Post on 05-Aug-2019
Chair of Carbon CompositesTUM Department of Mechanical EngineeringTechnical University of Munich
Manufacturing of a Thermoplastic CFRP Rocket Module
with Integrated Fiber Optical Temperature Sensors
Ralf Engelhardt, Jonathan Oelhafen, Stefan Ehard,
Andreas Kollmannsberger, Klaus Drechsler
29th SICOMP Conference on Manufacturing and Design
of Composites
Luleå, Sweden, 28 May 2018
Chair of Carbon CompositesTUM Department of Mechanical EngineeringTechnical University of Munich
Conclusion & Outlook4
Approach3
Concept2
Introduction1
Agenda
2Ralf Engelhardt | 29th SICOMP Conference | Luleå, Sweden | 28 May 2018
Chair of Carbon CompositesTUM Department of Mechanical EngineeringTechnical University of Munich
Conclusion & Outlook4
Approach3
Concept2
Introduction1
Agenda
3Ralf Engelhardt | 29th SICOMP Conference | Luleå, Sweden | 28 May 2018
Chair of Carbon CompositesTUM Department of Mechanical EngineeringTechnical University of Munich
REXUS program
Rocket EXperiments for University Students
Funding by DLR, SNSB, ESA
REXUS sounding rockets
2 launches per year
Maximum altitude: 80-100 km
Max. acceleration: ~20g
Max. vertical speed: ~1200 m/s
Modular structure
Aluminum
Ø=356mm
l=300mm
Introduction
Ralf Engelhardt | 29th SICOMP Conference | Luleå, Sweden | 28 May 2018
www.rexusbexus.net
4
Fig. 1: REXUS rocket and its components [1]
Fig. 2: REXUS trajectory [1]
Chair of Carbon CompositesTUM Department of Mechanical EngineeringTechnical University of Munich
CFRP module
Weight reduction
Efficient manufacturing approach
Manufacturing, testing, flight
Sounding rocket experiment
Structure internal temperature measurement
Integration of fiber optic sensors (FOS)
Set-up of a measurement system
for rocket applications
Project Goal
Ralf Engelhardt | 29th SICOMP Conference | Luleå, Sweden | 28 May 2018 5
Fig. 1: TUM-LCC CFRP rocket module as part of REXUS 23
Fig. 2: DLR SHEFEX heat input during re-entry [2]
Chair of Carbon CompositesTUM Department of Mechanical EngineeringTechnical University of Munich
Conclusion & Outlook4
Approach3
Concept2
Introduction1
Agenda
6Ralf Engelhardt | 29th SICOMP Conference | Luleå, Sweden | 28 May 2018
Chair of Carbon CompositesTUM Department of Mechanical EngineeringTechnical University of Munich
Concept – Overview
Ralf Engelhardt | 29th SICOMP Conference | Luleå, Sweden | 28 May 2018
RADAX rings
Shell
Adhesive
Cork[5]
7
Chair of Carbon CompositesTUM Department of Mechanical EngineeringTechnical University of Munich
Concept – Manufacturing Approach
Ralf Engelhardt | 29th SICOMP Conference | Luleå, Sweden | 28 May 2018 8
Long fiber reinforced thermoplastic (LFT) press-forming
Victrex 450CA30 30% CF reinforced PEEK
Fig. 1: RUCKS thermo-forming unit at TUM
Press-forming of RADAX-rings
Chair of Carbon CompositesTUM Department of Mechanical EngineeringTechnical University of Munich
Concept – Manufacturing Approach
Ralf Engelhardt | 29th SICOMP Conference | Luleå, Sweden | 28 May 2018
Press-forming of RADAX-rings Demolding and preparation Joining and sensor integration during
TP-AFP lay-up
9
Thermoplastic Automated Fiber Placement (TP-AFP)
TOHO TENAX UD, HTS45, 34 wt% PEEK matrix
AFPT GmbH TP-AFP equipment
Fig. 1: AFPT TP-AFP equipment at TUM
Chair of Carbon CompositesTUM Department of Mechanical EngineeringTechnical University of Munich
Concept – Manufacturing Approach
Ralf Engelhardt | 29th SICOMP Conference | Luleå, Sweden | 28 May 2018
