Project Funding:
FFG Take Off
Project Coordination:
Project Partners:
24 months

When look­ing at the future of aviation, we can see two clear trends: The first one is that air traffic volume will increase in such a way that the aviation industry will see a capa­city bottle­neck. The second one is that demands for faster, lighter and cheaper airplanes will grow. The current conver­sion of airplane hull mater­ial from aluminum to CFRP creates the need for the struc­tural parts of the hull, such as frames and stringers, to be made from CFRP. Current processes show that the produc­tion of profiles in Carbon Composite is feas­ible, yet highly inef­fi­cient in terms of cost and effort compared to the bene­fits in weight. Looking at the start­ing airplane programs A-350, Boeing 737 and the devel­op­ment of the new gener­a­tion single aisle airplanes like A-320neo, A-30X, Boeing 777, Embraer E-Jets SPARTA tool­ing addresses an urgent issue of modern cfrp-frame produc­tion. When the manu­fac­tur­ing of these aircrafts ramps up to the supposed 40ac/month, auto­ma­tion will need to be integ­rated in produc­tion lines. The peak of auto­ma­tion is already reached in state of the art produc­tion there­fore new processes have to be developed for the years 2020+. The auto­mot­ive approach shows poten­tial for integ­rated, auto­mated and optim­ated serial processes and the poten­tial to ramp up to between 10.000 and 100.000 parts p.a. based on resin trans­fer mold­ing processes. Thus the chal­lenge to bring the cost-, energy, and time effect­ive processes in line with the high qual­ity demands of aerospace struc­ture remains to be solved.

The project SPARTA tool­ing comprises the devel­op­ment of a cost- and energy effi­cient, auto­mated resin trans­fer mold­ing produc­tion process for aerospace fusel­age frames.

Within the SPARTA project AAC is respons­ible for the simu­la­tion of the produc­tion process – includ­ing the beha­vior of the mold under temper­at­ure and load, the simu­la­tion of the resin infu­sion process and the beha­vior of the part after demould­ing (spring – in effect).

In addi­tion AAC is devel­op­ing an integ­rated process- and struc­tural health monit­or­ing system based on piezo sensors allow­ing a through life monit­or­ing of the produced part.