Biteam Shares JEC 2010 Process Innovation Award

09 April 2010

Biteam will share this year’s JEC Process Innovation Award for together with partners from the MOJO project.

The MOJO demonstrator (Modular Joints for composite aircraft components) is one of the very first representative aeronautical structures designed for assembly by structural adhesive bonding, which provides damage tolerance characteristics. The other project partners were: S.A.B.C.A. (Belgium); Cooperative Research Centre for Advanced Composite Structures (CRC-ACS) (Australia), Dassault Aviation (France), Deutsches Zentrum für Luft- und Raumfahrt (DLR) (Germany), EADS Deutschland GmbH (Germany), EADS Innovation Works (France), Eurocopter Deutschland GmbH (Germany), KTH – University of Stockholm (Sweden), Premium AEROTEC GmbH (Germany), Secar Technologie GmbH (Austria), the University of Patras (Greece), Výzkumný a zkusební letecký ústav a.s.(VZLU a.s.) (Czech Republic).

The composite innovation is a full-size aerospace structure designed to gather all the features developed in the MOJO project. The innovation brings together various developed elements. These will ultimately find use in different domains by different end users, including SABCA, Dassault-Aviation, Premium AEROTEC, EADS Military Air Systems and Eurocopter.

The innovations will combine tailored preformed profiles for modular joints with structural bonding processes, including out-of-plane reinforcements. Applications will include stiffened wing-skin panels, vertical and horizontal tail planes, flap-track beams, cargo and pax doors, cargo- and pax-door surroundings, as well as unmanned air vehicles. The main components of this closed beam were manufactured with out-of autoclave infusion processes such as Resin Transfer Moulding (RTM) for the top and side panels, and Vacuum Assisted Resin Infusion (VARI) process for the lower panel. Non-crimp carbon fabrics (from SAERTEX and CYTEC) and tailored preformed profiles made of high-performance textiles (developed by the partners) were used.

Considering that structural bonding is the most compatible joining method for composite parts, adhesive processes with both film and paste adhesive were developed and successfully used for the assembly.

Structural bonding is still not a widely accepted alternative to riveting. Therefore, demonstration projects like MOJO, leading to the cost and performance benefits described, will help change minds and gain a wider acceptance, opening the way to “rivetless” CFRP structures. Structural bonding provides around 25% overall cost savings and 50% weight savings, up to 60% assembly cost savings as compared with “black metal” concepts. The project started in 2006 and was completed in 39 months. The launching of the innovation started with the selection of the MOJO project under the 6th European Framework Program.

“The Award indicates that the developed technology has a very high innovation level and confirms that our 3D-weaving process can revolutionize aircraft production method. We have, together with KTH, successfully shown that it is possible to produce profiled 3D woven materials directly and that they can be used for advanced constructions“ says Fredrik Winberg, Chairman and Co-founder of Biteam.

Other finalists in the Process category were:
▪ Microwave curing of composite components, presented by Dr. Ing. h.c. F Porsche AG (Germany) with its partners GKN-Aerospace GmbH (Germany); Karlsruhe Institute of Technology KIT (Germany).
▪ SQRTM processes combining the advantages of RTM with the mechanical properties of prepreg unidirectional tapes, presented by S.A.B.C.A. (Belgium) with its partners SABCA Limburg (Belgium); COEXPAIR (Belgium); DGO6/SKYWIN Aerospace cluster of Wallonia (R&D financial support).
▪ A super thermal conductive mandrel technology, presented by Acrolab Ltd. (Canada) with its partners McClean-Anderson (USA); Ameritherm Inc. (USA); TCR Composites (USA).

Continuing its practice of annually presenting a novel 3D woven product at JEC Show, Paris, Biteam will be this year displaying a flapped triangular cross-section preform insert for strengthening junctions.

The novelty of this material is the integration of flaps at the three edges of the triangular insert. The flapped triangular insert has been specifically developed for customers wanting to suppress crack propagation and delamination at junctions to achieve increased performance and reliability of the final composite material product. Such an insert is producible in different cross-sectional dimensions to suit different needs.

Biteam will be at the JEC Show, Stand V11.

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