High-Performance Composites

NOV 2014

High-Performance Composites is read by qualified composites industry professionals in the fields of continuous carbon fiber and other high-performance composites as well as the associated end-markets of aerospace, military, and automotive.

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4 4 | H I G H - P E R F O R M A N C E C O M P O S I T E S PLANT TOUR / FACC AG which uses a cutting-edge automated workcell custom-engineered by Fill. Large engine parts In Plant 4, another 21,000m 2 facility, FACC manufactures a wide array of en- gine and nacelle components. Filseg- ger highlighted FACC's large composite translating sleeves, critical components in the cascade thrust reverser systems used in today's commercial jet engines. Sleeve cowls are hand layed (see Fig. 8, this page) in large glass-fronted clean- rooms, the complex layups facilitated by laser projection systems (SL Laser, Traunreut, Germany). For the Boeing 787, FACC worked with customer UTC Aerospace Systems (UTAS, Charlotte, N.C., previously Good- rich Aerostructures) to develop, engi- neer and qualify the frst sleeve to use a double-degree acoustic surface and undulated (chevron) engine nozzle de- sign, both achieving signifcant noise re- duction. Working again with UTAS, FACC also developed a weight-optimized de- sign for the Airbus A350 XWB. Both pro- grams are now in production. Plant 4 also houses two large auto- claves (see Fig. 9, p 45) built by Scholz Maschinebau (Coesfeld, Germany). One is 12m/40-ft long by 4.5m/13 ft diameter and the other is 12m long by 6m/20 ft di- ameter. Each is capable of 250°C/482°F and able to accommodate the sleeve cowls and other massive parts. After cure, the various sleeve com- ponents are assembled, each sleeve is painted and then proceeds through quality assurance (QA). Plant 4 also ac- commodates an 8 by 4 by 2m (26- by 13- by 7-ft) 5-axis CNC milling machine and multiple laser coordinate measurement machines and ultrasonic inspection units that facilitate QA. Firmly on the edge Now a leading Tier 1 aerostructures supplier, FACC's visibility is increasing. The RTM composite annulus fller it de- veloped with Rolls Royce as part of the CleanSky Initiative was recognized with a 2014 JEC Innovation Award. FACC also is in active pursuit of technology that, Fig. 8 CFRP translating sleeve cowls are hand layed in large cleanrooms. The complex layups are facilitated by laser projection systems. Source: HPC/Photo: Ginger Gardiner Surface Engineering for Composites TFP's advanced nonwovens provide efective lightweight solutions for: • High Quality Surface Finish • EMI Shielding • Electrical Conductivity • Static Dissipation • Abrasion Resistance • Fire Protection TFP is part of James Cropper plc, a specialist paper & advanced materials group Technical Fibre Products is a leading manufacturer of advanced nonwovens, ofering both a diverse range of high quality nonwovens and the expertise to develop materials to meet specifc performance, process or aesthetic requirements. TFP's nonwovens are compatible with all common composite manufacturing techniques and resin systems and provide an improved surface fnish with additional functionality such as conductivity, EMI shielding or corrosion resistance. www.tfp-americas.com TFP is part of James Cropper plc, a specialist paper & advanced materials group www.tfp-americas.com Technical Fibre Products Inc. • E: inquiries@tfp-americas.com • T: 1 518 280 8500 Visit us at DMC 2014, San Antonio TX, December 1-4 on booth 109

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