Aerospace & Defence
Fig. 4. Composite materials are evident in new aircrafts such as the Airbus A400M military transport aircraft.
part-to-part uniformity, and reduced weight. The method is used on Airbus A350 XWB rear spar and trailing edge assembly, and allows steering of fibres and greater component complexity and features.
Resin transfer moulding
Resin transfer moulding reduces weight, cost and assembly time. Used on environmental lightweight fan blades, Lockheed Martin F-35 Lightning II front fan frame, Airbus A380 rudder actuator brackets and A340 rear pylon fairings, Saab Gripen weapon fairings and Taurus KEPD 350 missile wing, it provides quality and repeatability, integrated structures and accurate interface. Resin film infusion technology was developed by
GKN Aerospace and utilises a lay-up process that allows out-of-autoclave curing using either an oven or heated tools. Used on Efficomp, Tango spars, Awiator winglet and Airbus A380 trailing edge panels, it removes size and cost constraints of an autoclave, improves cycle times and quality, and offers the potential to reduce weight and cost, while allowing lean flow of product. Liquid resin infusion is a process where dry carbon
fibre material is laid into a tool. The carbon material can be pre-formed into 3D shapes. The resin is then injected according to precise requirements of temperature and pressure. Used on integrated wing
programme and next generation composite wing programme. Also used on integrated wing programme, microwave curing delivers direct heating to the part and does not require high pressure to be maintained inside the chamber. It allows a better coefficient of thermal expansion to be achieved between the part and the mould which means that more accurate complex components can be obtained. The modular design of the microwave chambers
allows them to be used in series so that materials can be passed through on a conveyor system. The equipment allows for metal items to be introduced into the process without the risk of arcing or damage. The process benefits from the heat up and cool down rates over a conventional autoclave.
Laser ablation
Finally with the ability to be used on all composite structures, laser ablation works by removing the matrix or resin from the composite by vaporising the resin with a low energy density using a TEA CO2
laser. There is
no contact during the process, avoiding the traditional machining and grinding where fibres may suffer local damage. The exposed fibres are brushed away until the repair is ready for replacement material to be bonded in place. ●
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