Fiber-patch preforming technology enables the automated production of composite preforms from a software lay-up plan, with the positioning of short fiber patches that have their fibers oriented along specific force paths to optimize the mechanical properties of carbon-fiber reinforced plastics.
This technology allows short fibers to be positioned according to nearly any specification, with a robot providing a full range of possibilities in the fibers’ position and orientation of the fibers. The preforms are easy to use in standard infiltration processes, and can be combined with other preform types.
The fiber-patch preforming technology patent portfolio includes four inventions:
• The method and apparatus for producing a preform for a force flux-adapted fiber composite structure based on pickup and laydown of short fiber patches.
• An elastic fiber-placing die – also referred as the layup head – which is a core component of the fiber-patch preforming process in the pick-up and placement of short fiber patches.
• A device for splaying a fiber filament bundle, which can be used in the fiber-patch preforming process to provide, and feed, short fiber patches.
• An endless belt to transport the short fiber patches for the performing process.
Software-programmable, highly-automated production process, with the possibility to create complex shapes.
Ready for licensing agreements and know-how transfer.
A challenge in using friction-stir welding with thick sections is the inhomogeneous heat distribution that occurs from the top-side to the root-side of the welded sheet or plate. The EADS-developed DeltaN® welding system tool decreases welding distortion and vertical down-forces on all section thicknesses and creates a nearly fully-symmetrical heat input throughout the welded section’s thickness.
The DeltaN® concept puts the high revolutions on the pin, and zero revolutions on the tool’s shoulder. It reduces contrapoints and opens new applications for friction-stir welding, such as dissimilar materials in butt joint configuration.
The DeltaN® tool generates a superbly smooth welded surface similar to that of rolled sheet, with no need for post-weld-machining. With a simple, robust design, it enables a reduction of the welding distortion, and significantly reduces vertical down-force (compared with typical standard tools).
Available for production applications, with technical consultancy support available for easier introduction and start-up.
EADS has developed holographic-based, daylightindependent technologies for a full range of uses – from applications in offices and at public events to installations on ground-based vehicles, watercraft, helicopters and aircraft.
EADS-patented display technologies include daylight independency, better brilliance and improved visibility with very bright backgrounds; enhanced displays of colors, higher contrasts and finer image resolutions.
Patents available for technology licensing from EADS are:
• A holographic display screen for aircraft and vehicles that can serve as a heads-up display.
• A system and method for stereoscopic imaging with a holographic screen, using glasses with polarizing filters.
• A method and device for producing holograms on screens that provide high image quality color projection.
• A screen for front laser projection that very effectively reflects narrow-band laser light of one or more colors over a defined spatial angle, but absorbs wideband ambient light.
• An image representation system for holographic screens on vehicles, which enables images to be displayed with higher image quality for better levels of safety in traffic.
• A projection system with a polarizing device to improve the projection on curved surfaces.
• A projection system, holographic screen and image projection system for front projection of images rich in contrast.
• A method and device for removing stationary defects in images during projection with spatially or temporally coherent light without adversely affecting the original image quality.
Holographic display technologies from EADS provide improvement in the positioning of displayed images on screens, as well as the enhancement of their sizes, shapes and brightness; the use of stereoscopic imaging; dual view and the ability to project images on flat and curved surfaces.
Development and validation.
EADS’ Vacuum Assisted Process (VAP®) enables the manufacture of cost-efficient primary carbon fiber-reinforced plastic (CFRP) composite parts with dry fiber layup, followed by infusion of the resin using a two-chamber setup separated by a membrane. This process enables composite structures to be manufactured without traditional large, expensive autoclaves – marking a major step forward in manufacturing technology.
With the application of VAP® technology for the production of CFPR parts, liquid resin is poured into molds and the entire structure is covered with a membrane laminate. This membrane laminate holds the resin in shape and also offers micropores through which gaseous molecules are able to escape – preventing the trapping of air molecules that could cause fractures. Advantages of the VAP® process include easier and quicker ply layup, the possibility to lay up thicker material for higher productivity, better draping capabilities, double-curved structure manufacturability and higher potential for integration, along with no climate control for the shop floor, no time limitation for the dry textile and much better environmental conditions in the factory.
