SAMPE Journal - January/February 2021 - 36
FEATURE / CFRP SANDWICH STRUCTURES
accurately positioned on the tool. After placement
of the inner plies and skins, pre- forming can be carried out beneath a silicone membrane under temperature and vacuum. Due to the heat, the fibers can
move and become attached to the skin fabric, without wrinkling, onto the surface of the tool or onto
the solid surface of the foam core. The foam sustains
the counterpressure necessary for compacting. After this process step, the preform is ready and can be
placed in the infusion tool or put into intermediate
storage, if necessary.
It is important to mention that layup need not
occur in the curing tool. Occupancy times in expensive curing tools are thus minimized and tool capacity increases significantly.
In the study, comparison of the time required
for each process step for manual versus automated
production showed that production time, as well as
mold occupancy time, could be reduced by 65%, see
Figure 6.
The placement tools are relatively simple and
the preform is storable. By changing the placement
Figure 4. The EVO system cuts semi-finished products, removes fabric as
well as cores and deposits the blanks (©DLR).
Figure 5. Automated sandwich production process with a
foam core (©Evonik).
tools and the end effector, a system for the automated placement and preform process can be used
cost-effectively for different components.
CONCLUSIONS
Sandwich design with an inherently stiff foam core
allows the use of automated manufacturing processes. In addition to meeting structural requirements, the foam core performs important functions
for automated handling. ROHACELL® HERO structural foam, certified by Airbus for use as a structural
core, is ideal here thanks to its inherent stiffness as
well as both heat and compressive creep resistance
during fabrication: The use of foam, compared with
honeycomb, reduces the total time required for pro-
36
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SAMPE JOURNAL
|
duction of a component, even without automation,
by about 40 %. The automated placement process
saves an additional 65 % in the production of the
preform.
With the manufacturing concept investigated, cost-effective large production runs are proven
possible with consistent quality. The capacity of the
usually expensive curing tools can be considerably
increased.
REFERENCE
1.
Lang, U., Automated Production of CFRP Compos-
ites with Structural Foam Cores. Lightweight Design,
Volume 12, Issue 2/2019, page 18 - 21, 2019.
J A N UA R Y/ F E B R UA R Y 2 0 2 1
w w w. s a m p e . o r g
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SAMPE Journal - January/February 2021
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