SE Conference 23 Madrid

Tutorial 1 – Process Automation and Digitalization
With 3 presentations of:

• MTorres (AFP / ATL)

This tutorial discusses the importance of flexibility in the manufacturing of composite parts using Automated Fiber Placement (AFP) and Automated Tape Laying (ATL) technologies. In the past, the choice between AFP and ATL was primarily based on the curvature complexity of the part, with high curvatures favoring AFP and low curvatures favoring ATL. However, the introduction of the TORRESFIBERLAYUP AFP machine by MTorres in 2007 revolutionized the market by significantly improving productivity and reliability.

• IDEKO (Digitalization)

This tutorial of IDEKO presents the Edge computing platform solution, Danobat Box, for machine data capture and software application processing. The “Process Fingerprint” application for anomaly detection during the machining process will be presented. Linked to it, the “Quality Hallmark” application for quality reporting will be shown. Finally, the “Machine Fingerprint” application for the development of a predictive maintenance strategy based on machine condition will be proposed. Real industrial use cases will be exposed in the tutorial.

• Danobat (Automation and precision robotics)

The tutorial of Danobat provides an overview of accuracy on robotics and the different approaches used to increase the performance of robots. The definition and standards applied on robot accuracy evaluation will be presented. Results on accuracy improvement related to kinematic and stiffness modelling will be discussed. Methods for online and offline robot accuracy error correction will be shown. Finally, the use of additional sensors to further increase robot accuracy will be proposed. The tutorial will present the accuracy improvement values obtained mainly in the use case of robotic machining.

Tutorial 2 – Sustainability
With 4 presentations of:

• URJC-Sustainability Centre (Mechanical recycling)

Mechanical recycling is the one that requires the lowest energy, the most environmentally friendly and the fastest processing and facile scalability, when compared to thermal and chemical processes and, moreover, to the production of virgin CF. Its main drawback is the own-recycled product. Recycled CF (r-CF) are short, single filaments and bundles, with non-uniform short lengths and containing possible resin residues. Therefore, the main challenge is their process optimization and the development of high-content r-CF products with thermosetting matrix, using preforms, nonwoven mat, 3D foams or/and scaffolds, to manufacture new multifunctional composites. On the other hand, to prevent serious problems in the future, new reversible bio-resins are being developed to get recyclable, repaired and reshaped composites.

• CIDETEC (Vitrimers)

The increasing global demand for sustainable materials has promoted extensive research efforts in the development of eco-friendly composites. Vitrimers, a type of dynamic polymers, possess the unique ability to rearrange their chemical structure while preserving their mechanical properties, allowing them to be reshaped, repaired and recycled. This tutorial introduces a novel approach to achieve more sustainable composites by utilizing vitrimers based on aromatic disulfide exchange chemistry. They can be easily formulated from readily available commercial products.

• Vestas (Wind blade recycling)

In this presentation, Irene Rodríguez, Head of Sustainability for Vestas in Southern Europe, Middle East and Africa, will explain Vestas’ Circularity Roadmap and what the novel technology consists of. Vestas is a leading wind turbine manufacturer with presence in over 80 countries and over 166 GW of wind capacity installed. In 2020, the company announced a Sustainability Strategy entitled “Sustainability in Everything We Do” and promoting circularity is one of its key pillars. Through its industry leading Circularity Roadmap, the company is committed to creating zero-waste wind turbines by 2040. This means creating technically and commercially recyclable blades and increase material efficiency by 90 percent.

• CSIC (Pyrolisis recycling)

B-Circular is a spin-off of the Spanish National Research Council (CSIC) aimed at developing and exploiting waste composite recycling technologies and has developed the R3FIBER technology with the aim of allowing the integral recovery of the composites generated in the aeronautical, automotive, wind and nautical industries, among other sectors. The recovered high-quality fibers can be re-used thus contributing to circular economy.