Press-forming of RADAX-rings Demolding and preparation Joining and sensor integration during
TP-AFP lay-up
Demolding and finishing NDI and hardware installation
10
Chair of Carbon CompositesTUM Department of Mechanical EngineeringTechnical University of Munich
Conclusion & Outlook4
Approach3
Concept2
Introduction1
Agenda
11Ralf Engelhardt | 29th SICOMP Conference | Luleå, Sweden | 28 May 2018
Chair of Carbon CompositesTUM Department of Mechanical EngineeringTechnical University of Munich
Approach
12Ralf Engelhardt | 29th SICOMP Conference | Luleå, Sweden | 28 May 2018
Coupon
Simulation
Sub-component
Launch
Material characterization on coupon level
Manufacturing
Full-scale
Sub-component testing
Simulation & design
Manufacturing
Full-scale testing
Chair of Carbon CompositesTUM Department of Mechanical EngineeringTechnical University of Munich
Approach – Testing
13Ralf Engelhardt | 29th SICOMP Conference | Luleå, Sweden | 28 May 2018
Full-scale level
Sub-component level
Coupon level
[7, 8]
[4, 5, 6]
Chair of Carbon CompositesTUM Department of Mechanical EngineeringTechnical University of Munich
Boundary conditions
Similar stiffness as aluminum modules
Max. bending moment 14 kNm
Manufacturing restrictions
FEM analysis via ABAQUS
Set-up with 2x200mm aluminum modules
Results [11]
AFP lay-up: 34 layers, symmetric, 0°, ±15°, ±45°, 90°
[0°,15°,-15°,0°,15°,-15°,0°,15°,-15°,0°,15°,-15°,0°,45°,-45°,0°,90°]s
Prediction of failure at interface TP-AFP/LFT
>40% weight reduction
Approach – Simulation and Design
14Ralf Engelhardt | 29th SICOMP Conference | Luleå, Sweden | 28 May 2018
Fig. 1: FEM set-up (left) and symmetric lay-up (right) [11]
Fig. 2: Strength analysis for TP-AFP laminate (left)
and RADAX load input rings (right) [11]
Chair of Carbon CompositesTUM Department of Mechanical EngineeringTechnical University of Munich
Tool concept
Ring shaped cavity
Excess in all directions
No vacuum
Manufacturing parameters
Heat up to 390°C with 10 K/min
Compaction with 50, 100, 150,
200 kN for 3 min each
Cooling <Tg with 5 K/min
Demolding at 100°C
Manufacturing – LFT Press-Forming
15Ralf Engelhardt | 29th SICOMP Conference | Luleå, Sweden | 28 May 2018
t [min]t [min]
F [kN
]
T [°C
]
Fig. 1: LFT press-forming tool design Fig. 2: Manufactured ring after demolding
Fig. 3: Compaction force over time Fig. 4: Temperature over time
Chair of Carbon CompositesTUM Department of Mechanical EngineeringTechnical University of Munich
Manufacturing – TP-AFP
16Ralf Engelhardt | 29th SICOMP Conference | Luleå, Sweden | 28 May 2018
Fig. 2: TP-AFP manufacturing tool incl. RADAX rings and FOS cavityFig. 1: TP-AFP tool concept
Chair of Carbon CompositesTUM Department of Mechanical EngineeringTechnical University of Munich
Manufacturing – TP-AFP
17Ralf Engelhardt | 29th SICOMP Conference | Luleå, Sweden | 28 May 2018
Fig. 2: TP-AFP lay-upFig. 1: TP-AFP tool concept
Chair of Carbon CompositesTUM Department of Mechanical EngineeringTechnical University of Munich
Qualification test specifications
RT and 135°C
Sinusoidal resonance search
Random Qualification Test:
Frequency range & level: 20-20.000 Hz, 0.081 g2/Hz
Sweep rate: 12.7gRMS
Results
EF shift of <10% after all tests
Similar behavior for room temperature and high temperature test
Full-Scale Testing – Vibration Test
18Ralf Engelhardt | 29th SICOMP Conference | Luleå, Sweden | 28 May 2018
Dummy-
load
CFRP
module incl.
