Fiber composite lightweight construction with automated microwave process technology of high energy efficiency (FLAME)

  • contact:

    Dr. Guido Link

  • funding:

    BMBF

  • Partner:

    Karlsruhe Institute for Technology, IHM, Projektkoordinator
    TU München, Lehrstuhl für Carbon Composites (LCC)
    Vötsch Industrietechnik GmbH
    Schunk Kohlenstofftechnik GmbH
    Maus GmbH
    Institut für Textil- und Verfahrenstechnik (subcontractor)
    Momentive (associate partner)

  • startdate:

    01.10.2011

  • enddate:

    30.09.2014

Until now fiber composites for lightweight construction are cured in thermal ovens or autoclaves. In particular for thick-walled components these curing processes are time-consuming and energy-intensive, since beside the components itself the furnace chamber has to be heated as well and held at temperature. A key to the reduction of manufacturing costs of fiber composite materials is the development and application of novel curing and manufacturing processes that enable faster and more energy-efficient production.

The research project FLAME follows an innovative approach with the industrial use of HEPHAISTOS microwave technology developed at KIT for the energy efficient production of fiber composite lightweight structures. The microwave technique is the only physical heating method that enables selective – i.e. temporally and spatially-limited - heating of construction parts. The environment, such as the furnace chamber, remains cold. This, together with the potential to produce heat directly inside the component volume, the microwave technique allows a process chain with low energy consumption and thus a good overall CO2 balance.

Based on these unique physical properties, energy and resource-efficient microwave chamber systems should be developed for innovative, autoclaveless manufacturing of thick-walled lightweight structures made from carbon fiber reinforced plastic (CFRP). In addition, a microwave-assisted pultrusion process for producing CFRP profiles will be developed and tested.