CERFAC - Cost Effective Reinforcement of Fastener Areas in Composites
Overview
Background & policy context:
CERFAC's major challenge is the design and manufacturing of strong and cost-efficient joints for high performance CFRP aero-structures. In particular, transfer of distributed loading along rivets lines in the assembly of flat or curved thin-walled stiffened panels, and introduction of concentrated loads for connecting lugs with thicker laminates are special & frequent problems.
CERFAC focuses on applications with significant volume and occurrence (butt straps & splices, orbital and longitudinal multi-functional joints, single and multiple bolts attachments), such that an increase of the strength to cost ratio of joints could lead to overall significant cost and weight savings.
Objectives:
CERFAC's high level objectives are:
- To increase the strength to cost ratio and damage tolerance of fastener areas in CFRP structures without weight, thickness and stiffness penalty;
- To reduce the number or fasteners (10 to 100% reduction), the local thickening of fastener areas and minimize the manufacturing & assembly costs (20% reduction).
Methodology:
This will be achieved thanks to advanced and rigorous research & development activities with the following major deliverables and outputs:
- A catalogue of validated reinforcement solutions at the locus of fastener holes or edges leading to lighter, stronger and more damage tolerant designs;
- This contribution would then help reducing further the number of fasteners, while increasing the load bearing capacity and damage tolerance of the assembly, with a significant step towards a reduced manufacturing cost. Repair and disassembly will be considered as mandatory requirements in this contribution;
- Upgraded design, analysis and testing methodologies as well as pragmatic guidelines for future exploitation of the new concepts in the next generation of aircrafts.
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