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Die Zielstellung des Forschungsprojekts REALight ist die Entwicklung eines Verfahrens zur Herstellung von Leichtgranulaten auf der Grundlage der Ergebnisse des BMBF-Projekts „Aufbaukörnungen“ unter Erweiterung der Technologie, um Gips zurückzugewinnen und weitere mineralische Einsatzstoffe zu nutzen. In einem thermischen Verfahren werden mineralische Bau- und Abbruchabfälle über ein rohstoffliches Recycling, d. h. einen thermisch-chemischen Stoffumwandlungsprozess, zu leichten Gesteinskörnungen verarbeitet. Dabei werden im Bauschutt vorhandene Sulfate zersetzt. In einer anschließenden Rauchgaswäsche werden die Sulfate abgetrennt. Sie können als Ersatz für REA-Gips verwendet werden. Dies ist Voraussetzung für die Übertragung der Produkt- und Verfahrensidee in die Praxis und für den Nachweis der Sulfatabtrennung und -rückgewinnung aus gipshaltigem Inputmaterial. Es werden Untersuchungen zur Verbreiterung der Rohstoffbasis durch Einkopplung spezifischer mineralischer Stoffströme durchgeführt, die im Ergebnis zu einer Reduktion des Blähmittelbedarfs und einer Absenkung der Brenntemperatur führen sollen. Die Herstellung ausreichender Mengen Leichtgranulate für eine umfassende Charakterisierung nach Norm und die Praxiserprobung in bekannten Anwendungen und neuen Einsatzfeldern ist ein weiteres Projektziel.
The nucleophilic substitution of fluorine of aromatic compounds with n-aminoalkyl trialkoxysilanes and consecutive sol-gel process have been used for the fabrication of various chromophoric sol-gel materials. The displacement of the fluoro substituent of an activated aromatic molecule occurs by a primary or secondary amino group of (CH3O)3Si-(CH2)3-NHR [R- = H-; CH3-, (CH3O)3Si-(CH2)3-] in tetraalkoxysilane or alcohol as solvent and the sol-gel process can be carried in the same vessel. The HF formed is trapped by a tertiary amine and simultaneously serves as the catalyst for the sol-gel process. Various aromatic compounds have been checked for this purpose: 1-(4-fluorophenyl)-2-nitroethylene, 1-(4-fluorophenyl)-2,2-dicyanoethylene, 4-fluorobenzonitrile, 4-fluoronitrobenzene, 4,4prime-difluorobenzophenone, 4,4prime-difluorobenzil, 7,7prime-difluorodibenzylideneacetone, tetrafluoro-p-benzoquinone, and 1,5-difluoro-2,4-dinitrobenzene. Mono and disubstitution has been studied by UV/Vis- and solid state NMR spectroscopy of the xerogels.
Nondestructive investigation of the VHCF-endurance on cyclically loaded CFRP by X-Ray-Refractography
(2016)
Carbon fiber-reinforced-plastics (CFRP) are already used under high-cycle- (HCF) and very-high-cycle-fatigue (VHCF) at relatively low loads not only in aerospace industry, but also in other growing markets like especially wind energy and increasingly also automotive industry. While the static strength of CFRP is satisfyingly predictable by means of layerwise-strenght-analysis and material data from single layers, it is more and more uncertain to predict residual strength or lifetime as the design lifetime increases. Previous studies showed that local minor cracks and inter-fiber-fracture (IFF) originate long before total failure of single layers. Reliable fatigue estimation for fiber-reinforced-plastics is not available at present. Subsequently safety-related primary structures made out of FRP are over dimensioned.
It is possible to detect the change of inner surface in a specimen by means of X-Ray-Refractography. This includes voids, intact fiber-matrix-interfaces as well as defective ones, cracks and all interfaces in plane with the X-Ray-beam. As the crack-density (including IFF) increases, the inner surface of the material correspondingly increases.
