CT, a leading engineering company in technological innovation across the entire product lifecycle, announces the completion of the SAAT project. This initiative was launched with the aim of transforming the competitiveness and sustainability of the aeronautics sector through the large-scale implementation of ultrasonic welding in thermoplastics, a key technology for advancing the development of zero-emission aircraft.
The project has successfully validated an advanced ultrasonic welding (UT) process for thermoplastic composite structures (TPCs). Among its most significant achievements is the ability to produce reliable joints in thicknesses of up to 8 mm, representing a major advancement over the technical limitations previously faced by the sector.
This progress has been made possible thanks to the collaboration of the consortium, made up of SOFITEC, AIMEN, MECASONIC, and SYSPRO.
CT improves joint accuracy through mechanical and thermal models
CT has focused its efforts on improving the accuracy and efficiency of joint design.
The CT team developed two physics-based simulation models—one mechano-elastic and one thermal—aimed at optimizing the welding process. These models were fed with experimental data from AIMEN, achieving outstanding predictive accuracy.
In addition, a design tool based on Model-Based Systems Engineering (MBSE) was developed. This environment makes it possible to centralize all information related to the analysis and manufacturing of TPC joints within a single framework, facilitating the development of more efficient joints tailored to real operational requirements.
A demonstrator that ensures industrial viability
To certify the success of the research, the consortium manufactured a full-scale demonstrator one meter in length. This component, featuring variable thicknesses, was assembled using two continuous ultrasonic welding seams, demonstrating that this technology is not only viable in laboratory conditions but is also ready for scaling up within the aerospace industry.
With the completion of SAAT, CT reaffirms its commitment to the development of technologies that enable lighter, more efficient, and more environmentally friendly air transport.
For more information about this project, visit its page by clicking here.
Título proyecto (ES): Proceso de soldadura avanzada para la fabricación de aeroestructuras de composite termoplástico.
Project title (EN): Advanced welding process for manufacturing thermoplastic composite aerostructures
Acronym: SAAT
Project: EXP – 00171201 / MIG-20241007
Duration: from 09/03/2024 to 12/31/2025
Project budget: €1,769,750.00
Granted funding: €1,090,917.13
