i-Composites - Microwave Curing to Increase Rate

Transcription

Feasibility study into Microwave curing of
composites
Victoria Coenen
Aircelle UK Ltd
Content
Introduction to Aircelle
 SAFRAN Group
 Aircelle
 Aircelle UK Ltd
i-composites project – Microwave Curing
 Scope of project / top level plan
 Literature review / technology
 Aircelle materials / products
 Cure cycle optimisation plan
 Microwave tooling methodology
 Business Case / Project KPIs
DIRECTION / Date
1
Ce document et les informations qu’il contient sont la propriété de Aircelle. Ils ne doivent pas être copiés ni communiqués à un tiers sans l’autorisation préalable et écrite de Aircelle.
Safran Group
Aircraft Equipment
Aerospace propulsion
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Snecma
Snecma Propulsion Solide
Turbomeca
Techspace Aero
27 %
Aerospace
Propulsion
10 %
54 %
Aircraft equipment
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9%
Aircelle
Hispano-Suiza
Labinal
Messier-Bugatti
Messier-Dowty
Teuchos
Defence
Electrically-actuated
carbon brake
Hemispherical
resonating gyro
Security
Thermal imager
3D RTM fan blade
Defense security

Sagem Défense Sécurité
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Sagem Sécurité
Mica missile seeker
LEAP-X engine
Revenue:
CMC nozzle and combustor
10,448 million euros
Recurring operating income: 698 million euros
Félin integrated
equipment suite
Net income – Group share:
376 million euros
Biometric recognition
DIRECTION / Date
2
SAFRAN GROUP ON COMMERCIAL AIRCRAFT
Engine equipment and parts
• Integrated engine control systems
• Power transmissions
• Engine modules and components
• Composite engine parts
Aircraft equipment
• Network server systems
• Back-up flight control
• Secure data link
• Cockpit control systems
• Electrical wiring systems
• Aircraft condition monitoring systems
• Composite aerostructures
• Auxiliary power units
• Hydraulic systems
• Sensors and actuators
• Ventilation/filtration
• Inertial references
Engine services
• Maintenance, repair and overhaul
• Engine testing and test equipment
Engines
• CFM56 family (50/50 with GE)
• SAM146 engine for the Russian
Regional Jet (50/50 with NPO Saturn)
• Participation in programs: CF6, GE90,
GE90-115B, GP7000, PW4000, AS900, CF34
DIRECTION / Date
3
Nacelles
Nacelles and components
(thrust reversers,…)
Landing & braking systems
• Landing gear for all types of aircraft
• Braking/landing control systems
• Wheels and carbon brakes
• Control systems and hydraulics
• Maintenance, repair and overhaul
Aircelle Presentation
Nacelles
that cover all engines
Aircelle Programs
Regional & Business Aircraft
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BOMBARDIER:
 Thrust reverser for the Global Express and the G5000
with the BR710, and Challenger 300 with the HTF7000
 Nacelle for the Learjet 85 with the PW307B
DASSAULT:
 Nacelle for Falcon 7X PWC307 (JV with MHD)
EMBRAER:
 Reverser + Air intake for the ERJ135.145 - AE3007
 Nacelle for the ERJ 170 with the CF34-8 (MHD)
GULFSTREAM:
 Reverser for the G500 and the 550 with the BR710
SUKHOI:
 Nacelle for the SaM146 on the SuperJet 100
DIRECTION / Date
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Single-aisle & widebody aircraft
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AIRBUS:
 Rolls Royce Trent 900 Nacelle on the A380
 Engine Alliance GP7200 Nacelle on the A380
 Rolls Royce Trent 500 Nacelle on the A340-500/600
 CFM56 Reverser on the A340-200/300
 CFM56 Reverser for the A320 family
 Rolls Royce Trent 700 Reverser on the A330
 PW6000 Nacelle on the A318
BOEING
 Rolls Royce RB211 Reverser on the 747
 Rolls Royce RB211 Reverser on the 767
DOUGLAS:
 CFM56 Reverser on the DC 8-71
3,000 employees, 7 sites
Pont-Audemer (60)
Aircelle Europe Services
Burnley (700)
Aircelle Ltd
Le Havre (1430)
Florange (200)
SLCA
Toulouse (220)
Plaisir (180)
Casablanca (330)
Aircelle Maroc
DIRECTION / Date
6
R&D
Customer Support
Nacelles assembly
Composites manufacturing
Aerostructures assembly
Hot exhaust manufacturing
Podding
Sheet metal forming
Repair and overhaul
Machining
Aircelle UK Programs & Processes
Rolls Royce Trent 700 Thrust Reverser on the A330
A380 Thrust Reverser
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Blocker doors for T900 & GP7200 engines
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Inner Fixed Structure (GP7200)
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Front Frame (T900 / GP7200)
Bombardier Challenger 300 Thrust Reverser (AS907)
Embraer ERJ135 & 145 Thrust Reverser & Air Inlet
Rolls Royce RB211 on the Boeing 747 & 767
Acoustic sandwich panel manufacture
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Metallic / Composite
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SDOF / 2DOF
Associated processes
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Adhesive reticulation – skin / core
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Acoustic drilling
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Hand lay-up / vacuum bagging
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Autoclave curing
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Inspection - C-scan / A-scan
DIRECTION / Date
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i-composites project
MICROWAVE CURING
DIRECTION / Date
8
Scope of The Project
A feasibility study into the use of microwave technology to cure composite aerospace components
The study will provide the following outputs;
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A curing process for a particular material system
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Cure cycle optimisation for a range of material thicknesses / component geometries
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Analysis of material properties obtained through the use of microwave curing
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An investigation into tooling requirements for this technology with cost implications
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A calculation of energy & cost savings
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Compatibility with existing infrastructure / equipment assessed
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A business case for the adoption of the technology