R3FIBER allows the integral use of composites without the production of waste. The composites undergo a thermochemical transformation process that allows the transformation of resins into combustible gases and liquid fuels, obtaining (glass or carbon) fibers suitable for reuse. Therefore, there are no limitations in the use of composites or in the management of the material if it contains carbon or glass fibers.

• No Tutorial

Pre-Conference Tutorials are not included but need to be booked in addition of the Conference Ticket or as Tutorial only.

See the registration form for the rates.

Thursday 5 October 14.00 – 18.00

Plant Visits (six choices):

• Airbus – AIRBUS Illescas

AIRBUS production plant of aeronautical parts in composites. Areas to visit: A350 Wing Lower Cover and Section19.

• HEXCEL – HEXCEL Parla

Visitors will have a plant tour of the new HEXCEL factory building in Parla to see Hot Melt impregnation lines. Visitors need to bring their own safety shoes.

• Aernnova – Aernnova Composites Illescas

Visit will follow the manufacturing process. Cutting, ATL, AFP and hot forming machines. Bagging, autoclave and demolding, visual, dimensional and UT inspection. Assembling: A350 HTP, A350 BK, A350 Pylon Spar, A350 pax doors, A220 CWB, A220 VTP, Dassault FX10 wing spars, Boeing 787 APB (depending on manufacturing possibilities).

• IMDEA Materials Institute & FIDAMC

IMDEA & FIDAMC offer a combined visit. The visit will start at the IMDEA auditorium, and after you will go to FIDAMC (walking).

We will visit IMDEA facilities including; Synthesis of advanced carbon nanofillers; Manufacturing of composites by infusion/injection and 3D printing for aerospace and healthcare; Advances in AI applied to manufacturing; Digital twins and the Multiscale mechanical & functional characterization laboratory.

Visit to the mechanical and physical laboratories and Workflow of FIDAMC. FIDAMC employees will show you all composites manufacturing technology facilities, mainly used for aeronautical sectors and others.

• TALGO – Talgo Las Matas

Talgo is a company, specialized in design, manufacture and maintenance of the rolling stock, funded more than 80 years ago. Talgo has the following key success factors: innovation, sustainability, safety, quality, competitive and full custom approach to every project. Talgo´s unique and highly efficient technology is recognized at the international level, with Talgo trains successfully operating in 44 countries of the four continents.

Las Matas one of the factories that Talgo has in Spain. Las Matas I is a manufacturing plant of trains and maintenance equipment, main engineering offices and the headquarters of the company. Las Matas II is the factory where power heads and locomotives are manufactured from the very beginning (welding and assembly) until the final checks. In addition, coaches interiors, mechanical and electrical installations are finished. You will see mainly high-speed intercity trains from Germany and Denmark, and some very high-speed trains for Spain.

Together with manufacturing activities of coaches and locos, manufacturing activities and maintenance activities of running gears are done. To finish the visit, they show the latest R&D project for the introduction of composite material in railway environment: CFRP running gear frame and CFRP-Al carbody shell in the mechanical test laboratory.

• INTA – Instituto Nacional de Tecnica Aerospacial

INTA Materials and Structures department is involved in cryogenic material testing since 1996. The cryostat testing device permits material characterization in tension/compression/flexure with standard specimen sizes at temperatures between 10K and 100K. Initially, this device was used for the cryogenic tank development of reusable launchers in ESA projects, but actually it is used for material characterization for sustainable aircraft with liquid hydrogen propulsion.

Additionally, the department is performing developments and tests on cryogenic tanks, including sloshing, and cryogenic tubing in close cooperation with AIRBUS for future
sustainable aircraft. During the visit, the cryogenic materials testing device, the cryogenic tank, and tubing testing device will be visited and explained. The visit may also include the fuel cell testing laboratory of the Propulsion department of INTA.

• No Plant Visit

Plant visits are free of charge and included in the Conference Ticket. Participation in a tour is dependent on approval of the hosting company.

Warning for all locations: don’t forget to take your passport when attending the excursion. Without a passport, no access!