Developments at KVE Composites - DPI Value Centre · KVE Composites Group Laan van Ypenburg 56 2497...

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


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


AEROSPACE

• Component manufacturing

• Composite repairs of aircraft structures

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DEFENCE

• Components for sensor systems

• Structural marine components


MEDICAL TECHNOLOGY

• CT patient tables

• Sensor housings


MECHATRONICS

• Machine components


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


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


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


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DUTCH TP TECHNOLOGY

• Dutch supply chain of tp composites

– Materials

– Part forming


– Components design and manufacturing / integration

• Research and Technology Development

– Technical Universities (Delft, Twente)

– NLR Dutch Aerospace Laboratory

– ThermoPlastic Research Center TPRC


THERMOPLASTIC RAW MATERIALS

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FORMING OF THERMOPLASTIC PARTS


ASSEMBLY OF THERMOPLASTIC PARTS


INTEGRATION


DEVELOPMENTS AT KVE COMPOSITES


– Compression moulding


INDUCTION WELDING


INDUCTION WELDING

• Demonstrator projects:

– A320 LE access cover demonstrator by KVE Composites

– Phantom Eye rudder: design and build by KVE Composites


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


INDUCTION WELDING IMPLEMENTED


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


LASER WELDING OF COMPOSITES

• Building block approach for development


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


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)

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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


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


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


DEVELOPMENTS

• Thermoplastic compression moulding

– Driver: combine compression moulding with welding

• Challenges:

– High temperatures (>400C): tooling; cycling

– Mould filling

– Consistent material properties

– Material/process qualification


TP COMPRESSION MOULDING

• PEEK/AS4 engine oil seal CFM56 (under development)

COMPRESSION MOULDING (4)


• PEEK/AS4 window frame (under development)

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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

[email protected]

www.kve.nl

Mr. Jeroen de Vries Commercial Manager [email protected]

Mr. Martijn van Wijngaarden R&TD manager [email protected]

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Developments at KVE Composites - DPI Value Centre · KVE Composites Group Laan van Ypenburg 56 2497...

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