Effects of defects in series production of hybrid CFRP lightweight components - detection and evaluation of quality critical characteristics

The field of application of carbon fibre reinforced plastics (CFRP) is expanded successively by the insertion of additional components in manufactured parts. These inserts can be used as mechanical interfaces between CFRP and external forces, which is why it is necessary to ensure that the interface is free of defects. Especially the CFRP component is prone to defects due to process and material properties. Currently there are very limited possibilities to evaluate the quality of this type of innovative combination of components. Therefore this publication presents the optimized operation of both 3D and 2D measurement systems in series production, which are used to detect defects that appear in the production of hybrid metal components in the Resin Transfer Moulding Process. The severity of these defects is characterized in both destructive and non-destructive testing and helps to evaluate the necessity of in-line measurement systems and their allocation in the production process.