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2699 |
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Wednesday, September 28, 2011, Saal B2.1 11:00 AM Alternative Power Generation |
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Cost effective manufacturing of moulds for CFRP component production |
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Maike Seeger* / EADS Innovation Works, Germany E. Reese / EADS Innovation Works, Deutschland Dietrich Jonke/ EADS Innovation Works, Deutschland Martin Englhart/ EADS Innovation Works, Deutschland Klaus Drechsler/ Technische Universität München, Deutschland |
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A cost effective manufacturing process for moulds which are used to produce components of carbon fibre reinforced plastics (CFRP) is proposed. A wire arc spray process has been employed to reinforce a thin electroformed nickel shell by a several millimetre thick layer of thermal spray coating, forming a vacuum tight mould system in a time saving and cost effective way. Here, the main challenge is the successful control of distortion which occurs due to the difference in thermal expansion of substrate and coating. It is also affected by the type of coating material as well as the coating thickness. In this paper, the influence of process parameters on shell distortion is reported. Key parameters influencing the heat flow into the substrate leading to distortion like, spraying path plan, continuous cooling, atomizing gas and spray distance are addressed. Temperature measurements were performed using infrared thermal imaging (infrared cameras and/or infrared pyrometry) as well as by use of thermocouples attached onto the surface of the test specimens. Distortion measurements were carried out by use of optical measurement devices recording 3D surface coordinates before and after the thermal spray coating process revealing distortion values. |