Posts Tagged ‘composites’
Aerospace and automotive industries are increasing their usage of plastics in aircraft and vehicle design. Specifically, high performance plastics, such as composites, carbon fiber, and similar carbon-based materials usage is on the rise. High performance plastics are being used more and more to replace current steel, aluminum, and even titanium components. High performance plastic components are increasing in popularity because they provide a good strength to weight ratio for many components and can be manufactured easily. In addition, many new automotive and aircraft designs, which are migrating towards advanced material applications, may use high performance plastics in emissions reducing goals, as lightweight components require less energy and fuel consumption to propel them. In high-production markets, the usage of high performance plastics is expected to increase from now until approximately 2024, when it will become a $3 billion dollar industry.
The rise of high performance plastics allows manufacturers to produce vehicles and aircraft that are lightweight. The goal of light weight and superior strength is not new; however achieving levels of strength not previously achieved and keeping the vehicle’s weight down has reached new levels due to the usage of high performance plastics. In addition, internal combustion engine-powered vehicles may soon be replaced to some degree by electric vehicles, which will utilize composites and high performance plastics in many different and challenging ways. Battery production and energy storage are two areas of electric vehicles that may benefit from the development and usage of high performance plastics.
Manufacturing processes that produce high performance plastics are also diversifying. Plastic components can be made through additive manufacturing quite easily. Additive manufacturing, otherwise known as 3D printing, produces much less waste than traditional manufacturing processes and can create intricate parts while maintaining tight tolerances. High performance plastics can take advantage of additive manufacturing to produce parts that ultimately cost much less to make than current metal components.
-taken from www.sae.org
Aerospace companies Boeing and Airbus are working on developing new components to aid in developing new aircraft structures. Forecasts of aircraft sales show that the worldwide demand of large passenger airplanes will increase and an overall production number of up to 40,000 new aircraft may be realized in the next 20 years. To meet this new demand, Boeing and Airbus are working on developing new honeycomb panels that are designed to be structurally stiff, strong, and importantly, easy to assemble and produce. For the increase in aircraft demand, new aircraft structures must be easy to assemble and sub-components must be manufactured rapidly.
The new structure composites or sandwiches are being developed for Boeing and Airbus by Belgium Company EconCore, along with Diehl Aircabin. The sandwich structures consist of a lightweight inner honeycomb lattice that is sandwiched between two thin layers of either aluminum or other lightweight material, to create a structure that is lightweight, strong, and has excellent thermal insulating qualities. Insulating against the cold external atmosphere while aircraft are in flight is crucial for passenger comfort and safety. In addition to the insulating properties, the inner honeycomb lattice can be made out of lightweight polycarbonate to create an excellent fire barrier within the sandwich structure. Polycarbonate is strong and resists flammability, making it a good choice for many aircraft structures.
The process developed by EconCore can be formed into many different shapes; however joining the layers of the sandwich material together may pose another problem. To remedy this issue, new formulae of bonding adhesives are being developed to properly secure the components together. The benefit of using bonding adhesives instead of traditional rivets, screws, or other hardware, is the weight savings, however ensuring that the bonds between composite components remains solid for the life of the aircraft is being tested before it is put into production.
-taken from www.sae.org