ENCOMB
 Extended Non-Destructive Testing of Composite Bonds
Even though composite materials are already used in the manufacturing of structural components in aeronautics industry a consequent light-weight design of CFRP primary structures is limited due to a lack of adequate joining technologies. In general, adhesive bonding is the optimum technique for joining CFRP light-weight structures, but difficulties in assessing the bond quality by non-destructive testing (NDT) limit its use for aircraft structural assembly. In consequence certification by the regulation authorities is restrictive. In order to implement robust and reliable quality assurance procedures for adhesive bonding, the main objective of ENCOMB is the identification, development and adaptation of methods suitable for the assessment of the adhesive bond quality. Since the performance of adhesive bonds depends on the physico-chemical properties of adherend surfaces and adhesives, testing methods for adhesive and adherend surface characterisation will also be developed.
The implementation of reliable adhesive bonding processes by advanced quality assurance will lead to an increased use of light-weight composite materials for highly integrated structures minimising rivet based assembly. The expected weight savings for the fuselage airframe are up to 15 %. These weight savings will have further effects on the size and weight of the engines. From the overall weight savings, significant reductions in fuel consumption (direct costs) and hence CO2 emissions per passenger-kilometre will result. In ENCOMB, a multidisciplinary consortium of 14 partners from top-level European research organisations, universities and industries brings together leading experts from all relevant fields. The participation of three major European aircraft manufacturers as well as one SME ensures the consideration of relevant application scenarios, technological specifications and use of the full exploitation potential of the results.
More information is available on the ENCOMB website www.encomb.eu
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INMA
 Innovative Manufacturing of complex Ti sheet component
The INMA project aims at developing an intelligent knowledge-based (KB) flexible manufacturing technology for titanium shaping that will lead to drastically reduce current aircraft development costs incurred by the fabrication of complex titanium sheet components with a minimal environmental impact. In particular, this project aims at strengthening European aircraft industry competitiveness, by transforming the current non-flexible and cost intensive forming processes into a rapid and agile manufacturing process. This brand new technology, based on Asymmetric incremental sheet forming (AISF), will transform the way many titanium sheet aeronautical components such as after pylon fairings, fan blades, exhaust ducts or air collectors are manufactured today. The innovative, cost-efficient and ecological forming technology to shape complex geometries in titanium that will contribute to strengthen the European aircraft industry competitiveness meeting society?s needs.
Currently, aircraft industry uses complicated and cost intensive forming processes to shape complex Ti sheet components, such as deep drawing, hot forming, super plastic forming (SPF) and hydroforming. In some cases parts are even obtained by hand working. These techniques show severe drawbacks which include high costs, long industrialisation phases and high energy consumption rates. On the contrary, main features of the innovative AISF technology to be developed will be an increased flexibility, cost reduction, minimised energy consumption and a speed up in the industrialisation phase.
The major impacts of the results obtained in the INMA project will be:
- Cost incurred by dedicated tooling will be reduced in a 80%
- The component lead times will decrease in a 90%
- Buy-to-fly ratios will be up to a 20% lower
The INMA Consortium is integrated by 2 end-users, 1 equipment provider, 4 research organisations, 3 universities and the EASN association. Participation of industrial partners who will directly exploit the project results will guarantee the impact of the project.
More information is available on the project website www.inmaproject.eu
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