demonstrator tool that is now in situ at its
Filton facility. This tool provides an
automated, low pressure RTM (resin transfer
moulding) system for the programme’s
composite wing spar. The spar is considered
one of the most challenging aerospace
components to design and manufacture, and
this will be one of the rst times that RTM
technology has been used on this scale.
GKN Aerospace engineers have used
proven toolmaking knowledge from the
automotive industry in developing the
demonstrator. The 4 m development testbed
will improve the productivity of the
composite manufacturing process by
removing one third of the production steps
involved. Technology will move from
traditional, pre-impregnated resin material to
dry composite bres that are injected with
resin as part of the initial manufacturing
process for the wing spar, resulting in
signi cant weight savings.
Composites innovation is no less
prevalent in the nuclear sector, where a 3D
woven composite component, capable of
withstanding extreme temperatures inside a
fusion nuclear reactor, is being developed at
the University of Shef eld Advanced
Manufacturing Research Centre (AMRC) in
collaboration with the United Kingdom
Atomic Energy Authority (UKAEA) as part of
the effort to accelerate the delivery of
limitless zero carbon fusion energy (https://
is.gd/upufi j).
The UKAEA is involved in developing the
next generation of magnetic con nement
reactor, called a ‘tokamak’, at its site in
Culham, Oxfordshire. Research is focused
on preparing for the global tokamak
experiment at the International
Thermonuclear Experimental Reactor (ITER)
in Saint-Paul-lès-Durance, France, and for the
subsequent machine that will demonstrate
the generation of power from fusion.
Left: The breeder blanket must capture
the heat energy of the neutrons in order to
raise steam for turbines to generate power
Fusion occurs when two types of
prevent the neutrons escaping and ‘breed’
Each blanket module typically measures
1 by 1.5 m, and weighs up to 4.6 tonnes.
“At the moment, the designs being tested
in ITER use steel for the structure of the
internal diameter to collect the heat,”
explains Steffan Lea, research fellow at the
AMRC Composite Centre. “Each one is
welded into place, and every connection has
to be inspected. That is what we were asked
to replace.”
To achieve a lightweight, temperatureresistant
structure, a silicon-carbide
composite material was chosen, with the
internal ow channels created by forming the
composite around a disposable core.
Lea adds: “We were able to replace a
metallic box, made of different steel
components, with a malleable textile fabric
that has cooling pipes running the length of
it. Using advanced manufacturing
technologies available at the AMRC, we have
integrated the functionality of cooling,
simpli ed the design and removed the
welding operation, so lessening the burden
of quali cation.” Maintenance is also eased,
because of the solution’s lighter weight.
Composites-related industry & product news in brief
A longstanding partnership between Base Materials (https://
is.gd/owufax) and Marbocote (https://is.gd/ceweca) has produced
a product to reduce curing times in the composites industry:
MTS12. With a fast cure time (15 minutes at 60°C), the noncontaminating,
high gloss product is quick and easy to apply, and
offers high adhesion to the mould/tool surface and inherent
release properties. The product can also be used to refurbish old
moulds and seal micro-porosity on carbon bre parts.
For machining composite materials, Mapal (https://is.gd/
yinaye) is introducing the OptiMill-Composite-Speed-Plus cutting
tool, an extension to its existing OptiMill-Composite-Speed. This
diamond-coated solid-carbide milling cutter has a newly developed
substrate that combines with a reinforced core diameter and
eight cutting edges. Fracture strength has been increased by
50%, while the optimised groove pro le ensures fast, reliable
removal of dust and process heat, says Mapal. Overall, the tool
life of the OptiMill-Composite-Speed-Plus is 20% higher than for
the previous model.
Spirit AeroSystems has opened a composite manufacturing
facility at its site in Prestwick. The facility leverages composite
technology from Spirit’s research and development portfolio, and
brings new work to the site in the form of the Airbus A320 family
spoiler. The Rt Hon Nicola Sturgeon MSP, First Minister of
Scotland, of cially opened the facility.
COMPOSITES IN MANUFACTURING PICK & MIX MATERIALS
hydrogen atoms, tritium and deuterium,
collide at enormously high speeds to create
helium and release a high energy neutron.
Once released, the neutron interacts with a
much cooler ‘breeder blanket’ to absorb the
energy. The blanket must capture the energy
of the neutrons to generate power, but also
more tritium through reactions with lithium.
breeder blankets, which have a network of
double-walled tubes measuring 8 mm
52 April 2020 | www.machinery.co.uk | MachineryMagazine | @MachineryTweets
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