Process for producing a component having a thermoplastic fiber composite and components made by the process

A process for producing a component for an aircraft, the process comprising steps of:

• Step a):
• producing a sheet-like object comprising a thermoplastic fiber composite which comprises a thermoplastic polymer material and reinforcing fibers embedded therein;
• producing the sheet-like object from a starting material which is selected from the group consisting of sheets, bands, tows, patches, strips and/or tapes comprising thermoplastic fiber composite;
• producing the sheet-like object from a starting material which is heated to a temperature at which a plasticity of the thermoplastic polymer material allows formation of the sheet-like object;
• producing the sheet-like object by placing a starting material on a surface of a placement apparatus by using a placement robot;
• producing the sheet-like object by placing a starting material to form a laminate;
• producing the sheet-like object by placing a starting material according to a predetermined three-dimensional placement pattern which prescribes an orientation of the reinforcing fibers and/or a position-dependent thickness of the sheet-like object;
• producing the sheet-like object by placing a starting material such that all or part of the reinforcing fibers form 0° reinforcing fibers in the finished component, based on one or more main axes, main edges, longitudinal axes, longitudinal edges of the component;
• producing the sheet-like object in a static process;
• and
• producing the sheet-like object by automated fiber placement and/or automated tape laying;
• Step b):
• after the sheet-like object has been produced, forming a semifinished part from the sheet-like object;
• forming the sheet-like object in a continuous forming process, or in a continuous high-speed forming process;
• forming the sheet-like object under pressure conditions and/or temperature conditions under which the thermoplastic polymer material or the thermoplastic fiber composite has a plasticity suitable for the forming process;
• forming the sheet-like object in a continuous profiling process;
• forming the sheet-like object in a roll forming process;
• forming the sheet-like object in a continuous pressure molding process, or by a simplified continuous compression molding process;
• forming the sheet-like object in a 3D preforming process;
• forming the sheet-like object with alteration of its cross section and/or its curvature;
• forming the sheet-like object with sliding of the reinforcing fibers into a desired fiber orientation position, or with setting of a required local orientation of the reinforcing fibers;
• forming the sheet-like object such that all or part of the reinforcing fibers form 0° reinforcing fibers in the finished component, based on one or more main axes, main edges, longitudinal axes and/or longitudinal edges of the component;
• forming the sheet-like object with partial solidification and/or consolidation of the thermoplastic fiber composite, or with retention of a minimum degree of formability of the thermoplastic fiber composite which is necessary for step c);
• and
• forming the sheet-like object in a static process, or by pressing the semifinished part in a one-sided or two-sided molding tool;
• and
• Step c):
• after the semifinished part has been formed, producing the component by solidifying the semifinished part;
• solidification of the semifinished part in a static process;
• solidification of the semifinished part by application of pressure, or with simultaneous heating of the semifinished part;
• solidification of the semifinished part in a heatable press in a static pressing process, or with simultaneous heating of the semifinished part;
• solidification of the semifinished part with retention of a shape of the semifinished part obtained in step b) or with further forming of the semifinished part;
• solidification of the semifinished part in a pressing process using a one-sided or two-sided stiff pressing tool;
• solidification of the semifinished part in a pressing process using a one-sided or two-sided stiff pressing tool having a tool insert which has been inserted into the pressing tool and serves for additionally altering a contour of the semifinished part;
• solidification of the semifinished part in a process which is a combination of pressing and embossing, pressing and forming or forming and embossing;
• and
• solidification of the semifinished part at a temperature in a range from 300° C. to 400° C. with application of pressure.