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High performance lightweight constructions for aviation and traffic

Leading edge made in hybrid design with CF-PEEK und metal

The main topic for aviation and traffic high performance lightweight constructions are affected by co-operation on interdisciplinary research with other institutes of the DLR (RK, WF, AE and FK) as well as companies of aeronautic and space industry and automobile suppliers in Baden- Württemberg, Germany and Europe. The engineering with fibre reinforced composite materials with duromere and thermoplastic matrices in the construction and computation as well as the use of suitable manufacturing routes, under consideration of cost-efficiency, economy and industrial needs, provides the supply of closed process chains. In this research field the ability can be illustrated from construction and design to finished prototypes.

The topic „High lift structures“ is arranged from the conversion of the competence in thermoplastic and duromere materials, the advancement of the processing and joining techniques and the know-how in High Velocity Impact behaviour of CFRP structures in prototypes in the full scale.

With the topic „structures for aero engines“, the development of engine structures in closed process chains, which are depending from structural needs completely present in the Institute and/or being based on developed and established interfaces to partners, can be completed by external expertise. Technologically for example the development of hybrid compressor blades out of CFRP material, is itself based on the vacuum consolidation technology for the realization of the material mating between thermoplastic and titanium for prototype production.

In the topic „Structures for transportation“ is focused on the demand for easy and cost effective structures. The experience shows however that a spin off from aviation the and requirements of the automobile industry are very different. The knowledge about modern high performance materials must be used, in order to develop car suitable structures with new plastics and fiber reinforced materials for terrestrial applications.

A somewhat broader beginning is pursued in the topic of „Thermoplastic and duromere CFRP components and hybrid structures“. In the last years the focus of CFRP technology at IBK was concentrated on the development of thermoplastic and duromere CFRP components and hybrid structures in non autoclave manufacturing methods. The thermoplastic technology at the IBK is based on process engineering like the vacuum consolidation, the vacuum moulding and the pressing with a heated press. Consequently in the area of the duromeren CFRP materials began with the development of non autoclave manufacturing methods with similar procedures as with the thermoplastics, as an alternative to prepreg methods. The VARI process offers in addition a maximum flexibility for the production of complex multi curved structures.

Today in all topics well co-ordinated co-operation with industrial partners, as well as with institutes of the DLR exist e.g. Airbus Germany GmbH and EADS Military, Rolls-Royce, MTU Aero Engines in the context of civilian and military projects of aviation.