The borderline where even at high cycles no early cracks were detected was identified for selected laminates out of woven and non-crimped fabric with epoxy-matrix.
When no micro-cracks were detected up to 106 cycles, the specimens also lasted in the VHCF-regime. Furthermore for the epoxy resin LY556 in combination with carbon fiber it was distinguished that at a load minor to 50% IFF-load level, no micro cracks were detected and consequently the VHCF-endurance reached.
The integration of the set-up small-sized testing machine into the X-Ray buildup in order to achieve in-situ non-destructive detection of the crack initiation while loading the specimens (CFRP and GFRP- woven fabric and non-crimped-fabric) at the same time will increase the performance of the studies.
In earlier investigations at BAM it was shown, that the matrix has a strong influence on the micro-crack formation and finally on the total lifetime. In order to determine the influence of the matrix properties on the boarderline to infinite life, research is done on laminates while replacing the epoxy-based matrix with an equivalent one with different fracture mechanical properties.
With the evolution of early cracks and IFF monitored as well as the influence of the matrix on the crack propagation investigated we are working on an appropriate model to improve lifetime prediction in CFRP. This work is done within the priority program “infinite life” (SPP 1466) funded by Deutsche Forschungsgemeinschaft (DFG).
Nondestructive investigation of the VHCF-endurance on cyclically loaded CFRP by X-Ray-Refractography
(2016)
Carbon fiber-reinforced-plastics (CFRP) are already used under high-cycle- (HCF) and very-high-cycle-fatigue (VHCF) at relatively low loads not only in aerospace industry, but also in other growing markets like especially wind energy and increasingly also automotive industry. While the static strength of CFRP is satisfyingly predictable by means of layerwise-strenght-analysis and material data from single layers, it is more and more uncertain to predict residual strength or lifetime as the design lifetime increases. Previous studies showed that local minor cracks and inter-fiber-fracture (IFF) originate long before total failure of single layers. Reliable fatigue estimation for fiber-reinforced-plastics is not available at present. Subsequently safety-related primary structures made out of FRP are over dimensioned.
It is possible to detect the change of inner surface in a specimen by means of X-Ray-Refractography. This includes voids, intact fiber-matrix-interfaces as well as defective ones, cracks and all interfaces in plane with the X-Ray-beam. As the crack-density (including IFF) increases, the inner surface of the material correspondingly increases.
The borderline where even at high cycles no early cracks were detected was identified for selected laminates out of woven and non-crimped fabric with epoxy-matrix.
When no micro-cracks were detected up to 106 cycles, the specimens also lasted in the VHCF-regime. Furthermore for the epoxy resin LY556 in combination with carbon fiber it was distinguished that at a load minor to 50% IFF-load level, no micro cracks were detected and consequently the VHCF-endurance reached.
The integration of the set-up small-sized testing machine into the X-Ray buildup in order to achieve in-situ non-destructive detection of the crack initiation while loading the specimens (CFRP and GFRP- woven fabric and non-crimped-fabric) at the same time will increase the performance of the studies.
In earlier investigations at BAM it was shown, that the matrix has a strong influence on the micro-crack formation and finally on the total lifetime. In order to determine the influence of the matrix properties on the boarderline to infinite life, research is done on laminates while replacing the epoxy-based matrix with an equivalent one with different fracture mechanical properties.
With the evolution of early cracks and IFF monitored as well as the influence of the matrix on the crack propagation investigated we are working on an appropriate model to improve lifetime prediction in CFRP. This work is done within the priority program “infinite life” (SPP 1466) funded by Deutsche Forschungsgemeinschaft (DFG).
Faser-Kunststoff Verbunde und insbesondere Kohlenstofffaserverstärkte Kunststoffe werden bereits im Bereich der hohen (HCF) und sehr hohen Lastspielzahlen (VHCF) eingesetzt. Während statische Festigkeiten für diese Materialien bereits gut vorhersagbar sind, gibt es noch keine verlässliche Methode Schwingfestigkeiten zu bestimmen.
