Технические науки/9. Авиация и космонавтика

C.t.sc. Lavris E.V.

Moscow State University of Design and Technology, Russian Federation

Seamless woven textile for aircraft and space industries

Seamless technologies were conceived more than hundred years ago. But at present time of composite materials these technologies come to be in great demand and due to the scientific works of Moscow State University of Design and Technology (MSUDT) they find great realization not only in the fashion but also in such branches as aircraft and space industries. In order to meet all requirements to 3-dimensional seamless goods for industrial use it is advantageous to employ seamless three-axial enclosure.

The architectural theory of shells and non-Euclidean geometry were taken as a basis for the development of design methods for creation of 3-axial enclosures [1]. The new woven structure differs from common two-axial by the fact that it consists of triangular cells. The woven three-axial enclosure is made of three types of basic threads: initial, right and left wefts, and also of the supplementary moulding threads (fig.1). This gives to the enclosure the determined three-dimensional form with possibility to make variable curvature and stability to the fabric structure.

Figure 1. Three-axial weaving with supplementary moulding thread

The present method of seamless textiles making removes the defects of previous well-known seamless technologies due to replacing of warp threads by right and left wefts. This allows getting the supplementary thread into the fabric structure with breakpoint so that it crosses each initial thread twice. In this case the algorithm of interlacing will be stable and the set changes of shell curvature will be provided exactly

Experimental researches showed that the anisotropy of three-axial enclosures is minimized due to the triangular unit cells. Therefore, methods of three-axial weaving is promising for the use in the manufacture of products with isotropic properties and products with preset strength properties on specific areas, which is especially important for creating of items for special technical purposes.

From the technological point of view, the process of seamless three-axial enclosures manufacturing consists of two stages: the calculation of the number of threads in the cross sections of manufacturing enclosure and the production of an item. So there is a consolidation of weaving and sewing production in one inseparable technological process and that makes it possible to reduce materials consumption and labour intensity by eliminating a number of seams and allowances and reducing of materials and labour costs in apparel manufacture.

The seamless woven three-axial enclosures are successfully used in the apparel manufacture. But now the main task is to adopt this seamless technology into production of fundamentally new and especially strong 3-d seamless forms which are needed for creation of special components in aircraft and space industries.

At present time seamless three-axial technologies have been successfully tested in the manufacture of astronaut’s space suit gloves enclosure (fig. 2). Modern orbital space suits meet all requirements for safety and ergonomics, but the development of a new type of planetary suits requires maximum reliability of the enclosure which is made of textiles, and that is difficult to achieve using traditional materials and sewing technology. Usage of three-axial seamless technology allows significantly improve the strength characteristics and, consequently, wear resistance, eliminate most of the seams and reduce the mass of a product, but most importantly it improves ergonomics. Studies have shown promise for further adaptation of seamless technology, therefore, the next step is to produce fully seamless glove together with sleeve for reinforcing space suit enclosure.

Figure 2. Seamless woven enclosure for astronaut’s space suit glove

The new century is the era of composite materials. The materials with textile base supplant metals. The composites are lighter, more durable than the metals and are not subject to weathering, i.e. composites do not rust. Now you do not see a bus or a car with the metal bumper, do not go for a walk on wooden skis and will not catch fish with bamboo rod. Composites are coming into our lives. Therefore, the strategic aim of the textile industry is not only clothes design, but also the creation of armouring textile for composite materials.

Three-axial seamless technology has a wide perspective as a basis of composites. Modern composite materials with textile basis have such disadvantage as dividing into layers, and that attributes to the use of seams for joining of layers. Usage of three-axial seamless technology in the manufacture of composite materials allows to create a material without seam but of any 3-d shape (hollow or variable in thickness) by methods of weaving, and that excludes the effect of delamination and significantly expands the scope of the composites.

The Moscow State University of Design and Technology together with the Russian National Institute of Aviation Technology have manufactured prototypes of woven seamless three-axial shell of aircraft model, which was successfully exhibited on the International Aviation and Space Salon in Moscow (fig. 3). The results of experimental production showed that the three-axial weave can be successfully used for the manufacture of carbon preforms with complex 3-d forms which are needed in the aviation industry.

Figure 3. Prototype of woven seamless three-axial shell for aircraft model

Summarizing, it is ought to be noted that the described examples of three-axial seamless enclosures usage are not the complete list of areas and opportunities for their use. At the present time we are considering the possibility of adaptation of seamless three-axial enclosures in the field of prosthetics and electronics industries. Now the industrial implementation of the three-axial seamless items is a capital-intensive but quickly repaid, it ensures high competitiveness to the textile products of new generation.

References:

1. Lavris E. V., Smirnov А.N. (2006), Design of 3-D Woven Textiles, Proceeding of the 1st International Workshop Design-Innovation-Development, Iasi, pp.(117-121).

2. Lavris E. Andreeva E. (2009), Seamless three-axial woven items, Internet journal Fibre2fasion: http://www.fibre2fashion.com/industry-article/23/2294/seamless-three-axial-woven-items1.asp.