Digital Transformation: More sustainable composite structures through in-situ process qualification

Abstract

The final characteristics of composite components are generated duringproduction, which is why the production parameters have a dominating impact on the exploitable structural properties. Consequently, for today's aerospace structures, only the lowest possible performance is considered for qualification. Furthermore, this potential is reduced even more by probability factors that include unknown effects during operation and production.Digitalization offers a new way of qualification by controlling quality relevant effects throughout the individual product history. Technically this means that during production all quality related chemical and physical parameters need to be recorded and analyzed by use of suitable and informative sensor systems. The dedicated data is often referred to as the "Digital Twin".To further develop performance based qualification the Institute of Composite Structures and Adaptive Systems has set up a fully digital processing environment for open and closed mold production processes (DigiComP). Besides the digital communication infrastructure our research focuses on sensor development and integration as well as software applications for real-time data analysis and control decisions. The baseline for the digitalization approach is that hardware and software features are designed as network services withdedicated APIs (Application Programming Interfaces). This enables e.g. that a heating unit can directly communicate with a cure simulation to ensure a reproducible and precise curing process. This in turn can eliminate the major reason for geometrical scatter caused by PIDs (Process induced Deformations). Another application for interconnected production systems is tracking resin flow and manipulating process parameters to eliminate dry spots and surface defects. In line with the vision "from mold to aircraft", this service approach offers the potential to reduce subsequent QA measures and enable holistic sustainable lightweight solution.For the first time, the "DigiComP" system digitally transforms composite production for impregnation and curing in a holistic way. Real-time data analysis and control decisions are made by combining appropriate sensors with software methods in a networked environment. In line with the vision "from mold to aircraft", this service approach offers the potential to reduce subsequent QA measures and enable holistic sustainable lightweight solution.