ECO-FAIRS

ECO-design and manufacturing of thermoplastic structural fairings for helicopters

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 Obiettivo del progetto (Objective)

'The project aims to design and manufacture three structural fairings for helicopters using thermoplastic composite materials, namely: - Upper Panel Rear Fuselage Demonstrator; - Sponson Fairing Demonstrator; - Radome Demonstrator. Materials and processes selection and technology guidelines will support the design phase in which tooling and process parameters will be designed and set-up. The three physical demonstrators will be produced and tested according to technical specifications, with a low environmental impact and with a TRL6 Technology Readiness Level. Resistance, induction and ultrasonic welding techniques will be studied in depth in the project for the manufacturing of the joinings required for the demonstrators assembling, and their use will be preferred to mechanical and bonded joinings, in order to decrease the extensive use of adhesives and mechanical fasteners and to make easier the recyclability at components end-life. In order to achieve the most economic design and manufacturing technologies, and in order to evaluate the mechanical performances and to achieve the eco-quotation of the demonstrators, a sound methodology will be used, together with reliable theoretical, numerical and technological instruments. The performances of the three demonstrators will be evaluated trough an extensive experimental campaign, starting from tests on coupons at different conditions up to the final tests on the demonstrators. Moreover the NDI plans for the demonstrators will be developed and executed, and the performances will be evaluated also through the eco-quotation of the components. At last all the actions required for the definition of the certification roadmap will be investigated and outlined.'

Introduzione (Teaser)

Polymeric composites have helped reduce aircraft weight without sacrificing performance. EU-funded scientists have advanced the state of the art and delivered design, processing and certification guidelines to the EU aerospace manufacturing sector.

Descrizione progetto (Article)

Thermoset plastics (those that are heated and formed once and then cannot be reused) have dominated the field. They are easier to process and have better performance at high temperatures compared to thermoplastic polymers that can be melted and reused. In addition, much more research and experience has been accumulated regarding processing and use.

The EU-funded project 'Eco-design and manufacturing of thermoplastic structural fairings for helicopters' (http://www.cetma.it/leggi_news.aspx?idnews=258 (ECO-FAIRS)) exploited recent advances in thermoplastics materials and processing for eco-friendly aircraft structural components. Scientists took advantage of their promising hot/wet mechanical properties, durability, short production cycles and joining efficiencies that support reduced tooling and production costs.

ECO-FAIRS developed a robust methodology for design and manufacture of thermoplastic composite structural components for the aerospace sector based on compression moulding. Compression moulding is a reliable technique that can be well-controlled for high-volume production of high-quality components. Development of numerical tools and experimental methods led to optimisation of materials and processing.

The high-performance complex shapes required by the aerospace industry make joining techniques a critical factor to successful manufacture and use. The team chose induction welding that relies on eddy currents to heat the material. Following extensive numerical and experimental work, scientists built a new optimised, fully automated, continuous induction welding machine. Its excellent performance was confirmed by the mechanical properties of the welds. This is a key project result.

Three technology demonstrators for helicopters were designed and produced with the materials and methods developed within the scope of ECO-FAIRS. They were subjected to non-destructive inspections and complete evaluation of mechanical performance. An eco-assessment confirmed lower environmental impact compared to that of thermoset composites. The team delivered important quality control and characterisation methodologies to ensure certification that will be of particular relevance to the aerospace community.

ECO-FAIRS has made an important contribution to the aerospace manufacturing sector that promises to substantially enhance competitiveness and support the EU economy in a time of crisis. Implementation promises high-quality aerospace components at reduced cost and with lower environmental impact of both manufacturing and use.