Mechanical behaviour of highly loaded fibre composite structures

IMWS Röntgen-CT Durchstrahlung zerstörungsfrei
© Fraunhofer IMWS
Test set-up for CT in-situ pressure testing, cylindrical test device made of CFRP material for optimum radiation penetration.
Lebensdauer Qualität Test
© Fraunhofer IMWS
Examination of a component made of fibre composite plastic in an X-ray computer tomograph.
© Fraunhofer IMWS
FRP structure on the multiaxial test field.

Fibre composites with a plastic matrix are characterised by high weight-specific stiffnesses and strengths. This predestines them for use in structurally highly stressed components in a wide variety of application areas, such as aircraft construction, automotive engineering, rail vehicle construction, boat building, mechanical and plant engineering, sports equipment construction, medical technology, etc.

Through targeted fibre alignment in the component, load-path-compatible lightweight constructions can be realised, which make a substantial contribution to resource-efficient material use and the minimisation of moving masses. Their material and structural behaviour is essentially determined by the internal structure of the fibre arrangement, the interface between fibre and matrix and the influence of process-related effects.

In the working group “Evaluation of Fibre Composite Systems”, the focus is on investigating the use of polymer-based fibre composites in highly loaded lightweight structures and components. We apply experimental and numerical methods to characterise the mechanical behaviour under both application- and process-related loads and adapt these to the special requirements of fibre composites.

One focus of the work is the evaluation of manufacturing defects and damage (e.g. delamination) using fracture mechanics methods. For morphological characterisation, non-destructive testing methods and microstructure diagnostics are used, among others.

Services

fraunhofer Spritzguss Bauteil
© Fraunhofer IMWS
Simulation of the filling process of an injection moulding component
  • Design and optimisation of highly loaded fibre composite structures and components by numerical simulation
  • Determination of mechanical and physical material properties of fibre composites and sandwich core materials
  • Development and execution of structural and component tests (e.g. sandwich shells)
  • Non-destructive material and component testing
  • Evaluation of damage tolerance of fibre composite materials and structures with fracture mechanics methods (e.g. for lifetime prediction of damaged structures)
  • Mesostructure and mechanism-based simulation methods for the analysis of structure-property correlations (e.g. RVE modelling)
  • Analysis of service life and ageing behaviour (e.g. under environmental influences)

Methods for the evaluation of composite systems

 

Air-Coupled Ultrasonic Testing

 

Mechanical testing

 

X-ray computer tomography (CT)

 

Evaluation of UD tapes and laminates for lightweight construction applications

Projects

 

20.4.2024

Lightweight construction, efficient and fit for series production thanks to sandwich structures with thermoplastic materials

 The flap, made from thermoplastic sandwich semi-finished products, demonstrates the enormous potential for saving weight with thermoplastic sandwich molding technology.

 

Innovative structural components with adapted electronics for e-vehicles

Together with partners, the Fraunhofer IMWS is researching the production of innovative lightweight vehicle structures with integrated electronic components for e-cars in the interdisciplinary project "InThElekt".

 

Investigation of the lightweight construction potential of hierarchically structured sandwich materials

The aim of the "HPHex" project was to investigate the lightweight construction potential of new hierarchically structured sandwich materials that can be produced cost-effectively in highly automated manufacturing processes.

 

Automated material data acquisition in polymer processing

As part of the research project "SmartSensor 4.0", an intelligent sensor system was developed. The sensor system serves as a data source for the complete description of a production chain, also known as a digital twin.

 

Damage-tolerant CFRP foam sandwich structures for aircraft construction

The SANDWICH² project, as part of the LuFo V aeronautics research programme, focuses on investigating and optimising the damage tolerance of such foam sandwich structures. The Fraunhofer IMWS is part of the research consortium and responsible for this research.