Abstract

In the operation of some structures, particularly in energy or chemical industry where pressurized pipeline systems are employed, certain unexpected critical situations may occur, which must be definitely avoided. Otherwise, such situations would result in undesirable damage to the environment or even the endangerment of human life. For example, the occurrence of such nonstandard states can significantly affect the safety of high-pressure pipeline systems. The following paper discusses basic physical prerequisites for assembling the systems that can sense loading states and monitor the operational safety conditions of pressure piping systems in the long-run. The appropriate monitoring system hardware with cost-effective data management was designed in order to enable the real-time monitoring of operational safety parameters. Furthermore, the paper presents the results obtained from the measurements of existing real-time safety monitoring systems for selected pipeline systems. Document type: Article

Abstract

Future aircraft manufacturing factories are moving towards more flexible and adaptable manufacturing systems that enable shorter manufacturing cycles, environmental friendliness, energy efficiency, and higher productivity. A global aeronautic trend to face this challenge includes the replacement of metal parts with composite counterparts with emphasis on thermoplastic composites (TPCs) for their unique ability to be recycled, reprocessed, and welded. Aiming to commit to the drastic projected increase in aircraft production rates, WELDER project, focused on the next-generation MultiFunctional Fuselage Demonstrator (MFFD), has promoted the development and investigation of highly integrated and robotized manufacturing technologies that needed to be scaled up from a laboratory to an industrial environment. To contribute to such an advance, resistance welding was investigated in this work and successfully automatized for fuselage components assembly.

Welding investigation, including process maturation, parameter optimization, and scale-up analysis was performed at laboratory using LM-PAEK/CF composites. A resistance welding Heating Element (HE), made of stainless steel metal mesh and embedded in glass fiber scrims, was first designed and manufactured using a hot press. The HE, priorly characterized by electrical analysis, was adopted, in conjunction with a lab-scale welding head, to optimize and define appropriate processing times (welding and cooling), welding power, and pressures for the welding of the composite parts. The welds were characterized by visual inspection, microscopy analysis, and mechanical tests (SLSS tests - AITM 1-0019). Once materials and processes were optimized, they were scaled up to finally perform the welding of the frame couplings into MFFD.