Manufacturing of a Thermoplastic CFRP Rocket Module with ... · Chair of Carbon Composites TUM...

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


Conclusion & Outlook4

Approach3

Concept2

Introduction1

Agenda

2Ralf Engelhardt | 29th SICOMP Conference | Luleå, Sweden | 28 May 2018



Approach3

Concept2

Introduction1

Agenda



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]

http://www.rexusbexus.net/


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]



Approach3

Concept2

Introduction1

Agenda



Concept – Overview


RADAX rings

Shell

Adhesive

Cork[5]

7


Concept – Manufacturing Approach


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




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




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



Approach3

Concept2

Introduction1

Agenda



Approach


Coupon

Simulation

Sub-component

Launch

Material characterization on coupon level

Manufacturing

Full-scale

Sub-component testing

Simulation & design

Manufacturing

Full-scale testing


Approach – Testing


Full-scale level

Sub-component level

Coupon level

[7, 8]

[4, 5, 6]


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


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]


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


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


Manufacturing – TP-AFP


Fig. 2: TP-AFP manufacturing tool incl. RADAX rings and FOS cavityFig. 1: TP-AFP tool concept


Manufacturing – TP-AFP


Fig. 2: TP-AFP lay-upFig. 1: TP-AFP tool concept


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


Dummy-

load

CFRP

module incl.

heating

blanket

Fig. 1: Vibration test set-up at ZARM


Destructive testing

Failure at 14.3 kNm

Circumferential crack within RADAX ring

Full-Scale Testing – Bending Test


Fig. 2: Bending test set-up at UniBWFig. 1: Circumferential crack within RADAX ring after destructive bending test



Approach3

Concept2

Introduction1

Agenda



Manufacturing concept

Qualification

Current status & next steps

Conclusion, Current Status & Outlook


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


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


23


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

[email protected]

D-85748 Garching n. Munich

+49 89 289 15097

www.lcc.mw.tum.de

Chair of Carbon Composites

Tel.

Fax


[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)



[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)


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