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Door surrounding structure of an aircraft fuselage with integrated SHM network

Integrated structural health monitoring (SHM) with Lamb waves is a promising technique for continuously checking fibre composite structures for damage during operation. Reliable detection and localisation of damage poses a particular challenge, especially in complex aerospace structures. For this reason, a door surrounding structure with an integrated SHM network is being developed and manufactured in order to verify the capabilities of an SHM system in real, complex aviation structures.

MASCOT asteroid lander

To explain the "missing link" in the formation of the solar system up to the development of life on Earth, asteroid missions are of great importance. In this context, MASCOT, a landing unit about the size of a shoebox and weighing 10kg, was developed at DLR in collaboration with the Japanese (JAXA) and French (CNES) space agencies. On 3 December 2014, it was launched on board JAXA's Hayabusa-2 probe to the C-class asteroid 1999 JU3. Once there, MASCOT will support the Japanese mother ship in selecting its landing site (for soil sampling). In order to cope with the very high mechanical loads during launch and the inclined installation position on the mother ship, MASCOT is divided into an external mechanical support structure and the landing module itself. The latter is a very rigid and high-strength truss structure in sandwich construction. The two extremely compact lightweight structures, developed and built at the DLR Institute of Lightweight Structures, together weigh just 1.4 kg.

Automated fibre composite production with consolidated CFRP tapes

In fibre composite production, automation is one of the decisive factors for the efficient use of fibre-reinforced semi-finished products. Established processes such as tape laying (ATL) and fibre placement (AFP) have shown that automated production of high-quality large structures is feasible. However, errors during deposition, complex material handling and cost-intensive post-treatment are critical issues that are the focus of current research endeavours. A new approach to counteracting these problems is to change the process chain for the automation process. Cured, unidirectional carbon fibre tapes are to be processed in conjunction with early consolidation.

M³F leading edge for the laminar wing

Driven by economic goals and the increased social awareness of ecological factors, laminar wing technology is increasingly becoming the focus of commercial aircraft development. The low-drag airflow around the wing enables fuel savings and thus leads to a reduction in CO2 emissions and lower operating costs. However, in addition to the requirements that also apply to a conventional aerofoil, a laminar aerofoil must fulfil high demands on its surface quality. Even the smallest gaps, steps, waviness or protruding rivet heads lead to a change from a laminar to a turbulent boundary layer. In addition to an already developed wing shell, a wing leading edge has now been developed that meets these requirements with a multi-material, multi-functional structure (m3f).

De-icing test rig

Icing of aerodynamic surfaces leads to significant losses in performance. Anti-icing systems are designed to counteract this. At the Institute for Lightweight Systems Engineering, new concepts are being developed based on a wide variety of effects. To prepare them for practical use, they are further developed on a test rig capable of simulating relevant icing conditions.