Short notice given only substantially as follows: Composite materials in aircraft structures are mainly based on thermoset matrix systems. In the past this kind of matrix system seemed to be more economical with view on material and processing costs. But the use of high performance thermoplastic matrix systems like CF-PEEK in primary structures can almost offer a cost saving potential in comparison to CF-EPOXY. The cost reduction is basically caused by alternative manufacturing techniques followed by minimized associated personnel expenditure. For example, the combination of short fibre and continuous fibre reinforced thermoplastic material with the same matrix system is used in an unconventional alternative process generating a typical airplane part. It shall be demonstrated that cheap short fibre techniques well known form automotive industry combined with high performance continuous fibre reinforced material lead to economic structures. In a first step the production of the generic part contains the consolidation of prepreg layers based on continuous fibre reinforced thermoplastics CF-PEEK, followed by a moulding process of these prefabricated plates giving them their final geometry. All these steps were realized in an economical vacuum consolidation process developed within the Institute of Structures and Design. In a second step the necessary shaping at some substructures can be manufactured using over injection moulding or short fibre pressing technology. The assembling of the structures was conducted using resistance welding methods. On the one hand this technique offers the potential for replacement of riveting within aircraft structures and on the other hand features like better handling of tolerances can be used. Repair aspects can be provided with welding and de-welding of structural parts. As well a reconsolidation step can be added to heal local delaminating. In the same manner joining of thermoplastic and thermo set material can be accomplished when a special treatment in the joining area is available.
Thermoplastic technologies - an alternative for aircraft structures
2008
1 Seite
Aufsatz (Konferenz)
Englisch
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