Periodic Reporting for period 1 - SOFIA (“Test Methods for analySis OF Infusion pAnels” (SOFIA))
Periodo di rendicontazione: 2021-03-01 al 2022-04-30
The aim of the project is to validate new proposals for thermoset composite manufacturing via tests based on coupons (Level 2 Tests) and a test based on component (Level 3 Test).
Today most structural composite components are manufactured by means of classical methods like the use of pre-impregnated fabrics or tapes which are laid-up on tools, vacuum bagged and cured in an autoclave under elevated pressure and temperature. These classical methods are energy intensive, expensive and have a higher environmental footprint.
The use of infusion as the process to add resin to the dry fiber together with the automatization of tape layer process will allow to reduce energy consumption and time and, in consequence, costs and the environmental footprint of manufacturing processes will also be reduced.
The project addresses the validation of the structural behavior of a defined thermoset panel consisting of stiffeners and skin manufactured using novel techniques indicated in previous paragraph.
Test results shall demonstrate the competitiveness of the newly developed manufacturing process and the potential of this technology. The response of the structure to defined static loads will also improve the understanding of the chosen manufacturing concept and design. The performance capability of the automated tape layer process with dry UD tape and its subsequent infusion shall be validated by a specified testing program.
Today most structural composite components are manufactured by means of classical methods like the use of pre-impregnated fabrics or tapes which are laid-up on tools, vacuum bagged and cured in an autoclave under elevated pressure and temperature. These classical methods are energy intensive, expensive and have a higher environmental footprint.
The use of infusion as the process to add resin to the dry fiber together with the automatization of tape layer process will allow to reduce energy consumption and time and, in consequence, costs and the environmental footprint of manufacturing processes will also be reduced.
The project addresses the validation of the structural behavior of a defined thermoset panel consisting of stiffeners and skin manufactured using novel techniques indicated in previous paragraph.
Test results shall demonstrate the competitiveness of the newly developed manufacturing process and the potential of this technology. The response of the structure to defined static loads will also improve the understanding of the chosen manufacturing concept and design. The performance capability of the automated tape layer process with dry UD tape and its subsequent infusion shall be validated by a specified testing program.
Work to be done in SOFIA project has been structured in 5 Work packages (WP in the following) whose content is briefly summarized hereafter.
Work Package 1
WP1 is oriented to analyse the overall behaviour of the component (panel skin with 2 omega stiffeners) when applying loads considered in Level3 test by means of numerical simulations.
Geometry, Mechanical properties of the materials (obtained from Level 1 tests) and requirements were provided by TM and the possibility given to SOFIA Consortium (SC in the following) of modifying stacking sequences and thickness.
These activities have allowed to know possible mechanisms of failure, important information to select Level 2 Tests to be performed in WP2.
During WP1 were released D1.1 Level 2 test specimens sizing, providing information about the dimensions and characteristics of panels for coupons extraction associated to Level 2 Tests, and D1.2 Level 3 test component pre-sizing, including more detailed information about the thickness and stacking sequence of panel Skin and Omega stiffener and results obtained from numerical analyses performed.
Work Package 2
One of the activities included in WP2 has been the elaboration of Level 2Test Plan proposal (D2.1) describing tests to be carried out in Level 2 where finally 4 tests were selected: Unfolding, Compression After Impact (CAI), Interlaminar Fracture Toughness (GIC) and Seven Point Bending (SPB).
Panels requested in D1.1 Level 2 test specimens sizing for the extraction of L2T specimens were provided in 2 shipments dated in January and March, 2022.
Design and manufacturing of tooling necessary for the performance of L2T (only identified the need for SPB test) has also been performed during this reported period as part of WP2 tasks.
Workshop of Level 2 Tests was celebrated by teleconference in March 2022 as a prelude to some Preliminary tests of each type (Unfolding, CAI, GIC and SPB) performed in April 2022
Work Package 3
Preliminary meetings for Level 3 Test Tooling design initial phase were carried out as part of WP3 activities.
Work Package 4
Dissemination and Communication activities performed as part of WP4 tasks are provided in next paragraphs.
Creation of a logo and brand for the project, present in templates for reports and presentations.
Creation of a specific web sites for project SOFIA within ALESTIS AEROSPACE website (https://www.alestis.aero/) and APPLUS website (https://www.appluslaboratories.com/global/en/about-us/innovation/sofia-project)
Planned presence of ALS and APPLUS in JEC world (celebrated in Paris from 03 to 05 May 2022) and USE in MATCOMP 2021 (to be celebrated in June 2022)
Work Package 5
Activities of Project Management and Coordination performed. All deliveries in WP5 haven been delivered except for IPR report, planned for the end of the project.
