Materials Presentations

Building a Case for Metals

The materials currently used by the Aerospace industry have not evolved as quickly as the airframe designs. As we look to the future, aircraft will need to be more fuel efficient and economical to maintain and operate. This dictates that engines will operate at higher temperatures, will need stealthier designs, and the materials will have to achieve the stringent engineering, environmental and economic targets being set by the Aerospace Industry. The materials of the future, metals, composites or others will need to have these features: high strength, the ability to operate at very high temperatures, corrosion resistance, fatigue resistance and damage tolerance.
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The Future of Composites

Material, fiber and processing technologies in composites aerospace manufacturing are in the midst of rapid and transformative change. This presentation reviews some of the most important technologies coming onto the market, including development of out-of-autoclave (OOA) resins, high-performance thermoplastics, three-dimensional fiber preforms, heated resin transfer molding (RTM), advanced fiber stitching and nano materials. Included are identification of major technology and material suppliers, current and potential applications in aerostructures and long-term outlooks
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Braided Solutions Enable Simplified Automation Yielding Low Cost Aerospace Parts

The preforming approach chosen by composite manufacturers is a critical cost driver. Braided materials provide the repeatable manufacture of near net shape preforms while providing a dramatic reduction in touch labor. A variety of braided preforming solutions exist providing designers with reinforcements that best fit their manufacturing processes. Automated preform solutions include: braided sleevings conforming to complex part geometries; overbraiding; and the use of braided fabrics, specifically fabrics with a quasi-isotropic (0°, +/-60° degree) and an off the shelf +/- 45° orientation. Braiding combines architectural precision and economic efficiencies found with automated methods of manufacture, and is applicable to the manufacture of large scale, structural preforms.
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Drilling Advanced Aircraft Structures

With the increased usage of Carbon Fiber Reinforced Plastics (CFRP) in commercial aircraft there is an increased demand for new cutting tool solutions. PCD (Polycrystalline Diamond) and CVD (Chemical Vapor Deposition) coated tools are the preferred solutions for the drilling of CFRP, however new drilling solutions are required to drill material stack combinations such as CFRP with aluminum (Al) and CFRP with titanium (Ti) to ensure accuracy, surface finish, coolant usage and minimal exit burr whilst also maximizing tool life and speed. This presentation offers solutions that fulfill these requirements on all possible stack combinations. The claim is supported with validated test results applicable to a variety of drilling approaches including automated drill/fastening system and pneumatic power feed applications.
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Composite Structures

With demand for air travel predicted to significantly increase in the near future, the aerospace industry is coming under scrutiny over the issue of its environmental impact. Thus the industry is constantly looking for ways in which it can reduce its impact and the most important approach currently used is the application of lightweight composites for airframe structures. The high level of confidence in application of advanced composite materials in primary structures is evidenced in the revolutionary design of Boeing 787. This presentation discusses and presents the results on the recent life cycle analysis of modern lightweight aircraft structures, including the aspects such as lower fuel consumption and optimized manufacturing parameters.
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