There is also the aspect of collaboration with the other partners in Theme C – Energy Reduction
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Airbus UK - Correlation between degree of cure prediction by modelling cure kinetics & direct measure of degree of
cure using real-time dynamic dielectric cure monitoring (DEA).
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Fraser Nash – Development of a validated coupled CFD-FE thermo-structural method for simulating the cure process
(oven & microwave)
DIRECTION / Date
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Top Level Project Plan
Definition (8 weeks)
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Material & component selection
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Consider simulation & cure monitoring techniques
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Assess TRL levels (equipment / process)
Design (12 weeks)
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Plan cure cycle Optimisation (define cure cycles to trial / tests to be performed)
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Investigate microwave tooling methodology / options / optimisation
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Design tool
Manufacturing (12 weeks)
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Flat panel manufacture (cure cycle optimisation / mechanical property verification)
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Element manufacture
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Tooling manufacture
Assembly / Commission (12 weeks)
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Manufacture of product demonstrator
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Tear down / inspection of product demonstrator
Report (8 weeks)
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Business case
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Results of feasibility study
DIRECTION / Date
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WP1 – Definition
Microwave oven to be used for the project is at TWI (The Welding
Institute) in Middlesbrough
Votsch HEPHAISTOS Microwave oven
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An internationally patented system characterised by a very high field
homogeneity.
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Hexagonal chamber enables more homogenous heating
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Conventional production systems (e.g. metal tools) may be kept.
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Microwaves are the only physical heating method for the specific,
volumetric heating of a product.
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The furnace chamber itself remains cold.
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Standard operating frequency is 2.45GHz, since organic materials are
most susceptible to this.
“Microwave curing has significant advantages in terms of the energy
& time required to cure components; typically, only one third of
the energy & time is required to cure a component when
compared to conventional autoclave methods thus leading to
potential cost savings.”
DIRECTION / Date
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WP1 – Definition
Internet based review of literature
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Microwave curing of polymers has been studied for > 20 yrs
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Models of microwave behaviour available
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Microwave technology / heating well understood
Majority of literature not applicable to understanding the factors affecting the manufacture of high
quality prepreg laminates in a microwave
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Analysis of resin only – reaction to microwave heating
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Studies into effect of altering resin chemistry
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Application of microwave curing / heating to resin transfer moulding
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Analysis of single fibre composites
Work has been done on microwave curing of prepreg but this is not typically in the public domain
Practical advice / guidance in terms of simple dos & don'ts
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Consumables
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Vacuum fittings
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Temperature sensors
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Tooling methodology
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Things to avoid!!!
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How to make good quality laminates??
DIRECTION / Date
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WP1 – Definition
Upper access panel
Hybrid Composite
913/54%/G783
Down select material
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Typical Aircelle materials & processes considered
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Carbon / epoxy prepreg – 5HS fabric, HTS 3K fibres, Hexcel 914 resin
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Bismaleimide prepreg (5HS fabric)
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Carbon / glass hybrid prepreg (Hexcel 913 resin)
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Lightning protection – copper or bronze mesh
Down select product demonstrator
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Integrated Inner barrel
Carbon epoxy
914C/40%/703
Typical Aircelle components / part families considered
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Thrust reverser cowlings – large thin skin, double curved structures
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Honeycomb reinforcement for stiffness & / or acoustic treatment
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Large complex structural components
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Smaller scale components – access panels / kicker plates / side members
Lower access panel
Hybrid Composite
913/54%/G783
Study will consider only monolithic for cure cycle trials / optimisation
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No bonding / adhesive / potting / splice adhesive etc
Size limitations
