How are composites used in aerospace structures?

Since the 1950s, composites have been growing in use in commercial and defense aircraft, ranging from struts and tail components, to wing skins and fuselages, to engine components and propeller blades. One of the largest challenges to adoption of composites by the aerospace industry is stringent standards especially for safety critical structures, necessitating time- and labor-intensive processes to qualify new materials for use on passenger aircraft. Qualified and well-tested autoclave-cured carbon fiber and thermoset-based prepregs are most often used for many structures, though other materials and formats, including thermoplastic tapes, are also in development or use. Source: The FAA: Keeping up with aerocomposites evolution

How are composites used in space structures?

At the time the Apollo capsule, which landed on the moon in 1969, was built by NASA, composites industry was still in its infancy and the materials were not yet in widespread use, though the Apollo capsule used early composite technology in the form of an ablative heat shield made from Avcoat, an epoxy novolac resin with silica fibers in a fiberglass-phenolic honeycomb matrix. A fiberglass honeycomb was bonded to the primary structure and the paste-like material was injected into each cell individually. Since Apollo , advanced composites have evolved by leaps and bounds, and have played a significant role in space programs with use in launch vehicles, the space shuttle, satellites, space telescopes and the International Space Station. Source: Composites in the race to space

AEROSPACE

Aerospace

Boeing reports full-year commercial orders, deliveries for 2022

Last year saw Boeing stabilizing 737 production, resuming 787 deliveries and launching its new freighter aircraft.

Grace Nehls
Managing Editor, CompositesWorld

Aerospace

Airbus releases 2022 full-year commercial aircraft orders, deliveries

The aerospace giant surpassed 2021 net orders, deliveries and aircraft in backlog covering all aircraft families.
#airbus

Thermoplastics

INN-PAEK project to develop 100% recyclable, lightweight thermoplastic flange wheels for future aircraft

The AITIIP Technology Center leads this research with partner Liebherr Group to develop a technology by June 2023 that contributes to more sustainable, eco-friendly production systems.

Construction

AMULET project funds 24 projects in composites, CMCs, metals

Trans-European project finalists for first open call identify material and process innovations in building, aerospace and aeronautics, energy and automotive sectors.
#ceramicmatrixcomposites

Testing

RACER achieves “power on” test, prepares for 2023 maiden flights

Initial function checks were conducted at the Airbus Helicopter facility in Marignane, France, signaling the next step for the composite rotorcraft demonstrator and its highly collaborative teams.

Large, high-volume, infused composite structures on the aerospace horizon

Infused carbon fiber composite structures are not new, but they have never been built at the rates anticipated for next-generation, single-aisle aircraft. It is a daunting prospect — but a feasible one.
#787 #autoclave #spiritaerosystems

Want The Basics?
START HERE

Urban Air Mobility |

Composites end markets: Aerospace (2023)

With COVID in the past and passengers flying again, commercial aircraft production is ramping up. The aerocomposites supply chain is busy developing new M&P for an approaching next-generation aircraft program.
#Basics #sourcebook #nextgenaerospace

Jeff Sloan Editor-in-Chief, CompositesWorld

Videos / Podcasts

Avel Robotics uses AFP tow steering to produce CFRP foil components

Carbon Fibers

Plant tour: Avel Robotics, Lorient, France

November 23, 2022 - 12:00 AM EST

From AFP hydrofoils to more efficient aircraft parts, Avel uses digital design, multiprocess production and a rule-breaking approach for complex 4D composites.
#planttour

Aerospace

ZeroAvia advances to certify ZA600 in 2025, launch ZA2000 with liquid hydrogen in 2027

November 10, 2022 - 12:00 AM EST

Lightweight composite tanks are key to ZeroAvia’s vision for H2 aircraft to rival range and utility of jet fuel aviation.
#hydrogen #trends

Carbon Fibers

Fast-FlexMont2 project targets optimized, large-structure CFRP assembly

October 31, 2022 - 3:00 PM EST

Advanced measuring and referencing methods, highly precise positioning technologies and continuous digital process control by Fraunhofer IFAM demonstrate automated rudder hinge assembly.
#automation

Digital Demos

Digital Demo: Aerospace Carbon Fiber Infusion

October 14, 2022 - 12:00 AM EST

Learn how this process combined with carbon fiber can offer the manufacturer the benefits of increased strength and the ability to make a lighter-weight part.

