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Induction welding development for sustainable thermoplastic fuselage


Title: Induction welding development for sustainable thermoplastic fuselage

Authors: Damien Sireude, Sandrine Meyer, Alexis Pierunek, Olivier Vincent, Nicolas Foucart, Pierre Magnin, Jérôme Raynal, Aurélien Philippe, Etienne Mayer, Philippe Klein, Luc Becker

DOI: 10.33599/nasampe/c.23.0045

Abstract: Development of large primary structure made with thermoplastic material is a key challenge to support commercial aircraft sustainability. Amongst ongoing research activities, large efforts are dedicated to the development of innovative joining technologies. This process must be compliant with high rate production and optimal performance airframe. In the framework of ECHOS2 project, Airbus Atlantic and Institut de Soudure Group, pursue maturation of innovative induction welding technology to integrate stringers to an Out of Autoclave skin panel. ISW technology, which is based on indirect induction, is patented by ARKEMA and INSTITUT DE SOUDURE GROUPE. This innovation has been awarded by the JEC INNOVATION AWARD AERONAUTICS 2020.First, feasibility test pyramid was establish to demonstrate the capability of welding technology on complex geometry, including Z stringers welded to curved panel with typical thickness variations, and curvature radius, representative of next generation of single aisle aircraft.Welding simulation was set up to support design of the welding effector, with the objective to maximize the healing rate at the interface. Moreover modelling was used to explore the process window and tune key process parameters. The presentation will go through successive modeling phases and feasibility trials performed to validate ISW technology, both on flat and curved panels. Overall quality of welded joins has been verified using NDI, microcuts, and validated via a mechanical performance testing campaign. In order to characterize the interface material properties, the methodology is based on the identification of the cohesive law parameters by correlation of coupons tests and then the evaluation of these properties on elementary tests, i.e. skin to stringer pull-out. Coupons tests results are also compared to consolidated samples defined as reference value.

References: 1. A. Philippe and M. Glotin, “Introduction of ISW technology”. SAMPE Chapter France Conference. 2020 2. J. Raynal, “Using mobile susceptor to innovate thermoplastic induction welding”. Composite World Article, Feb. 2020 3. G. Gardiner, “Thermoplastic composites welding advances for more sustainable airframes”. Composite World article, 2022. 4. C. Ageorges et L. Ye, Fusion Bonding of Polymer Composites. 2002. 5. D.Sireude, “Full Scale Composite Thermoplastic Demonstrator for Low Cost and High Volume Airframes”. 6th ITHEC Conference proceeding. Bremen, 2022. 6. AITM Standard 1-0019, 1994, “Determination of Tensile Lap Shear Strength of Composite Joints”, 1994. 7. AITM Standard 1-0005, “Carbon Fibre Reinforced Plastics. Determination of interlaminar fracture toughness energy - Mode I”, 2015. 8. S.Meyer, A.Pierunek, L.Dubreuil, “Innovative sizing method for fastener-free thermoplastic airframe”. CAMX Conference Proceedings. Anaheim, CA, 2022. 9. F. Lionetto et al., “Finite element modeling of continuous induction welding of TPC”. Materials and Design (2017).

Conference: CAMX 2023

Publication Date: 2023/10/30

SKU: TP23-0000000045

Pages: 11

Price: $22.00

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