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Simulation Based Solutions for Industrial Manufacture of Large Infusion Composite Parts

Objective

Today, advanced composites use either layers of plies impregnated with resin (pre-pregs) to form a laminate, or Liquid Composites Moulding (e.g. RTM) of dry textiles. Prepreg composites give superior mechanical properties due to toughened resins and high fibre content, but suffer from high material costs, limited shapeability, complex, expensive and time consuming manufacturing, and limited materials shelf life. Infusion technologies can overcome these limitations, but are not fully industrialised and rely on costly prototype testing due to the lack of simulation tools. Current infusion simulation technologies are approximate and really only suited to small scale components based on adaptations of Resin Transfer Moulding simulation; they are not accurate for large, thick and complex aerospace composites, where one sided tooling and vacuum membranes cause complex 3D heat/flow processes. The INFUCOMP project will develop the full simulation chain from preform design to manufacture (infusion), process/part optimisation and final part defects/mechanical performance prediction with a focus on the infusion step. The project covers all popular Liquid Resin Infusion (LRI) methods currently used in the Aerospace industry. Although focus is on aerospace applications, the work will be very relevant to other industries. The proposed technologies will allow economical manufacture of high performance, integrated, large scale composite structures; thus, positively contributing to their increased use. Benefits include lower cost, improved performance, greater payloads and fuel/emissions reductions. A team of two aircraft manufacturers, two tier one suppliers, a material manufacturer, university and industry researchers, and commercial software specialists; all with a recognised track record in this field have been selected from eight different CEC countries; one partner is an SME.

Field of science

  • /engineering and technology/materials engineering/composites

Call for proposal

FP7-AAT-2008-RTD-1
See other projects for this call

Funding Scheme

CP-FP - Small or medium-scale focused research project

Coordinator

ESI GmbH
Address
Mergenthalerallee 15-21
65670 Eschborn
Germany
Activity type
Private for-profit entities (excluding Higher or Secondary Education Establishments)
EU contribution
€ 301 500
Administrative Contact
Anthony Pickett (Dr.)

Participants (13)

ASSOCIATION POUR LA RECHERCHE ET LE DEVELOPPEMENT DES METHODES ET PROCESSUS INDUSTRIELS
France
EU contribution
€ 415 578
Address
Boulevard Saint Michel 60
75272 Paris
Activity type
Research Organisations
Administrative Contact
Jean-Luc Roche (Mr.)
CRANFIELD UNIVERSITY
United Kingdom
EU contribution
€ 214 710
Address
College Road
MK43 0AL Cranfield - Bedfordshire
Activity type
Higher or Secondary Education Establishments
Administrative Contact
Alex Skordos (Dr.)
DAHER AEROSPACE SAS
France
EU contribution
€ 224 415
Address
Route De Tours 23
41400 Saint Julien De Chedon
Activity type
Private for-profit entities (excluding Higher or Secondary Education Establishments)
Administrative Contact
Michael Hugon (Mr.)
ESI GROUP
France
EU contribution
€ 233 169
Address
3 Bis Rue Saarinen
94528 Rungis
Activity type
Private for-profit entities (excluding Higher or Secondary Education Establishments)
Administrative Contact
Yazid Hammoumraoui (Mr.)
HEXEL REINFORCEMENTS SAS
France
EU contribution
€ 233 083
Address
Zi La Plaine Bp
01121 Dagneux Montluel
Activity type
Private for-profit entities (excluding Higher or Secondary Education Establishments)
Administrative Contact
Patrick Henrat (Dr.)
KATHOLIEKE UNIVERSITEIT LEUVEN
Belgium
EU contribution
€ 332 640
Address
Oude Markt 13
3000 Leuven
Activity type
Higher or Secondary Education Establishments
Administrative Contact
Maria Vereeken (Ms.)
PANEPISTIMIO PATRON
Greece
EU contribution
€ 165 663
Address
University Campus Rio Patras
265 04 Rio Patras
Activity type
Higher or Secondary Education Establishments
Administrative Contact
Spiros Pantelakis (Prof.)
RISE SICOMP AB
Sweden
EU contribution
€ 210 938
Address
Fibervaegen 2 - Oejebyn
941 26 Pitea
Activity type
Other
Administrative Contact
Maciej Wysocki (Dr.)
SHORT BROTHERS PLC
United Kingdom
EU contribution
€ 174 575
Address
Airport Road, Queens Island
BT3 9DZ Belfast
Activity type
Private for-profit entities (excluding Higher or Secondary Education Establishments)
Administrative Contact
Gary Connery (Mr.)
ISRAEL AEROSPACE INDUSTRIES LTD.
Israel
EU contribution
€ 196 992
Address
Ben Gurion International Airport
70100 Lod
Activity type
Private for-profit entities (excluding Higher or Secondary Education Establishments)
Administrative Contact
Anthony Green (Dr.)
INASCO HELLAS ETAIREIA EFARMOSMENON AERODIASTIMIKON EPISTIMON EE
Greece
EU contribution
€ 260 730
Address
Napoleontos Zerva 18
16675 Glyfada Athina
Activity type
Private for-profit entities (excluding Higher or Secondary Education Establishments)
Administrative Contact
Dimitri Bofilios (Dr.)
UNIVERSITY OF STUTTGART
Germany
EU contribution
€ 197 880
Address
Keplerstrasse 7
70174 Stuttgart
Activity type
Higher or Secondary Education Establishments
Administrative Contact
Klaus Drechsler (Prof.)
PIAGGIO AERO INDUSTRIES SPA
Italy
EU contribution
€ 137 250
Address
Largo Angelo Fochetti 29
00185 Roma
Activity type
Private for-profit entities (excluding Higher or Secondary Education Establishments)
Administrative Contact
Aniello Cozzolino (Mr.)