Thermoplastic Fiber Composite Aircraft Component Production Process
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Solution Overview
Problem
The production of components composed of thermoplastic fiber composites for aircraft is complex due to the need for higher processing temperatures and the difficulty in achieving desired fiber orientations, especially with high-performance thermoplastic polymers like polyaryl ether ketones, which restrict carbon fiber mobility.
Innovation Solution
A process involving the production of a sheet-like object from thermoplastic polymer and carbon fibers, followed by continuous forming under pressure and heat to achieve desired fiber orientations, and subsequent static solidification to produce components like formers and stringers with specific shapes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If thermoplastic fiber composites with high performance plastics (e.g., polyaryl ether ketones) are used to achieve high mechanical strength and weight savings, then the mechanical properties and weight reduction are improved, but the processing complexity increases due to higher required temperatures and restricted fiber mobility
Solution Approach 1:
The processing is divided into distinct stages: a) production of sheet-like objects with fiber placement, b) forming of semifinished parts, and c) solidification to final components. This segmentation allows optimization of each stage independently, managing the overall processing complexity while maintaining high mechanical properties
Solution Approach 2:
The process utilizes temperature parameter changes to manage material properties: heating above the melting point of the thermoplastic matrix during forming to enable fiber mobility and shape adoption, then cooling below the melting point for solidification. This parameter control resolves the contradiction by enabling processing at required temperatures while achieving final component solidification
2Strength
If carbon fibers are correctly oriented along the main mechanical loading direction to ensure desired mechanical strength and weight saving, then the mechanical performance is improved, but achieving particular fiber orientations becomes difficult due to reduced fiber mobility in high melting point thermoplastic polymers
Solution Approach 1:
The reinforcing fibers are pre-oriented in the sheet-like objects during the AFP process before forming. This preliminary orientation ensures that fibers are correctly positioned along the main mechanical loading direction before the forming operation, maintaining manufacturing precision even though fiber mobility is restricted in the final solidified state
Solution Approach 2:
Temperature parameter changes enable fiber repositioning: heating above the melting point during forming increases matrix mobility, allowing fibers to be repositioned or consolidated into desired orientations, while cooling below the melting point locks in the achieved fiber orientation for final component strength
3Weight of moving object
If thermoplastic fiber composites are used instead of metallic components or thermoset composites, then weight savings are achieved, but the production process becomes more complex due to higher processing temperatures and cooling-based consolidation
Solution Approach 1:
The production process is segmented into three main steps: a) production of sheet-like objects, b) forming of semifinished parts, and c) solidification to final components. This segmentation simplifies the overall complex thermoplastic processing by breaking it into manageable stages, each with specific temperature and pressure conditions
Solution Approach 2:
The process exploits phase transitions of the thermoplastic matrix: melting above the melting point during forming to enable consolidation and fiber repositioning, then freezing below the melting point for final solidification. This phase transition approach simplifies the production process compared to thermoset curing, providing a clear thermal pathway for manufacturing
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This process enables the production of lightweight, mechanically strong aircraft components with precise fiber orientation, overcoming the limitations of existing methods by combining static lay-up, continuous preforming, and static consolidation, allowing for efficient production of complex shapes with reduced repetition costs.
Implementation Method 1
heating of the sheet-like object (28) in a forming device (30) to a temperature which is above the melting point of the thermoplastic polymer material
Implementation Method 2
the plasticity of the thermoplastic polymer material allows the formation of the sheet-like object
Implementation Method 3
pressing of the heated sheet-like object (28) with a pressing tool (32) having a pressing surface (33)
Implementation Method 4
subsequent static solidification to produce components like formers and stringers with specific shapes
Data Source
AI summary
A process for producing a component for an aircraft for the frame, e.g. formers and stringers. Aircraft are being increasingly constructed of polymeric fiber composite to reduce weight. Here, fiber composites were originally composed of thermoset polymer and carbon fibers. Thermoplastic fiber composites are increasingly a research focus. An example is poly(ether ether ketone). However, production of components of thermoplastic fiber composites is complex. An improved process for producing such components includes producing a sheet-like object with a thermoplastic fiber composite having a thermoplastic polymer material and reinforcing fibers embedded therein, forming the sheet-like object for a semifinished part, and solidification of the semifinished part to give the component. Components obtainable by this process are also disclosed.