Centre for Composite Production Technology

Dr. Herbeck / Hr. Kleineberg / Dr. Meyer / Prof. Wiedemann

07.05.08

Center of Excellence Composite Structures

Center of Excellence Composite Structures
ACTUAL - ANALYSE
The production of the Boeing 787 and the Airbus A 350 will be path breaking for
the future application of CFRP in aviation
60%

A350 XWB
structural weight
on Strukturgewicht

50% B787

40%
proportionam

30% A400M
Faserverbundanteil

A380
20%
Composite

A340-600
10% A320 A340-300 B777

A300 A310-200
B757 B767
B747-400 MD90
MD80 B737-300
0%
1970 1975 1980 1985 1990 1995 2000 2005 2010 2015
Year of first
Jahr des flight
Erstfluges
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DLR-Verbund CFK-Produktionstechnik, 16.04.2008
SYSTEM COMPETENCE of DLR-RESEARCH
Flight Dept.
Atmospheric Aerospace Communicat.
Aero- Physics Medicine
Aerodynamics Navigation
elasticity Flight-
& Flow Techn.
Guidance

Aircraft Materials /
Systems Structures
Technical Fiber Comp.
Physics Adaptronics

Technical
Air Transport
Thermodyn. System Structures &
Design

Flight
Materials
Systems Research

Robotics &
Mechatronics Air Transport &
Combustion- Propulsion Propulsion / Airport Research
technology -technology Combustion

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DLR „Centre of Exellence, Composite Structures“
Process chain of composite production

Semi-
Materials Finished Production Processing Product
Part

Fibres Woven fabric Impregnating Demoulding Product

Resin Non Crimp Fabric Curing Trimming Properties
Sandwich Prepreg Consolidation Milling

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DLR RESEARCH: MATERIALS and STRUCTURES
Fibre reinforced plastics (Duromere, Thermoplastics,
nano-strengthened Composites, Natural Composites)
Processing technologies (autoclave and non autoclave
technologies, …)
Joining and assembly techniques
High performance constructions (e.g. fuselage, high
lifting systems, crash and impact optimised designs)
Light alloys and hybrid metal-composites
Adaptronic – Structural health monitoring
Fibre reinforced ceramics
Coating techniques (thin layers)
Non-destructive testing (supersonic, thermo graphic,
computer tomography)
Material mechanic and test methods
Numeric methods (crash, impact, deformation
characteristics)
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The DLR Centre for Composite Production Technology

ZLP
volume parts big parts

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GOALS OF ZLP

Extension and securing of aviation production in Germany

(Airbus Work-share)

Implementation of flexible, fast manufacturing technologies

Significant reducing of production costs

Shortening of development time (virtual production)

Light-weight design reduces consumption of kerosene

Low-maintenance and robust structures

Integrated systems

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Challenges of ZLP
The light-weight production technologies can be divided in three fields:

1. Manufacturing of big shell shaped structures:

The next generation of automated shell production facilities is needed
(higher throughput for complex parts, theme: CFRP fuselage).
2. Production of precise, complex components with high number of
items:
The challenge is in the automation of complex processes and in the
shortening of production cycles with an increase of quality at the same
time (theme: frames).
3. Integral manufacturing and assembly of parts to one multi
functional system:
Therefore new production friendly design concepts and new joining
concepts will be needed for multi material design.

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 ZLP

Big
ZLP
DLR
grade of concretion

Assembly Parts
-
Integration
re s
tu of systems
truc Qualification
eS
Series-Adaptation
o sit Production-
Fertigungs-
Automation
m p
E Co techniques
technologien
es
iqu
Demonstrators
Co Demonstratoren
n
Concept ch
Dimension n -te Volume
tio
Design uc
-pr
o d Parts
Material- ht
development weig
-
ht
Lig
Material-choice

grade of finished product

Joining
Assembly
Finishing

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DLR Centre for Composite Production Technology
Big Parts - Technology

