Checking date: 11/06/2021

Course: 2023/2024

Aerospace Manufacturing
Master in Aeronautical Engineering / Máster Universitario en Ingeniería Aeronáutica (Plan: 328 - Estudio: 296)

Coordinating teacher: CINI , ANDREA

Department assigned to the subject: Aerospace Engineering Department

Type: Compulsory
ECTS Credits: 6.0 ECTS


Requirements (Subjects that are assumed to be known)
Student must own basic knowledge relative to the following fields: MATERIALS: + Properties and common uses in aerospace applications of polymeric, ceramic and composite materials. + Properties and common uses in aerospace application of metallic materials. ENGINEERING GRAPHICS: + Descriptive geometry. + Standard specification for the representation of basic industrial and aerospace elements. + Geometric dimensioning and tolerancing. + Computer aided design. MANUFACTURING PROCESSES: + Manufacturing in the aerospace industry: Manufacturing processes. Geometric and functional specifications. Tooling and assembly processes.
At the end of the course the student should be able to: -Identify manufacturing process capabilities. -Select properly the technology or group of technologies to product a piece, component or mechanism attending to its application. -Select the type of material to manufacture a piece, component or mechanism considering different aspects as service life, machinability and maintenance. -Recognize and predict a potential failure in aerospace structures and propulsion systems with analytical and numerical techniques.
Skills and learning outcomes
Description of contents: programme
REQUIREMENTS TO MANUFACTURING PROCESSES: PROCESS CETIFICATION, DESIGN Engineering requirements: data for manufacturing Quality requirements. Cost requirements Environmental requirements Lead time Plant lay-up Stability of the process: development vs production. Certification of manufacturing processes. MANUFACTURING PROCESS CAPABILITIES. Why we need to fix these capabilities How to define process capabilities Repeatability of the process Statistical analysis of manufacturing capabilities Tolerances Defects (composite materials) CONCURRENT ENGINEERING: MATERIALS, DESIGN AND PRODUCTION INTEGRATION Why concurrent engineering Product view from different company areas: local target vs global target Thinking out of the box. Mutual challenge and collaboration Concurrent engineering vs technologies Advanced Composite Materials MANUFACTURING PROCESSES FOR ADVANCED COMPOSITE MATERIALS: AUTOCLAVE PROCESS, RTM, FILAMENT WINDING. Processes Tooling (thermal effects) Vacuum bag Sandwich Defects Drilling Bonded Final trimming Joning FEM (Machining process simulation) MANUFACTURING PROCESS FOR POLYMERIC MATERIALS MANUFACTURING PROCESSES FOR SUPERALLOYS. FEM (Machining process simulation) INFLUENCE OF MACHINING AND ASSEMBLY PROCESSES ON SERVICE INSPECTION. Maintenance and inspection activities for in Service aircrafts Accessibility Design/production for maintenance In service damage. Allowable damage definition. In Service inspection Temporary/permanent repairs Non conformance material. Repairs in the production site. ASSEMBLY PROCESSES Definition of assembly process based on design requirements Consideration of small tooling on the assembly process. Back to the design phase. Ergonomic considerations Torsion boxes and fuselage examples on assembly INSPECTION METHODS Visual inspection and Tap coin Ultrasonic inspection: factory and in Service inspection. Defects vs inspection methods . ¿Uninspectable¿ details Thermography TOTAL QUALITY: KEY CHARACTERISTICS, PFMEA, FEEDBACK LOOPS. From quality control to total quality Impact of different Company areas on the final quality of the product Quality plans Key characteristics PFMEA-DFMEA Management of non conformance material. Feedback loop. Learning from the non quality. MAINTENANCE. FAILURE MECHANISM COMPOSITES FAILURE MECHANISM SUPERALLOYS LEAN MANUFACTURING
Learning activities and methodology
Theoretical lessons. Practical lessons Lab sessions
Assessment System
  • % end-of-term-examination 60
  • % of continuous assessment (assigments, laboratory, practicals...) 40

Calendar of Continuous assessment

Basic Bibliography
  • Jamal Y. Sheikh-Ahmad. Machining of Polymer Composites. Springer. 2009
  • Michael C.Y.Niu. Composite Airframe structures. Hong Kong Conmilit Press Ltd.. 1992

The course syllabus may change due academic events or other reasons.