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Additive Manufacturing of Structural Cores and Washout Tooling for Autoclave Curing of Hybrid Composite Structures

Türk, Daniel-Alexander and Ebnöther, Andreas and Zogg, Markus and Meboldt, Mirko (2018) Additive Manufacturing of Structural Cores and Washout Tooling for Autoclave Curing of Hybrid Composite Structures. Journal of Manufacturing Science and Engineering, 140 (10). Art. No. 105001. ISSN 1087-1357. http://resolver.caltech.edu/CaltechAUTHORS:20181024-161629104

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Abstract

This paper presents a study combining additive manufactured (AM) elements with carbon fiber-reinforced polymers (CFRP) for the autoclave curing of complex-shaped, lightweight structures. Two approaches were developed: First, structural cores were produced with AM, over-laminated with CFRP, and co-cured in the autoclave. Second, a functional hull is produced with AM, filled with a temperature- and pressure-resistant material, and over-laminated with CFRP. After curing, the filler-material is removed to obtain a hollow lightweight structure. The approaches were applied to hat stiffeners, which were modeled, fabricated, and tested in three-point bending. Results show weight savings by up to 5% compared to a foam core reference. Moreover, the AM element contributes to the mechanical performance of the hat stiffener, which is highlighted by an increase in the specific bending stiffness and the first failure load by up to 18% and 310%. Results indicate that the approaches are appropriate for composite structures with complex geometries.


Item Type:Article
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URLURL TypeDescription
https://doi.org/10.1115/1.4040428DOIArticle
Additional Information:© 2018 by ASME. Paper No: MANU-17-1796. Manuscript received December 20, 2017; final manuscript received May 19, 2018; published online July 9, 2018. Assoc. Editor: Zhijian J. Pei. We thank Professor P. Ermanni of ETH Zurich for providing unlimited access to the laboratory facilities of CMASLab, Professor G. Terrasi and T. Lämmlein of EMPA for assisting in three-point bending testing. We also thank R. Kussmaul of ETH Zurich for providing the optimization algorithms on which the truss design is based and L. Völker for his support on the honeycomb design. Financial support from the Product Development Group Zurich pd|z of ETH Zurich is gratefully acknowledged.
Group:GALCIT
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ETH ZurichUNSPECIFIED
Record Number:CaltechAUTHORS:20181024-161629104
Persistent URL:http://resolver.caltech.edu/CaltechAUTHORS:20181024-161629104
Official Citation:Türk D, Ebnöther A, Zogg M, Meboldt M. Additive Manufacturing of Structural Cores and Washout Tooling for Autoclave Curing of Hybrid Composite Structures. ASME. J. Manuf. Sci. Eng. 2018;140(10):105001-105001-14. doi:10.1115/1.4040428
Usage Policy:No commercial reproduction, distribution, display or performance rights in this work are provided.
ID Code:90407
Collection:CaltechAUTHORS
Deposited By: Tony Diaz
Deposited On:25 Oct 2018 16:59
Last Modified:25 Oct 2018 16:59

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