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Friday, March 29, 2024

Non-destructive testing convinces for composites

At ITV Denkendorf, a high-performing latest-generation computer tomograph enables just that. With a resolution in range and best quality 3D imaging, lightweight structures and textile construction are examined in a non-destructive manner. Fibre-reinforced plastics exhibit outstanding material properties when it comes to stability and rigidity in relation to material weight and make them perfect materials for lightweight construction. The automotive industry in particular is greatly interested in mass-production components made of fibre-reinforced plastics.

Components produced by fibre-reinforced plastic technology are exposed to high stress and require appropriately laid fibres concerning the distribution of forces. Especially due to the complex design of today’s vehicle body components, this represents a huge challenge. Before textile lightweight structures can be used in the industry, a detailed understanding and knowledge of their mechanical properties are essential. “At ITV Denkendorf, we have been researching the possibilities to simulate mechanical properties of textile fabrics for many years. The knowledge we gained can be effectively transferred to the production of fibre composites,” says Hansjürgen Horter, head of the divisions of automation, electronics and smart textiles here at ITV Denkendorf.

Modern technologies have provided access to completely new opportunities in textile research. For example, the ITV uses one of the most powerful computer tomographs (CT scanners) worldwide for its science projects. Combining the advantages of CT technology and numerical simulation leads to much more precise models of fibre composite parts and so to reliable calculations of component properties.
Non-destructive analysis of material samples of any kind

Some of the extraordinary features of the CT scanner at Denkendorf are its temperature-stabilised 7 mega pixel detector with highest resolution and grey scale dynamic available, the excellent signal to noiseratio, and the newly developed cooled nano-focus X-ray tube. Components of any type of material can be analysed; however, one of the special strengths of this CT scanner is the high-resolution analysis of textile materials, plastics and fibre composite parts. Due to its great capabilities, the system features outstanding 3D and contrast resolutions in various applications and guarantees best quality CT results that are hardly matched by any other CT-scanner.
Convincing results with carbon fibre composite structures

“Carbon fibre composite structures are extremely difficult to analyse,” explains Hermann Finckh who is a specialist in simulating textile production processes and complex deformations of fabrics using finite element method (FEM) and CT technology. With suitable CT parameters, the fibre orientation can be determined and extracted for even larger component areas.

“This is used as a basis for numerical simulations as FEM and computational fluid dynamics (CFD), which contain correct fibre information, either using a detailed model or an abstracted model,” adds Finckh. Currently, the scientists of ITV Denkendorf investigate whether computer tomography can be used in other areas of textile research as well. In general, CT is beneficial for all areas in which a non-destructive analysis method is desirable in order to evaluate research or development solutions.

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