Test before take off. Special development competence for your aviation and aerospace products

Transcription

1 Test before take off Special development competence for your aviation and aerospace products IMA GmbH Dresden, Germany I I November 2009 I 1

2 At the forefront Scarcely any other system consist of so many individual parts and must fulfill as many safety standards as an airplane. The challenges continue to grow. One of these is how to drastically reduce energy consumption without sacrificing safety and comfort. This raises the demands on engineering, particularly in terms of the verification of the lifetime of new materials and structures. Therefore we can offer you a wide spectrum of tailor-made services and solutions. IMA GmbH Dresden, Germany I I November 2009 I 2

3 Experience // 1 Verifying the reliability and safety of the material for the entire lifetime of a component is a demanding, even difficult matter. Our engineers are building upon knowledge which has been acquired here over the course of decades: The roots of IMA Dresden reach back to Dresden s airplane construction industry in the Fifties. Beginning in 1958, the Passagierjet 152 was statically tested here. Fatigue tests in a water tank began here in // IMA GmbH Dresden, Germany I I November 2009 I 3

4 Experience // 2 For the Institut of Leichtbau und ökonomische Verwendung von Werkstoffen (IfL, 1961 to 1990), it s name light wight provided the focus and the theoretical or experimental verification of stability was a core topic in many locations. //... Operational strength test of Trabant with electro-servohydraulic technology developed and built-on by IfL (1974) IMA GmbH Dresden, Germany I I November 2009 I 4

5 Experience // 3 The founding of IMA Dresden in 1993 signaled a return to aviation. The approval test for the one motor Pilatus PC 12 began in the same year; inquiries and orders have grown consistently since then. IMA GmbH Dresden, Germany I I November 2009 I 5

6 Synergy effects With our company, you ll find everything that s essential under one roof. We will accompany you, along the entire development of a product in order to verify its durability, function and safety. This begins with the load assessment and material consultation and ends with long-term monitoring and quality assurance. In between, you can expect a broad spectrum of services, including stability calculations, defect analysis, construction of FRP prototypes and, as a focus, experimental component and product tests. A wide range of costumers not only of aerospace engineering trust in the know-how of IMA s engineers. IMA GmbH Dresden, Germany I I November 2009 I 6

7 Portfolio Aerospace Automotive Test design Calculation Test Product design Railway Other branches IMA GmbH Dresden, Germany I I November 2009 I 7

8 From material to major test equipped for long Distance // 1 Fundamental tests Material characteristics Material databases Tension test of CFK sample IMA GmbH Dresden, Germany I I November 2009 I 8

9 From material to major test equipped for long Distance // 2 Component and structure tests Calculation Panel shear test (CAD draft, test assembly), simulation of seat panel IMA GmbH Dresden, Germany I I November 2009 I 9

10 From material to major test equipped for long Distance // 3 Curved fuselage panel tests Calculation Fuselage panel simulation and testing device IMA GmbH Dresden, Germany I I November 2009 I 10

11 From material to major test equipped for long Distance // 4 Full scale fatigue test Test procedure for full scale test with bended wing IMA GmbH Dresden, Germany I I November 2009 I 11

12 Full service test support Test consulting, concept development Project management, logistics services Test facility design and assembling Test performance Test article inspection, non-destructive testing Dismantling Reporting Calculation, stress analysis Damage and inspection databases IMA GmbH Dresden, Germany I I November 2009 I 12

13 Starting point: Materials and connections // 1 In the beginning is the question of the material. IMA Dresden has been developing databases since decades, including WIAM -METALLINFO, in which significant material properties are systematically integrated. At present you can comfortably research more than materials, modifications and/or more than two million parameters among others highalloy steels, aluminium, magnesium, nickel, titan and, very soon, fiber reinforced materials (FRP). We advise you on material application and develop customer specific databases upon request. IMA GmbH Dresden, Germany I I November 2009 I 13

14 Starting point: Materials and connections // 2 Fundamental tests in our own facilities provide a perfect basis for expanding our knowledge and strengthen your confidence in variant assessments. In this context we determine s/ncurves (Wöhler curves) and life curves, test materials under extreme temperature and climatic conditions and investigate the influence of media. We determine and analyse the inter fiber breakage behaviour of FRP, determine the lifetimes and character of adhesives, of welded and other mechanical joint connections for static as well as cyclical demands. Finally, we offer you acceptance and approval tests for materials. IMA GmbH Dresden, Germany I I November 2009 I 14

