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20/5000 Induction welding technology innovation brings thermoplastic composite aircraft a step closer
With more than 100 years of experience in welding metals, the French Institute of Welding (IS) group IS emerging as a leader in welding thermoplastic composites. IS group has developed the "dynamic induction welding" process used to connect carbon fiber/polyether ketone (PEKK) unidirectional truss band and fuselage skin in the Aero-thermoplastic composites demonstration project at Airbus' STELIA Aerospace.Although the process was successful, the lack of sensors at the interface limited the radius properties of the bonding truss and the global heating of the panels. A sensor is a material placed between two bonded materials in a thermoplastic composite welded joint heated by an induction coil in the welded joint. The receptor may be a resistively heated conductive body or a hysteresis heated magnetic body, melting the substrate at the welding interface and pressing it together to form a welded joint with high strength. Sensors used in induction welding thermoplastic composites are initially a metal screen or mesh, sometimes impregnated with a polymer.The IS Group has formed a partnership with Thermoplastic material supplier Arkema to jointly develop and acquire a patented technology called welding Innovation Solutions.The foundation of innovative welding solutionsThe innovative welding solution is based on the use of sensors to heat the welding interface, but this is a removable sensor connected to the welding joint. The sensor allows the process to perfectly position the heated area of the weld, and the head with the sensor is mobile, so there is no residue in the interface that will not interfere with the performance of the welded structure. In the early iterations of induction welding, the metal mesh receptor remained in the weld, but this was not the desired result. Because carbon fibre in ordinary aerospace laminates is conductive, the latest technology has been able to eliminate the receptors, allowing the use of carbon fibre as a sensor.Another feature of innovative welding solutions is the use of a pure thermoplastic matrix or low fibre layering at the welding interface to increase resin fluidity. The melt temperature and viscosity of the interfacial layer can be adjusted and functionalized to provide electrical conductivity or isolation to prevent electrical corrosion, such as between carbon fiber and aluminum or steel.Results of innovative welding solutionsThe joint coefficient of the solution is 80% ~ 90%. The joint coefficient corresponds to the welding strength. It is used in metals, plastics and composites. In a single lap shear test of two pre-cured plates welded together using the solution, 80 to 90 per cent of the performance of the unwelded, hot-pressed tank cured reference plates was obtained. The trials used unidirectional strips made of carbon fiber by Hextow AS7 and Kepstan 7002 PEKK.Innovative welding solutions can be used to weld any kind of substrate: PE, PA, PEKK, PEEK, and carbon, glass, or array-fiber reinforced thermoplastic composites. Moreover, components with copper grids can be welded to protect against lightning strikes, which are key to the construction of aeronautical structures. Innovative welding solutions are designed to be fully automated, with welding heads mounted on a 6-axis robotic arm.Welding temperature controlA common problem of metal mesh sensors subjected to magnetic field is the uneven temperature distribution of welded parts. The solution controls this by using a sensor to melt the welding interface, sensing the temperature using a laser pyrometer that actually measures the sensor's edge from the side. So you know the exact temperature at the interface. Cooling methods are also used to help control the temperature and ensure that the thermoplastic material is fully crystallized throughout the welding process.Girder skin welding testAirbus's STELIA was one of the first customers for the induction welding process. The IS group and Arkema conducted a special study for STELIA in which seven carbon /PEKK beams were welded to 14 layers of skin and covered with copper mesh to prevent lightning strikes. The ultimate goal is a structure with a welding length of 30 meters and a straight and double bending cross section. Components were fabricated using a 194 GSM unidirectional band consisting of Tenax HST45 carbon fibre and Kepstan 7002 PEKK. STELIA specifies a homogeneous weld with mechanical properties greater than 85% of the reference material solidified in the thermocompression tank, without degradation of the thermal or mechanical properties of the adhesive. STELIA also