CompositesWorld
Issue link: https://cw.epubxp.com/i/632301
47 CompositesWorld.com NEWS N E W S N S N E W S E N W S W Spirit AeroSystems Prestwick largest composite structures in the world, says Linda Cadwell Stancin, Spirit's director of core structures engineering and technology. Cadwell Stancin points out, for example, that Spirit produces the forward section for the Boeing 787 fuselage and the center section of the Airbus A350 XWB fuselage. It also produces propulsion structures, such as nacelles, with composites, and delivers composite helicopter structures and wing components, such as leading and trailing edges and spoilers. An example of a current large composite structure developed by Spirit is the Airbus A350's front wing spar. Although autoclave manufacture is a mainstay of the compa- ny's business, Cadwell Stancin points out that the company isn't limited to autoclave processing, noting that, "50% of our new contract development is some kind of out-of-autoclave [process]." Spirit, in fact, has always advanced emerging technologies of interest to its customers, including those involving out-of-auto- clave (OOA) cure, for which it has investigated most available forms of OOA materials, including prepreg, from Cytec, Toho Tenax, Toray, Albany, Saertex and Hexcel. Further, Spirit has fabricated prototypes and parts using OOA prepregs, thermoplas- tics, and via the method that prompted CW's visit to its Prestwick facility, resin infusion. In the words of Cadwell Stancin, "We know that development for future items has to be more nimble, more creative and signif- cantly less costly than in the past to meet challenging development schedules for the next aeroplane. OOA enables that and helps us serve our customers more efectively." Spirit is participating in UK government-sponsored research eforts for Factory of the Future and advanced composites. Cadwell Stancin emphasized that, "Government-sponsored research is really important to success in the aerospace industry." She further added that, "Early research, below Technology Readiness Level [TRL] 6, signifcantly benefts from the work of the universities and centers." Cadwell Stancin specifcally credited the National Composites Centre (NCC, Bristol, UK) and the Advanced Manu- facturing Research Centre (AMRC, University of Shefeld, UK). IRIS (Intelligent Resin Infusion System) One of the most compelling aspects of Spirit's OOA development work is its own propriety, patented system known as IRIS (Intel- ligent Resin Infusion System). A detailed examination of IRIS was the centerpiece of CW's site visit to Spirit's facility on the south- west coast of Scotland, approximately 50 km to the southwest of Glasgow. Here, Spirit has produced developmental demonstrator wing structures complete with stifeners, using its IRIS tech- nology, and work is progressing to produce entire wing structures. Crucially, IRIS and associated tooling technology developed by Spirit enables accurate placement of structural supporting features, such as ribs, and, says Cadwell Stancin, gives Spirit the ability to "put the properties exactly where they need to go." Te essential features of IRIS can be seen in Fig. 1, p. 48 . Te resin fow media is built directly into cavities in the tooling. David Watson, Spirit's senior manager at the Advanced Technology Centre at Prestwick, and our guide during the tour, explains that Haven for research and development Spirit's director of core structures engineering and technology Linda Cadwell Stancin (left), shown discussing a composite fuselage aft-section prototype with engineering colleagues Elisa Acosta and Chris Boshers (right) at the Spirit AeroSystems, facility in Wichita, says the Prestwick facility was positioned to take advantage of composites research sponsored by the UK government and nearby universities and technology centers. Pushing the limits of automation Spirit AeroSystems makes use of both automated fber placement (AFP, shown here) and automated tape laying processes, but also is seeking automated means to lay down more complex fber forms, such as non-crimp fabrics (NCFs) and 3D woven cleats.