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COMPOSITES IN AEROSPACE
Developments at KVE Composites
Polymer Innovation Day 2015
Papendal, 3 November 2015
4 November 2015 1 kve composites group
KVE COMPOSITES GROUP
Advanced Composite Structures
• Design and Engineering
• Manufacturing
• Repairs
• R&D
Facilit ies: • The Hague
• Maastricht Aachen Airport
• Treviso, Italy
4 November 2015 2 kve composites group
COMPANY PROFILE
• Knowledge intensive projects
• Combine engineering and manufacturing capabilities
• Strong position in product development
• Advanced composite structures:
– Complex, structural components
– Manufacturing: 5 – 500 pcs / component / yr
4 November 2015 3 kve composites group
AEROSPACE
• Component manufacturing
• Composite repairs of aircraft structures
4 November 2015 kve composites group 4
DEFENCE
• Components for sensor systems
• Structural marine components
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MEDICAL TECHNOLOGY
• CT patient tables
• Sensor housings
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MECHATRONICS
• Machine components
4 November 2015 kve composites group 8
COMPOSITES
• Define composites:
– Fiber reinforced plastics
– Continuous fibers / discontinuous fibers (25-50mm)
– Resins: thermoset / thermoplastic
• Conventional manufacturing:
– Prepreg layup, cure in/out of autoclave
– Resin transfer moulding
– Compound compression moulding
– …
• Mix of manual and automated manufacturing steps
4 November 2015 kve composites group 9
COMPOSITES IN AEROSPACE
4 November 2015 kve composites group 10
COMPOSITES IN AEROSPACE
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AEROSPACE COMPOSITES DEVELOPMENTS
• Current drivers/developments:
– General trend in aerospace:
• Increase production rates
• Decrease cost price
• At equal or better quality levels
– Automation of manufacturing
• Automated fiber placement
• Braiding
• Automated assembly
4 November 2015 kve composites group 12
THERMOPLASTIC COMPOSITES
• Growing interest in thermoplastic composites
• Fibers: glass fibre, carbon fiber
• Resins: PPS, PEI, PEEK, PEKK
• Drivers for thermoplastic use:
– Quick and easy processing into formed parts
– Assembly by welding
– Excellent fire, smoke and toxicity properties
– Resistance to aggressive fluids
– Recyclable
4 November 2015 kve composites group 13
DUTCH TP TECHNOLOGY
• Dutch supply chain of tp composites
– Materials
– Part forming
– Assembly by welding
– Components design and manufacturing / integration
• Research and Technology Development
– Technical Universities (Delft, Twente)
– NLR Dutch Aerospace Laboratory
– ThermoPlastic Research Center TPRC
4 November 2015 kve composites group 14
THERMOPLASTIC RAW MATERIALS
4 November 2015 kve composites group 15 ADVANCED COMPOSITES
FORMING OF THERMOPLASTIC PARTS
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ASSEMBLY OF THERMOPLASTIC PARTS
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INTEGRATION
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DEVELOPMENTS AT KVE COMPOSITES
– Assembly by welding
– Compression moulding
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INDUCTION WELDING
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INDUCTION WELDING
• Demonstrator projects:
– A320 LE access cover demonstrator by KVE Composites
– Phantom Eye rudder: design and build by KVE Composites
4 November 2015 21 kve composites group
INDUCTION WELDING
• Induction welding licensed for commercial programmes:
– Fokker Aerostructures
• Gulfstream G650 elevator and rudder
• Dassault 5X elevators and rudder
– Aviacomp, France
• Bombardier C-series fuel tank access panels
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INDUCTION WELDING IMPLEMENTED
4 November 2015 kve composites group 23
INDUCTION WELDING
New developments:
• High volume welding (20 min cycle)
• Single sided lightning strike
• Other materials from PEEK/PEKK family
• Welding of edge stiffeners
– Induction welding
– Laser welding
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LASER WELDING OF COMPOSITES
• Building block approach for development
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clamping pressure
laser absorbing part (LA)
laser transparent part (LT)
laser light
welding area
COMPRESSION MOULDING
• KVE implemented a modified Compression Moulding process
• The process offers:
• Higher specific strength and stiffness compared to metals
• Co-Moulding of metal inserts
• Integration with UD or tri-axial reinforcements
• Freedom of design (3D shapes)
• (Potential for) automated production
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COMPRESSION MOULDING PROCESS
• The process
Starting from short fibres (25-50mm) compound (1)
a preform is created (2)
which will be compressed into it’s final shape (3)
And cured in short cycle times (4)
4 November 2015 28 KVE Composites Group – Confidential
COMPOUND CHARACTERISTICS
• Compounds compared to other composites
• Advantages:
• Small dimensions (high level of detail)
• High tolerance (~0.05 mm out-of-mould)
• Isotropic material
• High production rate (typical range: 100 to 50.000 /year)
• Low cycle time
• No machining necessary
• Disadvantages:
• Tooling costs
• Material costs
• Material variation
4 November 2015 30 KVE Composites Group – Confidential
SATELLITE STRUCTURAL COMPONENTS
• Structural part on outside of a satellite
– Main requirement: stability (stiffness, thermal)
• Requirements:
– CTE: <1 ppm/°C
– Strength: >300 MPa
– Stiffness: >110 Gpa
– Outgassing
• Alternatives:
– Ceramics: too expensive, poor in tension
– Invar: too heavy
4 November 2015 31 KVE Composites Group – Confidential
SATELLITE STRUCTURAL COMPONENTS
• Product challenge:
– Thermal cycling
– High stresses at load introduction
– Complex shapes
– Tight tolerances
• Solutions:
– Co-moulding of metal inserts with
low CTE
– Complex mould
– First time right
4 November 2015 32 KVE Composites Group – Confidential
DEVELOPMENTS
• Thermoplastic compression moulding
– Driver: combine compression moulding with welding
• Challenges:
– High temperatures (>400C): tooling; cycling
– Mould filling
– Consistent material properties
– Material/process qualification
4 November 2015 36 KVE Composites Group – Confidential
TP COMPRESSION MOULDING
• PEEK/AS4 engine oil seal CFM56 (under development)
COMPRESSION MOULDING (4)
4 November 2015 38 kve composites group
• PEEK/AS4 window frame (under development)
4 November 2015 39 confidential in business
For more information please contact:
KVE Composites Group
Laan van Ypenburg 56
2497 The Hague
The Netherlands
Tel +31 70 3074710
Fax +31 70 3074711
www.kve.nl
Mr. Jeroen de Vries Commercial Manager [email protected]
Mr. Martijn van Wijngaarden R&TD manager [email protected]