Project

The MISSP Project

Objectives

  • achieve further development, integration and validation of metallic technologies such as innovative light-weight alloys, environmentally friendly and low-cost manufacturing processes, and innovative recycling concepts at the end of the product life cycle.
  • characterize and evaluate the relevant properties of specific new light high-strength alloys
  • develop and combine advanced manufacturing processes such as High energy hydroforming, Creep Forming, Laser or Friction Stir Welding.
  • optimize and automate these advanced manufacturing processes through experiments and numerical modelling to increase their efficiency, repeatability and security.
  • design and manufacture metallic structures applying the developed technologies
  • validate the properties of the parts and structures after application of the forming and welding processes
  • assess the use of these manufacturing processes and advanced alloys for the production of future metallic airframe structures
  • reduce the overall lead time and production costs for the manufacturing of cargo door structures by limiting the number of parts and assembly operations. The possible cost savings and lead time reduction associated to each of the three proposed design concepts will be evaluated. It is expected that an important overall manufacturing cost reduction can be achieved but this will also depend on the level of integration of the chosen concept, the automation of the manufacturing processes and the production rate

Some possible future business models associated to each design concept will be proposed and analysed. Depending on the chosen concept, most of the manufacturing operations might be sequenced and concentrated in a unique shop floor thus allowing a high level of automation and a drastic cycle time reduction.

By the end of the project, demonstrators will be manufactured for each of the proposed concepts. These demonstrators shall allow assessing the involved manufacturing processes in pre-industrial condition (TRL 6), opening the door to their industrial transfer to aircraft cargo doors structures.

Milestones

The project will be carried out over a period of 30 months. The development of the 3 manufacturing methods (stretch formed door, creep formed door skin with welded stringers and integrated structure machined from a preformed billet) will run simultaneously:

  • preliminary material investigations (by month 7)
  • numerical modelling (by month 14)
  • parts/structures manufacturing (by month 22)
  • evaluation of the effect of manufacturing on material properties (by month 27)

A final comparison between the proposed new manufacturing routes and the conventional forming and assembling route is foreseen after the modelling and manufacturing activities.

  • technical & economic analysis (by month 30)

Progress

Currently the preliminary materials investigations and numerical modelling are being finalized. The particular aluminium plates have also been obtained from the selected materials suppliers.

The necessary design specifications of the cargo doors are being fixed and the tooling for the various forming and welding activities is being designed.