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Process Fragility in the Manufacture of Kevlar Wing Root Panels Location of wing root panel 2m James Curran Complex curvature Kevlar Sandwich panel Geometrical.

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Presentation on theme: "Process Fragility in the Manufacture of Kevlar Wing Root Panels Location of wing root panel 2m James Curran Complex curvature Kevlar Sandwich panel Geometrical."— Presentation transcript:

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

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

3 NDT Failures Simplified cross-section 14 plies

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

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

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

7 Problems with honeycomb trim under floating intensifier: 2: Resin bleed3: Poor consolidation Core filler

8 Kevlar prepreg volatile content

9 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 Solutions:


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