Advanced Aluminium Fittings in CFRP tubes
ESA has for quite some time been interested in masts, platform reinforcements and flexible structures that combine precision, robustness, foldability and lightness. Aluminium and carbon fibre reinforced plastics are considered promising in this context due to their mechanical properties and low density.
ADALFIC is developing new connections between composite tubes and aluminium fittings. The goals are weight savings, lower costs, higher performance efficiency and solving problems of conventional techniques. Versatile use for payloads and platforms is envisaged.
Project goals
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Innovative aluminium fittings and connection technologies are developed for carbon fibre reinforced plastic (CFRP) tubes.
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The connection system is characterised by high precision and exact dimensional tolerances.
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The developed joint is suitable for temperatures in the range of -70ºC to +70ºC, based on previous aerospace applications.
In addition, the innovative connection is expected to be cost and mass efficient compared to the current state of the art. The new concept, which combines aluminium fittings and CFRP tubes, is expected to deliver a 25 per cent weight reduction compared to conventional titanium solutions. Operating costs are reduced by around 20 %, as fewer assembly operations are required and the manufacturing process is more reliable.
Project results
It was possible to manufacture and test the connections at coupon level and component level - in normal as well as in cold and very warm ambient conditions. The functionality was confirmed, the weight target was achieved and further application tests are being planned.
