Breakthrough for Carbon Fiber Fabrics in Aircraft
Carbon fiber article by Walter Wirz
Lightweight carbon fiber composites in aircraft
Less weight in an aircraft reduces fuel consumption, which is beneficial both financially and in terms of environmental responsibility. But carbon fiber composites not only increase fuel efficiency due to reduced weight. They also allow for more creative scope for engineers when searching for improved aerodynamic performance.
Customized solution for carbon fiber fabric weaving
One of the latest CREALET breakthroughs is a warp feeding device developed specifically for weaving lightweight carbon fiber fabrics for aeronautic applications. The most commonly used pattern for carbon fibers is 2/2 twill. In this pattern the weft goes over two intersecting warps and then under another two to create a woven fabric with a predominantly diagonal pattern. This weave pattern is looser than plain weave, allowing the fabric to drape more easily.
The shed formation influences the load of warp threads and fabric quality. The weave pattern determines the number of heald shafts and which warp threads are in lower and upper shed during weft insertion. The shed is normally asymmetric and the result is an unequal warp thread tension per heald shaft. These warp tension variations have a negative impact on the weaving process and fabric quality.
The CREALET solution
Expertise in finding customized solutions for the warp feed to weaving and knitting machines is the foundation of CREALET’s success. As warp tension has a major influence on the weaving process and fabric quality, the following warp feeding system was developed and installed:
- Creel with tension control
- Electronically controlled dummy feed system
- Warp tension compensating unit
The carbon fibers are drawn from the creel by an electronically controlled dummy feed roller, and then transferred to the compensating unit. While the dummy feed roller unit provides a constant yarn feed the additional compensating unit absorbs the tension peaks created by the heald shafts, enabling optimization of the weaving process and the fabric quality.
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