Work Package 1
WP1 is oriented to analyse the overall behaviour of the component (panel skin with 2 omega stiffeners) when applying loads considered in Level3 test by means of numerical simulations.
Geometry, Mechanical properties of the materials (obtained from Level 1 tests) and requirements were provided by TM and the possibility given to SOFIA Consortium (SC in the following) of modifying stacking sequences and thickness.
These activities have allowed to know possible mechanisms of failure, important information to select Level 2 Tests to be performed in WP2.
During WP1 were released D1.1 Level 2 test specimens sizing, providing information about the dimensions and characteristics of panels for coupons extraction associated to Level 2 Tests, and D1.2 Level 3 test component pre-sizing, including more detailed information about the thickness and stacking sequence of panel Skin and Omega stiffener and results obtained from numerical analyses performed.
Work Package 2
One of the activities included in WP2 has been the elaboration of Level 2Test Plan proposal (D2.1) describing tests to be carried out in Level 2 where finally 4 tests were selected: Unfolding, Compression After Impact (CAI), Interlaminar Fracture Toughness (GIC) and Seven Point Bending (SPB).
Panels requested in D1.1 Level 2 test specimens sizing for the extraction of L2T specimens were provided in 2 shipments dated in January and March, 2022.
Design and manufacturing of tooling necessary for the performance of L2T (only identified the need for SPB test) has also been performed during this reported period as part of WP2 tasks.
Workshop of Level 2 Tests was celebrated by teleconference in March 2022 as a prelude to some Preliminary tests of each type (Unfolding, CAI, GIC and SPB) performed in April 2022
Work Package 3
Preliminary meetings for Level 3 Test Tooling design initial phase were carried out as part of WP3 activities.
Work Package 4
Dissemination and Communication activities performed as part of WP4 tasks are provided in next paragraphs.
Creation of a logo and brand for the project, present in templates for reports and presentations.
Creation of a specific web sites for project SOFIA within ALESTIS AEROSPACE website (https://www.alestis.aero/) and APPLUS website (https://www.appluslaboratories.com/global/en/about-us/innovation/sofia-project)
Planned presence of ALS and APPLUS in JEC world (celebrated in Paris from 03 to 05 May 2022) and USE in MATCOMP 2021 (to be celebrated in June 2022)
Work Package 5
Activities of Project Management and Coordination performed. All deliveries in WP5 haven been delivered except for IPR report, planned for the end of the project.
Results from Level 2 and Level 3 Tests are not available within the reported period so it is not possible a complete evaluation of the influence of the results with respect of expectations.
Mechanical properties of material are promising and component behaviour in numerical simulations performed seems appropriate. However, as the object of the project is the validation of a new manufacturing process, it is key to study the real behaviour of the material as part of an aeronautical structure widely used (as omega stiffened panel) manufactured using a combination of automatized lay up tape process and infusion in order to identify defects derived from the novel manufacturing process. Only after the performance of the tests (Level 2 and Level 3) and processing of their results it will be available information for a preliminary evaluation of how competitive novel manufacturing process is, compared with classical manufacturing process.
For this new process to be considered as possible substitute of current one, it is expected similar (or better) level of quality and mechanical behaviour with the reduction of energy and time (reducing cost and environmental footprint).
According to visual inspection (external) of the panels already manufactured for the extraction of Level 2 Test Coupons, the impression is that superficial quality is clearly inferior than obtained using current manufacturing process (specially in omega stiffener internal surface) but the interface between skin and stiffeners seems to be indistinguishable from any other ply to ply interface in stacking sequence (what is expected to improve the behaviour of the component at these locations where debonding between skin and stiffener is usually a critical failure).
Mechanical properties of material are promising and component behaviour in numerical simulations performed seems appropriate. However, as the object of the project is the validation of a new manufacturing process, it is key to study the real behaviour of the material as part of an aeronautical structure widely used (as omega stiffened panel) manufactured using a combination of automatized lay up tape process and infusion in order to identify defects derived from the novel manufacturing process. Only after the performance of the tests (Level 2 and Level 3) and processing of their results it will be available information for a preliminary evaluation of how competitive novel manufacturing process is, compared with classical manufacturing process.
For this new process to be considered as possible substitute of current one, it is expected similar (or better) level of quality and mechanical behaviour with the reduction of energy and time (reducing cost and environmental footprint).
According to visual inspection (external) of the panels already manufactured for the extraction of Level 2 Test Coupons, the impression is that superficial quality is clearly inferior than obtained using current manufacturing process (specially in omega stiffener internal surface) but the interface between skin and stiffeners seems to be indistinguishable from any other ply to ply interface in stacking sequence (what is expected to improve the behaviour of the component at these locations where debonding between skin and stiffener is usually a critical failure).