Bonding Thermoplastic Polymers on Preconsolidated Thermoplastic Laminates by Additive Manufacturing

By 2050 Airbus has the ambition to fly an aircraft made mainly from additive manufactured parts. In order to reach this goal by 2050 different parts are being designed for additive manufacturing production processes. For example fuel engine nozzles, door hinges and seat belts. Fokker Aero Structures, Materialise NV and the faculty of Aerospace Engineering want to take a next step by developing a 3D spoiler demonstrator representing a group of aircraft spoilers, ailerons and flaps. The 3D spoiler demonstrator consists of a pre-consolidated CF laminate skin with an additive manufactured rear structure fitting in the wing of the aircraft. The rear structure is additive manufactured using the fused deposition modelling, abbreviated as FDM, technology and bonds to the pre-consolidated CF laminate skin by the principle of autohesion during additive manufacturing of the rear structure. Autohesion between the two polymers is dominated by pressure, temperature and time. Obtaining good shear strength at the interface, between the pre-consolidated CF laminate skin and the additive manufactured rear structure, is the first step in the design of the 3D spoiler demonstrator. By using an experimental additive manufacturing set-up the influence of the joint surface temperature, influenced by FDM working parameters, on the shear strength is investigated.

Subject

additive manufacturing
thermoplastic
preconsolidated laminate
autohesion
filament

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