Periodic Reporting for period 2 - DEWTECOMP (Development of innovative welding systems for structural joints of Thermoplastic matrix-based Composites)
Periodo di rendicontazione: 2021-05-01 al 2022-06-30
In the aerospace industry, there is a delay in the exploitation of thermoplastic composites, since the final efficiency and robustness of the component is a priority with more product development cycle time with much more resources and investment needed. A greater exploitation of TPCs must be related in the development of new processes able to ensure the production of components with high performances and low costs for manufacturing without the need of autoclave. One key combination to get complex shapes and take full advantage of thermoplastic, could be:
Joining has proved to be a critical step in the process of manufacturing thermoplastic composite TPC products, because it can initiate several irregularities in the structure that can result in weakening of the properties.In order to overcome the limitations in the use of IW process in the aerospace industry, Dewtecomp project aims at the development of:
-Fully automated induction welding system with a software/hardware integration between the IW machine and the robotic arm in order to perform structural bond of reinforcement parts to structural frames to obtain highly integrated Door Surround Structure (DSS).
-A process control system based on the use of a thermal camera, which taking the real time image check of temperature at the surface of the component being welded and get process control depending on this measured temperature. Today this control at prototype system in CETMA is done with pyrometers which being enough for lab prototype installation, as well some trials with thermal camera has been carried out.
The project will also generate impact to the society in general as follows:
Impact with respect to science and technology: Progress thermoplastic composite joining technologies with aerospace relevance. The R&D work will generate new scientific knowledge as well as new methods and models for welding which will strengthen the European positions in this field of advanced joining technologies.
Impact with respect to industry and economy: Composite technology in general is an area where Europe tend to lag other regions such as North America. CLEANSKY 2 is one of the enormous efforts which are underway and funded by the European Commission as well as the member states of the EU to catch up. The project will strengthen the position of the European industry by innovative welding technologies and intellectual property rights. In the long term, it will contribute to an economic strengthening of related European industry as well as to the scientific position of European research entities. A key opportunity of the supply chain is to establish strong working relationships with major international players in this industry, who are positioned to ensure that the outcomes of this research are efficiently transferred to a broader marketplace.
Impact with respect to labour: It will generate new jobs in the short term for young scientists.
The main objectives of Dewtecomp projects are:
-to demonstrate the suitability of the IW welding process to achieve innovative and efficient way of structural bond of parts in LM PAEK/UD
-To design a manufacture an induction welding system that allows to performing structural bond of reinforcement parts to structural frames to obtain highly integrated Door Surround Structure (DSS).
-to automatize the process selecting the optimal combination of the welding head and robot arm for specimens indicated by the TM but widening the flexibility to allow welding of other structures, if needed, in example the skins.
DEWTECOMP showcased the obtained results with dissemination and communication activities in line with its plan participating in international fairs and B2B meetings with aerospace industry companies. Moreover, additional actions were performed such as project web page and social media management and update, liaison with other sister projects, and poster design and update.
Joining has proved to be a critical step in the process of manufacturing thermoplastic composite TPC products, because it can initiate several irregularities in the structure that can result in weakening of the properties.In order to overcome the limitations in the use of IW process in the aerospace industry, Dewtecomp project aims at the development of:
-Fully automated induction welding system with a software/hardware integration between the IW machine and the robotic arm in order to perform structural bond of reinforcement parts to structural frames to obtain highly integrated Door Surround Structure (DSS).
-A process control system based on the use of a thermal camera, which taking the real time image check of temperature at the surface of the component being welded and get process control depending on this measured temperature. Today this control at prototype system in CETMA is done with pyrometers which being enough for lab prototype installation, as well some trials with thermal camera has been carried out.
The project will also generate impact to the society in general as follows:
Impact with respect to science and technology: Progress thermoplastic composite joining technologies with aerospace relevance. The R&D work will generate new scientific knowledge as well as new methods and models for welding which will strengthen the European positions in this field of advanced joining technologies.
Impact with respect to industry and economy: Composite technology in general is an area where Europe tend to lag other regions such as North America. CLEANSKY 2 is one of the enormous efforts which are underway and funded by the European Commission as well as the member states of the EU to catch up. The project will strengthen the position of the European industry by innovative welding technologies and intellectual property rights. In the long term, it will contribute to an economic strengthening of related European industry as well as to the scientific position of European research entities. A key opportunity of the supply chain is to establish strong working relationships with major international players in this industry, who are positioned to ensure that the outcomes of this research are efficiently transferred to a broader marketplace.
Impact with respect to labour: It will generate new jobs in the short term for young scientists.
The main objectives of Dewtecomp projects are:
-to demonstrate the suitability of the IW welding process to achieve innovative and efficient way of structural bond of parts in LM PAEK/UD
-To design a manufacture an induction welding system that allows to performing structural bond of reinforcement parts to structural frames to obtain highly integrated Door Surround Structure (DSS).