The VAP process leads to improved worker protection and low emissions due to its closed process, provides high process reliability, and enables shorter cycle times with the fast infiltration process through a higher vacuum. Its use is accompanied by the possibility of low initial investment through the use of tools that already are available.
Used in a growing number of production applications, including wind turbine blades, assemblies for submarines and aircraft structures.
The Plug & Twist connector provides the force- and form-fitting contact of at least three conductive surfaces, which are extensively compressed when the connection is made. The design ensures safe, high quality contacts for high-current connections, while the contact quality is unaffected by vibration, corrosion or other environmental influences.
This novel high-performance electrical connector uses a simple plug-and-twist action, enabling rapid installation and removal while also providing safe, sure contacts through a force-fitting and form-fitting connection. While many industries have introduced new production materials and manufacturing technologies, the method of making electrical connections has generally not kept pace with such evolution.
The Plug & Twist connector offers a next-generation solution to such older methods as bolted contacts (which may fail due to compression settling, clamp load loss or mounting faults), and spring-type high performance contacts (that are susceptible to vibration).
Utilization of the Plug & Twist connector reduces manufacturing production time, ensures safe and fast contacts, and offers the potential for reduced weight.
The connector’s enduring, reliable contacts require less monitoring during the operational lifetime and provides the additional benefits of reduced warranty and repairs.
Product definition.
Inorganic-organic hybrid coatings reinforced with nano-particles have been developed by EADS to protect fiber-reinforced polymer (FRP) components against the mechanical damage of rain erosion.
EADS erosion protection coatings are based on an inorganic-organic hybrid matrix reinforced with hard nano-particles and are designed to be applied as a top coat either on painted FRP components or painted metallic parts as an erosion-resistant top coat. The use of composite materials such as fiber-reinforced polymers (FRPs) is continuously increasing in the aircraft industry, along with their growing application in the wind energy and automotive industries, as well as other sectors.
While FRPs offer the advantages of high strength-to-weight ratios, low density and low thermal expansion coefficients, they are more sensitive than metallic materials to mechanical impacts caused by solid particles (such as sand) and liquid impacts (including rain). The erosion protection coatings developed at EADS demonstrate increased rain erosion protection performance in comparison to standard organic paints (which have not demonstrated sufficient durability) and offer a replacement opportunity for metallic caps (which have the disadvantage of high weight).
Increased durability and extended service intervals.
Development; feasibility demonstrated in laboratory conditions.
Scalmalloy® is EADS’ second-generation aluminummagnesium-scandium alloy (AlMgSc) alloy. It was developed for high and very high-strength extrusions, offering exceptionally high fatigue properties and the same positive manufacturing propensities as AlMgSc sheet material.
EADS’ continued work in AlMgSc alloy technologies resulted in development of the second-generation Scalmalloy® alloy, which offers a material that is strength- and densityadaptable, with exceptional high-fatigue properties. The maximum profile cross-sections for parts produced with Scalmalloy® depends on the billet size, with diameters possible of up to 15-18 inches. Scalmalloy® provides robust solutions for the use of aluminum alloys when high specific strength and exceptional high corrosion resistance are desired – while also offering the additional advantages of robust manufacturing chains and low-cost production schemes. Additionally, it has the highest micro-structure material stability for “low carbon footprint” applications.
Compared to all other aerospace aluminum alloys, AlMgSc offers a unique high-level of corrosion resistance, which allows the material’s use without cladding and to simplify the conversion from hexavalent chromium (CrVI) compounds.
AlMgSc alloys show excellent weldability both for laser beam and friction stir welding, benefitting from robustness of the processes and the excellent properties of their welded joints.
Available for production applications.