The new building complex of the DLR Center for Lightweight-Production-Technology (ZLP) at the site in Augsburg was opened in May 2013. The laboratory hall in the left-hand part of the building resembles an aircraft hangar.
DLR (CC-BY 3.0).
Artist impression of Augsburg Innovation Park from an aerial perspective. The current location of the DLR Institute of Test and Simulation for Gas Turbines within the Technology Centre Augsburg and the prospective building plot for the future institute are marked in red.
Augsburg Innovation Park/Kees Christiaanse.
In future, aircraft should be quieter, more fuel efficient and produce fewer emissions. Materials, technologies and components for aerospace applications must be able to withstand maximum loads. To this end, the German Aerospace Center (Deutsches Zentrum für Luft- und Raumfahrt; DLR) in Augsburg conducts research in various disciplines across various institutes and sites. The facility was opened in May 2011, has approximately 50 employees and is located in the research triangle formed by the University of Augsburg, Technology Centre Augsburg and Augsburg Innovations Park. It houses the DLR Center for Lightweight-Production-Technology (ZLP), with its over 30-metre-long large-scale research facility. The ZLP was founded in 2009 and its work focuses on production technology and the development of optimum manufacturing methods for lightweight components for the aerospace industry. Since July 2017, another research facility has also been under construction in Augsburg: the DLR Institute of Test and Simulation for Gas Turbines will expand the site with additional large-scale facilities and the expertise of up to 45 staff members. This new Institute researches and develops engine technologies for aircraft turbines of the future. Until the building work is completed in 2021, the Institute will be based at the Technology Centre Augsburg, which is immediately adjacent to the ZLP.
DLR Center for Lightweight-Production-Technology (ZLP)
Carbon fibre and carbon-fibre reinforced plastic (CFRP) are used as materials for, among other things, the production of the next generation of commercial aircraft – lighter, more fuel efficient and more environmentally friendly. The demand for lightweight CFRP structures has therefore grown sharply. This requires economical production methods that meet the specific needs of the aerospace industry. The objective of the DLR Center for Lightweight-Production-Technology (ZLP) is to develop a fully automated production process, because the use of flexible, interactive robotic systems lowers production costs while increasing productivity and manufacturing quality.
The ZLP is a national DLR research facility that comprises the site in Augsburg and another site in Stade, Lower Saxony. At the ZLP, the DLR Institute of Structures and Design in Stuttgart collaborates with the DLR Institute of Composite Structures and Adaptive Systems in Braunschweig and the DLR Robotics and Mechatronics Center in Oberpfaffenhofen. ZLP Augsburg therefore completes process chain for the development and production of carbon-fibre reinforced plastic (CFRP) components at DLR.
DLR Institute of Test and Simulation for Gas Turbines
New engine technologies play a key role in achieving European aviation objectives. For this reason, the DLR Institute of Test and Simulation for Gas Turbines is working on technical solutions to reduce fuel consumption, exhaust emissions and noise. The challenges are high rotational speeds, high temperatures, high pressure ratios and the correspondingly complex load scenarios of the engine components, in conjunction with demanding lifetime requirements. The new DLR Institute of Test and Simulation for Gas Turbines in Augsburg focuses on the aircraft engines of the future. Together with other DLR institutes, the researchers are developing a digital platform – the 'virtual engine'. In addition to all the engine components, the digital engine also includes all the physical aspects and their interactions. An additional undertaking is the development and construction of sophisticated test rigs.
The digital models of new compressor and turbine solutions will be tested to scale in Augsburg in future. In addition to their numerical simulation, the real models will also be examined on a unique test rig in which turbine components will be exposed to mechanical and thermal loads for the first time, as well as to aggressive combustion gases. Scientists can then calculate and test whether new construction methods, materials or manufacturing processes satisfy the demanding durability requirements.
The DLR Institute of Test and Simulation for Gas Turbines is currently housed in the Technology Centre Augsburg. Offices, laboratories and technical facilities have been rented in order to be able to fully perform work on the virtual engine and conduct numerical research. The first test rigs will also be developed and set up there. A separate building for the Institute is due to be completed in 2021, which will allow the construction of additional very large and highly complex test rigs.
Last modified:30/11/2017 15:22:14