A Robust Multifunctional Sandwich Panel Design with Trabecular Structures by the Use of Additive Manufacturing Technology for a New De-Icing System

Abstract

Anti-ice systems assure a vital on-board function in most aircraft: ice prevention or de-icing is mandatory for all aerodynamic surfaces to preserve their performance, and for all the movable surfaces to allow the proper control of the plane. In this work, a novel multi-functional panel concept which integrates anti-icing directly inside the primary structure is presented. In fact, constructing the core of the sandwich with trabecular non-stochastic cells allows the presence of a heat exchanger directly inside the structure with a savings in weight and an improvement in thermal efficiency. This solution can be realized easily in a single-piece component using Additive Manufacturing (AM) technology without the need for joints, gluing, or welding. The objective of this study is to preliminarily investigate the mechanical properties of the core constructed with Selective Laser Melting (SLM); through the Design of Experiment (DOE), different design parameters were varied to understand how they affect the compression behaviour.

Mechanical properties of 3-D printed truss-like lattice biopolymer non-stochastic structures for sandwich panels with natural fibre composite skins

“…Moreover, Zok et al [50] developed mechanism maps for possible failures of pyramidal metallic truss cores based on beam theory with respect to face and core dimensions. In the past, many researchers have studied the potential use of AM lattice structures for various applications [51][52][53][54]. Yoon et al [55] characterisation and also developed beam and solid elements based FEM.…”

Modeling and characterization of mechanical and energetic elastoplastic behavior of lattice structures for aircrafts anti-icing systems

“…However, the application of the design for additive manufacturing (DFAM) to this engineering problem is able to provide alternative and more efficient solutions. 4,5 In fact, the leading edge area hosting the anti-icing system is also subjected to accidental loads (e.g., birds strikes). At this purpose, additive processes can support specific design for heat management and energy dissipation at the same time.…”

Design and characterization of trabecular structures for an anti-icing sandwich panel produced by additive manufacturing

“…The use of a new sandwich panel has been proposed as anti-icing systems in various parts of the aircraft, such as wings, replacing traditional ice prevention systems [9]. As described in the patent [10], the new multi-functional sandwich panel directly integrates a thermal anti-ice system into the structure: internal skin, external skin, and a trabecular core of aluminum alloys (Figure 1). The hot compressed air tapped from the engine is entered into the trabecular periodic sandwich via feeding tubes (indicated in Figure 1 as multiple hot air inlet), integrated in the internal skin.…”

“…Furthermore, aluminum alloys are completely compatible with the operating temperature of the sandwich panel, that is about 130–150°C, depending on the aircraft. Trabecular structures shall provide adequate mechanical resistance to bird strike impacts and the internal passageways will provide adequate stiffness to the whole system [9].…”