GKN Aerospace opens new U.K. composite wing facility
GKN Aerospace has opened a new facility in Bristol for the high-speed, high-precision manufacture and assembly of carbon fibre composite aircraft wing components that span nearly 30m long. The facility has more than 30,000m 2
of floor space across two buildings, one focused on manufacture, the second on assembly. It uses the latest robotic technologies needed to produce complex wing structures. Employment is expected to rise to 450 employees by 2016. Two major work packages are already underway at the site: manufacture of A350 XWB all-composite rear wing spars and assembly of wing trailing edge and main landing gear parts to the spars to create complete 27m-long aircraft wing trailing edges; and manufacture of the all-composite main wing spars for the A400M military transporter, also huge assemblies at just less than 20m long.
CompositesWorld.com Weekly, 1 May 2012. http://tinyurl.com/d67ovto
Johnson Controls, Fraunhofer cross-link on materials research
Johnson Controls is to enter into what it plans to be a long-term cooperation agreement with the German Fraunhofer Research Institution for Polymeric Materials and Composites (PYCO), a developer of highly cross-linked polymers (reactive resins/duromers) and fibre-reinforced composites. Both organisations will be cross-linking their know-how to develop polymer systems that are recyclable and repairable while integrating required mechanical properties and achieving weight savings for the automobile industry. In common with most suppliers, Johnson Controls is constantly working toward weight savings to offset weight-increasing aspects of seat design, including associated controls, that are driven by safety requirements and perceived market expectations.
Automotive Engineering Online. 18 Apr. 2012. http://tinyurl.com/7ewwmoj
GKN Aerospace progresses composite damage detection
Researchers at GKN Aerospace's Luton facility are working with a team from the University of Bristol on an 18 month programme to explore coatings chemistries that will indicate the existence and extent of damage in composite structures. The company says its new coating will contain 'smart microspheres' which will signal in the ultraviolet visible spectrum when damage has occurred. Careful design of the microspheres will mean the coating is able to provide a signature reflecting different energy levels, indicating the extent and level of damage to trained maintenance staff.
Reinforced Plastics Weekly, issue 435, 25 Apr. 2012. http://tinyurl.com/czfo5sx
Lola-Drayson electric race car employs 'green' composites
The Lola-Drayson B12/69EV prototype electric race car employs recycled composites and flax reinforced composites, both products born out of joint development programmes involving Umeco. The car is designed to demonstrate the potential of sustainable 'green' technologies in the motorsport industry. Lola's use of recycled composite materials follows the completion of a collaborative R&D programme involving Umeco, WMG at the University of Warwick, and ELG Carbon Fibre Ltd. The application of flax-reinforced composites is the result of a joint R&D programme involving Umeco, WMG and Composites Evolution Ltd.
Reinforced Plastics Weekly, issue 435, 25 Apr. 2012. http://tinyurl.com/dxh6nqh
GKN laser technique speeds composite repairs
GKN Aerospace is continuing testing of a laser-based system for surface preparation of composite components prior to repair. It believes that use of the technology will result in faster and more accurate repair than is possible with traditional techniques. Tests have concentrated on two-dimensional surface preparation of composites using a gantry-mounted laser. In the next 12-18 months, it will attempt to replicate the technique on 3D structures with the laser mounted on a robotic arm.
Flight International, 8-14 May 2012. p.18.
Impact testing of composite materials
The first attempts to study the impact response of composites used the Charpy impact test method. However it was difficult to relate the measured absorbed energy of the Charpy specimen to that of an actual structural component and, after considerable research, this method was abandoned. Attempts were than made to develop a pure tensile impact test. This test method was to be followed by the development of similar compression- and shear-impact test methods. These methods were also subsequently abandoned. Because a primary concern is potential damage to composite structures induced by low-velocity impact, striking a flat plate with a falling weight has been adopted as the impact test method of choice.
High Performance Composites, May 2012. pp.8-10.
Production composites manufacturing specialist secures C-130J contract
Quickstep Holdings has been selected as the supplier for the wing flaps on the C-130J Hercules military transport following an international commercial tender offer by Lockheed Martin. The first orders for the programme's non-recurring activities (such as planning, tooling, training and project management) are expected in the second quarter of this year. The first aircraft parts are scheduled for delivery in 2014.
High Performance Composites, May 2012. p.13.
Ford, Dow team to bring low-cost carbon composites to next-gen cars
Ford Motor has announced a partnership with Dow Automotive Systems to research the use of advanced carbon fibre composites in high-volume vehicles. Cutting the weight of new vehicles by as much as 750lb by 2020 is a key component of Ford's strategy to improve fuel efficiency enough to meet new fuel efficiency standards of more than 50 mpge. Until recently carbon fibre has been too costly for use in high volume, mainstream applications. However, Ford and Dow researchers will focus on establishing an economical source of automotive-grade carbon fibre and develop manufacturing methods for high-volume auto parts, particularly in Ford's plug-in hybrid and battery electric vehicles.
High Performance Composites, May 2012. p.15.
Automotive CFRP: repair or replace?
With carbon fibre-intensive volume production automobiles likely to be taking to the road in increasing numbers there is increased likelihood of them being involved in a greater number of accidents. There are thus two questions for OEMs, dealerships and body shops: how to determine the extent of damage to carbon fibre structures; and how to decide whether to repair or replace those structures? On high end autos damaged structures will generally be removed and replaced. However for structural components in high-volume applications, those involved are looking for ways to repair/rebuild structures economically. Details the experience of auto spots motor manufacturers. Also reports on methods for repairing bonded substructures.
High Performance Composites, May 2012. pp.46-53.
Composites in general aviation 2011-2020
Presents forecast for the general aviation industry's likely demand for composite goods and services for the period 2011-2020 and relates this to a previous forecast for the period 2008-2017. Says that, barring renewed economic turmoil, recent GA sales and production increases suggest 12% more aircraft in 2012 than in 2011. From 2011 through to 2020, aircraft OEMs and their suppliers are expected to produce more than 28M lb of GA composites. At the peak of its predicted growth in 2017, it is forecast that the GA composites market will be valued at more than $1bn.
High Performance Composites, May 2012. pp.54-61.
Integrated, optimised aircraft door
French manufacturer Latecoere has investigated aircraft doors, whose basic structure is dictated by safety requirements, to see if creative design and engineering could make them even lighter. The company initiated a project called COMDOR (composite door), which focused on matching the material, tooling and process with the application. The objective was to develop a door that features a unified unbounded, fastener-free structure that could be moulded via resin transfer moulding. Having achieved this, the next objective is to place the door on a functioning aircraft.
High Performance Composites, May 2012. pp.62-68.
Composite fuselage helps Hondajet upend biz-jet market
Hondajet is being promoted as the quietest and most fuel efficient of its class. Although composites were not able to demonstrate an advantage over aluminium in the design of the wing, it did offer a 10-15% weight saving over aluminium in the fuselage. Composites also optimise the jet's nose structure aerodynamics and construction and enable an integral fuselage design that minimises joints and maximises interior volume. Construction of the fuselage will be outsourced to GKN Aerospace in Redditch.
High Performance Composites, May 2012. pp.78-81.