requested the development of a robust process to change the thickness of the adhesive. The IS group conducted chemical and performance tests on the welded components.The IS group and Arkema were able to meet STELIA's requirements, achieving 85% greater than the single lap shear and interlaminar shear strength performance compared to the thermal tank cured reference laminates. No dispersal or degradation in component laminates or lightning resistant grids. The only downside is speed, STELIA requires welding speed of at least 1 m/min. Currently, the solution has a speed of 0.3 meters per minute. In terms of the thickness of the base material that can be welded, the typical thickness of aerospace structures can be welded and 5 mm thick parts can be welded to 5 mm substrates.Technological opportunities and challengesThe IS Group and Arkema are co-owners of innovative welding Solutions technology and have secured this technology through a reliable patent portfolio that has included five French and international patent applications. Innovative welding solutions can be used in conjunction with any thermoplastic composite substrate and IS demonstrating the technology through a programme of collaboration with European and Us companies. For Arkema, the focus is on PEKK, which has formed a strategic alliance with Hershey in 2018 to develop carbon/thermoplastic belts for future aircraft, focusing on providing customers with lower costs and faster production speeds. As part of the partnership, France will establish a joint research and development laboratory.The €13.5 million, 48-month highly automated integrated composite material project for adaptive structures is a continuation of the Strategic alliance between Arkema and Hershel. The project will optimize the design and manufacture of materials for the production of composite parts in order to achieve competitive costs. It will also develop a more productive composite placement/placement technology and a new system with online quality control to weld the final parts together. The targeted applications include the main structures of aircraft, structural components for the automotive industry and pipelines for the oil and gas industry. The recyclability and sustainability advantages offered by thermoplastic materials are also important to these markets and will be demonstrated and quantified in the project.Compared to the dynamic induction welding process in 2017, one of the benefits that the innovative welding solution can provide is a more than 50% reduction in power requirements. With conventional induction, large power is required to heat the surface, but with sensors at the interface, the surface is much smaller and requires much less energy. This also helps to prevent the beam radius from loosening, as too much heat can soften the material in the radius and allow the fibers to move. However, there are still cooling problems. For flat shapes, thermal control is very simple, but as shape complexity increases, it becomes more challenging. At present, the main objective is to continue to develop and achieve the typical scale of skin beam welding, and the emphasis is still on introducing the technology into the new aircraft development program.
The 111m blade of 14MW fan adopts carbon glass composite main beam to reduce the cost
In order to lay a technical foundation for the development of 11-15 MW wind turbines, German aerodyn company has preliminarily designed a 14MW wind turbine, which will adopt 111m TC1B fan blade. The main beam of the blade is made of carbon fiber and glass fiber mixed reinforced composite material, which will reduce the consumption of high cost carbon fiber to the minimum.Modern structural design concepts, coupled with aerodyn's over 30 years of experience in fan blade development, have resulted in the development of TC1B fan blades for 14 MW fans. The blade can be adjusted and optimized according to rated power, fan type, wind farm environment and other specific conditions. The blade was developed using the most advanced materials and manufacturing techniques.At a power rating of 14 MW, aerodyn's fan blades can achieve a impeller diameter of 228 m, a speed rating of 7.54 RPM, and a tip speed of 90 m/s. Meanwhile, the maximum chord length of 14MW fan blade is 7.018 m, and the tip is pre-bent 4 m. In addition, the diameter of the blade root bolt circle (the diameter of the root pitch circle) reaches 5050 mm.At present, the company is focusing on the development of 10 MW fans, which will be put into production next year. Next, more powerful turbines, about 15 MW, could be on the market around 2025. Right now, supply chains and the necessary infrastructure are the big challenges to implementing future plans.