Vergangene Studien an Faser-Kunststoff Verbunden an der BAM zeigten, dass bei Schwingbelastung Mikrorisse und Zwischenfaserrisse bereits weit vor dem finalen Versagen auftreten. Diese Schäden erhöhen die innere Oberfläche des Materials. Die Änderung der inneren Oberfläche kann mittels der Röntgenrefraktion bestimmt werden.
Damit konnte im Rahmen der aktuellen Arbeit eine Lastgrenze ermittelt werden, bei der im untersuchten Lastwechselbereich keine Mikrorisse auftreten. Unter den gegebenen Material- und Versuchsparametern kann damit von einer ermittelten Dauerfestigkeitsgrenze gesprochen werden.
Carbon Fibre Reinforced Plastics (CFRP) are more and more used in modern civil aircrafts. These days the whole fuselage is made of this material (B787; A350). Due to strict certification standards the normal in-service loading gives a low stress level compared to the static and even the fatigue strength of the material. Hence CFRP are assumed to have an infinite life. To evaluate this assumption, fatigue tests on CFRP-specimens were performed up to 108 load cycles and the first inter-fibre failure was evaluated non-destructively by accompanying Xray-refraction topography. A tensile testing machine was integrated in a small angle X-ray scattering (SAXS) setup. X-ray refraction topography was performed while the CFRP samples were tensile loaded. This non-destructive technique enables the detection of micro-cracking and inter-fibre failure especially for CFRP. For Glass Fibre Reinforced Plastic (GFRP) X-ray refraction and in-situ loading has already been successfully used. The increase of inner surfaces due to inter fibre failure was measured as a function of the stress state. Fatigue tests were performed at and below the limit of inter-fibre failure strength. State of the art is to assume the failure of the samples under cyclic loading as the fatigue life. Accompanying non-destructive X-ray refraction measurements reflects the damage state and enables to trace its evolution even if the total failure of the specimens does not occur. This investigation technique is of high interest to give the engineer a design value of infinite life which is practically often reached due to knock down factors of certification standards. Finally the infinite life was found for cyclic fatigue loaded CFRP-samples even under high inter fibre transverse and shear loading investigated up to 108 load cycles.
The described investigation of carbon-fibre-reinforced plastics (CFRP) documents that damage evolution can be observed by means of X-ray refractography. Comparative investigations with synchrotron technique on CFRP and grey-scale analysis on glass fibre-reinforced-plastics (GFRP) confirm these results. Moreover it was found that the fracture mechanical properties of the matrix system influence damage nucleation and propagation in the laminate during static and fatigue loads. Single-step fatigue tests were carried out on Laminates with RIM135 and LY556 matrix systems made from non-crimped fabric (NCF) or twill weave in different fibre orientations. The damage to the LY556 laminates was characterized by laminate cracks growing rapidly over the whole specimen width, whereas the damage on the RIM135 laminates was characterized by an earlier onset of micro-cracking followed by laminate cracks. The specimens were fatigued up to 108 (very high cycle fatigue (VHCF) regime) load cycles. S-N-curves of damage initiation were drawn and boundaries were identified for endurance within the VHCF regime. A phenomenology based model focusing on matrix stress was applied to reproduce the first inter-fibre failure (IFF) under static and fatigue loads.
Durch den großflächigen Einsatz der Computertomographie (CT) in unterschiedlichen Industriebereichen steigen auch die Anforderungen an die quantitative Bildanalyse. Subjektive Bildwahrnehmung muss durch objektive Algorithmen ersetzt werden. In diesem Artikel stellt die Bundesanstalt für Materialforschung und -prüfung (BAM), die seit den 1980er Jahren an der Entwicklung der industriellen CT beteiligt ist, anhand ausgewählter Beispiele den aktuellen Stand ihrer Analysemethoden an verschiedenen Anwendungsbeispielen der CT vor.