RTM

Plant tour: ÉireComposites, Galway, Ireland

August 19, 2022 - 12:00 AM EST

An in-house testing business and R&D focus has led to innovative materials use and projects in a range of markets, from civil aerospace to renewable energy to marine.
#planttour #space #windblades

Aerospace

Airbus and CFM launch flight test demonstrator for advanced open fan architecture

July 20, 2022 - 12:57 PM EST

Flight test demonstrator aims to mature and accelerate development of advanced propulsion technologies as part of CFM RISE program, with CFRP blades as key part of design.
#aeroengines #airbus

Machining/Drilling

German UniFix project develops mobile holding fixture to enhance production efficiency of large CFRP structures

June 23, 2022 - 12:00 PM EST

Fraunhofer IFAM and Airbus Operations in Stade demonstrate reduced manual handling and non-productive time in flow-oriented manufacturing of vertical tail plane.
#nextgenaerospace #composites4_0

Thermoplastics |

From plant tours to EV battery enclosures: The top 10 CompositesWorld articles of 2022

Through a variety of editorial content, CW explored the trends and topics that are rapidly flourishing in the industry. Based on Google Analytics, these top 10 articles were considered the most popular.

Cara Decknadel Digital Content Editor, Gardner Business Media, Inc.

Aerospace

Natilus partners with Janicki for blended wing autonomous aircraft

The Tier 1 supplier will design, fabricate and provide quality assurance of primary composite structures for the Natilus N3.8T prototype, to be used for air freight transport.

Aerospace

ZeroAvia receives CAA approval for next phase of hydrogen-electric test flights

ZeroAvia closed off 2022 by securing Part 21 permit to fly for retrofitted Dornier 228, following successful ground testing campaign.

Aerospace

Rolls-Royce prepares UltraFan technology demonstrator for testing

The UltraFan aeroengine, with a fan diameter of 140 inches, is designed with a suite of technologies to contribute to fuel efficiency for narrowbody and widebody aircraft.
#aeroengines

Aerospace

Spirit AeroSystems, Joramco sign MRO services cooperation

MOU agreement will provide customers a wide range of repairs to and services of composite and metallic aerostructures.
#repair

ATL/AFP

EU-funded GENEX project to develop digital twin framework for aircraft lifecycle tracking

Novel digital framework to enable holistic and comprehensive data capture through the entire aircraft lifecycle, supporting composite component/structure manufacture optimization and maintenance.
#nextgenaerospace #composites4_0 #repair

Aerospace

BBG supplies electric composite press for aircraft interior parts production

Ordered by a reputed U.S. aerospace company, the press gives the advantage of high efficiency, quiet operation, easier maintenance and overall shorter cycle times.

Carbon Fibers |

Optimizing AFP for complex-cored CFRP fuselage

Automated process cuts emissions, waste and cost for lightweight RACER helicopter side shells.
#insidemanufacturing

Ginger Gardiner Senior Technical Editor, CompositesWorld

NEW PRODUCTS: AEROSPACE

Aerospace

Cygnet Texkimp develops high-tension carbon fiber overwrapping solution

Fiber winding technology achieves greater power at higher rotating speeds via high-tension composite wrapping, resulting in enhanced fiber-volume ratio, dimensional stability and lighter parts.

Aerospace

CAMX 2022 exhibit preview: Composites Horizons

Composites Horizons’ services specialize in polyimide- and oxide-based CMC materials used to produce high-temperature structures for aerospace customers.
#ceramicmatrixcomposites #camx

Aerospace

CAMX 2022 exhibit preview: TE Wire and Cable

TE Wire and Cable creates high-performance temperature measurement, signal processing wire and cable solutions targeting aerospace and other industries.
#sensors #camx

Aerospace

CAMX 2022 exhibit preview: Collins Aerospace

Collins Aerospace identifies its extensive thermoplastics portfolio, including the display of an aircraft nacelle’s integrated curved stiffener and upper and lower longerons.
#camx

Aerospace

CAMX 2022 exhibit preview: Park Aerospace Corp.

Park Aerospace Corp. highlights its range of thermal protection system resin systems, structural polymer material systems and its services in structural design and composite strut fabrication for aerospace and space markets.
#space #camx

ATL/AFP

CAMX 2022 exhibit preview: Qarbon Aerospace

Qarbon Aerospace exhibits its capabilities in manufacturing composite components and assemblies, highlighting its proficiencies in major assembly and systems integration, automated layup, hand layup, high-temp composites and core fabrication.
#space #camx #layup

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