Arkema and Hexcel complete first aviation structure

Arkema and Hexcel complete first aerospace structure made from thermoplastic composites. The HAICoPAS project aims to optimize the design and production processes of unidirectional composite tapes made from high-performance thermoplastic resins and continuous carbon fibers. As part of a strategic partnership between Hexcel and Arkema, a high-performance thermoplastic composite structure was designed and manufactured using HexPly® thermoplastic tapes. These aerospace and space-class materials were developed from Arkema's Kepstan® PEKK resin and Hexcel HexTow® AS7 and IM7 carbon fibers. The demonstrator project was carried out as part of the joint project known as HAICoPAS. The primary objective of HAICoPAS is to optimize the design and production process for unidirectional composite tapes made from high-performance thermoplastic resins and continuous carbon fibers. The project also aims to develop a new continuous and dynamic in-situ welding (ISW) assembly system with more efficient tape placement technology and real-time quality control. The ultimate goal is to produce composite parts capable of replacing metallic materials (such as steel, aluminum and titanium) in aircraft structures, thereby achieving lower costs and higher production rates. The project partners' work successfully overcame the technological barriers identified at the project's outset. These included the development, application and characterization of carbon/thermoplastic materials (C/PEKK) tapes; the creation of an automatic layup process for consolidation outside autoclaves; and the establishment of ISW welding technology for assembly. The design of key parts intended to form the assembled components of the HAICoPAS demonstrator was carried out in close collaboration with an industrial advisory committee comprising Airbus, Safran, Daher, Hutchinson and ATC. The aerospace demonstrator made from composite tapes and assembled using ISW technology was displayed in the Mobility section of the JEC World Innovation Planets exhibition. Source