Approach for Damage-Free Disassembly of Highly Stressed CFRP Structures

Kurzfassung

In today’s pursuit of sustainability, the aviation industry faces challenges in reusing materials and structural components made from carbon fiber-reinforced polymer (CFRP). Conventional downcycling methods degrade CFRP’s structural integrity by cutting load-bearing fibers and embedding them in new matrices, reducing performance. The authors propose a nondestructive disassembly concept using a precise wedge-based separation technique that preserves fiber integrity. This enables direct reuse of materials and components in identical or alternative applications, advancing recycling technologies and paving the way for Structural Life 2.0. Analytical and finite element analyses show the wedge separation mechanism is feasible and effective in shell structures without damaging the base material. Thinner wedges generate lower forces, depend less on panel stiffness, and require shorter crack initiation lengths, minimizing failure risk. Critical parameters should be defined during the design phase since retroactive changes are difficult. Thus, the philosophy of Design for Disassembly is proposed to integrate nondestructive separation features into new components. Building on previous analytical and numerical work, this paper extends investigations with experiments on coupon-level specimens and full-scale components using a self-developed test rig. Results confirm controlled separation of bonded elements without damaging fiber-reinforced materials. Key findings demonstrate the wedge-based process’s practical applicability, supporting advanced recycling strategies and sustainable reuse. The technique proves highly effective for nondestructive disassembly of stiffening elements and offers a promising solution for future sustainable component reuse.