MOJOProject ID: 30871
Modular Joints for Aircraft Composite Structures
MOJO is set to introduce a material driven design for Aeronautics composite components. Composites are associated with integration, complexity, manufacturing risk, weight savings and high costs. Cost savings are achieved with out-of autoclave infusion processes and tailored pre-forms made of high performance textiles. Adhesive bonding, as the most compatible joining method for composite parts, provides also significant cost and weight savings.
The challenge is to create synergy between pre-form infusion and adhesive bonding processes. In this respect, MOJO is representing a boltless differential structural design as a modular approach. MOJO makes a construction set available with cost and weight saving potentials of at least 20% and 15%, respectively. Highly loaded T- or Pi- (?) shaped joints are integrated into the skin using 3D reinforcements in order to take up out-of-plane loads. Simplified structural elements are subsequently inserted into the joints and bonded using adhesives. Here pure shear loads are transferred. The same applies for intersections (e.g. ribs). These are replaced with construction set profiles in shapes of, e.g. H, HL, (? ) or HX (?). To fulfil the objectives, MOJO is focussing on Pi, T, and H profiles.
The profile pre-forms will be realised using advanced textiles, among them a unique 3D profile weaving technology. For precision manufacturing of moderately integrated parts new rig concepts will be developed and proved. For a continuous process pultrusion technology will be investigated. Methods of adhesive bonding (e.g. pressure free bonding) will be investigated.
Analysis and tests will be performed by means of interface failure mechanics and manufacturing simulation. An aeronautical application featuring all elements will prove the design. Results will be summarised in guidelines and design rules. Making parts simpler in design and assembly enables flexibility and rapid adaptation to market demands.
FISHERMANS BEND, VIC.