Cast-to-size aluminium bronze tooling for fabrication of advanced fibrous composite aircraft components

Cast–to–size aluminium bronze tooling has recently been developed for the manufacture of tooling used in the shaping and curing of advanced fibrous composites. The technology is examined critically from the standpoint of meeting the present needs of the industry, as well as future needs arising from the integration of newly developed fibre–resin systems and advanced processing technologies into aircraft design and production. Currently used tooling systems are reviewed and compared with the cast–to–size aluminium bronze tooling in six important categories: cost, lead time, durability, temperature resistance, expansion characteristics and dimensional tolerances. Ratings are assessed for each system for specifically defined applications. Examples of the use of cast–to–size aluminium bronze tooling by the US aerospace industry for the manufacture of advanced fibrous composite parts are described.