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Fusible-Core Technology Enables Design of Complex, Victrex PEEK Fuel Housings to Improve Aircraft Fuel and Manufacturing Efficiency

14 April 2015

Fusible-Core Technology Enables Design of Complex, Victrex PEEK Fuel Housings to Improve Aircraft Fuel and Manufacturing Efficiency

In the manufacturing of complex fuel housings for the global aircraft industry, cost savings of more than 30% and weight savings of up to 50% have been achieved as a result of Egmond Plastic combining their own fusible-core technology with a high performance PEEK polymer solution provided by Victrex.

According to Victrex, carbon fibre reinforced grades of Victrex PEEK polymer eliminate the use of a separate bearing, for example, since this is now integrated into the overall design of the housing. It says fuel housings for aerospace applications have very complex inner geometries which are not mouldable using conventional injection molding technology. It says Egmond Plastic's fusible-core technology enables mouldings of complex hollow housings, manifolds, and pipes. 

Richard Brandwijk, Managing Director at Egmond Plastic, explains, "Our technology, in combination with carbon fibre reinforced Victrex PEEK polymer, delivers numerous benefits. These include cost reduction, enhanced manufacturing speed, and weight reduction leading to improved fuel efficiency and reduced CO2 emissions. Along with part consolidation, this exceptional technology and material combination enables the design of very complex parts, beyond the capabilities of standard injection moulding and metal processes."

Victrex explains that utilising a near net-shape manufacturing process for the fusible core allows for an 80% time saving versus machined parts. Secondary treatments for corrosion protection, such as anodising, can be eliminated. Lead times can be reduced by 50%. These factors collectively result in part cost savings of more than 30% versus metal equivalents.

“The global aerospace industry stands to gain enormously by persistently replacing metals in key applications, in which Egmond has demonstrated tremendous leadership,” said Uwe Marburger, Aerospace Business Development Manager at Victrex. “Clearly, our PEEK knowledge and material solutions help enable the use of a technology that addresses some of the toughest challenges in complex aerospace part design and productions.”

Previously, Victrex explains that the end-user had generally specified aluminum for the production of fuel containing parts, but a carbon fibre reinforced PEEK polymer demonstrated superior fatigue performance when compared to aluminium. It claims it does this while meeting all the engineering requirements for this application, including stiffness, effective flame, smoke and toxicity (FST) performance, and resistance to aggressive chemicals, including notably, for this aerospace application, resistance to jet fuel and Skydrol* hydraulic fluid. Parts can range in size all the way up to 30 cm x 30 cm x 40 cm (11.8 in x 11.8 in x 15.8 in), and typically the process is used for production runs of up to 2,000 parts.

Photo provided by Victrex.





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