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Microwave dimensions
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Transportation
Tooling – compatibility with microwave………….
DIRECTION / Date
13
WP2 – Design
Cure cycle optimisation plan
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Cure cycle time reduction through the use of microwave curing – how??
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Increase in ramp rates = reduction in cure cycle duration
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Typical rapid curing techniques reduce time taken to reach dwell temperatures
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Dwell durations as recommend by manufacture / autoclave cure cycle specifications
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Considerable reductions in cure cycle duration, increasing ramp rates from 1-2°C to 12-15°C / minute
Microwave curing may offer completely different options
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Instantaneous volumetric heating of material
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How does the material react?
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What is the effect on cure reactions?
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What is the effect on material quality / mechanical properties?
Laminate is heated in an effectively ‘cold’ environment
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Opportunity to monitor the material as it cures & respond / tailor the cure cycle accordingly
Influence of tooling material / laminate thickness / lay-up etc
All of the above are unknown…………..
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A trial & error approach is required
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A simple step by step approach to defining a suitable microwave cure cycle is proposed..…..
DIRECTION / Date
14
WP2 - Design
Sample definition
To optimise a cure cycle it is necessary to assess a range of laminate thicknesses
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For each cure trial panels of 2mm, 4mm, 8mm and 12mm will be manufactured
Tool size – 500 x 500 mm
2mm
4mm
8mm
12mm
Panel size – 200 x 200 mm
It is also necessary to assess the affect of microwave curing on different lay-ups
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Panels of [0], and [0/+45/-45/90]s lay-up will be trialled
Analysis of suitable consumables will be performed during the preliminary stages of the process
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Bagging material / vac putty
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Aluminium tape
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Breather material
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Thermocouples
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Bleed pack / edge damming
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Lightning protection
DIRECTION / Date
15
Phase One – Characterisation of Microwave Cure Process
Theme C Collaborative
activity – Thick MTM44-1
flat panel (with ply buildups) incorporating cure
monitoring sensors, cure
cycle modelled / simulated.
5 off cure trials, 4 off 200 x 200mm samples of
thickness 2,4, 8 and 12 mm, 0 degree lay-up
10%
power
20%
power
30%
power
40%
power
50%
power
Assessment of the ramp rate achieved
Material quality tests: volume fraction, void content
Microwave power setting / ramp rate selected
Thickness effects
assessed
Assessment of
consumables
DIRECTION / Date
16
1 off cure trial, 4 off 200 x 200mm
samples of thickness 2,4, 8, 12 mm,
Quasi Isotropic [0/+45/-45/90]s lay-up
Selected power setting used to assess
effect of lay-up on heating,
material quality verified using c-scan &
microscopy
2 off cure trials, 4 off 200 x 200mm
samples of thickness 2,4, 8, 12 mm,
0 and [0/+45/-45/90]s degree lay-up
Selected power setting used to assess
homogeneity of heating for different
laminate thicknesses and lay-up
Cure process characterised & ramp rate selected
Phases 2 & 3 - Cure Cycle Definition & Validation
Cure trials to assess different cure profiles as below, 4 off 200 x
200mm samples of thickness 2,4, 8 and 12 mm, 0 degree layup, standard dwell durations used
T
T
T
180
180
130
130
time
180
Flat samples, 2 mm thickness for
mechanical testing.
Number of material batches??
Sample conditioning??
time
time
Mechanical tests;
Tensile & Poisson’s ratio, Shear modulus (+/45), DSC, DMA, flexural, ILSS, density, fibre
volume fraction, void content
Laminate quality verified using microscopy, void content analysis
& ILSS tests, degree of cure assessed through DSC & DMA
Microwave cure cycle validated
Cure Profile & dwell durations selected
DIRECTION / Date
17
WP2 – Design
Microwave Tooling Methodology
Temperature recording – sensors suitable to the microwave?
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Material compatibility – shielding / local hotspots
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Signal interference – reliable data
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A range of sensors have been considered
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Resistance temperature detectors (RTDs)
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Fibre optics with Fibre Bragg Gratings
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Thermocouples – Type K, Type E, Type N
Tool Materials suitable for microwave:
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Copper : transparent
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Bronze : alloy of copper & tin - both transparent to microwaves
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Aluminium : reflects the magnetic field
Not suitable for use in the microwave :
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Steel or Nickel : ferromagnetic
Other considerations
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No sharp edges – sparks (tool material & laminate)
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Other design features – nuts / bolts / screws / backing structure
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Low pressure cure – lightweight tools
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Redesign for new process
DIRECTION / Date
18
WP2 – Design
Tool Design
