Fan cowls replace aluminum honeycomb with foam core

Bombardier is using Evonik's ROHACELL foam core to fabricate composite fan cowl doors for the Rolls-Royce BR710 and the Pratt & Whitney V2500 engines.

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Evonik Industries (London, UK) reports that aircraft engine manufacturer Rolls-Royce's BR710 fan cowl door flying on Bombardier's Global Aircrafts and Gulfstream jets is now being manufactured using Evonik's ROHACELL high-performance foam core. Evonik says previously used aluminum honeycomb core was replaced with machined ROHACELL stringer profiles.

In addition, says Evonik, ROHACELL XT-HT foam core was chosen as a mandrel for the layup as it provides good dimensional stability and back-pressure during the 180°C co-cure autoclave cycle. Due to the foam’s isotropic and completely closed cell structure, the stringer profiles are able to withstand lateral pressure during curing.

Evonik also says Pratt & Whitney's V2500 fan cowl door flying on the Airbus A320 Family of aircraft is also manufactured by Bombardier using ROHACELL foam core. Resin transfer infusion (RTI), a process patented by Bombardier, is used to manufacture the new V2500 cowling doors.

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