• Automated processes with tapes and

Today

known mechanical properties

• Autoclave-curing
• Non-autoclave-curing
Tomorrow

• Automated vacuum-infusion-technique
• Energy optimised heating and temperature management
• Increase of material performance, incl. damage tolerance
• Automated resin preparation and spreading at infiltration

• Continuous curing methods

Future

• High structure complexity

• Integrated functions e.g. electrical conductivity
• Fibres in the material as a sensor or actuator
• Online-monitoring in secured production corridors
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 Manufacturing of big parts: e.g. fuselage shells

4 shell-concept: ? Top-shell, left and right

Side-shell as well as Bottom-shell
16m 18m 13m

• Inside-winding • Conversion of long shells with integrated, • Cost and time optimised
of barrels local strengthened cut-outs production of long,
uninterrupted shells
source: Airbus, Boeing
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Inside-winding / Inside „Automatic Fibre Placement“
of CFRP-fuselage-barrels

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„Automatic Fibre Placement“ of CFRP-fuselage-barrels
Structure / design concepts
for CFRP-fuselage in Iso-Grid
and “Lattice Structure” designs

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DLR Centre for Composite Production Technology
Volume Parts - Technology

• Automated press and vacuum

Today

consolidation processes
• One-component-resin
• Semi-continuous press processes
Tomorrow

• Tool logistics and stepped processes

• Mechatronic controlled feeding and tighten systems
• Increase of material performance comparable to Prepreg
• Application optimised preforming technologies

• Automated Dry-Fibre-Placement
Future

• Energy and residual stress optimised curing methods

• Triggerable matrices of next generation
• Integrated add-on-functions (self-healing, …)

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Challenges of the future series production (NSR):

source: CTC / Airbus

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Automated Preforming for the CFRP-frame-production

source: CTC / Airbus, IBM

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 Manufacturing of volume parts: e.g. frame segments

• Automated production of high precise parts with final dimensions and a high grade of integration

• Minimising of production cycle time (production rate > 100,000 parts per year)

• Process immanent quality control for reduction of inspection effort

source: Airbus, NLR

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Production of the BMW M3 CSL CFRP-roof

Quelle: BMW
clock cycle approx. 30 minutes

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DLR Centre for Composite Production Technology
Assembly and Joining technique - Technology
• Black Metal Design
Today

• Bolt-connections
• Prepreg-technology
Tomorrow

• Hybrid-connections
• Integral Structures out of CF-Thermoplastics
• Automated assembly and joining
• Production-friendly CFRP-designs
Future

• Induction and laser-based temperature guiding

• Welding of duromere / thermoplastics
• Sensor and picture giving QM at bonding processes
• Multi functional structures

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Assembly: e.g. fuselage-shell-assembly

• Measuring / adaptation of joining areas / intelligent, visual referencing in 3D room

• Intelligent concepts for joining of individual shells to one barrel

• Intelligent concepts for joining of barrels to one fuselage

Quelle: Airbus, Boeing

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DLR Centre for Composite Production Technology
Main features
The ZLP offers an international portfolio of skills and technological
possibilities for developments, fed by the competences by the
DLR-institutes
The ZLP shall be understood as a central institution of the DLR to promote
the CFRP production technology Germany-wide with a minimum of
redundancy between research and investments
The ZLP is a institution applied in perpetuity with defined research plans
and projects
The location is based upon industrial and political boundary conditions
Redundancy-free outposts of the centre are possible

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DLR ZLP locations partners and customers

Stade
Bremen
Braunschweig

Augsburg
Stuttgart
München

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DLR ZLP structure and integration into DLR

Lead consultant Industry-

DLR-Centre for
curatorship
Composite Production Technology

Oberpfaffenhof. 10 MA
Project big parts

Bremen, 10 MA
Braunschweig

Nordenham
Project volume parts

Augsburg

Stuttgart
57 MA

41 MA

39 MA

22 MA
Stade

Varel
Project assembly

Project materials

Project cross-sections

Institute for Composite Institute of Structures Institute of Robotics

Structures and and Design and Mechatronics
Adaptive Systems

Prof. Dr. Wiedemann Prof. Dr. Voggenreiter Prof. Dr. Hirzinger

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