore for automated processing

Rapidcore rapid prototypes



Reasons for Mandrel Production Common problems with processing

Service to offer ready to use water soluble mandrels

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Products AquaBlock

Pressed & Sealed

Machinable

Machined surface must be sealed with tape or sealer



Products Manufactured Mandrels



Applications Hollow Door Structures

Door Hinges

Airducts

Stringers

Example: compositesworld.com 201307



Different mandrel shapes

Wash-out station Door assembly

Aircraft Passenger Door Hinge

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Air-/Cableducts

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Airducts

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Different Airducts Missile Airduct



Landing Flap 1.5m length

RTM Processing

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Omega Stringer Up to 7m length



Pressure Vessels Mandrel made from block or with mould

Composite processing by winding or tapelaying

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Automotive Parts

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Maintenance Door

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Dimension 600x690mm (24”x 27”)

Volume 8.0 litre

OEM in Germany

Lay-up of the SMC material

Temperature 140°C / 284°F

Pressure 40bar / 580psi

Cycle time each part 8 – 11min

SMC Part

Very accurate in wall thickness

Weight reduction 51% (16.5kg => 8.0kg)

Better acoustic insulation



Manufacturing



Production Equipment

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Hot Air Ovens

Microwave Heating



CAD/CAM Design

CNC Milling

Production Equipment

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Logistics / Serial Production



Customers

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Aero Consultants

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Your Partner in the

Aerospace

Composites

Industry

Aero Consultants (UK) Ltd 13-14 Clifton Road, Huntingdon PE29 7EJ T +44 (0) 1480 432111 [email protected] www.aero-consultants.co.uk

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AERO CONSULTANTS (UK) LTD