heating
blanket
Fig. 1: Vibration test set-up at ZARM
Chair of Carbon CompositesTUM Department of Mechanical EngineeringTechnical University of Munich
Destructive testing
Failure at 14.3 kNm
Circumferential crack within RADAX ring
Full-Scale Testing – Bending Test
19Ralf Engelhardt | 29th SICOMP Conference | Luleå, Sweden | 28 May 2018
Fig. 2: Bending test set-up at UniBWFig. 1: Circumferential crack within RADAX ring after destructive bending test
Chair of Carbon CompositesTUM Department of Mechanical EngineeringTechnical University of Munich
Conclusion & Outlook4
Approach3
Concept2
Introduction1
Agenda
20Ralf Engelhardt | 29th SICOMP Conference | Luleå, Sweden | 28 May 2018
Chair of Carbon CompositesTUM Department of Mechanical EngineeringTechnical University of Munich
Manufacturing concept
Qualification
Current status & next steps
Conclusion, Current Status & Outlook
21Ralf Engelhardt | 29th SICOMP Conference | Luleå, Sweden | 28 May 2018
LFT press-forming of load input rings
TP-AFP lay-up of cylindrical shell
In situ joint interface
REXUS 23 mission postponed due to non-nominal flight during previous REXUS mission
Launch re-scheduled to 2019
Characterization on coupon level RT/HT
Sub-component testing of interface and thread inserts
Full-scale testing on qualification level and until failure
Sta
tus &
Ou
tlo
ok
Ap
pro
ach
Co
nce
pt
Chair of Carbon CompositesTUM Department of Mechanical EngineeringTechnical University of Munich
TUM-LCC: Luciano Avila Gray, David Colin, Stefan Ehard, Andreas Kollmannsberger, Jonathan Oelhafen,
Marina Plöckl, Robin Taubert, Jakob Weiland
Students: Michael Bösl, Teddy Brault, Duc Thien Dinh, Raphael Eckfeld, Adrian Garcia, Julian Hörmann,
Gerrit Illenberger, Robert Setter, Tobias Wolf
DLR MORABA: Oliver Drescher, Johannes Göser, Frank Hassenpflug, Alexander Schmidt, Katharina Schüttauf
ZARM Bremen: Dieter Bischoff, Andreas Greif, Uli Kaczmarczik, Torsten Lutz, Simon Mawn, Irina Schön,
Tanja Weber
DLR Agency Cologne: Michael Becker, Maria Roth, Tobias Saltzmann
DLR ZLP Augsburg: Somen Dutta
UniBW: Ottmar Breuer, Helmut Rapp
Acknowledgements
Ralf Engelhardt | 29th SICOMP Conference | Luleå, Sweden | 28 May 2018 22
23
Chair of Carbon CompositesTUM Department of Mechanical EngineeringTechnical University of Munich
www.tum.de
Contact
Ralf Engelhardt, M.Sc.
Research Associate
Technical University of Munich
TUM Department of Mechanical Engineering
Boltzmannstr. 15
+49 89 289 10314
engelhardt@lcc.mw.tum.de
D-85748 Garching n. Munich
+49 89 289 15097
www.lcc.mw.tum.de
Chair of Carbon Composites
Tel.
Fax
Chair of Carbon CompositesTUM Department of Mechanical EngineeringTechnical University of Munich
[1] Schuettauf, K. (2017): REXUS User Manual, Version 7.13, 15.12.2014, http://rexusbexus.net/wp-
content/uploads/2017/12/RX_UserManual_v7-15_07Nov17.pdf, last retrieved 02.05.2018.
[2] DLR, SHEFEX, artist's impression, http://www.dlr.de/en/DesktopDefault.aspx/tabid-728/1208_read-
2038/gallery-1/gallery_read-Image.1.723/, last retrieved 02.05.2018.
[3] Fos4X GmbH, Alexander Tindl, Faser Bragg Gitter, https://www.fos4x.de/blog/Wissensdatenbank/faser-
bragg-gitter/, last retrieved 02.05.2018.
[4] García López, A., Characterization of an Endless-Fiber Reinforced Tape Material for the Automated
Fiber Placement Process, Master’s Thesis, Technical University of Munich, 2016.
[5] Hörmann, J., Process Development of a Discontinuously Fiber Reinforced Thermoplastic Load Input
Structure for a Sounding Rocket, Diploma Thesis, Technical University of Munich, 2015.
[6] Dinh, D., Charakterisierung und Optimierung eines Pressverfahrens von langfaserverstärkten
Thermoplaststrukturen, Term Project, Technical University of Munich, 2016.
References (1/2)
Ralf Engelhardt | 29th SICOMP Conference | Luleå, Sweden | 28 May 2018 24
Chair of Carbon CompositesTUM Department of Mechanical EngineeringTechnical University of Munich
[7] Wolf, T., Optimierung und Charakterisierung der Verbindung von endlosfaserverstärkten Tapes und
kurzfaserverstärkten CFK-Strukturen, Master‘s Thesis, Technical University of Munich, 2016.
[8] Brault, T., Screw pull-out tests in LFT pressforming material, Internship Report, Technical University of
Munich, 2016.
[9] Tappex® Gewindeeinsätze, Multisert, http://www.kvt-fastening.at/downloads/e67b9e44-9fca-2bc9-cc40-
f320ab1fabd1, last retrieved 02.05.2018.
[10] Böllhoff, Helicoil https://www.boellhoff.com/de-de/produkte-und-
dienstleistungen/spezialverbindungselemente/gewindeeinsaetze-helicoil.php, last retrieved
02.05.2018.
[11] Illenberger, G., Auslegung eines Experimentalmoduls aus thermoplastischem Faserverbundwerkstoff für
eine Höhenforschungsrakete, Bachelor‘s Thesis, Technical University of Munich, 2016.
References (2/2)
Ralf Engelhardt | 29th SICOMP Conference | Luleå, Sweden | 28 May 2018 25