Innovation for a Sustainable Aviation in a Global Environment
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1 Sixth European Aeronautics Days Innovation for a Sustainable Aviation in a Global Environment 30 th March - 1 st April 2011 Madrid (Spain), Palacio Municipal de Congresos
2 Modular Joints for Aircraft Composite Structures March 31 st 2011, Madrid Dr. Llorenç LLOPART P. Development Engineer Materials & Processes at MOJO Dr. Llorenç Llopart Prieto, Premium AEROTEC GmbH March the 31 st 2011, Madrid 2
3 Overview MOJO: Partners MOJO: Objectives MOJO: Strategy Task 1: Preforming Task 2: Infusion & Assembly Task 3: Quality assurance & Effect of Defects Task 4: Simulation Task 5: Demonstrators MOJO Dr. Llorenç Llopart Prieto, Premium AEROTEC GmbH March the 31 st 2011, Madrid 3
4 MOJO: Partners 1. EADS Deutschland GmbH Germany: Ottobrunn, Manching and Augsburg 2. Biteam AB Sweden: Bromma 3. SECAR Technology GmbH Austria: Mürzzuschlag Hönigsberg 4. Kungliga Tekniska högskolan Stockholm (Royal Institute of Technology) Sweden: Stockholm 5. University of Patras UP Greece: Patras 6. Vyzkumny a Zkusebni Letecky Ustav a.s. (Aeronautical Research and Test Institute, Plc.) Check Republic: Prag MOJO Dr. Llorenç Llopart Prieto, Premium AEROTEC GmbH March the 31 st 2011, Madrid 4
5 MOJO: Partners 7. Dassault Aviation France: Saint Cloud 8. Eurocopter Deutschland GmbH Germany: Ottobrunn 9. EADS Innovation Works France France: Suresnes 10. Societe Anonyme Belge de Constructions Aeronautiques Belgium: Brussels 11. Deutsches Zentrum für Luft und Raumfahrt (German Aerospace Center) Germany: Braunschweig and Stuttgart 12. Co operative Research Center for Advanced Composite Structures Limited Australia: Melbourne MOJO Dr. Llorenç Llopart Prieto, Premium AEROTEC GmbH March the 31 st 2011, Madrid 5
6 MOJO: Objectives Scope of MOJO was to provide synergy between: preform technology low cost resin infusion, and structural adhesive bonding for a specialised composite material design without fasteners Technical objective was to develop a material driven composite design philosophy, new structural design principles, in order to fully utilise fibre related advantages, thus resulting in weight savings. MOJO Dr. Llorenç Llopart Prieto, Premium AEROTEC GmbH March the 31 st 2011, Madrid 6
7 MOJO: Strategy Introduction of a modular design concept using advanced preforms and textile methods for 3D reinforcement in combination with bonding by means of a demonstrator structure. The principle of MOJO laid in the design of CFRP joining elements for pure shear load transfer. The activities were complimented with an effects of defect research task in order to assess structural consequences of most common manufacturing faults and in service damages. MOJO Dr. Llorenç Llopart Prieto, Premium AEROTEC GmbH March the 31 st 2011, Madrid 7
8 MOJO: Strategy - The mechanical performance of Modular Joints were determined with an extensive testing program according to the Rouchon pyramid (building block approach). Representative structure testing definition Sub element testing definition to test a structural assembly displaying all the isolated features characterised separately earlier in the test program to test an article focused on joint fittings onto other reinforcement elements including bonding methods and profiles tested previously Assembled panel testing definition to produce assembled panels properties with the studied configuration profiles Individual join element testing definition Basic material properties testing definition to produce join element properties with woven profiles to produce basic materials properties of adhesives and composite and evaluate process parameters MOJO Dr. Llorenç Llopart Prieto, Premium AEROTEC GmbH March the 31 st 2011, Madrid 8
9 Task 1: Preforming MOJO Dr. Llorenç Llopart Prieto, Premium AEROTEC GmbH March the 31 st 2011, Madrid 9
