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Full scale innovative pressure bulkheads for Regional Aircraft Fuselage barrel on-ground demonstrators

Periodic Reporting for period 1 - FUSINBUL (Full scale innovative pressure bulkheads for Regional Aircraft Fuselage barrel on-ground demonstrators)

Reporting period: 2019-04-01 to 2020-08-31

FUll Scale INnovative pressure BULkheads for Regional Aircraft Fuselage barrel onground demonstrators

The scope of this project is to perform the full barrel demonstrator tests, needed to validate the new concept of fuselage created and manufactured in the Green Regional Aircraft context.

Two advanced manufacturing processes will be developed and validated to achieve full scale innovative pressure bulkheads for Regional Aircraft Fuselage barrel on-ground demonstrators.

The different manufacturing techniques to carry out these bulkheads will be:

• Prepreg CFRP Bulkhead using a cobonding process in autoclave
• Dry fiber CFRP Bulkhead using LRI infusion process (out of autoclave)

For both manufacturing processes, the most advanced techniques of lay-up will be used to reduce recurrent cost and increase the level of automatization and production rates.
This report covers the work perform in the first period from M1 to M17. The second period will cover from M18 to M30 where the bulkhead demonstrators will be manufactured.

In this first period, the main requirements for the bulkheads has been studied and analyzed to develop the manufacturing process for both techniques.

After that, the required tooling to manufacture the Bulkheads has been designed taking into account the main needs of the manufacturing process and the industrials requests of the Topic Manager.

Once the tooling drawings were released, the manufacturing of the tooling has been carried out. Then, the quality control has been completed to achieve the required standards in aeronautical industry.

So the main achievements/milestones that this consortium has accomplished are the following ones:
• Definition of requirements
• Process detail assessment
• Tooling Critical Design Review
• Start the tool farbication

In the following period, the next tasks will be the final assembly of the tooling and the manufacturing of the bulkheads using the two different technologies.
This project will set up an innovative tool configuration to manufacture bulkhead in CFRP using different process.

This in turn will facilitate the implementation of composite materials for structural components in a market segment like SAT where performance and cost are of primary importance. The main advantage of the use of carbon fiber is the ratio stiffness/weight, getting a reduction of the final weight for the parts which decrease the emissions CO2 of the aircrafts and reduce operating cost during the life of the aircraft.

Other primary industrial factors, like manufacturing cost, manufacturing process flow, energy saving, waste reduction, etc. will be addressed by the solution carried out during the project.

In addition to this, the main technological jump is the use of the infusion technology in this type of structure (high dimension part). This manufacturing process would be viable to obtain a high integrated structure by infusion in one shoot. However, for the budget limitations at the project and the used of one tooling for both technologies in accordance with the Topic Manager, the dry fiber omega stringers would be integrated to the skin bulkhead by riveting and the prepreg bulkhead will be obtain by a cobonding process.

In any case, these developments will have an important impact in the global market and in the society by providing a more efficient tooling and manufacturing process helping in the achievement of high rate productions expected from composite aeronautical parts.

In particular, FUSINBUL has the ambition of representing a step forward in technology and approach to improved part quality; shorten process cycle and less energy consumption for a full structural component in composite materials.
Master Model Tool in FIDAMC Facilities
Master Model Tool in FIDAMC Facilities