15 Starting point: Materials and connections // 3 Material strength per experiment an example of a patent As we determine the pressure characteristics of fiber reinforced plastics you receive one of the most important tests for the characterization of this material group. Our self-developed test equipment meet their specifications better than conventional devices. Patented IMA pressure testing device for flexible sample geometry and high test loads IMA GmbH Dresden, Germany I I November 2009 I 15

16 In focus: Components and structures Reams of development tests are necessary to verify the stability of the complete aircraft structure and guarantee its safety at the end. We provide all possibilities to compare material applications and construction principles to verify calculation procedures and to analyse various influences on stability experimentally. IMA GmbH Dresden, Germany I I November 2009 I 16

17 In focus: Components and structures A mosaic of components and load conditions Whether its drop tests of landing gear structures, fatigue tests of flaps tracks or vibration test of airplane toilets, we check every detail desired with our component. IMA GmbH Dresden, Germany I I November 2009 I 17

18 Real loading // 1 What loads can be expected? How are they to be introduced into the structure? Our drafted test constructions ensure that the applied loads will be introduced correctly. IMA GmbH Dresden, Germany I I November 2009 I 18

19 Real loading // 2 Within the context of efficient testing, this means firstly that dummy structures will be implemented where the test subjects themselves are elements of more complex systems. Secondly the dummies must be sufficiently close to the strength and stiffness of the original components. IMA GmbH Dresden, Germany I I November 2009 I 19

20 Real loading // 3 During the static and dynamic tests to the compressor housing, a central engine component, a system of dummies (red) precisely simulates the environment of the component being inspected (blue). IMA GmbH Dresden, Germany I I November 2009 I 20

21 IMA Panels // 1 If someone mentions IMA Panels, then they mean the testing sample whose test has made a special name for the IMA engineers in recent years. In place of complex and expensive barrel tests we offer you an optimized concept: the fuselage panel test. Instead of larger fuselage sections, we only inspect simple curved sections (panels) while creating the basic conditions required for these. IMA GmbH Dresden, Germany I I November 2009 I 21

22 IMA Panels // 2 The multi-axial and continually applied cyclical loads on the load-bearing structures sufficiently portray the reality: the pressure difference between the cabin and environment, mass and movement related tensile, compressive and shear stresses Dependent upon the position in the fuselage, different, quasi-homogenous section load conditions prevail. Aluminium, CFK or glare made panels, upper, side or lower panels, start phase, landing or maximum flying height our panel tests simulate every relevant load. The procedure is validated by the barrel test. IMA GmbH Dresden, Germany I I November 2009 I 22

23 IMA Panels // 3 Our company has four types of testing devices for various fuselage panels by now. IMA GmbH Dresden, Germany I I November 2009 I 23

24 IMA Panels // 4 Small damages are a part of the damage tolerance of the safety concept and an important area within the spectrum of our experiments. We investigate when and where damages take place, how they grow, which residual stability remains and how a structure subject to cyclical loads reacts after an impact. IMA GmbH Dresden, Germany I I November 2009 I 24

25 IMA Panels // 5 Small damages are a part of the damage tolerance of the safety concept and an important area within the spectrum of our experiments. We investigate when and where damages take place, how they grow, which residual stability remains and how a structure subject to cyclical loads reacts after an impact. IMA GmbH Dresden, Germany I I November 2009 I 25

26 IMA Panels // 5 Small damages are a part of the damage tolerance of the safety concept and an important area within the spectrum of our experiments. We investigate when and where damages take place, how they grow, which residual stability remains and how a structure subject to cyclical loads reacts after an impact. IMA GmbH Dresden, Germany I I November 2009 I 26

27 Flap Track test A380 flap track certification test IMA GmbH Dresden, Germany I I November 2009 I 27

28 Full scale tests // 1 A final highlight of each airplane development: The approval test for fuselage sections or the complete aircraft structure. IMA Dresden assumed the complete management of the breakage and fatigue tests of the Fairchild Dornier Do 328JET wing. Development tests for additional airplanes followed, such as the Do 728JET barrel tests. IMA GmbH Dresden, Germany I I November 2009 I 28

