The general objective of the BRACKETWELD project is to contribute to the green and cost-efficient integration of system and aircraft structure by the development of an innovative technology for the rapid assembly of thermoplastic brackets in general, and in particular PEI brackets, to thermosetting composite components currently used in aircraft structures. This innovative assembly technology is based on the idea of using the fast and efficient ultrasonic welding technology to assemble thermoplastic brackets to thermosetting composite structural components. As thermosetting materials cannot be welded, a thermoplastic surface media will be strongly attached to the thermosetting composite structure by a co-curing process, being this surface media used as an anchor interface for the latterly welding of the thermoplastic brackets by any fusion bonding technique, and especially by the ultrasonic welding. The key challenge for the development of this innovative technology will be the development of the appropriate surface media that must be compatible with the typical thermoplastic materials used for the injection of brackets, while at the same time achieving a high adhesion strength to the thermosetting composite laminate during the curing of the structural components. The integration of brackets into the structure of the aircraft will lead to significant weight, manufacturing costs and energy reductions compared to the current adhesive bonding methods, since is that there is no need for surface preparation, adhesives, and curing time nor expensive quality control procedures. The project is launched under the Platform 2 of the Large Passenger Aircraft IADP (LPA), “Innovative Physical Integration Cabin–System–Structure”, orientated to the development, assessment and selection of integrative concepts, which will be completed by specific technologies development to optimize assembly and integration of elementary parts, subcomponents and modules.

During the last century, the unique properties of plastics have enabled human civilization to continuously improve its living conditions. An example is the polyethylene-terephthalate (PET) that has become the primary packaging material of beverage containers. However, the short life cycle of these materials created a significant environmental problem, as they tend to end up in landfills or occasionally in the environment. In this project, the mechanical reprocessing method of colored PET is going to be combined with extrusion foaming assisted by supercritical carbon-dioxide (sc-CO2) that presents high advantages as a high dissolution in polymers (enables foamed products with very low density) and a green process since CO2 is an environmentally friendly physical foaming agent. The project is fully in line with the interests of the Researcher, Dr. Daniel Vadas. He has been studying the CO2-aided extrusion foaming technology for 7 years, firstly he successfully produced and characterised flame-retarded poly (lactic acid) (PLA) foams in 2015 and managed to secure 1st place on the Conference of Student Research Societies at both University and National level. The project proposed herein will enable him to acquire and reinforce unique research-related experiences and transferable skills in mechanical recycling of lower value post-consumer PET waste as well as in Management and entrepreneurship. The intersectoral industrial relationships of the host organization whom the candidate will closely and intensively collaborate with, would significantly improve his leadership competences. The project results will improve the recyclability of almost non-recyclable colored PET, thereby reducing the volume of plastic materials sent to landfill or incineration.