Evaluation and Development of a Continuous Longitudinal Joining Process for Carbon-Reinforced High-Performance Composites in Aircraft Primary Structure (Masterarbeit)

Abstract

Although (carbon) composites seem to be arrived in aircraft structures, the full lightweight potential is not reached and state of the art processes are usually not fibre-fair. In addition, most frequently used are thermoset matrices which require energy demanding material cooling and curing, high added-value processing materials and labour-intensive process steps. This work presents the state of the art aircraft manufacturing with spotlights on the main challenges and potentials for thermoplastic resin systems. An overview and evaluation of fusion bonding approaches is given leading to ultrasonic welding as process of choice. Theoretical considerations on heating mechanisms lay the foundation for subsequent parametric study of statically ultrasonically welded CF/PEEK specimen. Observations and results are discussed and transferred to an continuous welding concept for robotic application. Therefore, this work does not only provide a technological overview and experimental data on - so far rather neglected - ultrasonic welding of CF/PEEK composites, but also suggestions and first steps towards the aircraft manufacturing of the future.