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Design of sandwich structures for sensor integration, optimisation and manufacturing of sandwich core

Final Report Summary - SANDWICH FOAM CORES (Design of sandwich structures for sensor integration, optimisation and manufacturing of sandwich core)

Executive Summary:
The goal of the project was the design and manufacture of carbon fibre reinforced plastic (CFRP) sandwich structures with embedded Structural Health Monitoring (SHM) sensors. This goal was reached.
Suitable ROHACELL foam cores were designed and machined. An autoclave was used to manufacture demonstrator parts. Fibre optical bragg gratings (FOBG) were chosen as SHM system, the demonstrator parts were designed as profile stiffened shells with foam-filled omega profiles. The performance of the FOBG in the cured demonstrator parts was shown.
It was conluded that the implementation of SHM systems in profile stiffened shells is feasible. SHM systems integrated in structurally loaded aircraft parts can lead to a significant reduction of safety factors, thus reducing weight and decreasing fuel consumption. Furthermore SHM systems would allow for a reduction of maintenance effort.
The project consortium consisted of the single member Evonik Röhm GmbH, Kirschenalle, D-64293 Darmstadt.

Project Context and Objectives:
The goal of the project was the design and manufacture of carbon fibre reinforced plastic (CFRP) sandwich structures with embedded Structural Health Monitoring (SHM) sensors. This goal was reached.
Suitable ROHACELL foam cores were designed and machined. An autoclave was used to manufacture demonstrator parts. Fibre optical bragg gratings (FOBG) were chosen as SHM system, the demonstrator parts were designed as profile stiffened shells with foam-filled omega profiles. SHM systems integrated in structurally loaded aircraft parts can lead to a significant reduction of safety factors, thus reducing weight and decreasing fuel consumption. Furthermore SHM systems would allow for a reduction of maintenance effort.

Project Results:
The performance of the FOBG in the cured demonstrator parts was shown.
It was conluded that the implementation of SHM systems in profile stiffened shells is feasible.

Potential Impact:
SHM systems integrated in structurally loaded aircraft parts can lead to a significant reduction of safety factors, thus reducing weight and decreasing fuel consumption. Furthermore SHM systems would allow for a reduction of maintenance effort.

List of Websites:
Contact: Felix Goldmann, +49 6151 186380, felix.goldmann@evonik.com.