ZEUS

Thermoplastic fiber reinforced polymer composite materials (TP-FRPC) are increasingly being used for aerospace applications due to their advantages in terms of weldability and recyclability. Within the ZEUS project, IVW is therefore investigating the challenges arising from the application of TP-FRPC, particularly in structural aircraft parts. The feasibility and performance of this technology is being validated with a complex door environment with thermoplastic stringers. The main task is to develop a closed process chain supported by process simulation. Technologies such as tape laying, co-consolidation and overmolding are used along the process chain to obtain highly integrated components. In line with the project approach, the concept for a new type of door environment was developed and validated using extensive FEM simulations. Topology optimization techniques are utilized to design stiffening elements such as ribs, thus creating a lightweight-optimized integral structure. In addition, the process simulation enables a thermally compensated tool design for optimum pressure distribution and a prediction of component quality and especially warpage. Comprehensive data recordings of the real reference processes are employed for quality prediction and control. The developed process chain also allows local reinforcement and local thickness changes of the profiles (Figure 2) by utilizing the joining possibilities resulting from the application of thermoplastics. Furthermore, the ecological footprint can be reduced by using TP-FRPC and resource-efficient manufacturing processes.

The objective of this project is the development of structural thermoplastic parts and suitable process technologies for high performance aircraft structures as well as digitization of the process chain for both quality prediction and assurance.