Daher Aerospace

Airbus Operations (s.a.s.)

Airbus Operations Gmbh

Didier Kurtz

Julie Vaudour

David Bouvet

Florian Chotard

Stephane Pauchet

Marc Challet

A method for forming a thermoplastic composite material with continuous fiber reinforcement by stamping. A flat blank comprising a pre-consolidated stack of plies by automatic fiber placement of fibers referred to as the thermoplastic pre-impregnated fibers is obtained. The flat blank is reheated to a temperature greater than or equal to the melting temperature of the thermoplastic polymer making up the matrix of the thermoplastic pre-impregnated fibers. The reheated flat blank is hot stamped and the part formed between the stamping punch and die is consolidated.

Method of forming a composite thermoplastic material with continuous fiber reinforcement by stamping

A device for welding the bottom flange of a stiffener on the side of a skin. The stiffener and the skin are made of a composite comprising a thermoplastic polymer matrix. The device comprises a punch, an anvil and a press to make a clamping between the punch and the anvil. The punch comprises a part forming a pressure table with a cross-section width less than or equal to the width of the stiffener bottom flange and a heating element with width less than the width of the pressure table. The anvil comprises a cooling component and has a cross-section width smaller than the width of the skin. A method for implementing the device.

Device for high-temperature welding of a stiffener on a composite panel having a thermoplastic matrix

A device for compacting and consolidating a stack of fibrous plies pre-impregnated with a thermoplastic polymer, configured to be placed in an oven. The device comprises containment blocks, a flexible compacting plate and a vacuum pump. The containment blocks are supported by a board and demarcate the perimeter of the stack. The containment blocks comprise open grooves that open into the perimeter of the stack. The flexible compacting plate has an area equal to that of the stack but is capable of being inserted inside the perimeter demarcated by the containment blocks. The vacuum pump applies a vacuum to the wrapped volume of the stack comprising a plurality of holes in the board that open outside the perimeter of the stack. A method for implementing the device for manufacturing a thick composite panel having a thermoplastic matrix.

Method and device for compacting and consolidating a thick composite panel having a thermoplastic matrix

A method for manufacturing a structural part including at least two wings extending in intersecting planes made of thermoplastic fiber-reinforced composite material including at least two plies of continuous fibers. The fibers extend from one wing to another. The method includes cutting the at least two plies in a fabric and/or a tape of fibers pre-impregnated with a thermoplastic resin; assembling the plies to create a preform; and compacting the preform to a final shape of the part by subjecting the preform to a defined cycle of temperature and pressure. A toolset can implement the method described above. Such a toolset includes a rigid punch and die such that closing the tool creates a sealed chamber in a shape of the part between the punch and the die.

Method for finished-rib compacting a thermoplastic composite part with continuous fibers

A method of manufacturing a blank made from thermoplastic composite material, in which a pressure and temperature cycle is applied by pressing on top of a compacting plate that is itself on top of a stack of fibers including continuous fibers pre-impregnated with a thermoplastic resin, which stack has been previously placed on a board with the film enveloping the stack being brought into contact with fixing blocks arranged at the periphery of the board, and by heating the stack so as to reach at least the melting temperature of the resin while leaving the film infusible and smooth, and allowing the gas(es) present in the stack to escape through at least one opening left in the enveloping film and then through at least one emerging channel formed in the compacting plate and/or in the board and/or in the fixing blocks.

Method of manufacturing a blank made from thermoplastic composite material, associated manufacturing tool and use of the method to produce structural aircraft parts

A method of manufacturing a panel made of a composite material using a tool having a support on which a lay-up is performed, the lay-up producing a stack of plies of fiber prepregs, followed by consolidating the stack aiming to obtain the panel using a compacting plate arranged above the stack. The method is implemented such that a first set of polyimide films partially covering each other is located in contact with the stack of plies, between the latter and the compacting plate.

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Pornic, France

Didier Kurtz