Initial trial steel plate covered with aluminium tape
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Steel plate all covered : OK
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Steel plate + composite plies : OK
Initial trial – lightning protection
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External panels are covered with a fine metallic
mesh to conduct lightning across the surface to
protect systems & structure beneath
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Trials have shown these materials are safe to put
in the microwave
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Intention is to include in product demonstrator
Steel plate + aluminium tape +
composite plies + bronze mesh : OK
Steel plate + aluminium tape +
composite plies + copper mesh : OK
NB : All tests have been done in a commercial microwave, 2.45 GHz
DIRECTION / Date
19
WP2 – Design
Tool Design
4 off Test Panels (200mm x 200mm)
6mm aluminium plate (610mm x 610mm)
Fibre optic instrumentation embedded in underside of tool
Temperature Sensing – Fibre Bragg Grating fibre
optic sensors selected
Sensors embedded in tool to reduce risk of damage
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Machined groove around each laminate position to
ensure each panel is laid up in same place
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Temperature sensors under laminates measure how
much of the heat absorbed by the laminate is ‘lost’ to
the tool
Each laminate will have fibre optic sensors
embedded in the lay-up
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SMART fibres chosen as supplier
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Training planned on data capture equipment which
will be rented for the trials
Temperature sensor
DIRECTION / Date
20
WP3 - Manufacturing
Status
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Test panel drawings raised & issued
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Tool drawings raised & issued
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Tool in manufacture
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Plies cut
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Sensors on order
Manufacturing plan
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Panels will be laid up in Burnley (sensors embedded)
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Vacuum bagged & checked on site then transported to TWI
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Arrive at TWI
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Vacuum check & connection
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Sensors connected & calibration
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Press go & wait / watch
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Analyse laminate quality & mechanical properties
Timescales
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Cure cycle definition during October
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Cure cycle validation during November
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MTM44-1 panel (collaborative activity) during November
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Manufacture & test of product demonstrator by end of January
DIRECTION / Date
21
WP5 - Report
Throughout the project a cost analysis will be performed comparing the autoclave & microwave
processes, potential cost savings are as follows;
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Recurring Costs;
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Low temperature / pressure cure process may allow the use of lower cost consumables
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Microwave curing provides reduced energy consumption as only part to be cured is heated
 Non Recurring Costs
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Low temperature / pressure cure process may allow the use of cheaper / less complex tooling
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Reduced cure cycle time allows higher production rates, less tooling required to meet rate
Throughout the project a business case for the use of microwave curing will be prepared;
 Cost of microwave oven vs. cost of autoclaves
 Infrastructure required
 Tooling costs
 Compatibility with
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Existing infrastructure
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Aircelle products / part families
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Aircelle materials & processes
 Other uses for the equipment ?
DIRECTION / Date
22

Postcuring
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Paint shop - drying
Conclusion
Microwave curing has the potential to reduce the time, cost & energy required to produce
composite parts, however………..
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Microwave curing / technology is completely new to Aircelle
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Project timescales extremely speedy
Plan in place for a structured step by step approach
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Initial trials show material will cure in the microwave
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Next step is to try more cure cycles & more component geometries
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Assessment of the repeatability & quality of the process is required
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Validation of the cure process through mechanical testing & inspection of parts
Collaboration with Airbus UK & Frazer-Nash will accelerate understanding & optimisation of the
process

Simulation of the microwave curing environment to aid further exploitation of process

Optimisation of the cure process, with the possibility of further cure time reduction
Work is underway to assess the impact on our business

Realisation of savings
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Applicability of current tooling
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Applicability of parts / processes

Other areas where the technology could be used
DIRECTION / Date
23
Thank you for listening………….
QUESTIONS?
DIRECTION / Date
24

i-Composites - Microwave Curing to Increase Rate

Transcription

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