Advanced OoA and Automated Technologies for the Manufacturing of a Composite Outer Wing Box

¹ CIRA - Italian Aerospace Research Centre, Via Maiorise snc, 81043 Capua ( CE), Italy
² NOVOTECH Aerospace Advanced Technology S.r.l., 80125 Napoli, Italy
³ SICAMB, Strada Eschido 1, 04100 Latina, Italy
⁴ ONERA - The French Aerospace Lab, F-92190 Meudon, France
⁵ IMAST - Polymeric and Composite Materials and Structures, P.zza Bovio 22, 80133 Napoli, Italy
⁶ Siemens Industry Software SAS, 150 Avenue de la République, 92320 Chatillon, France

^* e-mail: f.romano@cira.it

Abstract

This work resumes the results achieved until today in the European project AirGreen 2 of Clean Sky 2 programme, deriving from the application of two different dry preforming processes for the manufacturing of a composite outer wing box of the next generation turboprop aircrafts. Liquid Resin Infusion and Out of Autoclave techniques, by Hand-Layup and Automated Fiber Placement, are considered. The optimisation and validation of the manufacturing processes have been done according to key performance indexes: weight and cost reduction, lower energy consumption, high productivity and minimal reworking time, less intensive labour, minimal scrap and less waste of materials. The work has been performed through manufacturing tests and optimisation of the process parameters, implementation of several bagging techniques, numerical simulations of the infusion process and material characterization tests in operative conditions, from coupons level up to details and elements level (flat stiffened panels). Pro and cons, suggestions and technical considerations useful for the next step of the project (final manufacturing of large parts and components) are assessed.