Aeroplan Composites Repair Monitoring and Validation in Aeronautical Industry
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Transcript of Aeroplan Composites Repair Monitoring and Validation in Aeronautical Industry
Copyright © TWI Ltd 2013
AeroPlan
“Composites repair monitoring and validation
Dissemination of innovations and latest
achievements to key players of the aeronautical
industry”
September 2011 – February 2014
AeroPlan is a collaboration between: TWI Ltd. NATIONAL TECHNICAL UNIVERSITY OF ATHENS, LZH LASERZENTRUM HANNOVER E.V.,
FUNDACION TECNALIA RESEARCH & INNOVATION, GMI AERO SAS, INASCO - INTEGRATED AEROSPACE SCIENCES CORPORATION O.E. and EADS DEUTSCHLAND GMBH
MRO Europe 2013 - Advanced Material Repair Technologies
24 September 2013, London
Kamer Tuncbilek TWI
www.aeroplanproject.eu
Copyright © TWI Ltd 2013
Agenda
Introduction
AEROPLAN “Background” Projects
Questions & Answers
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• INTRODUCTION
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The Need
The time from the generation of an innovation until its inclusion into a Structural Repair Manual (SRM)
Need for new technologies – for innovative repair and monitoring solutions to reduce operating costs
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AeroPlan Main Project Goal
The aim is
to introduce the foreground knowledge generated
under 10 EU funded research projects’
in repair and monitoring of metallic and composite
structures
to Aeronautical industry so that both existing aircrafts
and future designs can take benefit of the these
innovations.
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About AeroPlan
Beneficiary name Country Type
1 TWI Ltd (Coordinator) UK RTD
2 NTUA Greece RTD
3 LZH Germany RTD
4 Tecnalia Spain RTD
5 GMI France SME
6 Inasco Greece RTD
7 EADS Germany Industry
Start Date: 1 September 2011
End Date: 28 February 2014
AeroPlan project has received funding from the European Union's Seventh Framework Programme managed by REA
Research Executive Agency [FP7/2007-2013] under grant agreement no 285089.
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Projects
COMPRES - Composite Repair of Metallic Structure for Ageing Commercial Aircraft
SENARIO - Advanced Sensors and Novel Concepts for Intelligent and Reliable
Processing in Bonded Repairs
PLASER - Portable Laser system for the Surface Preparation of Composite Repairs
INDUCER - Induction Heating and Health Monitoring Solutions for Smart Aircraft
Maintenance Using Adapted Composite Patches
COMPAIR - Continuous Health Monitoring and Non-destructive Assessment of
Composites and Composite Repairs on Surface Transport Applications
IAPETUS - Innovative Repair of Aerospace Structures with Curing Optimization and Life
Cycle Monitoring Abilities
EXPECT - Examination of Practical Aspects of Innovative Bonded Composite Repair
Techniques
INDUCTOR - Induction Based Curing Tool for Optimized Heating of Composite Repairs
COMPARE - Comparative Evaluation of NDT techniques for High Quality Bonded
Composite Repairs
ADVANCED - Advanced Heating System and Control Mode for Homogeneous High
Temperature Curing of Large Composite Repairs
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Main Technical Issues
Addressed
Innovations related to bonded composite repairs:
Heating Issues (mode of heat generation [conduction – induction],
homogeneity etc.)
Surface preparation
NDT & Health monitoring of structures / repairs
Degree of cure monitoring
Design of composite to metal repairs
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• AEROPLAN
“BACKGROUND” PROJECTS
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COMPRES
Project Acronym: COMPRES Period of Implementation: 1999 - 2002
Project Title: Composite Repair of Metallic Structure for Ageing Commercial Aircraft
Research Framework: FP5
Research Project Partners: HAI, IAI, ALENIA, OGMA, CYTEC, GMI, NTUA, DUT, DERA
Partners participating to AeroPlan: GMI, NTUA
Contribution of COMPRES innovations to AeroPlan: -Simulation, design, application and certification of bonded composite repairs to metallic aircraft structures -Surface preparation for metal to metal or metal to composite bonding -Heat transfer issues in composite repairs -Equipment and tooling for composite to composite and composite to metal repairs
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SENARIO
Project Acronym: SENARIO Period of Implementation: 2007-2010
Project Title: Advanced Sensors and Novel Concepts for Intelligent and Reliable Processing in Bonded Repairs
Research Framework: FP6
Research Project Partners: Inasco, GMI, NTUA, IAI, TAU, LZH, Inasmet, SENER BOMBARDIER, University of KHARKIV
Partners participating to AeroPlan: Inasco, GMI, NTUA, LZH, Inasmet
Contribution of innovations to AeroPlan: - Optical fibre development for repair monitoring - Dielectric sensors for monitoring of repair curing process
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aluminium substrate
M20 pre-preg
sensing mat21
heating blanket
vacuum bag
vacuum bag
perforated sheet
glass fibre breather
T/CT/C
wirewire
powerpower
control
T/C
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Project Acronym: PLASER Period of Implementation: 2009-2012
Project Title: Portable Laser system for the Surface preparation of composite Repairs
Research Framework: EUROSTARS E!
Research Project Partners: GMI, LZH, CleanLaserSystems GmbH, NTUA
Partners participating to AeroPlan: GMI, LZH, NTUA
Contribution of innovations to AeroPlan: -Surface preparation of composite repair areas to be repaired using laser. -General composite surface treatment, drilling and processing issues.
