| Project Detail |
On the way to 3D-printed flap tracks on aircraft wings
Flap track structures control the flaps located on the trailing edge of aircraft wings. The goal of the EU-funded ADDIFLAP project is to develop a new concept of a flap track mechanism that combines a flap track support system manufactured by direct energy deposition with a carriage system based on a sliding pad. The development of the direct energy deposition process will be supported by numerical tools to reduce distortion on the final flap track structure and by online process monitoring and control. Compared to conventional techniques, this additive manufacturing technique should reduce material waste by 60 %. The sliding carriage system is expected to increase the flying hours of the component by a factor of two.
ADDIFLAP project’s general aim is the development of a new concept of flap track system by combining a novel flap track support manufactured by Laser Wire Direct Energy Deposition (W-DED-LB) with a new design of carriage system based in sliding pad concept, made using a self-lubricant MMC coating.
Deployment of W-DED-LB process will be supported by numerical models to reduce the distortion effect on the final flap track structure and establish the manufacturing strategies for process manufacturing and by online process monitoring & control. Sliding pad design for the flap carriage system will be based on self-lubricant surfaces approach. ADDIFLAP involves the following objectives:
• Development of simulation models and optimized manufacturing strategies will reduce the effort in reducing the
distortion on the flap track support up to 50% regarding the trial-and-error approach. This will impact in the time to market, reducing even further the time from design to manufacturing.
• Flexibility (on design, enabling part consolidation…) provided by AM technologies (W-DED-LB) will enable to reduce the time to market into 20%.
• Reduction of 60% on material waste regarding conventional manufacturing is expected (Reduction of the BTF ratio).
• Reduction of 20-30% on component distortion will be achieved by combination of simulation, and optimization of WDED-LB process parameters and online monitoring & control developed in ADDIFLAP Project.
• The sliding carriage system will increase the component flying hours for a conventional Business Jet in a factor of two regarding conventional roller system.
The technology developed in ADDIFLAP will enable the design of a multifunctional flap which combines aileron and high lift functions in one flap body having direct impact on weight reduction. |
