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Automated Production of an CFRP-Aircraft Side Shell using AFP and Inductive Co-bonding Technology

Stüve, Jan and Krombholz, Christian and Ucan, Hakan and Kruse, Felix and Kühn, Michael and Torstrick, Sven (2016) Automated Production of an CFRP-Aircraft Side Shell using AFP and Inductive Co-bonding Technology. AirTec 2016, 2016-10-25 - 2016-10-27, München.

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The paper will deal with the work of German Aerospace Center (DLR) within the EU FP 7 project 'Maaximus'. The major aim of the project is to develop highly integrated and precise design methods for aeronautical structures made of Carbon Fiber Reinforced Plastics (CFRP), which allows validating computations with smaller testing samples. With the state of the art design methods, a full scale fuselage barrel is needed for validation. With the new design methods, only a smaller part structure like a side shell is necessary. Thus, the time and costs for testing of physical demonstrators and therefore the overall development-time for a new aircraft is dramatically reduced. A team of researchers at the Center for Lightweight Production Technology (ZLP), Stade, Germany, was responsible for the task 7.6 Production of the full scale demonstrator. For the validator structure an Airbus A 350 like side shell with a pax door was chosen. The project tasks of DLR during manufacturing of the demonstrator will be presented. These include the process steps automated skin layup, manufacturing of all stringers, co-bonding of cured stringers with wet skin and automated production of near net-shaped preforms of the C73-frames. Focus will be put on the quality monitoring system during the production of the side shell skin using Automated Fiber Placement technology (AFP). Methods for the detection and the adjustment of layup-defects like tow-gaps will be discussed. Another focus will be put on the innovative co-bonding technology using inductive heating. The dependencies between process parameters and the properties of the co-bond will be discussed. The paper will close with a presentation of the relevant steps for the fully automated textile preforming process of the z-type C73-frames. An outlook will be given about the potential of the presented technologies for an economic production of aeronautical structures made of CFRP and the challenges which still are to overcome.

Item URL in elib:https://elib.dlr.de/107780/
Document Type:Conference or Workshop Item (Speech)
Title:Automated Production of an CFRP-Aircraft Side Shell using AFP and Inductive Co-bonding Technology
AuthorsInstitution or Email of AuthorsAuthor's ORCID iDORCID Put Code
Krombholz, ChristianUNSPECIFIEDhttps://orcid.org/0000-0002-1802-4110UNSPECIFIED
Ucan, HakanUNSPECIFIEDhttps://orcid.org/0000-0002-5568-4564UNSPECIFIED
Torstrick, SvenUNSPECIFIEDhttps://orcid.org/0000-0002-0865-9964UNSPECIFIED
Date:25 October 2016
Refereed publication:Yes
Open Access:Yes
Gold Open Access:No
In ISI Web of Science:No
Keywords:Design; Structures; CFRP; Preforming
Event Title:AirTec 2016
Event Location:München
Event Type:international Conference
Event Start Date:25 October 2016
Event End Date:27 October 2016
HGF - Research field:Aeronautics, Space and Transport
HGF - Program:Aeronautics
HGF - Program Themes:fixed-wing aircraft
DLR - Research area:Aeronautics
DLR - Program:L AR - Aircraft Research
DLR - Research theme (Project):L - Structures and Materials (old)
Location: Stade
Institutes and Institutions:Institute of Composite Structures and Adaptive Systems > Verbundprozesstechnologie
Deposited By: Kobelt, Doris Andrea
Deposited On:20 Dec 2016 09:46
Last Modified:24 Apr 2024 20:12

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