Effects, Detection and Prediction of Defects in Hybrid Composite Parts for Metal/CFRP-Lightweight Structural Structures Suitable to Large-Volume-Production

适用于大批量生产的金属/CFRP-轻质结构结构混合复合材料零件缺陷的影响、检测和预测

• 批准号: 255886929
• 负责人: Professor Dr.-Ing. Hans-Georg Herrmann
• 金额: --
• 依托单位: Institut für Produktionstechnik (WBK)
• 依托单位国家: 德国
• 项目类别: Priority Programmes
• 财政年份: 2014
• 资助国家: 德国
• 起止时间: 2013-12-31 至 2020-12-31
• 项目状态: 已结题
• 来源: https://gepris.dfg.de/gepris/projekt/255886929?language=en
• 关键词: Effects; Detection; Prediction; Defects; Hybrid

The research on innovative joining elements offers the potential to increase the field of applications in the use of carbon fibre reinforced plastics (CFRP). In order to reach this goal it is necessary to evaluate their functional capability under scientific aspects. These aspects concern the design and dimensioning but also the production of parts. In the Priority Programme 1712 it could already be shown that quality critical defects need to be detected during the production process itself because they significantly contribute to a decreased functionality of the joint connection between CFRP and inserted components (Inserts). This finding was made during a so called Effects of Defects analysis, where both part and material specific defects were purposely inserted into two-dimensional and curved joints. Mechanical testing methods have shown the influences of individual defects on load bearing capacity and other part properties leading to the identification of critical defect types. By applying methods of non-destructive testing simultaneously to the mechanical testing typical failure behaviour could be directly linked to the defect types, leading to the necessity of their detection in the Resin Transfer Moulding process chain by in-line measurement systems. The goal of the project is based on the results of the described preliminary project. Therefore it is necessary to create a basic method for the development of three-dimensional hybrid joints and to determine the dimensions of potential critical defects that are weakening the bond. The findings are used in a three-staged control loop approach that is associated with the design, non-destructive testing as well as the production of hybrid parts. In the field of design, innovative methods of part construction are developed and applied in order to influence the damage propagation inside the joint due to quality critical defects. By manufacturing parts with purposely inserted defects of varying dimensions and locations the application of innovative methods such as the inductive thermography allows the analysis of different damage cases. In addition to the results of the preliminary project phase, this approach not only allows the identification of critical defects but also the determination of critical defect sizes and their positions that need to be detected in production. In order to do so, methods of process integration are investigated for the integration of thermography and ultrasonic testing in the production process for the quality control of manufactured parts. For the simultaneous application of different measurement principles a data fusion approach need to be investigated in order to enable a combined analysis of thermal, acoustic as well as optical data resulting from the preliminary project. Furthermore the findings of the damage analysis are returned to the field of design in order to increase the insensitivity of the hybrid joint towards critical defects and their characteristics.

对创新连接元件的研究提供了增加碳纤维增强塑料（CFRP）应用领域的潜力。为了实现这一目标，有必要从科学的角度对他们的功能能力进行评估。这些方面不仅涉及设计和尺寸标注，还涉及零件的生产。 在优先计划1712中，已经表明需要在生产过程本身中检测质量关键缺陷，因为它们显著降低了CFRP和插入部件之间的接头连接的功能性。这一发现是在所谓的缺陷效应分析中得出的，其中部件和材料特定缺陷都被故意插入到二维和弯曲接头中。机械测试方法已经显示了单个缺陷对承载能力和其他部件性能的影响，从而识别出关键缺陷类型。通过将无损检测方法与机械测试同时应用，典型的失效行为可以直接与缺陷类型联系起来，从而有必要在树脂传递模塑工艺链中通过在线测量系统进行检测。该项目的目标是基于所述初步项目的结果。因此，有必要建立一个基本的方法，三维混合接头的发展，并确定潜在的关键缺陷，削弱债券的尺寸。研究结果被用于一个三阶段的控制回路的方法，是与设计，无损检测以及混合动力部件的生产。在设计领域，开发并应用了零件构造的创新方法，以影响由于质量关键缺陷导致的接头内部的损伤传播。通过制造具有不同尺寸和位置的故意插入缺陷的零件，应用感应热成像等创新方法可以分析不同的损坏情况。除了初步项目阶段的结果外，这种方法不仅可以识别关键缺陷，还可以确定生产中需要检测的关键缺陷尺寸及其位置。为了做到这一点，过程集成的方法进行了研究，在生产过程中的热成像和超声波检测的质量控制的制造零件的集成。为了同时应用不同的测量原理，需要研究数据融合方法，以便能够对初步项目产生的热、声和光数据进行综合分析。 此外，损伤分析的结果返回到设计领域，以增加对关键缺陷及其特性的混合节点的不敏感性。