AUTOMATED PRODUCTION AND JOINING OF HIGH PERFORMANCE STRUCTURES OUT OF CARBON FIBER REINFORCED THERMOPLASTICS

Abstract

Carbon fiber reinforced plastics (CFRPs) have been widely applied in modern wide-body aircrafts, but they are also increasingly interesting for structural parts in single-aisle aircrafts. So far CFRPs failed to get into single-aisle aircrafts on a great scale for cost reasons. To be able to compete with metal based solutions it is necessary to consider alternative production technologies for CFRPs as well as to optimize established cost intensive production processes. To address these challenges the Center for Lightweight Production Technology (ZLP) at the German Aerospace Center (DLR) in Augsburg investigates production technologies for carbon fiber reinforced thermoplastics (CFRTPs). The complete process chain, from ply book generation to assembly, is investigated regarding automation and optimization potentials. A generic skin segment has been chosen as demonstrator geometry. Several solutions like automated preforming, Out-of-Autoclave vacuum consolidation as well as automated electrical resistance welding are developed to build a competitive process chain. The process costs for each step are evaluated and the most cost intensive production steps are identified. It can be shown that automated production of CFRTP parts may also be suitable for larger structural parts. Remaining tasks are identified and outlined in order to benefit from all major advantages of thermoplastic material.