Process Fragility in the Manufacture of Kevlar Wing Root Panels

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Presentation transcript:

Process Fragility in the Manufacture of Kevlar Wing Root Panels James Curran Process Fragility in the Manufacture of Kevlar Wing Root Panels Location of wing root panel 2m Complex curvature Kevlar Sandwich panel Geometrical tolerances Foiling cure Increased production rate

Plan to double production rate Roll-out in Toulouse Increasing scrap rate NDT (ultrasonic, X-ray, geometry) RED panels further down production line Unconventional No destructive analysis Production item (no interference, limited changes)

Simplified cross-section NDT Failures 14 plies Simplified cross-section

Key operations half-way through build Vac bag Ply 8 Adhesive Honeycomb Plies 1-7 Steel Tool Problems: Bridging Core (positioning & moisture content) Volatiles Filler material Poor consolidation

Steel Tool Areas signalled for more intensive working Adhesive lay-up modified Steel Tool Plies 1-7 Honeycomb Adhesive Vac bag Bleed pack Bleed pack introduced for improved consolidation

Inadequate moisture management Steel Tool Plies 1-7 Honeycomb Vac bag Plies 8-14 Intensifier Inadequate moisture management

Problems with honeycomb trim under floating intensifier: Core filler Problems with honeycomb trim under floating intensifier: 2: Resin bleed 3: Poor consolidation

Kevlar prepreg volatile content 19.4 19.6 19.8 20.0 20.2 15:00 15:30 16:00 16:30 17:00 17:30 18:00 Time Mass (g)

Solutions: New adhesive lay-up Use of a bleed pack for all consolidation operations Core moisture control Core trimming Core filler control Kevlar moisture management Perforated adhesive Self-adhesive foil / elimination of separate foiling cure New tooling