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Full scale innovative composite pax and cargo floor grids for regional Aircraft Fuselage barrel on -ground demonstrators.

Periodic Reporting for period 1 - SPARE (Full scale innovative composite pax and cargo floor grids for regional Aircraft Fuselage barrel on -ground demonstrators.)

Reporting period: 2018-10-01 to 2020-03-31

The object of Full scale innovative composite pax and cargo floor grids for Regional Aircraft Fuselage barrel on-ground demonstrators project is to fabricate two full ship sets of pax and cargo floor grids with innovative solutions for components integration and high volume automated solutions. All single parts of floor grids shall be manufactured using innovative solution in order to gain a competitive configuration in terms of weight and cost saving compared to metal configuration and to traditional composite solutions (thermoset). The best process solution will be select and a full scale part for each of the major composite element will be fabricated and inspected in order to validate and freeze process steps. After that two on ground composite fuselage demonstrators will be manufactured and assembled. Technical and economic impact deriving from the introduction of the selected innovative technology will be assessed.
During the first reporting period production technology to be used for each part of pax and cargo floor was fixed. Infact, the technology indicated in the project proposal for some items was confirmed, in other cases, due to design and construction constraints, the technology has changed as for the pax floor beam that will be manufactured in thermoset composites.

The following activities were done during this period:

• FEM simulation of PRF production process activities were concluded in time
• Tools design and realization for the induction welding of thermoplastic composite profiles are been concluded
• IRT procedure for the real time monitoring of PRF production process was designed and tested on real scale
• Tools design and manufactured for composite parts are been concluded
The ambition of SPARE project is to resolve the open issues of Progressive Roll Forming and to optimize the process for industrial application.
Moreover, the ambition of SPARE project is to use induction welding for the manufacturing of H-Shaped bars, using in-line continuous Induction Welding technique on the two C-Shaped bars obtained by progressive roll forming.
The achievement of this purpose will provide a significant contribution to the aeronautic industry, since will be a considerable result in the direction of developing complex and highly loaded parts with reduced costs and increased reliability.

Starting from a technical point of view project results are expected to introduce some
innovative features in pax and cargo floor grid for Regional Aircraft Fuselage:
1. Weight Reduction: Target value attended for weight reduction thanks to composite material is around 20% compared to aluminium solution.
2. Cost Reduction: If compared with aluminium solution, composite processes can involve a manufacturing cost reduction of 40%.
3. Maintenance Cost Reduction: The introduction of composite materials represent the most important feature in life cycle management cost of the components; more over composites offer also additional capability in repairing cycles. A reduction of 50% for maintenance cost is attendeed.

The technological solutions promote the use of advanced lightweight composite materials and an overall reduction of weight leads to a further reduction of fuel consumption and consequently to a reduction of air pollution. In this way SPARE will make a significant contribution to meeting the ambitious challenges towards the greening of air transport.

The major socio-economic impact of the SPARE project will be the reinforcement of the competitiveness of Europe’s aircraft industry and European aircraft operators. This is in full alignment with the European Union strong focus on innovation as a basis for societal growth and prosperity, as well as the emphasis placed on the R&D impact on job creation, societal growth and investment associated with the creation of a strong industrial base and on reducing the environmental impact of technology in line with a forward-looking climate change policy.
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