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OPTIMIZED VACUUM BAGGING FOR CFRP ROCKET BOOSTER CASES

Faber, Jan and Schmidt-Eisenlohr, Clemens (2018) OPTIMIZED VACUUM BAGGING FOR CFRP ROCKET BOOSTER CASES. 8th International Symposium on Composites Manufacturing for High Performance Composite Applications ISCM 2018, 21. - 22. Nov. 2018, Marknesse, Niederlande.

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Abstract

State of the art vacuum bagging for vacuum infusion technologies still involves a high amount of manual process steps. More efficient production technologies could increase the economic attractiveness of vacuum infusion processes for large aerospace structures. In the context of a research project, the German Aerospace Center (DLR), Augsburg and MT Aerospace GmbH, Augsburg have developed design methods and application concepts for vacuum bagging auxiliary materials on a full-scale CFRP rocket booster case. With a diameter of 3.4 m manual application of auxiliary materials is challenging in terms of deposition accuracy, reproducibility and reachability. Facing these challenges, first, a design method has been developed to generate near net-shape auxiliary material packages of peel ply, perforated release film and flow media with reduced wrinkling. As joining technology continuous ultrasonic welding has been selected and validated based on the suitability for vacuum infusion and out-of-autoclave curing. Manual application tests were conducted with these packages on a full-scale booster case demonstrator. The results show, that a developable shape design of the packages for the doubly curved dome sections allows best results with regards to wrinkle minimization and the complexity of the handling procedure. Second, a concept study on the application of the outer vacuum bag, consisting of membrane and vacuum foil, is presented. Therefore, an optimized shape design of a VAP membrane combined with a new application concept has been developed and validated. In a final outlook, the results will be discussed focusing on intended low manufacturing rates of about 20 boosters per year.

Item URL in elib:https://elib.dlr.de/124485/
Document Type:Conference or Workshop Item (Speech)
Title:OPTIMIZED VACUUM BAGGING FOR CFRP ROCKET BOOSTER CASES
Authors:
AuthorsInstitution or Email of AuthorsAuthors ORCID iD
Faber, Janjan.faber (at) dlr.dehttps://orcid.org/0000-0002-6810-6982
Schmidt-Eisenlohr, ClemensClemens.Schmidt-Eisenlohr (at) dlr.deUNSPECIFIED
Date:2018
Refereed publication:Yes
Open Access:Yes
Gold Open Access:No
In SCOPUS:No
In ISI Web of Science:No
Status:Published
Keywords:CFRP rocket booster case, vacuum bagging, ultrasonic welding, 3D shape design
Event Title:8th International Symposium on Composites Manufacturing for High Performance Composite Applications ISCM 2018
Event Location:Marknesse, Niederlande
Event Type:international Conference
Event Dates:21. - 22. Nov. 2018
Organizer:NLR
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
Location: Augsburg
Institutes and Institutions:Institute of Structures and Design > Automation and Production Technology
Deposited By: Faber, Jan
Deposited On:13 Dec 2018 12:06
Last Modified:31 Jul 2019 20:22

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