Development of process- and system-engineering fundamentals for a quality controlled and fully automated manufacturing of RTM-Aerospace-parts by a novel and adaptable injection-unit

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A decisive problem for the high volume production of structural parts out of fibre reinforced plastics (FRP) with fibre volume contents of 50 % and more is, that the processes applied up to now are only partly automated, have a low process robustness, are not controlled and for a quality controlled qualification of the parts, time consuming post processes are necessary. Therefore, three process chains for the serial production of FRP structural parts have been developed during the investigations of the Research Group 860. In addition to an extensive understanding of the processes a comprehensive knowledge about process monitoring and the guidance of automated processes could be developed in all process chains. Based on these results the research requirements to develop a method, which enables a controlled and quality secured process, by combining different individual solutions into a holistic approach were defined. As an innovative and scientifically approach the hypothesis will be pursued, that the control and the hedging of all quality decisive process parameter could be achieved, by integrating different sensors into an injection unit. Beside thermocouples, dielectrical and pressure sensors will be integrated into the injection unit. Thus the online measuring of the conversion of the resin system, the porosity of the manufactured part and the permeability of the preform is possible. By a selected arrangement of the pressure sensors the build-up of an online rheometer is enabled. Due to integrating the sensors into the injection unit and the thereby possible build-up of an online quality assurance and process control, extensive scientific investigations are necessary. Thereby, the measured parameters have to be transferred on the part characteristics for the quality assurance and the calibration of the process control, by suitable reference measurements. The development of this method takes place on the example of FRP vertical tailplane fittings. For the qualification of these parts, according to the high testing standard of the aerospace industry, currently extensive component testing is necessary. The vertical tailplane fittings are particularly suitable for the planed research project, because the currently used manufacturing process of this part implies all steps and sub-processes which are combined into the holistic method of the injection unit.Finally an extensive verification and validation of the methodology and the belonging injection unit is necessary. Therefore, specific part values are determined with different destructive and non-destructive testing methods, which are brought into contrast with the data of the quality assurance system of the injection unit. Furthermore, the manufactured parts are compared with parts, which are manufactured with a state of the art injection system.