A challenge for next A/C Fuselage: New Hybrid Thermoplastic Material, Testing activities definition

A new hybrid thermoplastic concept patented by Leonardo allows to obtain a material that can be processed at temperature lower than usual thermoplastic resin processing temperature without any problem concerning the crystallinity. The high-performing hybrid material based on commercial PEEK-Carbon Fiber prepreg with the addition of amorphous (PEI) films overcomes the disadvantage of high/narrow processing parameters window and allows to take full advantage of prepreg material automated lamination, essential to make thermoplastic parts economically convenient respect to thermoset ones. Thus the new concept answers to the needs to have reduced weight and consequently reduced fuel consumptions and emissions on aircraft, as well as reduced manufacturing and operational costs. The preliminary tests performed on the new hybrid material showed good results, the goal of this work is to define an extensive mechanical test campaign to elaborate on material structural properties and validate static and dynamic behaviour of structural parts for next A/C fuselage.