Report

Teaser, summary, work performed and final results

Periodic Reporting for period 1 - NEWCORT (Novel Processes and Equipment in Composite Repair Technology)

Teaser

The main objective of NEWCORT is to develop and validate novel processes and equipment for the repair of advanced composite airframes. To this end, “Composite Repair Heating and Polymerization Process Monitoring” has been identified as being the most critical issue while...

Summary

The main objective of NEWCORT is to develop and validate novel processes and equipment for the repair of advanced composite airframes. To this end, “Composite Repair Heating and Polymerization Process Monitoring” has been identified as being the most critical issue while having the highest potential for further developments. Novel heating processes and equipment will focus on the polymerization of new types of resins (e.g. starting from M20/M21 variables ranging at curing at 120-140oC), possibly including thermoplastic materials, through application of innovative instruments and methods:
• Design of range of GMI heating blankets adapted to most frequent internal structural configuration specificities (i.e. according to internal heat sinks due to structural elements etc.),
• Sensing mats with embedded thermocouples and dielectric sensors, for resin curing progress and viscosity monitoring,
• New power supply and control logic of heating consoles for optimized performance and for “driving” the novel heating blankets and sensing mats,
• Development of heating simulation software for selection of blankets and Thermocouples installation topology,
• Introduction of the CONDUCTOR* blanket logic (i.e. consumable heating blankets) to target repair configurations.
• Development of Quick Composite Repair (QCR) kits for most frequent aircraft repair cases.

In addition, “Composite Repair Associated Procedures”, namely material removal & surface preparation, NDT and positive pressure application for improved compaction of patch layers, will be similarly addressed:
• For material removal, main developments include process optimization to enable close tolerance applications for curved thick composite structures. This will be potentially combined with scarfed pre-cured patches, examination of simplifications in stepping requirements and adaptation of material removal equipment to most frequent repair geometries (e.g. fuselage curvature).
• The development of positive pressure application equipment for flat / curved structures will be examined, together with optimized pressure measurement devices and control software, mountable to most frequent repair cases (e.g. composite fuselage curvature).
• Finally, in terms of NDT, optimization of existing U/S NDT application procedures will be studied, together with the development of repair specific calibration specimens. Moreover, the development of an NDI / quality assurance process as an alternative to Process Control Specimen will be attempted.

Work performed

The following activities have been performed during the 1st Reporting Period:
• Determination of all parameters and constraints related to the operation of equipment, software and procedures. Issue of corresponding Deliverable 1.1
• Preliminary analysis and design of the novel equipment and issue of corresponding Deliverable 1.2
• Definition of the demonstration cases and the exact validation plan for the project technologies, in order to issue the corresponding Deliverable 1.3.
• Technical work for the development of innovative solutions contained in WP2-WP3, as described in detail within the corresponding Tasks.
• Further to the Kick-Off meeting (January 2016) implementation of visits to the Topic Manager\'s premises (December 2016 and April 2017) corresponding to several project Tasks, focusing on thermal equipment and methodologies.

Final results

The overall concept of the NEWCORT is to provide the Topic Manager with a “toolset” of novel processes and associated equipment, so as to enable the development of tailored solutions to address typical damages to be repaired by the whole range of stakeholders of the aeronautical industry (aircraft manufacturers, airlines, MROs etc.), such as lightning strike and accidental impact. As detailed in the following Paragraphs of the NEWCORT proposal, this “toolset”, which covers the whole range of the bonded composite repair procedure, (e.g. damage removal, NDT, repair patch polymerization, etc) is comprised of:
- State-of-the-art solutions, currently available to the aeronautical market by GMI Aero (i.e. TRL-9), which will be tailored to Topic Manager’s requirements within NEWCORT.
- Innovative solutions developed in previous FP7/Transport and Cleansky projects in cooperation with NEWCORT partners (TRL5-6), which will be further matured within NEWCORT.
To this end, structure configurations will be selected by the Topic Manager and the composite repair processes and associated equipment will be commonly selected between the Topic Manager and the NEWCORT Consortium, so that the “toolset” solutions are tailored to those configurations. The selected processes will be characterized, as per a test matrix defined by the Topic manager, against time saving vs. state of the art repair process, mechanical properties of the repair patch, NDI capability of the repair patch, resistance to aggressive media, electrical properties etc. Based on a defined qualification process applicable in aeronautical context, a full testing and validation process of innovative solutions and equipment will be performed, according to requirements defined by the Topic Manager, in order to demonstrate the different repair process compatibility with surface coatings generally used in aeronautics, typical ageing with temperature and humidity cycling corresponding to normal use of aircraft.

Socio-economic impact: The major socio-economic impact of the NEWCORT project will be the reinforcement of the competitiveness of Europe’s aircraft industry and European aircraft operators. In the year 2011, the European aerospace industry employed 479.600 persons; Europe’s airline industry employed approximately 390.000 persons. Both the aircraft production and airline operation industries are active on the most globalized markets; therefore the conservation and future expansion of employment will necessitate a highly increased competitiveness. The project results will play a key role in addressing this issue, both by generating added product value for aircraft manufacturers and reduced cost and time investments for production and ground operations. Additionally the NEWCORT project will assist the development of high technology SMEs, where job opportunities will be developed for the final industrialization of composite repair and OOA manufacturing techniques as well as future market entry within Europe. Another important aspect will be the increased safety resulting from more reliable components and processes. This is one of the major criteria for the European aerospace industry to belong to the market leaders within this business sector.

Technical impact: The innovations aimed at within NEWCORT will have strong technical impacts regarding the knowledge about highly integrated lightweight CFRP structures in all aerospace applications and necessary certification. Due to the development of reliable repair techniques and equipment, the increased integration of innovative materials will be enabled. Novel light-weight design of CFRP structural components will be possible and will lead to weight savings (up to 15%) of the aircraft. Even further weight saving are expected for CFRP integration in interior design and system components. Additionally the delivery of new, reliable bonded composite repair processes and equipment improves the safety and operational capability