Ongoing projects
that continued in 2022

EWIRA

The Product Definition team has completed the release of plans for the external wing demonstrator.

The Product Definition team has completed the release of drawings of the external wing demonstrator, a step that will allow the validation of TRL6 levels in flexible assembly jig technologies developed at Aciturri, as well as in-situ thermoplastic consolidation technologies developed by FIDAMC and integrated assembly infusion by Airbus Defense & Space. Similarly, Aciturri Assembly has completed the transformation of the demonstrator's flexible assembly jig.

Technical difficulties in other Clean Sky 2 partners have not allowed to start the assembly of the demonstrator, but Aciturri has continued the activity to validate supplementation techniques using additive manufacturing and manual drilling techniques with semi-automatic machines that allow drilling and assembly in a single step.

FEINA

It plans to develop the WAAM (Wire Arc Additive Manufacturing) technology for additive manufacturing with titanium.

FEINA aims to develop the WAAM (Wire Arc Additive Manufacturing) technology for titanium additive manufacturing that could become an alternative to forging parts, as well as an alternative to preforms of titanium structural parts.

The project will be practically completed in 2022, with the execution of the entire battery of tests on specimens covering all possible combinations of processes and heat treatments. From the interpretation of these results, conclusions will be drawn regarding the optimal manufacturing process in this technology and the basis for a possible scale-up for the manufacture of parts with real geometries and requirements will be established.

COPERNICO

Processes for the manufacture of HTP (Horizontal Tail Plane) hardware using RTM (Resin Transfer Moulding) technology have been developed.

Within the framework of the COPÉRNICO project, the necessary processes for the manufacture of HTP (Horizontal Tail Plane) hardware using RTM (Resin Transfer Moulding) technology have been developed.

Relevant advances have been recorded for the reduction of process costs through the injection of the parts in a multi-cavity tool, which allows the simultaneous manufacture of several units, and the adjustment of the cutting processes of the dry fiber by laser, which would allow to build the parts to net edge and thus avoid the process of trimming by CNC. As a final part of the project, the hardware is being assembled on a structure that simulates the HTP box, in order to perform static and fatigue tests that will give an indication of the load levels that the hardware is able to withstand and allow a comparison with current in-flight hardware.

DOMMINIO

A first FEM model generator tool for torsional caissons has been developed.

2022 was a very relevant year for Aciturri in this program. Taking advantage of the context of the development of a demonstrator for new manufacturing techniques (promoted by other partners), the Product Definition department (and specifically the calculus office) has developed a first tool to generate FEM models of torsion boxes. This progress is part of an activity of digital tools promotion that will allow to reach little by little a multidisciplinary support by these tools.

Within DOMMINIO, a prototype concept will be tested in the coming years with the other project partners.

AEROCOST

It comprises several technologies related to the manufacturing processes of thermoplastic matrix composite materials.

The project has completed its first year and started its second year within the framework of the Aeronautical Technology Program (PTA), 2021 call, led by Aciturri Engineering.

In the first year, in collaboration with Alestis, the design of the manufacturing process in dry fiber and infusion of a tail cone has been addressed, integrating all structural elements such as stiffeners and frames. We have also investigated automatic processes for the manufacture of high curvature frames and coatings for this same section of the aircraft.

On the other hand, the analysis of the manufacturability of high curvature frames of section 19 has been approached, through the automation of the lamination operation and the use of press forming, given the geometry of these frames.

The validation of RTM injection technology for the manufacture of a wing tip device, with its integrated reinforcement elements, has also been investigated by defining the manufacturing process and carrying out the first manufacturability tests, which will be continued in the second year.

COMPCOAT

Aciturri continued this year its research on ceramic coatings on composite materials in collaboration with technology centers and companies.

In collaboration with CTME and CIDAUT, the Aciturri team has continued this year with the research of ceramic coatings on composite materials, with the aim of achieving improvements in the functionalities of these materials, within the regional line (Castilla y León) of R&D in effective collaboration between technology centers and companies.

In addition to the fabrication of the specimens of the different materials selected as base substrates, research has been carried out on the pre-treatment of these substrates to prepare the laminates for the ceramic coating projection operation. Different materials have been studied as anchoring layer, as well as different ceramic materials, looking for the one that provides the best results in terms of erosion and temperature resistance. From the tests carried out on these first tests, the best combination of anchoring material and coating material has been selected, taking into account the base substrate material, and complementary tests are being carried out, including erosion tests, to validate the final selected solution.

NEOTAIL

It completed its first year and has begun the second under the Aeronautical Technology Program (PTA).

It encompasses several technologies related to the manufacturing processes of composite materials with thermoplastic matrix, instead of thermoset matrices, which are more common in today's aeronautics. Thermoplastics improve some of the performance of thermosetting resins but their manufacturability suffers as they require process temperatures above 400ºC compared to the usual 180ºC curing temperature of some epoxies.

During 2022, omega section stiffeners were manufactured using two technologies: stamping and press forming. In the second half of the year, these first productions have allowed to introduce more complexity to the development with the manufacturing of a demonstrator of a crossbar section by means of flat taping using AFP (Automated Fiber Placement) of thermoplastics and subsequent forming and consolidating in hot plate presses. At the same time, AFP taping processes are currently being fine-tuned for coatings, in this case with taping on curved tooling, which will be subsequently consolidated in the press.

Another major advantage of thermoplastics is that they are weldable, which means significant savings in assembly times and processes. This is why, during 2022, we have also begun to study conduction welding processes, which will be completed in 2023 and extended to other types of welding, such as induction welding.

MULTIGLIDE

Aciturri has begun the activities to manufacture large composite integrated structures for the new generation of zero-emission aircraft.

Aciturri has begun activities to manufacture large integrated composite structures for the new generation of zero-emission aircraft at high production rates. Thus, the design of a torsion box demonstrator has been defined both for its manufacture with automatic taping and hot forming processes, and for a solution that incorporates Glide Forming. Different tools have been defined, designed and manufactured, both for forming and curing, which incorporate composite solutions with the aim of facilitating the manufacturing process of this type of structures.

In parallel, research is being carried out on the technological limits of the Glide Forming technology for the forming of high curvature frames, in particular section 19, and to provide an alternative to the hot forming process and even to the press forming process.