GKN developing laser-based, automated composite repair system

Sample of plies removal techniques...

Well just want to share latest technology update for composite repair... Cool techno! I love composite!

Source: Composites World

GKN Aerospace (Isle of Wight, U.K.) reportts that it is harnessing leading-edge laser technology to automate the repair of composite structures. The company says that the repaired structure has the strength of current manual repair but is achieved with greater consistency and 60 percent cost reducton.

With program partners SCLR Lasertechnik GmbH (SLCR), GKN Aerospace has installed the first prototype robotic machine using laser technology to remove damaged composite structure on aircraft. The new robotic cell, housed at GKN Aerospace’s composites research centre in the U.K., replaces the time-consuming, manual grinding away of damaged structure with a precise, contact and vibration-free laser removal process

John Cornforth, head of technology at GKN Aerospace, comments, “With the first installation of this prototype equipment we are now commencing work on extending the ability of this new process to handle various shapes and sizes of structure. We believe this process has enormous potential; composite materials increasingly dominate the airframe meaning their reliable, effective repair is critical for operators and the industry alike. This technology will allow the efficient, cost effective and high quality preparation of almost any composite assembly for repair.”

Olav G. Schulz, managing director of SLCR, adds, “The newly designed system is the outcome of more than two years intensive collaboration and we are proud of the results achieved already. It is strong motivation for us to continue this program with GKN Aerospace and we invite potential users to participate.”

The new process uses lasers to remove damaged material, leaving the remaining fibers and resin intact. The technique applies no force or vibration onto the structure and so has no detrimental impact on its overall strength or integrity. The affected area is left clean and ready for repair using a replacement patch which is cured in place using a localized heating mat. - end

Comments : Awaneer :)

Nice techno right? The removal plies process in Composite repair is THE MOST unpleasant... time consuming... stressful... So if you can have automated plies removal than it will be great and wonderful!

Sample of plies removal using grinder+peeling... can take up to 5-6 hours to complete.

Current repair method used grinder to remove plies or peeling method. Well for me I like peeling method because it is dust free, easy and precise control on the step method removal without damaging underlying plies.

So, welcome to the club new techno! Cheers!

TCM Composites Introductory Video on Temperature Controlled Molding

By : Awaneer

Seriously I never heard a mould that can be use as an elevated temperature curing. This technology can reach elevated ramp temperature of 2 deg F! That's pretty cool stuff for non-aerospace technology. Seems like autoclave future need to be revise!



Description :

TCM Composites, a division of Kenway Corporation, was created to provide manufacturing process and technology services that will support companies adopting Arkemas remarkable IS300 product. Through our collaboration on the R&D program, what we discovered is that without the advantage of Temperature Controlled Molding (TCM) the ability to both heat and cool the molds that the IS300 product is not effective. But by incorporating the TCM process with IS300 nanotechnology, then composites manufacturing is revolutionized. Improved flow characteristics, the ability to cure-on-demand, enhanced physicals properties, consistent and faster production times, laminates exceeding 6 thickness. All this is possible when IS300 nanotechnology is combined with the TCM process.

Partnered exclusively with industry expert Andre Cocquyt, the TCM Composites team will provide the following solutions to companies:

•Manufacturing of Temperature Controlled Molds & Tools (from lab tables, to large production tables, to complex shapes for the Wind Industry and beyond)
•Consulting services on how to incorporate the TCM process into the manufacturing environment
•Employee training (in collaboration with SMCC)

The TCM process is based on 10-years of research and development conducted by Andre Cocquyt (ACSM, Inc.). The concept is simple: Use an efficient BTU transfer media to both heat and cool your molds, thereby eliminating ambient conditions from the composite manufacturing equation. The execution of this simple concept and avoiding the need to repeat 10-years of learned lessons is where TCM Composites adds value to our customers.

Composite Culvert Repair Technology

By : Awaneer

I find this video is interesting for new use of composite technology for non-aerospace. Seems composite can withstand loads more than I can think. Lets see :



Description :

Kenway Corporation and the University of Maine AEWC Advanced Structures and Composites Center introduce an innovative composite repairs system for the nation's culvert systems.