As Project Coordinator, LATECOERE led the administrative, financial and technical management of the ELCOCOS project, in order to allow the beneficiaries to focus entirely on research, development and demonstration activities.
LATECOERE realized design and analysis activities and converged to an optimized demonstrator complete definition and associated test pyramid. The door demonstrator architecture principles, material and manufacturing processes choice (dry fiber AFP, hot forming and Liquid Resin infusion) has been selected as the best compromise for project objective achievement demonstration. Then, Concept design phase had been performed in closed collaboration with manufacturing and tooling partners taking into account production constraints. Finally, the complete definition and associated test pyramid had been reviewed and provided good results to show compliance with weight and design NRC reduction goals.
ESTIA/Compositadour led the manufacturing activities for dry fiber AFP (Automatic Fiber Placement) lay-up and Hot Forming processes. Simulations on AFP have been done to predict behavior, avoid defects and find optimized technical and time consuming solutions adapted to the door complex geometry shape. Process trials and parameters adjustments contributed to the definition of an optimized process for lay-up and hot forming in respect with recurring costs targets. In parallel, several toolings for lay-up and hot forming had been designed and manufactured by Corima Technologies. All specimen for process and mechanical test pyramid has been produced, and manufacturing of demonstrator preforms finalized. All toolings have been produced.
ISA led the manufacturing activities for infusion. Permeability tests have been performed to characterize material of preforms and subsequent results have been used as input data for impregnation simulation. Trial has been conducted on plates and subcomponents to correlate and adapt models. Then, the full door one shot-structure has been simulated to define the different steps of resin impregnation and the dimension of the injection device for tooling specifications. In parallel, toolings for infusion of plates and subcomponents have been designed and manufactured. Design of final door infusion tooling finalized and the tool is available. All those toolings integrate innovative self-heating devices and re-useable silicone bags.
LATECOERE conducted tests at component level. All low level specimen have been manufactured and 100% of tests have been performed. Tests results analysis has been performed. LATECOERE also prepared the finishing activity of composite structure and additional metallic fittings to be installed on final demonstrator. LATECOERE has successfully manufactured and performed a ground test of a full scale demonstrator.
A final industrial assessment on the scaling up to the serial production level has being performed to evaluate the project objectives and to validate the profitability of the ELCOCOS solutions.
A communication strategy has been applied during the project period, supported mainly by media tools (websites, LinkedIn, twitter, EU portal) to inform the European Community and industrial key-players about the general progress of the project. Today a patent is still pending. As soon as the patent is published a dissemination strategy will be implemented, including conferences, technological coffees and aviation shows.