PLASER
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Project Acronym: INDUCER Period of Implementation: 2009-2011
Project Title: Induction Heating and Health Monitoring Solutions for Smart Aircraft Maintenance Using Adapted Composite Patches
Research Framework: FP7
Research Project Partners: GMI, TWI, NTUA – ALENIA (Topic Manager)
Partners participating to AeroPlan: GMI, TWI, NTUA, ALENIA
Contribution of innovations to AeroPlan: -Induction heating solutions for curing composite repairs. -Thermal transfer and temperature homogeneity across repair issues. -Use of magnetostrictive sensors for health monitoring.
INDUCER
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Project Acronym: INDUCER Period of Implementation: 2009-2011
Project Title: Induction Heating and Health Monitoring Solutions for Smart Aircraft Maintenance Using Adapted Composite Patches
Research Framework: FP7
Research Project Partners: GMI, TWI, NTUA – ALENIA (Topic Manager)
Partners participating to AeroPlan: GMI, TWI, NTUA, ALENIA
Contribution of innovations to AeroPlan: -Induction heating solutions for curing composite repairs. -Thermal transfer and temperature homogeneity across repair issues. -Use of magnetostrictive sensors for health monitoring.
INDUCER
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Project Acronym: COMPAIR Period of Implementation: 2009 - 2011
Project Title: Continuous Health Monitoring and Non-Destructive Assessment of Composites and Composite Repairs on Surface Transport Applications.
Research Framework: FP7
Research Project Partners: TWI, KTU,VTT, Atoutville, G-Tronix, ENEA, Envirocoustics, Hexcel, KCC, CERETETH
Partners participating to AeroPlan: TWI
Contribution of innovations to AeroPlan: - Development of inspection and monitoring sensors (thermal, ultrasonic, mechanical) for the examination of aircraft structure composite materials.
Development of multi-axis robotic scanner for in-service
inspection of composite components
• Capability of carrying thermographic, U/S and AE equipment.
• Ability to place and orientate the NDT equipment with 6
degrees of freedom
• Ability to inspect curved samples
ComPair
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Project Acronym: IAPETUS Period of Implementation: 2009-2012
Project Title: Innovative Repair of Aerospace Structures with Curing Optimisation and Life Cycle Monitoring abilities
Research Framework: FP7
Research Project Partners: Tecnalia, PZL, HUNTSMAN, UoP, Inasco, DAHER, GMI, USFD, HAI, UoI
Partners participating to AeroPlan: TECNALIA, Inasco, GMI
Contribution of innovations to AeroPlan: -Induction heating solutions for curing of composite repairs -Thermal transfer and temperature homogeneity across repair issues -Application of CNT doped resin heating and health monitoring of repairs.
Aluminium
Composite
Induction Coil
Susceptor
IAPETUS
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Project Acronym: EXPECT Period of Implementation: 2010-2012
Project Title: Examination of Practical Aspects of Innovative Bonded Composite Repair Techniques
Research Framework: FP7
Research Project Partners: GMI, NTUA – Fraunhofer IFAM(Topic Manager)
Partners participating to AeroPlan: GMI, NTUA
Contribution of innovations to AeroPlan: -Innovations concerning surface treatment of composite repairs. -Practical issues concerning processing of composite repairs.
EXPECT
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Project Acronym: INDUCTOR Period of Implementation: 2010-2012
Project Title: Induction based Curing Tool for Optimised Heating of Composite Repairs
Research Framework: FP7
Research Project Partners: GMI, NTUA – Fraunhofer IFAM (Topic Manager)
Partners participating to AeroPlan: GMI, NTUA
Contribution of innovations to AeroPlan: -Induction heating solutions for curing of large composite repairs. -Thermal transfer and temperature homogeneity across repair issues.
INDUCTOR
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Project Acronym: COMPARE Period of Implementation: 2010-2012
Project Title: Comparative evaluation of NDT techniques for high-quality bonded composite repairs
Research Framework: FP7
Research Project Partners: TWI, GMI, NTUA – Fraunhofer IFAM(Topic Manager)
Partners participating to AeroPlan: TWI, GMI, NTUA
Contribution of innovations to AeroPlan: -Inspection and Quality Assurance of composite repairs -Non Destructive Testing of bonded composite repairs.
COMPARE
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ADVANCED
Project Acronym: ADVANCED Period of Implementation: 2011-2012
Project Title: Advanced heating system and control mode for homogeneous high temperature curing of large composite repairs
Research Framework: FP7
Research Project Partners: GMI, NTUA, Tecnalia – Aircelle (Topic Manager)
Partners participating to AeroPlan: GMI, NTUA, Tecnalia (subcontractor)
Contribution of innovations to AeroPlan: -18-zone, 48kW, 80 thermocouples heating device for very large composite repairs -Advanced thermal simulation of repair area to retrieve thermal signature and optimize thermal blankets design.
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• Development of Power Supply and Control unit for heating up to 18 heating zones for homogeneous heating of very large composite repairs (e.g. reversers) at 225oC +/-5oC
• Complete 48 KW prototype delivered and tested at industrial environment .
• Simultaneous data acquisition from eighty control & monitoring thermocouples.
• User MMI.
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Thank you for your attention
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