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3-D-coordinates measuring machine Fa. Wenzel Typ LH 108 / CNC
The CNC controlled coordinate measuring machine for the measurement of ruled and free-form surfaces is used for the final measurement of mostly ceramic components as well as for measurements during production in order to detect dimensional changes between different production steps.
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Heated Vacuum Table
Thermoplastics technology at BT is based on process techniques such as vacuum consolidation, vacuum moulding and hot pressing. The main focus of research today, using these techniques, is to combine different reinforced and unreinforced thermoplastic grades into new designs.
Gas gun facility
The Institute of Structure and Design operates several gas guns for high velocity impact (HVI) experiments,. Currently various barrels with calibres between 12 and 200 mm are available, in which projectiles between approx. 1 gram and 7 kg can be accelerated. Scenarios involving impact velocities between 50 and 500 m/s depending on the projectile weight are possible.
Computed tomography (CT)
CT 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.
To support highly automated pick and drape processes of large aerospace structures, a cutting center has been installed in the ZLP. Various materials such as dry fiber or thermoplastic fabrics can be either cut sequencially or to minimize the cutting waste.
The droptower serves to investigate the crash behavior of materials, components and complete structures.
Fiber Placement Cell (FPZ)
The ZLP Augsburg view of a new, unique research facility since March 2020. The Fiber Placement Cell is used to research tape laying and fiber placement processes such as Automated Fiber Placement.
The Institute of Structures and Design (BT) operates three hot presses at its two sites in Augsburg and Stuttgart to investigate the production processes of structural components made of fibre-reinforced thermoplastics.
Digital high-speed video camera
The institute has several high-speed cameras. The usual frame rates range from 50 frames per second (fps) for quasi-static testing up to 200.000 fps in high-speed crash tests. Selected measurement signals can be recorded simultaneously by very fast transient recorders (1GHz) and displayed synchronously.
High strain rate test machine
A high strain rate test machine is available for the determination of mechanical material properties as well as for the investigation of structural components and their failure behavior. Loading of a material or a structural component can be realized up to 500,000 times faster compared to quasi-static loading in a standard test machine.
Inline quality assurance cell (IQZ)
The production of high-performance lightweight structures requires full control over material and production process. Inline-capable methods of quality assurance are increasingly in focus. The IQZ quality assurance cell enables process development, adaptation and testing to be carried out directly on an industrial robot.
Multifunctional Robot Cell
Research in the area of lightweight structures is going to be heavily influenced by automation technology. The DLR center for lightweight production technology in Augsburg addresses all steps of the production of lightweight structures. A key component is the multifunctional robot cell (MFC), which is a robot-based research platform that allows investigating different manufacturing processes of large parts for the air and space industries with respect to their potential for automation.
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.
Optical Deformation Analysis
The optical deformation analysis by digital image correlation allows non-contact measurements of strains and displacements both in 2D and 3D.
Servohydraulic testing machines
The institute has eight servohydraulic testing machines designed for high speeds, high static loads, extremely high temperatures or for determining the fatigue strength of materials.
Components, which are not fitting in our testing machines can be tested on our clamping field.
Facility Technology Evaluation Cell (TEZ)
The Technology Evaluation Cell (TEZ) consists of two Kuka Quantec KR210 R3100 robots mounted on a common eight-meter linear axis. In addition, the system has sufficient space to carry out experiments with large tools.
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.
Thermoplast Cell (TPZ)
The DLR Centre for Lightweight Production Technology in Augsburg features an integrated robotic work cell - the so-called TPZ - for the investigation of the production technologies of fiber-reinforced thermoplastic composites.
Automated Fiber Placement (AFP) facility
The Institute for Structures and Design at DLR Stuttgart features a state-of-the-art Automated Fiber Placement (AFP) facility for manufacturing fibre-reinforced thermoplastic components.
Universal testing machines (Zwick)
The institute has a mechanical precision measuring laboratory consisting of four electro-mechanical universal testing machines from Zwick©. Using a wide range of sensors, properties of various materials (metal, composite, hybrid material) can be determined according to international standards or individual tests can be carried out on components and structures.
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 6000 bar with pure water or with abrasive water jet has become a standard procedure.
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