-to automatize the process selecting the optimal combination of the welding head and robot arm for specimens indicated by the TM but widening the flexibility to allow welding of other structures, if needed, in example the skins.
DEWTECOMP showcased the obtained results with dissemination and communication activities in line with its plan participating in international fairs and B2B meetings with aerospace industry companies. Moreover, additional actions were performed such as project web page and social media management and update, liaison with other sister projects, and poster design and update.
In WP1 a preliminary definition of the induction welding system able to weld the DSS components provided by the TM has been performed.
After WP1, the following activities were carried out in WP2:
-Definition of assembly plan for IW system;
-Detailed definition of system components:
-the automated IW cell including Induction power system and ancillaries; -the transfer system to manage the induction head (robotic arm); -the control system (including thermal camera for process monitoring).
At the end of this WP, CDR was carried out on the design of IW unit, tools, jig and end-effector in order to validate the activity and start with manufacturing step.
In WP3 the following experimental activities were carried out:
-Optimization of induction welding process based on the dynamic susceptor technology.
-Process validation by following the defined test matrix which included mechanical and physical tests.
Within WP4 the following activities were performed:
• Programming and electrical definition of the IW cell elements;
• IR camera communication tests;
• TME Robot communication tests;
• Development of the control and software system of the IW cell.
The integration and mechanical optimization of the IW head, harnesses and components onto the robot were also performed during WP4.
At the end of WP4, the pre-acceptance tests were carried out at CETMA facilities.
The cell represents the physical deliverable of WP5 and it includes:
• The robotic arm;The induction welding equipment;The tools and jigs for the welding of the final demonstrators.
At the end of WP the following final demonstrators were welded:
• cassette coupling;
• Aux sill;
• Z-profile;
• frame/intercostal Assembly.
In WP6 a joint NDA was signed between partners and topic manager to explore future business opportunities on IW of thermoplastics. Several dissemination activities were perfomed like JEC 2022 and a paper was sent to SAMPE Europe for the next conference to be held in November.
After WP1, the following activities were carried out in WP2:
-Definition of assembly plan for IW system;
-Detailed definition of system components:
-the automated IW cell including Induction power system and ancillaries; -the transfer system to manage the induction head (robotic arm); -the control system (including thermal camera for process monitoring).
At the end of this WP, CDR was carried out on the design of IW unit, tools, jig and end-effector in order to validate the activity and start with manufacturing step.
In WP3 the following experimental activities were carried out:
-Optimization of induction welding process based on the dynamic susceptor technology.
-Process validation by following the defined test matrix which included mechanical and physical tests.
Within WP4 the following activities were performed:
• Programming and electrical definition of the IW cell elements;
• IR camera communication tests;
• TME Robot communication tests;
• Development of the control and software system of the IW cell.
The integration and mechanical optimization of the IW head, harnesses and components onto the robot were also performed during WP4.
At the end of WP4, the pre-acceptance tests were carried out at CETMA facilities.
The cell represents the physical deliverable of WP5 and it includes:
• The robotic arm;The induction welding equipment;The tools and jigs for the welding of the final demonstrators.
At the end of WP the following final demonstrators were welded:
• cassette coupling;
• Aux sill;
• Z-profile;
• frame/intercostal Assembly.
In WP6 a joint NDA was signed between partners and topic manager to explore future business opportunities on IW of thermoplastics. Several dissemination activities were perfomed like JEC 2022 and a paper was sent to SAMPE Europe for the next conference to be held in November.
The ambition of this DEWTECOMP proposal is to carry out R&D activities for the development of a induction welding automated system, based in a robotic arm to weld the proposed Specimens made of thermoplastic composite (TPC); the automated system will allow continuous Induction Welding technique for joining these and other type of parts. As well the system will incorporate friendly user interface and an innovative close loop control of the induction power by thermal camera images.
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, with considerable reduction of assembly time.The possibility to develop low-cost and effective processes for thermoplastic composites, to substitute metallic structures or thermoset composites structures still the dominating technology in polymer matrices, is due to the nature of thermoplastic resins.
The use of TPC can have an interesting exploitation in aerospace sector if continuous, automated and fast processes are developed. The consolidation process of TPCs is reversible “thermoplastic matrix can be melted and cooled a number of times before degradation”. This property, together with the possibility to use fast consolidation process, allows the possibility of continuous processes, such as the induction welding, more over in the case of induction welding it allows also to think in repair strategies.
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, with considerable reduction of assembly time.The possibility to develop low-cost and effective processes for thermoplastic composites, to substitute metallic structures or thermoset composites structures still the dominating technology in polymer matrices, is due to the nature of thermoplastic resins.
The use of TPC can have an interesting exploitation in aerospace sector if continuous, automated and fast processes are developed. The consolidation process of TPCs is reversible “thermoplastic matrix can be melted and cooled a number of times before degradation”. This property, together with the possibility to use fast consolidation process, allows the possibility of continuous processes, such as the induction welding, more over in the case of induction welding it allows also to think in repair strategies.