Institute of Composite Structures and Adaptive Systems

Hybridisierungsansätze

für

Faserverbundbauteile

B. Wieland, M. Kleineberg

www.DLR.de • Folie 2 > Faserverbundtechnologie > Dipl.-Ing. B. Wieland

Content

What means Hybrid

Hybridization Strategies

Examples

Outlook

Summary

www.DLR.de • Folie 3 > Faserverbundtechnologie > Dipl.-Ing. B. Wieland

What means Hybrid?

Mixture of different materials with specific

properties combined during processing

What you want:

Powerful combination of all strengths

while avoiding specific weaknesses

What you might get:

Generation of even less applicable combinations

because strengths got lost and weaknesses

remained

http://whichboxmedia.com/14/eierlegende-wollmilchsau

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What means Hybrid

Hybridization Strategies

Examples

Outlook

Summary

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Hybridization Strategies

Plastics

Metal Non- metallic

materials

Fiber

Layer

Insert Particle

Foam

Material type Semi- finished material

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Hybridization Strategies – Specific Characteristics

Particles and Foams

Continuous Fiber

Composites

Non metallic particles

Metal Particles

Polymer Foam

Metallic Foam

+ Tailored matrix properties

- Viscosity, quality assurance

+ Thermal and electrical conductivity

- Filtration effects

+ Tailored performance, process aid

- Bond line, resin uptake

+ Support structure with metal properties

- Tailoring of cell structure, resin uptake

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Hybridization Strategies – Specific Characteristics

Layers and Elements

Continuous Fiber

Composites

Thermoplastic

/Elastomer

Sheet Metal

Metal

Components

+ Recycling, thermoforming

- Microstructure, creeping

+ In-Plane performance, conductivity

- Thermal compatibility, surface

preparation, corrosion

+ Combination of properties

- High Interface loads, corrosion

Active Elements + Additional functions

- compatibility

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Hybridization Strategies – Specific Characteristics

Fibers and processes

Continuous Fiber

Composites

Short and Long

Fibers

Continuous Fibers

2D/3D Fiber

Products

+ Recycling product

- Very limited performance

+ Tailored performance

- Process management, compatibility

+ Higher lay-up rates, complex surfaces

- Reduced performance, handling

High/Low Viscosity

Thermoset

+ Reduction of material and process

costs

- Additional process steps, performance

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What means Hybrid

Hybridization Strategies

Examples

Outlook

Summary

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Example: Particles and Foam

Flame protection with nanoparticles

Intention:

Aluminiumtrihydroxid Nanoparticles

(ATH) are cooling flue gases

Delay of inflammation

Slowing down of flame spread

Reduction of heat transfer 5% ATH

Nanopartikel

10% ATH

Nanopartikel

20% ATH

Nanopartikel

Structural conform integration of

sensor layers

Intention:

Design of new materials to implement

sensor layers in laminates

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Example: Particles and Foam

Radar Absorbent Material for

wind turbine blades

Intention:

Minimize the impact of wind

tubines on ATC-

Radarsystems. Integration of

particle like Carbon,

Polyaniline and Ferrite

GRE GRE

Absorbing Layer

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Example: Layers and Elements

Thermoset/Thermoplastic- Hybrid

Intention:

Combination of a thermally activated,

contamination resistant bond line with

thermally and chemically resistant

structural thermoset components

Thermoset Prepreg

PEI-Bondline

PEEK Stringer

977-2 Prepreg Skin

PEI Interface

Interphase

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Example: Layers and Elements

CFRP/Sheet Metal –Hybrid (Protection)

Intention:

Wear resistant very thin outer metal sheet

is combined with multifunctional, light

weight CFRP substructure to provide a

thermally compatible abrasion resistant

leading edge

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Example: Layers and Elements

Perforated erosion shield

Porous or perforated CFRP

substrate

Co-cured load carrying and

pressurized CFRP substructure

Perforated metallic heating layer

Defined porosity through removed

additional material

Random porosity through

specialized process parameters

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Example: Layers and Elements

Segmented LM23.3 with T-bolts

Root section of rotor blades

for wind turbines

Intention: reduction of material

at root section, improvement

of bonding line

Split rotor blades

Reduction of Blade length

because of logistic reasons.

Joint should be weight

efficient and robust.

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Example: Fibers and Processes

CFRP/GFRP/Foam-Hybrid Rotor blade

Intention:

Cost efficient design. Performance induced

material selection

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Example: Fibers and Processes

Thermoset Prepreg / Infusion - Hybrid

Intention:

Combine toughness and automated lay-up

options of prepreg products with drapability

and cost efficiency of infiltrated dry fiber

products

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What means Hybrid

Hybridization Strategies

Examples

Outlook

Summary

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Outlook

Integrated Elastomere Hinge Integrated Elastomere-Area

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Outlook

Bio Fiber /CFRP Composite for

ecological product design Integrated LED’s and Solar Cells

with embedded electrical wiring and

suitable connectors

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What means Hybrid

Hybridization Strategies

Examples

Outlook

Summary

www.DLR.de • Folie 22 > Faserverbundtechnologie > Dipl.-Ing. B. Wieland

Summary and conclusion

• The bandwidth of hybrid solutions is extremely wide

• Many composite related challenges can be addressed with hybrid

approaches.

• Hybrid solutions do require globally or even locally adapted process

• Further improve the understanding of manufacturing processes are

deeded

• Recycling of hybrid components should be included in research

activities.

www.DLR.de • Folie 23 > Faserverbundtechnologie > Dipl.-Ing. B. Wieland

Dipl.-Ing Birgit Wieland Deutsches Zentrum

für Luft- und Raumfahrt

Faserverbundtechnologie Institut für Faserverbund-

leichtbau und Adaptronik

Lilienthalplatz 7

38108 Braunschweig

Telefon 0531 295-2911

E-Mail Birgit.Wieland@dlr.de

Internet www. DLR.de/FA/