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FAUSt: material characterization of low-cost foam materials under real boundary process conditions for RTM large-scale production

Opitz, Mark and Bertling, Dominic and Liebers, Nico (2018) FAUSt: material characterization of low-cost foam materials under real boundary process conditions for RTM large-scale production. Springer Vieweg. Tagung Faszination Hybrider Leichtbau 2018, 29-30. Mai 2018, Deutschland, Wolfsburg. DOI: 10.1007/978-3-662-58206-0 ISBN 978-3-662-58205-3 ISSN 2524-4787

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Official URL: https://www.springer.com/de/book/9783662582053


The Resin Transfer Molding (RTM) process is the first choice for large-scale production of continuous fiber reinforced composite structures due to its capabilities of industrialization and automation at low price. However, the process is currently limited to monolithic structures. Low-cost and yet powerful foam materials do not seem to be compatible with the manufacturing conditions of the RTM process. Available measuring methods do not sufficiently analyze the foam behavior during processing, so that expensive preliminary manufacturing tests are necessary. The use of high-performance foam material, as known in aerospace applications, is not an alternative due to their high price. In order to enable the use of low-cost foam materials, it is important to match material and process. For this reason, a simple but highly efficient method based on ultrasonic sensors has been developed and patented by the Institute of Composite Structures and Adaptive Systems at DLR. The Foam Analysis Ultrasound System (FAUSt) enables a quantified property description of foam materials under realistic manufacturing conditions for the first time. Without contact to the sample the time-dependent deformation of foam materials depending on temperature and pressure can be determined. In addition to the material characterization itself, the measurement results benefit primarily the development of efficient, material-adapted impregnation strategies. Also process parameter identification for ideal processing and quality assurance is supported. Furthermore, the data can be used for numerical simulation methods in the early development process.

Item URL in elib:https://elib.dlr.de/128085/
Document Type:Conference or Workshop Item (Speech)
Title:FAUSt: material characterization of low-cost foam materials under real boundary process conditions for RTM large-scale production
AuthorsInstitution or Email of AuthorsAuthors ORCID iD
Opitz, MarkMark.Opitz (at) dlr.dehttps://orcid.org/0000-0001-8708-2165
Bertling, DominicDominic.Bertling (at) dlr.dehttps://orcid.org/0000-0003-1851-3333
Liebers, Niconico.liebers (at) dlr.dehttps://orcid.org/0000-0002-0124-896X
Date:30 May 2018
Refereed publication:Yes
Open Access:No
Gold Open Access:No
In ISI Web of Science:No
DOI :10.1007/978-3-662-58206-0
Page Range:pp. 221-233
Publisher:Springer Vieweg
Series Name:Technologies for economical and functional lightweight design
Keywords:foam core material, experimental material characterization, resin transfer molding, measuring system, ultrasound sensor, material-adapted process strategies
Event Title:Tagung Faszination Hybrider Leichtbau 2018
Event Location:Deutschland, Wolfsburg
Event Type:international Conference
Event Dates:29-30. Mai 2018
Organizer:ITS mobility GmbH
HGF - Research field:Aeronautics, Space and Transport
HGF - Program:Transport
HGF - Program Themes:Terrestrial Vehicles (old)
DLR - Research area:Transport
DLR - Program:V BF - Bodengebundene Fahrzeuge
DLR - Research theme (Project):V - NGC Fahrzeugstruktur (old)
Location: Braunschweig
Institutes and Institutions:Institute of Composite Structures and Adaptive Systems > Composite Technology
Deposited By: Opitz, Mark
Deposited On:25 Nov 2019 08:35
Last Modified:25 Nov 2019 08:35

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