Abstract
The paper presents an approach to determine the durability of hybrid metal-CFRP components combining the results of non-destructive testing (ndt) and finite element simulation The advantage of hybrid metal-CFRP components lies in the use of the properties of the materials used. CFRP parts with higher specific stiffness and strength are combined with metallic joining points, so that established joining processes for metal components can be applied to these lightweight components. In order to further promote the use of these hybrids in industry, it is necessary to guarantee a high level of component reliability through 100% quality control in order to avoid production-related defects. These defects such as delamination or fibre disorientation however vary in shape, size and position and lead to different effects on the part performance and reliability. Therefore the presented approach includes the application of non-destructive testing methods that are applied as in-line quality control measures in order to determine defect characteristics of the inspected parts. Due to the novelty of the component under test it is necessary to evaluate the individual criticality of detected defects and how they affect part performance during the testing procedure. Therefore the acquired ndt-data is used in finite element simulations where defect characteristics are added to the component model and whose effects on part reliability are evaluated. The generation of additional information combining non-destructive testing and simulation is referred to as data fusion. In order to evaluate the validity of the presented approach the determined part performances are compared to experimental mechanic tests.
Similar content being viewed by others
References
Camanho PP, Fink A, Obst A, Pimenta S (2009) Hybrid titanium-CFRP laminates for high-performance bolted joints. Compos Part A Appl Sci Manuf 40(12):1826–1837
Pottmeyer F, Muth M, Weidenmann KA (2017) Research of the load bearing capacity of shape-optimized metal inserts embedded in CFRP under different types of stresses. In: Key engineering materials, pp 636–643
A Herwig et al (2016) Entwicklung eines mehrlagigen Inserts für dünnwandige Hochleistungs-CFK-Strukturen. Lightweight design: die Fachzeitschrift für den Leichtbau bewegter Massen 9(1):22–27. https://doi.org/10.1007/s35725-015-0064-7,
Kießling R et al (2017) The Interface of an intrinsic hybrid composite—development, production and characterisation. Proc CIRP 66:289–293
Ucsnik S, Scheerer M, Zaremba S, Pahr DH (2010) Experimental investigation of a novel hybrid metal-composite joining technology. Compos Part A Appl Sci Manuf 41(3):369–374
Pohl M, Stommel M (2016) Designing a metal-CFRP-hybrid by using a structured polymeric component on the interface. In: ECCM 2016—Proceeding of the 17th European conference on composite materials
Heuer H et al (2015) Review on quality assurance along the CFRP value chain—non-destructive testing of fabrics, preforms and CFRP by HF radio wave techniques. Compos Part B Eng 77:494–501
Gholizadeh S (2016) A review of non-destructive testing methods of composite materials. Proc Struct Integr 1:50–57
Unnþórsson R (2005) NDT methods for evaluating carbon fiber composites. In: Shaw MT, MacKnight WJ (eds) Introduction to polymer viscoelasticity. Wiley, Hoboken, pp 1–6
Spiessberger C, Dillenz A, Zweschper T (2010) Active thermography for quantitative NDT of CFRP components. NDT Aerosp 3(2):1–7
Brabandt D, Lanza G (2015) Data processing for an inline measurement of preforms in the CFRP-production. Proc CIRP 33:269–274
Chrysochoos A, Louche H (2000) An infrared image processing to analyse the calorific effects accompanying strain localisation. Int J Eng Sci 38(16):1759–1788
Jegou L, Marco Y, Le Saux V, Calloch S (2013) Fast prediction of the Wöhler curve from heat build-up measurements on short fiber reinforced plastic. Int J Fatigue 47:259–267
Palumbo D, de Finis R, Demelio PG, Galietti U (2016) A new rapid thermographic method to assess the fatigue limit in GFRP composites. Compos Part B Eng 103:60–67
Harizi W, Chaki S, Bourse G, Ourak M (2014) Mechanical damage assessment of glass fiber-reinforced polymer composites using passive infrared thermography. Compos Part B Eng 59:74–79
Cuadra J, Vanniamparambil PA, Hazeli K, Bartoli I, Kontsos A (2013) Damage quantification in polymer composites using a hybrid NDT approach. Compos Sci Technol 83:11–21
Maldague X (2001) Theory and practice of infrared technology for nondestructive testing. Wiley, New York
Weckenmann A, Gawande B (2012) Koordinatenmesstechnik: Flexible Meßstrategien für Maß, Form und Lage, 1st edn. Carl Hanser Fachbuchverlag, Munich
Brosch T (2010) Koordinatenmesstechnik 2010: Technologien für eine wirtschaftliche Produktion; 8. VDI-Fachtagung, Braunschweig, 3. und 4. November 2010. VDI-Verl., Düsseldorf
Bernstein J (2011) Optisches Multi-Sensor-Messverfahren zur dimensionellen in-line Messung von Strangprofilen im Fertigungsprozess
Ruser H, Puente F, León (2007) Informationsfusion—Eine Übersicht (Information fusion—an overview). tm Technisches Messen, 74(3):74
Mersmann C (2013) Industrialisierende Machine-Vision-Integration im Faserverbundleichtbau, 1st edn. Apprimus Wissenschaftsverlag, Aachen
Forum Bildverarbeitung (2014) Forum Bildverarbeitung 2014: [27.-28. November 2014 in Regensburg]. KIT Scientific Publishing; Technische Informationsbibliothek u. Universitätsbibliothek, Karlsruhe
Holstein P (2015) Automatische Fehlererkennung in Kunststoffkompositbauteilen. DGZfP DACH Jahrestagung
Schulze MH, Goldbach S, Heuer H, Meyendorf N Ein Methodenvergleich—ZfP an Kohlefaserverbundwerkstoffen mittels wirbelstrom- und ultraschallbasierender Prüfverfahren
Zaiß M, Demmerle J, Oergele J-N, Lanza G (2017) New concepts for quality assurance of lightweight material. Procedia CIRP 66:259–264
Berger D et al (2017) Effects of defects in series production of hybrid CFRP lightweight components—detection and evaluation of quality critical characteristics. Measurement 95:389–394
Grasse F, Zur M Composite testing, US-plus—test system for online process monitoring [online]. http://grassezur.de/en/prozesskontrolle. Accessed 30 Mar 2018
Grasse F, Zur M (2016) Grasse Zur Composite Testing - Prüfsystem für das Online-Prozessmonitoring von reaktiven Kunststoffen
Mayes J, Hansen AC (2004) A comparison of multicontinuum theory based failure simulation with experimental results. Compos Sci Technol 64(3–4):517–527
Mayes J, Hansen AC (2004) Composite laminate failure analysis using multicontinuum theory. Compos Sci Technol 64(3–4):379–394
Naik RA, Patel SR, Case SW (2001) Fatigue damage mechanism characterization and modeling of a woven graphite/epoxy composite. J Thermoplast Compos Mater 14(5):404–420
Hansen AC, Baker-Jarvis J (1990) A rate dependent kinetic theory of fracture for polymers. Int J Fract 44:221–231. https://doi.org/10.1007/BF00035518
Bhuiyan FH, Fertig RS (2016) A multiscale approach for progressive fatigue failure modeling of a woven composite rve. In: Proceedings of the American Society for Composites—31st technical conference, ASC 2016
Author information
Authors and Affiliations
Corresponding author
Rights and permissions
About this article
Cite this article
Berger, D., Zaiß, M., Lanza, G. et al. Predictive quality control of hybrid metal-CFRP components using information fusion. Prod. Eng. Res. Devel. 12, 161–172 (2018). https://doi.org/10.1007/s11740-018-0816-1
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s11740-018-0816-1