HELIOS

Problem Statement

The overall project "HELIOS" aims at the development and validation of novel design principles and technologies for weight-optimized and high-rate capable CFRP fuselage shells. The core of the project is the design of a fuselage shell architecture based on rivet-free joining technologies such as the bonding of longitudinal seams and the hybrid welding of frame-to-skin connections. By the end of the project duration, technological feasibility is to be demonstrated. Furthermore the process chains shall be evaluated regarding their lightweight potential, high-rate capability, and cost-efficiency.

Project Objective

The overall project "HELIOS" aims at the development and validation of novel design principles and technologies for weight-optimized and high-rate capable CFRP fuselage shells. The core of the project is the design of a fuselage shell architecture based on rivet-free joining technologies such as the bonding of longitudinal seams and the hybrid welding of frame-to-skin connections. By the end of the project duration, technological feasibility is to be demonstrated. Furthermore the process chains shall be evaluated regarding their lightweight potential, high-rate capability, and cost-efficiency.

Realisation

The collaborative work is divided into five main work packages: Requirements & Design Principles, Holistic Design & Manufacturing Solutions, Holistic Assembly & Integration Concepts, Certification Methodology & Generic Technologies, and Validation & Evaluation. Airbus Operations GmbH is the consortium leader of this project. All consortium partners from industry and research are developing key technologies, including innovative rivet-free joining processes, adapted design and certification methods, as well as automated procedures for quality assurance. The results will be tested and evaluated through structural tests and non-destructive testing on demonstrators.

The consortium consists of the following partners: Airbus Operations GmbH, Deutsches Zentrum für Luft- und Raumfahrt e. V. (DLR), Fraunhofer-Gesellschaft zur Förderung der angewandten Forschung e. V. (FhG), INVENT Innovative Verbundwerkstoffe Realisation und Vermarktung neuer Technologien GmbH, MICOR Gesellschaft für industrielle Wärme und Trockentechnik mbH, SWMS Systemtechnik Ingenieurgesellschaft mbH,TU Braunschweig, TU Hamburg, Universität Stuttgart, Wölfel Engineering GmbH + Co. KG

In the joint research project HELIOS, the DLR Institute of Structures and Design as well as the Institute of Lightweight Systems contributes in several subject areas to the goal of light-weighting CFRP fuselage shell structures. Regarding the boltless joining of thermoset-thermoplast parts, DLR develops hybrid welding processes while ensuring the structural performance. High-rate capable non-destructive test methods for quality assurance are also a domain of DLR in HELIOS.  Furthermore, thermo-forming methods are further developed for the fabrication of cost-efficient and high-rate capable frames. Developments for the adhesively bonded longitudinal seam are supported and analytically assured by residual strength methods of DLR. In addition, DLR contributes to the development of novel design principles and performs a sustainability assessment of the new solutions over the entire life cycle.