Manufacture, Simulation and Testing of Torsion Bars made of Carbon-Fiber Reinforced Carbon-Silicon Carbid
ARDAC E. 1, LEHNERT T. 1, BAIER L. 1, DAUTH L. 1
1 German Aerospace Center, Stuttgart, Germany
In terms of sustainability and reduction of greenhouse gases, more efficient processes and thus new technical solutions are required in addition to new production methods. Especially in areas where efficiency is guaranteed at high ambient temperatures, materials are required that not only have high temperature resistance, but also have high chemical stability under demanding conditions. An example of such an application is the transmission of rotational moment using a torsion shaft. In order to reliably transmit movements even under extreme conditions, the use of shafts made of fiber-reinforced ceramics (CMCs) which were produced using the wet filament winding process provide a promising solution.
Filament winding technology has been utilized in many industries and shows great flexibility in catering to material demands. At DLR-Stuttgart winded preforms are processed into carbon-fiber reinforced carbon-silicon carbide (C/C-SiC). The combination of SiC with carbon fiber results in materials where the disadvantages of monolithic SiC, like brittle crack behavior are minimized while still utilizing the advantages of high-strength, chemical stability, abrasion resistance and high-temperature resistance.
The opportunity of conducting porosity measurements and CT scans without affecting the material ensures assessment of the micro structure throughout the entire production process. This further allows small adjustments to be integrated into the production chain when necessary to achieve the best possible outcome. Eventually, increasing the amount of flexibility and quality control provided in the overall material manufacture.
Combined with FEM simulations, predetermined conditions and requirements can be evaluated even before production. A suitable design can be developed with minimal trial-and-error thus considerably cutting down production time and material costs.