29 Barrel test Casting door Barrel Cockpit IMA GmbH Dresden, Germany I I November 2009 I 29

30 Wing test Static test Pilatus PC-12 Static and fatigue wing test Do 328 Jet IMA GmbH Dresden, Germany I I November 2009 I 30

31 Full scale tests // 2 Until 2003, the approval test for the Airbus A took place in IMA Dresden s test hall. The cooperation project in which IMA Dresden was subcontracted by IABG mbh Ottobrunn went one step further: the full scale test of the largest passenger airplane in the world, the Airbus A IMA GmbH Dresden, Germany I I November 2009 I 31

32 Full scale tests // 3 A new testing hanger at the Dresden airport was built, where this approval test has been being conducted since IMA Dresden company coordinated the construction of the facility and the transportation of the structure to Dresden, provided the test infrastructure with hydraulic and pneumatic systems and assumed a large portion of the implementation of the testing as well as the structural inspections. IMA GmbH Dresden, Germany I I November 2009 I 32

33 Full scale tests // 4 So IMA Dresden bundles all of the competencies necessary for full scale tests: Project management, infrastructure, concept and realization, transportation and set up of the testing structure, supervision and monitoring of the testing, structural inspections and documentation. IMA GmbH Dresden, Germany I I November 2009 I 33

34 Non-destructive testing In our laboratories as well as at your facility we can test the quality of your test specimen. Our staff qualified according to the standards EN 473 and EN 4179 provides these methods of non-destructive testing: Ultrasound testing (contact and immersion technique) Magnetic powder testing (including fluorescent) Penetration testing (including fluorescent) Eddy current testing Electronic knocking testing Endoscopy IMA GmbH Dresden, Germany I I November 2009 I 34

35 Reference Projects Static test of the Aircraft 152 Static test of Pilatus PC-12 Wing test of Fairchild Dornier Jet 328 Barrel test of Fairchild Dornier Jet 728 Cockpit test of Fairchild Dornier Jet 728 Full scale fatigue test of Airbus A Full scale fatigue test of Airbus A Various Liebherr-Aerospace landing gear tests Component tests of Airbus A400M IMA GmbH Dresden, Germany I I November 2009 I 35

36 Reference Projects Aircraft type 152 Pilatus PC-12 Fairchild Dornier 728 Jet Liebherr * In cooperation with IABG mbh Fairchild Dornier 328 Jet* Airbus A * Airbus A * IMA GmbH Dresden, Germany I I November 2009 I 36

37 Test locations in Dresden 3 premises in Dresden s north A380 test hangar, 4800 m² of test area New test hangar, 5000 m² of test area (under construction) Main building, 5000 m² of test area Figure: Google Earth IMA GmbH Dresden, Germany I I November 2009 I 37

38 Human resources development Mitarbeiter Employees 2 davon Apprentices Auszubildende 9 Gründ presently aktuell IMA GmbH Dresden, Germany I I November 2009 I 38

39 Education IMA GmbH Dresden is involved in engineering education: TestIng - a new Bachelor and Master study course Test Engineering with a study and a research centre IMA GmbH Dresden, Germany I I November 2009 I 39

40 IMA network Berlin Henningsdorf near to Berlin Leipzig Senftenberg Coswig near to Dresden Dresden An-Institut an der TU Dresden Mittweida IMA GmbH Dresden, Germany I I November 2009 I 40

41 Seal of quality You rely upon proven quality? We follow the German and international norms and regulations for aviation and aerospace travel and are certified in accordance with DIN EN 1900 and DIN EN ISO All aviation relevant testing laboratories are accredited in accordance with DIN EN ISO/IEC by the Deutschen Akkreditierungssystem Prüfwesen GmbH (DAP, registration number DAP- PL ). Flexible accreditation by DAP allows us to inspect materials in accordance with diverse norms and to develop new testing. IMA GmbH Dresden, Germany I I November 2009 I 41

42 With the exception of the contractually usage rights agreed with the contract partners, the reproduction use and transmission of this document and passing on of the contents to third parties, even in abstract form, is only allowed with the prior permission in writing of IMA GmbH Dresden. All rights reserved. IMA GmbH Dresden, Germany I I November 2009 I 42