DLR - Institute of Structures and Design

Equipment

Water Jet Cutting Facility

To the reaping of special materials, like fiber reinforced composite, ceramics, foam, hybrid layered materials from metal and non-metallic materials, the reaping with high-pressure jet of water up to 3500 bar with pure water or with abrasive water jet has become a standard procedure. With the abrasive water jet, erosive quartz sand particles are added by a special mixing nozzle which cuts then the material like a diamond wire saw.

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Heated Vacuum Table

The thermoplastic technology at the IBK is based on process engineering like the vacuum consolidation, the vacuum molding and processes in a heated press. The development of these process technologies is extensively optimized. The emphasis of the research work today is under use of these process technologies in the combination of different reinforced and homogeneous qualities of thermoplastic material into new design methods. To limit the investment cost for consolidation and shaping plants to process continuous fiber reinforced thermoplastics, the research is concentrated on vacuum consolidation with a heated table.

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Furnace Facilities

For the development of CMC materials and structural parts, various high temperature furnaces for pyrolysis, graphitization and siliconization are used. Thereby, a wide range of different facilities from small laboratory furnaces, for material research, up to large systems with 900 mm x 900 mm x 900 mm furnace room, for the manufacture of CMC prototypes in original geometry are available.

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	Computed Tomography (CT) Computed tomography is providing a deep insight into the inner structure of materials and structural parts. Beside the possibility of non-destructive evaluation, the main benefit of this method is the three-dimensional imaging which opens the way of precisely detecting and picturing internal structures and therefore material and structural defects as well.
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3-D-coordinates measuring machine Fa. Wenzel Typ LH 108 / CNC

The Institute of Structures and Design holds a CNC controlled coordinates measuring device to survey norm surfaces and freeforms. The measuring device is used in miscellaneous areas, like final surveyings of mostly ceramic components, surveyings during production in order to determine dimensional change between different manufacturing steps, and surveyings during integration in order to locate all components accurately and to determine the actual dimension of all parts.

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	Thermomechanical Test Facility INDUTHERM The test stand INDUTHERM is intended for the thermal and mechanical test of structure components such as load introductions. Heating of the test specimens takes place inductively via a suscepor tube which produces a homogeneous temperature field in its interior.
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Digital high-speed video camera

Zur detaillierten Untersuchung von Crash- und Impact-Vorgängen werden digitale Hochgeschwindigkeitskameras eingesetzt. Durch die hoch aufgelösten Bildfolgen lassen sich so die Verformungen und Zerstörungen detailliert studieren. Das Institut arbeitet mit zwei dieser Kameras Durch Kopplung mit der optischen Verformungsanalyse lassen sich auch aus hochdynamischen Vorgängen dreidimensionale Verformungsdaten gewinnen.

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	Drop Tower Das Institut betreibt einen Fallprüfstand in dem Experimente zum Crash- und Energieabsorptionsverhalten von Werkstoffen, Bauweisen, Komponenten und Strukturen untersucht werden kann. Die Bandbreite der Prüfkörper reicht von kleinen Crash-Rohren über Unterbodenstrukturen bis hin zu Rumpfsektionen von Hubschraubern.
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Gas Gun Impact Centre

Die im Jahr 2006 neu installierte Beschussanlage des Instituts besitzt drei Gaskanonen mit einem Kaliber von 32/25 mm, 60 mm und 200 mm. Damit lassen sich alle Szenarien für Hochgeschwindigkeitsaufprall (High Velocity Impact) in der Zivilluftfahrt und anderen Verkehrssystemen darstellen. Projektile dafür sind beispielsweise Stahlwürfel, Steine, Reifenteile oder Kunstvögel.

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	High-speed Test Equipment Zur Gewinnung von mechanischen Kennwerten auch bei erhöhten Belastungsgeschwindigkeiten steht eine Schnellzerreißmaschine zur Verfügung. Eine Vielzahl an Proben und Belastungsarten lassen sich dynamisch unter bis zu 100 kN Last und bis zu 20 m/s prüfen.
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	Optical Deformation Analysis Die optische Verformungsanalyse kann sowohl in quasi-statischen wie auch dynamischen Versuchen zur Bestimmung des Fließverhaltens von Materialproben eingesetzt werden. Mit dem System GOM Aramis lassen sich Fließkurven oder wahre Spannungs-Dehnungskurven bestimmen.
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Filament Winding and Tape Laying Plant

For the automated processing of rovings and prepreg tapes, a combined filament winding and tape laying machine is available in the institute. The dimensions of the work space are: Maximum diameter 1200 mm, maximum length between centers 3500 mm and the maximum weight of the mandrel is 2000 kg. The width of the working area of the tape laying component is about 1500 mm. The length of the working area is 3500 mm. A prepreg tape with a width up to 75 mm is operable. The machine is equipped with a modified Siemens control system, so that up to 13 axies can be controlled. Into the plant a IRB2000-Robot with a track length of 5 m is integrated.

Heated press

For fast shaping and consolidation of more complex parts, a modified Dieffenbacher heated press is installed in the Institute. Especially for automobile industry low cycle times with fiber reinforced thermoplastics are important. In combination with a pre heating field, cycle times can be obtained down to 95 seconds on the basis of the shaping of organic sheet. The plant is equipped with two heatable plates and reaches a temperature up to 450 °C. The closing pressure is maximum 400 kN. The working area is limited to 1250 X 1200 mm. Apart from the shaping the plant can be used also for consolidating flat plates under pressure. An integrated cooling system permits the fast temperature controlled cooling down of the plant.

Water Jet Cutting Facility

Heated Vacuum Table

Furnace Facilities

Computed Tomography (CT)

3-D-coordinates measuring machine Fa. Wenzel Typ LH 108 / CNC

Thermomechanical Test Facility INDUTHERM

Digital high-speed video camera

Drop Tower

Gas Gun Impact Centre

High-speed Test Equipment

Optical Deformation Analysis

Filament Winding and Tape Laying Plant

Heated press