This proposal addressed the fibre winding manufacturing of a sleeve structure (rotor part) for an aircraft cooling unit, which is subjected to a highly variable environment, e. g. a large temperature range, and has excellent mechanical properties to withstand mechanical loading from high speed rotations. The replacement of existing metallic structures with continuous fibre reinforced polymer parts shall allow a weight reduction and higher rotational speeds at elevated temperatures. The proposal included a detailed analysis of requirements, current designs, and constraints to allow the proposal of a suitable manufacturing concept including material and cost assessment.

A new siphon impregnation system developed at IVW allows a complete wet-out of fibres with stable processing conditions and can further improve laminate quality. Cyanate esters are high sophisticated thermoset polymer resins suitable to be used in high temperature environments with highly desirable properties and encompass characteristics of epoxy resins, e.g. benzoxazines, bismaleimides or phenolic resins, but are sensitive to processing conditions, i.e. moisture uptake before and during curing. Therefore, this proposal addressed the development of a monitoring of gelation and curing of the matrix resin during processing e. g. by ultrasonic transducers, via dielectric analysis with rheological correlations, and indentation tests. Also, monitoring of filament tension, moisture and void content are addressed. The monitoring is included in or accompanies an automated and CNC-controlled fibre winding process. An optimum design for the structure was achieved via structural analyses including mechanical and thermo-mechanical stress analyses, design and ply book generation. Fabrication was set-up and prototypes manufactured and mechanically tested under near-operation conditions. Finally, manufacturing was optimised and 5 demonstrators manufactured and TRL-5 readiness assessed.

This project suggested fixed starting date to comply with the Eco Design program.