COMBINING AUTOMATED PROCESSES AND MATERIALS FOR FUNCTION INTEGRATED ZERO EMISSION FUSELAGES

Abstract

The aerospace industry faces a huge challenge nowadays. Global warming and climate change require the drastic reduction of fuel consumption and CO2 emissions. This, and consequently zero emission aviation, including new propulsion systems (electrical flying, hydrogen fuels), require new concepts not only for engines but for fuselage, too. Usage of lightweight materials and a revision of the whole aircraft is a challenge, but also offers the opportunity for design for automation. Carbon fiber reinforced plastics (CFRP) are a promising material for weight reduction due to their high strength-to-weight ratio. However, their complex manufacturing, trimming, and joining processes are a challenge. This paper presents a concept for the function-integrated manufacturing of an aircraft skin part, which combines materials and processes to optimize the overall structure. Aim is to manufacture a hybrid part, more specifically a thermoset skin with thermoplastic reinforcement elements. The concept involves the use of autonomous preforming with dry carbon fibers to achieve the desired shape of the skin part. Thermoplastic inlays are introduced to enable welding and joining of thermoplastic components such as stiffeners and system components. The welding of stiffeners is an essential step in the manufacturing process to ensure the integrity and strength of the structure. Furthermore, it is possible to dispense with bolting and thus achieve a dust free assembly. The application of electrical conductors in the manufacturing process allows for the integration of electronic systems into the skin part. The scope of the project is to develop a manufacturing process that is both efficient and cost-effective. A smart combination of thermoset and thermoplastic components allows to facilitate the advantages of both materials, while the integration of low voltage conductors can reduce time and effort in assembly. The approach for autonomous preforming, inlays, welding, and integration of electrical conductors is described in detail. The concept has the potential to significantly reduce the weight of aircraft structures, leading to reduced fuel consumption and emissions.