Overview
Thermoplastics (TP) are high molecular weight polymers which, unlike thermosetting (TS) resins, do not form a rigid three-dimensional cross-linked chemical structure after processing. This allows the TP to be readily re-melted and re-formed, not the TS. Additional advantages are: chemical/impact resistance, range of temperatures, low level of moisture uptake then low hot/wet conditions degradation, eco-friendly/reusable properties that can make them a primary selection when the part life cycle is considered.
In situ consolidation automated processes with TP (ISC/TP) are currently at a level of development that does not allow efficient series production of complex TP components. More research was still needed to manufacture double curvature panels including strong thickness changes, plies drop-off, etc. Disadvantages for a good industrialisation were: difficult process management, high process temperatures and pressures, material handling for an efficient ISC/TP process.
The four main drivers of the ISINTHER project were:
- To assess an in situ consolidation process for TPM orientated to industrial outcome
- To apply the above main guidelines for trials and demonstrators manufacturing
- To investigate on repair solutions and process to restore nominal quality of parts
- To assess the potential benefit impact of the ISC/TP process in terms of environment, costs and elongated life cycle.
The project work plan was supported on a strong collaboration of a Technology Center (FIDAMC) with an experimented Automation Manufacturer (MTorres) able to transfer their experience to ISC/TP process.
PEEK APC2-AS4 was the material reference but open to evolution or new materials. Reparability was another aspect to be investigated with a high budget and mechanical tests.
Finally, process eco-assessment was a key objective of the ECODESIGN ITD, widened here to the concept of process sustainability (environment plus cost efficiency) to see if ISC/TP could be the preferred selection.
Funding
Results
Executive Summary:
ISINTHER Project, which full title is “Industrialization Set up for In Situ Consolidation Process in Thermoplastics” is a FP7 project of 27 months, which begun on November 2011, the 1st and ended on January 2014, the 31st. The project is related to the CfP of Clean Sky: JTI-CS-2011-1-ECO-01-021. ISINTHER consortium is composed of 2 partners: FIDAMC as coordinator and MTORRES. Both are located in Spain.
In the pursuit of eco-efficient process, future structures were manufactured with new materials, materials that nowadays it has not been used in primary structures of aeronautical sector as thermoplastic.
Therefore new automated process need to be developed and compared with current process solutions to quantify the improvement offered by these new process over traditional composites automated process.
Within the scope of this project, the main goal that we had obtained was the optimisation of the co-consolidation process.
The four main drivers for ISINTHER were:
- To assess an in situ consolidation process for thermoplastic material orientated to industrial outcome;
- To apply the main guidelines from above for trials and stiffened panels demonstrators;
- To investigate on repair solutions;
- To assess the potential benefit impact of the ISC TP process in terms of environment, production costs, higher chemical/mechanical properties for structural design and elongated life cycle.
Finally, one demonstrator of the full scale was built to study manufacturability issues. In parallel with this last stage of the project, an eco-statement of the new process had been realised and compared with traditional process by ATL and thermoset material to ensure the benefit of the new thermoplastic process.