Periodic Reporting for period 2 - ELCOCOS (Enhanced Low-cost COmplex COmposite Structures)
Berichtszeitraum: 2020-10-01 bis 2021-06-30
For years, the ecological transition is one of the main challenges and priorities in the aviation sector with a focus placed on innovative technologies for responsible consumption and production. An effective way to increase energy efficiency and reduce fuel consumption is reducing the mass of aircraft. Composite materials are particularly attractive to aviation as an alternative to save structural weight. However, composite manufacturing processes for small and medium size aerostructures are featured by substantial labour effort, small automation level and high costs for development (mainly tooling and equipment).
In this context, supported by Clean Sky and Airbus Defense and Space, the “Enhanced Low-cost COmplex COmposite Structure” project (ELCOCOS) was launched in 2019 to develop a cost competitive composite door using Liquid Resin infusion (LRI) technologies.
The project has fully defined technical and cost performances of an optimized infused structure, predicting the fiber and resin behavior correlated with physical specimen, mastering the infusion process through numerical simulation, and optimizing the curing cycle thanks to a self-heated composite mould. The project was tailored to reduce the structural weight by 20%, to reduce the production costs by 20% for the primary structure and the reduction of non-recurring costs (NRC) by 20%. These objectives were achieved through one shot concepts, Out of Autoclave (OoA) process and the development of innovative low cost tooling techniques.
ELCOCOS has relied on the strong partnership of leading European industrials and research organizations in the area of aerospace and material development: Latécoère for the project management, door design and sizing, composite coupons and door tests; Corima Technologies for the composite tooling design and manufacturing; ESTIA/Compositadour for the lay-up; and Institut de soudure (ISA) for the injection process.
After 30 months, this Consortium has successfully manufactured and performed a ground test of a full scale demonstrator that will significant contribute to the performance of next generation aircraft reducing fuel consumption and CO2 emissions.
In this context, supported by Clean Sky and Airbus Defense and Space, the “Enhanced Low-cost COmplex COmposite Structure” project (ELCOCOS) was launched in 2019 to develop a cost competitive composite door using Liquid Resin infusion (LRI) technologies.
The project has fully defined technical and cost performances of an optimized infused structure, predicting the fiber and resin behavior correlated with physical specimen, mastering the infusion process through numerical simulation, and optimizing the curing cycle thanks to a self-heated composite mould. The project was tailored to reduce the structural weight by 20%, to reduce the production costs by 20% for the primary structure and the reduction of non-recurring costs (NRC) by 20%. These objectives were achieved through one shot concepts, Out of Autoclave (OoA) process and the development of innovative low cost tooling techniques.
ELCOCOS has relied on the strong partnership of leading European industrials and research organizations in the area of aerospace and material development: Latécoère for the project management, door design and sizing, composite coupons and door tests; Corima Technologies for the composite tooling design and manufacturing; ESTIA/Compositadour for the lay-up; and Institut de soudure (ISA) for the injection process.
After 30 months, this Consortium has successfully manufactured and performed a ground test of a full scale demonstrator that will significant contribute to the performance of next generation aircraft reducing fuel consumption and CO2 emissions.
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.
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.
This project built upon the lessons learned in previous projects as COMDOR or MAXIMUS, going beyond the state-of-the-art in a number of areas, including:
(1) definition, design and analysis methodology and economic performance of an optimized infused complex one-shot composite structure relevant for aircraft door future developments;
(2) optimization of Automatic Fiber Placement processes for complex shape geometry (human error and material waste reduction);
(3) improvement of hot forming processes on non-developable geometry and complex shape;
(4) energy savings with Out of Autoclave production process using self-heating mold for infusion and save industrial non-recurring costs with regards to RTM tooling;
(5) environment preservation using re-useable silicon bags for manufacturing.
These progress pave the way for optimized composite structure production processes, being a major pillar to future aircraft production, operations, maintenance and dismantling sustainable life-cycle by:
• More than 20% weight reduction;
• About 15% reduction of production recurring costs;
• Significant reduction of tooling non-recurring costs (between 20%-50% depending on production rate).
By integrating the environmental concerns from the design process to the manufacturing, the innovations of ELCOCOS projects allow a step forward through the responsible consumption and production in the aeronautic sector. The results of this project, in terms of technology and skills, will help the project partners to be ready for the next aeronautic development programmes and therefore to contribute to the aeronautical industry goals and actions on climate change, more precisely to the reduction in net aviation CO2 emissions.
(1) definition, design and analysis methodology and economic performance of an optimized infused complex one-shot composite structure relevant for aircraft door future developments;
(2) optimization of Automatic Fiber Placement processes for complex shape geometry (human error and material waste reduction);
(3) improvement of hot forming processes on non-developable geometry and complex shape;
(4) energy savings with Out of Autoclave production process using self-heating mold for infusion and save industrial non-recurring costs with regards to RTM tooling;
(5) environment preservation using re-useable silicon bags for manufacturing.
These progress pave the way for optimized composite structure production processes, being a major pillar to future aircraft production, operations, maintenance and dismantling sustainable life-cycle by:
• More than 20% weight reduction;
• About 15% reduction of production recurring costs;
• Significant reduction of tooling non-recurring costs (between 20%-50% depending on production rate).
By integrating the environmental concerns from the design process to the manufacturing, the innovations of ELCOCOS projects allow a step forward through the responsible consumption and production in the aeronautic sector. The results of this project, in terms of technology and skills, will help the project partners to be ready for the next aeronautic development programmes and therefore to contribute to the aeronautical industry goals and actions on climate change, more precisely to the reduction in net aviation CO2 emissions.