Repair instead of dispose
Inspection-, repair- and testing methods for damaged carbon fibre reinforced components
This example is translated from the Success Story leaflet ZIM-KOOP 107
The project idea
Carbon fibre reinforced plastics (CRP) make their way into several branches and areas of applications during the last years due to outstanding mechanical material features. With suitable fibre strengthening CRP can as well gain the stiffness and solidity of steal. Due to variable possibilities of shaping the material can be used in a wide spectrum of lightweight constructions at state of the art mentioning the realisation of resistance in fatigue, abrasion and corrosion. Nowadays these features make CRP very successful in the application of aerospace, automotive and high-performance sports. For example the tail plane units assembled at Airbus account for the biggest structural component made of CRP in commercial aircrafts worldwide. Resulting from the extreme mechanical load these components can as well show severe damage in material structure which could not be fixed properly up to today. Current approaches in a case of damage show repairing techniques on an experimental level which do not present the requirements of a stable process of reproducible quality and high component stability. Suitable technical equipment for an exact analysis of the damage as well as mechanical inspection procedures for repaired CRP components were not existing so far. Damaged parts used to be disposed relatively often.
Cooperation partners out of small / medium sized enterprises and research institutes counting two from Austria and seven from Germany are committed in a joint EraSME project to develop an innovative technical service for this specific area of application.
The product and its innovation
Result of this European research cooperation is an integrated system of repairing damaged CRP components with a new method inspection-, repairing- and testing. It is applicable in small and medium sized enterprises and enables the non-destructive examination and reparation in a wide spectrum of CRP assemblies.
As single components the following results can be offered
- Analysis methods to detect damages
- Comprehensive basis of data for the analysis of typical damage cases in various CRP branches with regard to specific damage characteristics and the frequency of the particular type of damage
- Classification model of different damages
- Method based techniques for repairing CRP components
- Mechanical screening procedure for fixed components
- Analysis of expenditure
Market and customers
The cooperating companies are already using the results of the project in order to repair CRP components. Thereby the newly developed repairing systemat can be used for functional component features as well as for restored load bearing and safety relevant structural components. The Fraunhofer project group “Process Innovation” plans on implementing the results in maintenance seminaries, in order to offer the innovative technology to a wide circle of SMEs.
The cooperation partners
Universität Bayreuth, Fakultät für Ingenieurwissenschaften, Lehrstuhl für Umweltgerechte Produktionstechnik, 95447 Bayreuth
AX Lightness GmbH, 95473 Creußen
velotech.de GmbH, 97424 Schweinfurt
CG TEC Carbon und Glasfasertechnik GmbH, 91174 Spalt
XtremeAir GmbH, 39444 Hecklingen
Fraunhofer Gesellschaft e.V., Institut für Produktionstechnik und Automatisierung IPA, Projektgruppe Prozessinnovation, 95447 Bayreuth
FIBER - TECH Construction GmbH, 09116 Chemnitz
FH OÖ Forschung & Entwicklung GmbH, A-4600 Wels
Peak Technology GmbH, A-4020 Linz
AiF Projekt GmbH
Telefon +49 30 48163-3