Competitive Composite Manufacturing Processes (CoCoMaP)

With several work packages at Technology Readiness Levels (TRL) 3 to 5, CoCoMaP addressed potential new product requirements, while developing enabling technologies for sustaining production to maturity.

CoCoMaP has been key to Spirit AeroSystems furthering its competitiveness on high value-added wing and engine nacelle products. This includes through reducing cycle times, reducing costs, increasing productivity/efficiencies and enhancing product through weight reduction or increasing strength.

Improvements in environmental footprint were achieved through developing more fuel-efficient aerospace products, reducing hazardous materials and reducing factory energy usage and costs.

Work packages have demonstrated improvements on current product platforms through adding value, improving quality and increasing margins.

Progress within each work package included:

WP1.1: Process Sensing

A unique sensing capability for monitoring cure was developed to give early insight into flow times. This developed to full production wing size determining mould fill times in a hostile process environment.

WP1.2: Automated preforming

Three work packages were undertaken to preform wing, stringer and spar manufacture, each using different novel automation approaches to meet projected higher production rates.

Technologies produced full scale demonstrators which are being further developed on new work programmes, addressing preforming for medium and high-rate manufacturing.

WP1.3 Process development

In composites including Resin Transfer Infusion (RTI) optimisation activity and shimming development, both activities are now being implemented in production while there is further potential to develop applications for shimming.

On metallic materials development, several sub-tasks addressed potential cost reduction opportunities across a range of metallic products. Work focused primarily on improving sheet metal forming including evaluation of alternative titanium alloy, hydroforming simulation to introduce compensated tooling/reducing manual adjustment, simulation of a novel lipskin forming process, and expanding capability to form new aluminium lithium alloys in the final temper. Additionally, CoCoMap allowed preliminary evaluation of novel near net shape processes such as powder HIPPING, additive manufacturing, and Coldspray.

Lipskin activity and near net shape studies have continued into subsequent funded research programmes. Net shape capability offers cost potential in reducing material waste compared to current techniques.

WP1.4 Tool optimisation

This embraced several novel tooling developments addressing composite part manufacture at scale.
A key part of the unique infusion process involved developing novel IML (Inner Mould Line) tooling. i.e. the top closing flexible tool that seals to the lower OML (Outer Mould Line) tool (Figure 1). This improved injection of resin into the component cavity formed by the tools when located together. Resulting large scale tools have been introduced into production successfully. Further work involved environmentally friendly release agents, and successfully reducing material waste.

WP2.1 Infused repairs

A necessary part of a proprietary process is to have a repair method in place. Spirit has developed complex repair methods, and a full repair process has been implemented in production.

WP3.1 Laminar flow integrated skin

This development was to create an aerodynamic stiffened skin with lightweight stringers. Significant learning was achieved, with further work required to achieve commercialisation.

WP3.2 Component integration

Investigated novel lightning strike protection within a composite wing. This is undergoing further development before potential exploitation can be achieved.

WP3.3 Design Studies

Erosion strips and crack resistant fasteners to improve durability of composite components. A low TRL has been achieved, with both areas still in development.

WP3.5 Composite perforate developments

Developing composite acoustic liners more efficiently than conventional drilling.
Full scale demonstrators were produced to TRL5 and are currently in further development with an aeroengine supplier.