A new high pressure hydrogen storage system with composite material for integrated vehicle was developed in Germany
BRYSON (Baurauffiziente HYdrogenSpeicher Optimierter Nutzbarkeit) project is funded by the Federal Ministry of Economy and Energy of Germany, meaning "a space-efficient hydrogen storage system with optimized availability". The main participants of the BRYSON project are German enterprises, including BMW AG, The Institute of Light Engineering and Polymer Technology (ILK) of Dresden Polytechnic University, Leichtbauzentrum Sachsen (LZS), the composite engineering and development company, The composite distributor WELA Handelsgesellschaft and the University of Munich Applied Sciences.The objective of the BRYSON project was to develop a new high-pressure hydrogen storage system designed to be easily integrated into a common vehicle architecture, so the project focused on building a flat design hydrogen storage system.ILK, LZS and Composite Design have worked closely with manufacturer Herone GmbH to develop a hydrogen storage system consisting of chain tubular tanks. The storage tank is made of braided fabric reinforced thermoplastic composite material. The rapid production advantage of braided and thermoplastic composite material can effectively reduce the production cost of fuel cell vehicle hydrogen storage tank and make the recovery of the tank structure easier. The design of the new hydrogen storage system not only improves the product competitiveness, but also realizes better sustainability.Alexander Rohkamm, co-founder of Herone GmbH and director of the BRYSON project, said: "The goal of the BRYSON project is to develop modular storage systems that can adapt to a given vehicle design space." The machining properties of thermoplastic composites make part design more integrated, reducing manufacturing costs and improving energy efficiency. Improves the ratio of performance to cost compared to traditional metal and thermosetting composite solutions."Alternative transport concepts also need to be rethought at every step of the development and manufacturing chain," Rohkamm points out. In the current internal combustion engine vehicle architecture, gasoline and diesel engines share the same installation space, and significant cost savings can be achieved by using the same architecture. Similarly, in order to achieve maximum flexibility and economy in future ev architectures, hydrogen storage systems can be designed in areas where high voltage batteries would otherwise be. Integrating the two types of energy (hydrogen and batteries) into the same installation space reduces costs and enables more flexible production."
The world's first aircraft using carbon fiber thermoplastic reinforced laminate officially delivered
Teijin Limited today announced that the A350 XWB aircraft, a new generation of Airbus ultra wide body medium-sized airliner, which uses Teijin tpcl carbon fiber thermoplastic reinforced laminates, has been delivered to Japan Airlines and arrived at Tokyo Haneda airport on June 14.As Airbus's top supplier for more than 30 years, we provide aircraft manufacturers with Tenax ? carbon fiber for aircraft parts manufacturing. In May 2014, Tenax ? tpcl was registered as a qualified product of Airbus, which is the first time in the world to use carbon fiber reinforced thermoplastic (CFRTP) for the main structural components of Airbus aircraft. Tenax ? tpcl is a carbon fiber composite made of high impact, heat and chemical resistant Peek (PEEK) thermoplastic resin provided by Teijin carbon Europe GmbH.More and more attention has been paid to the research and development of solid, light and high-performance materials, which provide environmental protection solutions for improving fuel efficiency. The company has focused its carbon fiber business on aircraft and rapidly expanded its application in the middle and lower reaches. Looking forward to the future, we intend to further strengthen our carbon fiber and intermediate materials business and strive to become a leading solution provider in aviation applications.
The effect of large-scale application of carbon fiber sucker rod in Shengli Oilfield is good
Recently, Sinopec's key scientific and technological research project "Research on application and optimization matching technology of carbon fiber sucker rod" undertaken by the production unit of Shengli Oilfield Petroleum Engineering Technology Research Institute passed the appraisal of Sinopec's Ministry of science and technology. According to the appraisal of the expert group, the research results of the project have reached the international leading level. It is understood that the achievements of the project have been applied in large-scale in many oilfields across the country, with an accumulative oil increase of nearly 100000 tons and a direct economic benefit of more than 200 million yuan.Carbon fiber continuous sucker rod is light, high-strength and corrosion-resistant. Its density is one quarter of that of steel rod, and its strength is three times of that of steel rod. It can reduce the load of rod column by more than 50% to replace the traditional sucker rod. In view of the problems of heavy lifting load, high energy consumption, limited depth and short maintenance free period of metal sucker rods in the middle and late stage of oilfield development, the Institute of production machinery has carried out "Research on the application technology of carbon fiber sucker rods" since 2014, and "Research on the application optimization matching technology of carbon fiber continuous sucker rods" in 2016, making full use of the advantages of carbon fiber materials, and tackling key problems, forming a mature carbon rod manufacturing The application technology system with connection, operation, optimization of lifting system, special lifting equipment and application supporting mode as the core has formed four application modes, i.e. deep pumping for production increase, large pump for liquid extraction, corrosion prevention for life extension and load reduction for energy conservation. By the end of 2018, carbon fiber technology has been tested in 459 wells in Shengli, northwest, Zhongyuan and other oilfields, with 760000 meters of carbon rods applied, 98600 tons of oil increased, 13.62 million kilowatt hours saved, 1520 days of longest production cycle, 1.5 times longer average pump inspection cycle for corroded wells, and 245 million yuan of direct economic benefits realized.
