automated gap filler device - welcome to the clean sky website

Automated Gap Filler Device JTI-CS-2012-01-SFWA-02-020

January 2011

Presented by

Jeremy Bradley – Airbus, Materials & Processes Engineer

CFP Information Day

© AIRBUS Operations LTD. All rights reserved. Confidential and proprietary document.

Background

• Natural Laminar flow (NLF) has been identified as a key

technology to contribute to the reduction of emissions for future

short range aircraft.

• Studies have been launched within SFWA to investigate the

feasibility of producing such a design. The work will include ground

based and flying demonstrators.

• One potential concept includes a joint between the main wing box

and leading edge structure.

This joint must be filled to the specified

surface finish requirements to maintain

NLF.

January 2011


Main Objective

‘To develop an automated device that

is capable of filling panel gaps to the

required tolerance in a high rate

production environment.’

January 2011


Main Objective

• The joggle joint shown below will include a gap between the

panels to allow application of a filler material. The gap dimensions

are of the order of 3mm wide by 4.5mm deep.

• The surface finish requirements will include:

• Misalignment tolerance on the panels to be joined.

• Variation caused by sealant expansion or contraction.

• Isolated roughness requirements on the filler surface.

(Full details of the surface finish will be made to successful applicants)

January 2011


Main Objective

• Panel misalignment may be up to ±0.3mm

• Gap geometry will be carefully controlled.

• Filler tolerance is likely to be in the order of ±0.1mm

Δt

Δt

January 2011


Main Objective

• The total length of the joint to be filled will be between 4 and 15

metres and may go across chord wise joints.

• This means that the minimum uninterrupted length to be filled is

approximately 4 metres.

• To achieve rate, this process should be able to fill a 30 metre

length in less than 3 hours.

January 2011


Main Objective

• As shown on the A320 wing below, a typical span wise joint

exhibits some double curvature.

• A suitable filler device should be able to operate in a fully 3D

environment.

• Surfaces either side of the joint may be painted or unpainted and

may be dissimilar.

• It would be beneficial but not essential for the device to be able to

fill chord wise joints, countersinks and minor in service defects.

Filler Line

January 2011


Materials Information

• Current baseline filler material is based upon standard

polysulphide sealant technology. + Long proven track record

+ Good adhesion, flexibility, fluid resistance, temperature stability

– Known shrinkage issues

• Toughened epoxy fillers are under investigation. + Much lower shrinkage

+ Improved surface finish

– Unknown long term performance

• UV cureable sealant technologies are currently under

development and should be available for evaluation. + Tack free times measured in seconds

+ An enabler for automation

– Materials still under development

• Airbus will be able to supply filler materials with agreement of relevant suppliers.

• Successful candidates will be expected to have some materials background and

seek innovation in this area.

January 2011


Work Programme

• The successful applicant shall develop a prototype device capable

of filling the panel gap on the ground based demonstrator (See

original topic description).

• The work programme is constrained to 12 calendar months.

• The body of work shall include:

• A background study on filling techniques and devices

• Benchtop prototype development

• A method of evaluating the performance of the device,

including test coupon production.

• Technical drawings of the device

• Submission of a final prototype for further evaluation

• A detailed final technical report

Mid-Term

End of Project

January 2011


Scope for innovation

•Degree of automation

•Novel Materials (Photosensitive, thixotropy)

•Multiple operations (single or multi-pass)

–Gap analysis

– Secondary finishing

– Post application metrology

•???

January 2011


Any Questions?

January 2011


© AIRBUS Operations LTD. All rights reserved. Confidential and proprietary document. This document and all information contained herein is the sole property of AIRBUS Operations LTD. No intellectual property

rights are granted by the delivery of this document or the disclosure of its content. This document shall not be reproduced or disclosed to a third party without the express written consent of AIRBUS Operations LTD. This

document and its content shall not be used for any purpose other than that for which it is supplied. The statements made herein do not constitute an offer. They are based on the mentioned assumptions and are expressed

in good faith. Where the supporting grounds for these statements are not shown, AIRBUS Operations LTD. will be pleased to explain the basis thereof.

AIRBUS, its logo, A300, A310, A318, A319, A320, A321, A330, A340, A350, A380, A400M are registered trademarks.

January 2011

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