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Towards a thermoplastic upper shell demonstrator: Production technologies for future fuselages

Fischer, Frederic (2020) Towards a thermoplastic upper shell demonstrator: Production technologies for future fuselages. Deutsche Luft- und Raumfahrtkongress 2020, 1.-3. Sep. 2020, online.

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The Center for Lightweight Production Technology (ZLP) in Augsburg together with Premium Aerotec, Aernnova and Airbus will deliver the 8 m long upper half shell for the full-scale multifunctional fuselage demonstrator (MFFD) made of carbon fiber reinforced thermoplastics. This work discusses the development of production technologies for this new single aisle aircraft approach undertaken within the greater European Clean Sky 2 large passenger aircraft (LPA) project. For the skin layup automated fiber placement (AFP) with a novel flashlamp heating system is investigated, benchmarked against laser-assisted AFP, and backed by process simulation for optimization. The in-situ consolidation of the newly developed low melt Polyaryletherketone (LM-PAEK) material enables a lean, single-stage process. However, it requires detailed investigation to generate material-specific processing parameters. For stringer integration robot-based continuous ultrasonic welding is being matured to further improve robustness, and tailor the weld parameters to LM-PAEK. Frame, cleat and frame coupling integration will be carried out by means of electrical resistance welding (RW). In recent years, RW has been matured to exhibit homogeneous welds of high joint strength on coupon and component level. Upscaling effects and challenges of full scale fuselage shell assembly, however, still require further investigations to ensure process reliability. Especially geometric tolerances with mismatch between mating part surfaces can only be compensated to a limited extent within the joining processes. Special attention is hence given to proper design to manufacture, i.e. align design principles with manufacturing engineering requirements. We will showcase the latest developments on thermoplastic manufacturing and joining techniques, which are key to this fuselage shell assembly concept.

Item URL in elib:https://elib.dlr.de/137359/
Document Type:Conference or Workshop Item (Speech)
Additional Information:This project has received funding from the Clean Sky 2 Joint Undertaking (JU) under grant agreement No 945583. The JU receives support from the European Union’s Horizon 2020 research and innovation programme and the Clean Sky 2 JU members other than the Union.
Title:Towards a thermoplastic upper shell demonstrator: Production technologies for future fuselages
AuthorsInstitution or Email of AuthorsAuthor's ORCID iDORCID Put Code
Fischer, FredericUNSPECIFIEDhttps://orcid.org/0000-0001-5421-4336UNSPECIFIED
Date:3 September 2020
Refereed publication:Yes
Open Access:No
Gold Open Access:No
In ISI Web of Science:No
Keywords:Thermoplastic Composites, LM-PAEK, Automated Fiber Placement, Flashlamp Heating, Ultrasonic Welding, Resistance Welding, Fuselage of Tomorrow
Event Title:Deutsche Luft- und Raumfahrtkongress 2020
Event Location:online
Event Type:national Conference
Event Dates:1.-3. Sep. 2020
Organizer:Deutsche Gesellschaft für Luft- und Raumfahrt
HGF - Research field:Aeronautics, Space and Transport
HGF - Program:Aeronautics
HGF - Program Themes:fixed-wing aircraft
DLR - Research area:Aeronautics
DLR - Program:L AR - Aircraft Research
DLR - Research theme (Project):L - Structures and Materials (old)
Location: Augsburg
Institutes and Institutions:Institute of Structures and Design > Automation and Production Technology
Deposited By: Fischer, Frederic
Deposited On:13 Nov 2020 14:10
Last Modified:20 Jun 2021 15:54

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