"Spaceship" with a strong sense of future
What about the next generation of subways?No Cab - passengers can experience the speed and passion of high-speed driving in the first row of seats in the subway from the perspective of the driver.The window is a touch screen display screen - which buses can be taken in each subway station, which scenic spots and shopping malls are around the station, and what news information are there on that day? Touch the window to get the answer.The "spaceship" with a strong sense of future - streamlined front, silver and blue car body, makes the vehicle full of a sense of technology and future. And the application of new materials on the car body also makes the subway "fly" faster after weight reductionDifferent pictures correspond to safety, intelligence, environmental protection and other key words, as well as technological breakthroughs in driverless, large capacity vehicle ground communication, all carbon fiber vehicle structure and so on.Recently, under the leadership of Qi Yuwen, the design manager of the "next generation subway" project of the overall R & D Department of CRRC Changke Co., Ltd., the reporter set foot on the next generation subway. The train is the latest train developed by CRRC Changke for the project of "research and demonstration application of next generation metro vehicle technology" by the Ministry of science and technology. 28 breakthrough technologies of "getting on" have comprehensively improved the technical level of rail transit equipment and led the development of urban rail vehicles in the direction of green, energy saving and environmental protection.Green environmental protection, energy conservation and emission reduction are the future development trend of metro trains, while the next generation of metro will realize another "speed up" on the way to the "future".
Saishipinweio and Jiangling Automobile launch the first composite truck rear bucket in China
As a leading automotive composite parts supplier in China, saishipinweio (Tangshan) structural composite material Co., Ltd. (hereinafter referred to as saishipinweio) announced on April 22 that the first domestic SMC composite truck rear bucket has been successfully applied to Jiangling pickup Yuhu 3 SMC reinforced container model and Yuhu 5 SMC reinforced container model. The SMC back bucket, developed and produced in cooperation with Jiangling Automobile, comprehensively solves the problems of heavy weight, easy corrosion and high investment of traditional sheet metal materials.The cooperation between the two sides began in 2017. Saishipinweio R & D team provides Jiangling with a package of solutions from raw material development, production technology to product design. The project also draws on the successful experience of CSP, the parent company, in developing similar products in North America. This innovative project adopts SMC sheet molding composite material, and the whole back hopper of the pickup is molded by integrated molding, which greatly reduces the product manufacturing cycle and the number of tooling and dies.Compared with sheet metal, SMC rear hopper has the advantages of light weight, corrosion resistance and impact resistance, which greatly improves the user experience of severe conditions and high corrosive conditions. After tests including tool box impact, oil barrel drop and masonry impact, it is shown that the rear bucket of SMC will not leave large dents like the sheet metal material.Saishipinweio is a joint venture company established by CSP and Qingdao Weiao Railway Co., Ltd. Sespinvio's target market is mainly focused on passenger vehicles, commercial vehicles and new energy vehicles, which can provide all-round lightweight solutions for customers including new energy vehicles. The China regional management headquarters of the joint venture is located in the automobile science and technology innovation port of Shanghai Anting International Automobile City. The first production base is located in Tangshan City, Hebei Province. The second production base will be built in Changzhou City, Jiangsu Province in 2020.
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