HELIOS

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.

Click here to learn more of the joint project HELIOS, funded by the German Federal Ministry for Economic Affairs and Energy within the framework of the Aviation Research Program LuFo VII-1.

Challenge

One of the enablers to achieve the ambitious climate goals of the aviation industry, is for future aircraft generations to be built lighter. Existing manufacturing and design methods using riveted joints do not fully exploit the lightweight potential of Carbon Fiber Reinforced Plastics (CFRP). Furthermore, continuous, industrialized process chains for rivet-free joining technologies will contribute to achieve increased production rates. In addition, innovative and automated construction methods require new validated design and certification methods to ensure the approval and safety of these advanced structures.

Solution

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.