The development of hybrid yarns (CF/LM-PAEK) and related processing is the focus of the work and enables the implementation of a window frame with complex geometry to meet the mechanical requirements. The manufacturing process being developed will make it possible to produce load-bearing lightweight structural components more efficiently.
The process chain should reduce the manufacturing time significantly (-50%), consume significantly less energy (-50%), and increase the geometric complexity at lower costs and reduced mass.
The hybrid construction combining endless fibre CFRP with injection molding in functional areas with low mechanical stress and load introduction via induction welding and metallic inserts. This allows a post-processing free process chain with high automation potential. In addition, the use of thermoplastics allows a simple recycling without separation of fiber and matrix.
For insert production, both MAG and TFP preforms based on adapted hybrid yarns are used, thus achieving a high degree of automation and online quality assurance. The preforms are then isothermally pressed, which enables short cycle times and high laminate quality
Overmolding is used to stiffen the overall structure and integrate functions (integration of load introduction elements and sensors). The basis for the necessary connection strength of the individual components is the use of special PEEK variants from Victrex.
Weight and cost reductions are to be achieved in particular by welding the window frame to the fuselage structure, which is implemented in currently used window frames by Hi Lock connections. Costly work steps for the rivet connection can be saved and so the shown construction can compete with RTM and aluminum window frames, despite high material costs.