OOA-Composite-Processing-Phase-II-wing-box-structure

UK-based GKN Aerospace has created a composite wing structure using out-of-autoclave (OOA) processes and materials, as well as PI-shaped woven preforms, as part of its composite manufacturing and assembly research programme.

Capable of transforming the future manufacture and assembly of large composite aero-structures, these technologies are expected to offer the performance benefits that the industry is seeking in the next-generation of airframes, according to GKN Aerospace.

The OOA Composite Processing Phase II programme used OOA materials to design, develop and manufacture a lightweight, blended aircraft wing box.

The wing box features integrally stiffened skins, complex contours and four different stringer shapes.

The parts were manufactured using vacuum bag technology; the low-cost tooling becomes practicable when curing outside the extreme autoclave environment, and the wing box was then assembled using PI joints.

GKN Aerospace stated that the company sought to improve airframe manufacturing by reducing its cost and weight.

"The results we have achieved serve as a technology enabler, allowing us to progress to next stage in composite wing structure and blended wing box manufacture."

GKN Aerospace Materials and Process engineer Stephen Grojean said that in order to achieve these goals, the company has been designing larger, lighter, more integrated aircraft structures.

"This programme addresses two of the major challenges we face, overcoming the limitations imposed by autoclave curing and proving effective fastener free, joining processes," he said.

"The results we have achieved serve as a technology enabler, allowing us to progress to next stage in composite wing structure and blended wing box manufacture."

In January this year, GKN Aerospace joined the UK’s Manufacturing Technology Centre (MTC) as a tier-one member, in order to strengthen and share its research into automated assembly technologies.

The company is a manufacturer of metal and composite airframe and aero-engine structures.

Image: The out of autoclave (OOA) Composite Processing Phase II wing box structure. Photo: courtesy of GKN Aerospace.

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