Production of a stringer-stiffened skin segment as intermediate demonstrator

Abstract

After optimizing the parameters on coupon level, resulting in high joint strength the transfer to the element level has now been successfully demonstrated. It was found that the processing parameters could be transferred with minor adjustments that were required to address the rougher and wavier surface of the fiber place laminates as compared to the press-molded pre-consolidated organo sheets that were used for coupon testing. In addition, an edge-detection system for automated stringer guidance to increase the process reliability of the welding was validated during element production. Prior to the welding process all parts, i.e. laminates and stringers were 3D measured to assess the as-delivered quality. These measurements thus allowed to correlate weld process performance to the input part quality. Within this report the welding setup, the test execution and its results are described.