Combination of Carbon Fibre Sheet Moulding Compound and Prepreg Compression Moulding in Aerospace Industry

Abstract The demand for fuel efficient aircraft led to the development of innovative lightweight constructions and the use of lightweight materials, such as carbon fibre reinforced plastics. In the same manner competences in new production technologies have been built up in the aerospace industry. However, current processes for producing lightweight composites with an excellent mechanical performance cause high costs and long process cycles in comparison with approved metal processes. Furthermore the used raw materials, such as carbon fibres and resin, are very expensive. In contrast to these technologies Sheet Moulding Compound is characterised by a very high productivity, excellent part reproducibility, cost efficiency and the possibility to realise parts with complex geometries and integrated functions, e.g. inserts or colouring. The biggest disadvantage of Sheet Moulding Compound parts is a low level of stiffness and strength because of a low fibre-volume fraction, a short fibre length and isotropic fibre distribution. In this context the combination of Sheet Moulding Compound and Prepreg compression moulding in an one-shot compression moulding and curing process merges the advantages of both materials to create load-bearing and autoclave-quality parts without an autoclave. In the following article, this new technology and its potential will be presented. This paper will also deal with the resulting material characteristics.