Pilot projects in aerospace manufacturing

1. Manufacturing joints

The main goal is to exchange knowledge and conduct a feasibility study concerning the development of manufacturing processes for high-load-transfer and high-lifetime joints for Ukrainian aerospace structures. The study will assess:
  • Development of manufacturing processes for high-load-transfer and high-lifetime joints
  • Selection of fasteners
  • Development of test specimens
  • Assembly and fatigue testing of specimens
  • Impact on strength of assembled structures including metal-composite ones.
Fraunhofer is specialized in the development of innovative measurement technologies to assure the quality and efficiency of manufacturing equipment and processes. Their expertise includes optical 3D metrology, model-based inspection, industrial image processing and visual assistance and inspection systems. During the study, Fraunhofer will apply this expertise to a number of aerospace case-studies presented by the UA partners.

2. Manufacturing aerospace composite structures

The aim is to exchange knowledge and training between the EU and UA partners concerning:
  • Dry-fibre preforms and out-of-autoclave process for integral composite structures production
  • Rational approaches for integral composite structures testing
UoM’s expertise consists in composite structures manufacturing by means of RTM process using dry-fibre preforms manufactured by 3D weaving, filament winding/braiding, tow placement with z-reinforcement. Meanwhile, the UA partners – in particular KhAI - have experience in complex composite structures manufacturing by means of prepreg lay-up and autoclave curing with specific attention to in-process and residual stresses. As for composites structures testing and NDT, UoM has experience of new methods due to its involvement in the activities of the National Composites Certification and Evaluation Facility (NCCEF) of the UK Composites Centre of Excellence whilst the UA partners have experience of standard approaches and methods used by Ukrainian aerospace enterprises.

The knowledge exchange is expected to include:
  • Dry-fibre preforms manufacturing by means of 3D weaving, filament winding/braiding, tow placement with z-reinforcement
  • Specific features of braided and 3D reinforced structures
  • Optimization of composite structure curing cycle to minimize in-process and residual stresses and guarantee structures high quality and load-carrying capacity
  • Advanced methods and approaches for composite materials characterization and composite structures testing
  • Modelling of composite structures under cyclic loading and ballistic loading
  • Fatigue, impact and ballistic test methods

The training is expected to cover:
  • Capabilities and operation of the dry-fibre preforms manufacturing equipment
  • Development of composite structure manufacturing process (incl. preparation processes, dry-fibre perform production, impregnation, curing, and post-processing)
  • Simulation of composites microstructure failure
  • Testing facilities operation and experimental results processing according to basic standards