First composite assemblies delivered for the A380

Citation

(2004), "First composite assemblies delivered for the A380", Aircraft Engineering and Aerospace Technology, Vol. 76 No. 2. https://doi.org/10.1108/aeat.2004.12776bab.002

First composite assemblies delivered for the A380

First composite assemblies delivered for the A380

Keywords: Composites, Assembly, Aircraft

GKN Aerospace Services (GKNAS) recently delivered the first of the three major composite assemblies that the Company is contracted to supply to Airbus for the A380 (Plate 4).

Manufacture of the tip falsework and other composite assemblies for the A380 has presented new challenges to GKNAS. At 3:5 m × 4 m; the tip falsework is over four times the size of the more traditional piece that GKNAS supplies for the A340. Initial plans saw this assembly being manufactured in aluminium; however, the final assembly is an entirely composite structure bringing weight savings of some 20 per cent over a traditional optimised metallic assembly.

Plate 4 GKN Aerospace Services (GKNAS) has currently delivered the first of the three major composite assemblies that the company is contracted to supply to Airbus for the A380

In order to successfully manufacture this composite structure with the strength and low weight required for the A380, GKNAS has employed the very latest standard of carbon pre-preg moulding and has developed impressive and innovative new composite manufacturing techniques that will achieve new levels of product quality and consistency.

The composite structure is manufactured using a process developed by the company, and uses a new material, “N636”. This structure incorporates a lightweight honeycomb core which greatly increases the strength of the part whilst reducing its weight.

Product quality is increased as a result of the tooling suite used in the production of the assembly. This is made from “Invar 36”, a steel like material which has a very low co-efficient of expansion, guaranteeing that parts can be manufactured repeatedly and with a very high degree of accuracy and consistency. The use of this material has brought machine standard manufacturing tolerances of ±0.16 mm to the production process for composite parts for the first time. Invar 36 tooling has also enabled the production of innovative “integral flanges” on the tip falsework which has reduced the number of parts and fasteners in the assembly. This has simplified the production process and brought additional weight savings to the airframe.

In another production improvement, GKNAS has developed the first ever process able to drill countersinks to 0.05 mm accuracy. This has overcome a major production hurdle encountered in the manufacture of both composite and metallic structures. There are 3,200 countersunk holes drilled along the ribs and intercostals of the two tip falsework required for each A380 aircraft. All these require matching and riveting in what is typically a time-consuming and complex task. Using the new process, this matching was achieved at the first attempt.

GKNAS is the leading independent supplier of composite parts to the aerospace industry worldwide. The company is contracted to supply fixed trailing edge secondary structure (FTESS) and shroudbox for the A380, work valued in excess of $600 million over the life of the programme.

Details available from: GKN Aerospace Services. Tel: +44 (0)1983 283690; Web site: E-mail: www.aerospace.gknplc.com