10 MOJO: Preforming Preforming using compacting techniques Redirection of NCF tapes & Positioning Compacting Fixed Preform MOJO Dr. Llorenç Llopart Prieto, Premium AEROTEC GmbH March the 31 st 2011, Madrid 10
11 MOJO: Preforming & 3D Reinforcements Analysis for different types of connections, 3D reinforced joints, and design concepts, altering the failure mode hence improving the mechanical performance. MOJO Dr. Llorenç Llopart Prieto, Premium AEROTEC GmbH March the 31 st 2011, Madrid 11
12 MOJO: 3D Woven profiles - From the scientific point of view the focus is laid on the application of especially 3D-Woven preforms in order to alter the failure mechanism in favour of higher limit loads and overall improved mechanical performance. MOJO Dr. Llorenç Llopart Prieto, Premium AEROTEC GmbH March the 31 st 2011, Madrid 12
13 Task 2: Infusion & Assembly MOJO Dr. Llorenç Llopart Prieto, Premium AEROTEC GmbH March the 31 st 2011, Madrid 13
14 MOJO: Infiltration RTM, VAP and VARI process (Vacuum assisted resin infusion) L Profiles Pi profile Cross section of Pi profile MOJO Dr. Llorenç Llopart Prieto, Premium AEROTEC GmbH March the 31 st 2011, Madrid 14
15 MOJO: Infiltration by means of pultrusion MOJO Dr. Llorenç Llopart Prieto, Premium AEROTEC GmbH March the 31 st 2011, Madrid 15
16 MOJO: Adhesive bonding - Structures bonded with film adhesive - Structures bonded with paste adhesive MOJO Dr. Llorenç Llopart Prieto, Premium AEROTEC GmbH March the 31 st 2011, Madrid 16
17 Task 3: Quality assurance & Effect of of Defects MOJO Dr. Llorenç Llopart Prieto, Premium AEROTEC GmbH March the 31 st 2011, Madrid 17
18 MOJO: Quality Assurance Basically by means of NDT and Tolerance/ Assembly management MOJO Dr. Llorenç Llopart Prieto, Premium AEROTEC GmbH March the 31 st 2011, Madrid 18
19 MOJO: Effect of Defects NDT, mechanical behaviour and simulations 2% 2% MOJO Dr. Llorenç Llopart Prieto, Premium AEROTEC GmbH March the 31 st 2011, Madrid 19
20 Task 4: Simulation MOJO Dr. Llorenç Llopart Prieto, Premium AEROTEC GmbH March the 31 st 2011, Madrid 20
21 MOJO: Support adhesive bonding process & on Woven structures Tapered 1 Tapered 2 Rounded Insertion Squeeze flow process optimisation 3D Woven structures MOJO Dr. Llorenç Llopart Prieto, Premium AEROTEC GmbH March the 31 st 2011, Madrid 21
22 MOJO: Failure analysis on different structure level testing MOJO Dr. Llorenç Llopart Prieto, Premium AEROTEC GmbH March the 31 st 2011, Madrid 22
23 Task 5: Demonstrators MOJO Dr. Llorenç Llopart Prieto, Premium AEROTEC GmbH March the 31 st 2011, Madrid 23
24 MOJO: Demonstrator One shot PAX Door Demonstrator (Fubacomp); 2004 Reference Structure for MOJO: Quarter Element for Preform Studies ALCAS / MOJO Shear concentration profile MOJO Dr. Llorenç Llopart Prieto, Premium AEROTEC GmbH March the 31 st 2011, Madrid 24
25 MOJO: Industrial Applications and Demonstrator choice MOJO Dr. Llorenç Llopart Prieto, Premium AEROTEC GmbH March the 31 st 2011, Madrid 25
26 MOJO: Industrial Applications and Demonstrator choice MOJO Dr. Llorenç Llopart Prieto, Premium AEROTEC GmbH March the 31 st 2011, Madrid 26
27 Damage tolerant and structural bonded demonstrator MOJO Dr. Llorenç Llopart Prieto, Premium AEROTEC GmbH March the 31 st 2011, Madrid 27
28 MOJO: Damage tolerant and structural bonded demonstrator Disbonding at 7 8mm at many locations MOJO Dr. Llorenç Llopart Prieto, Premium AEROTEC GmbH March the 31 st 2011, Madrid 28
29 MOJO: Damage tolerant and structural bonded demonstrator The demonstrator passed successfully the sequence of tests dealing with limit load, fatigue test until Cycles, limit load and ultimate load The disbonding area in the Pi has propagated and stopped during fatigue testing. MOJO Dr. Llorenç Llopart Prieto, Premium AEROTEC GmbH March the 31 st 2011, Madrid 29
30 Thank you for your attention See the Flap Track demonstrator at Booth 18 Thank to all partenrs and the European Commission MOJO Dr. Llorenç Llopart Prieto, Premium AEROTEC GmbH March the 31 st 2011, Madrid 30
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