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The paper presents an approach to determine the durability of hybrid metal-CFRP components combining the results of non-destructive testing (ndt) and finite element simulation The advantage of hybrid metal-CFRP components lies in the use of the properties of the materials used. CFRP parts with higher specific stiffness and strength are combined with metallic joining points, so that established joining processes for metal components can be applied to these lightweight components. In order to further promote the use of these hybrids in industry, it is necessary to guarantee a high level of component reliability through 100% quality control in order to avoid production-related defects. These defects such as delamination or fibre disorientation however vary in shape, size and position and lead to different effects on the part performance and reliability. Therefore the presented approach includes the application of non-destructive testing methods that are applied as in-line quality control measures in order to determine defect characteristics of the inspected parts. Due to the novelty of the component under test it is necessary to evaluate the individual criticality of detected defects and how they affect part performance during the testing procedure. Therefore the acquired ndt-data is used in finite element simulations where defect characteristics are added to the component model and whose effects on part reliability are evaluated. The generation of additional information combining non-destructive testing and simulation is referred to as data fusion. In order to evaluate the validity of the presented approach the determined part performances are compared to experimental mechanic tests.

Growing requirements of Sheet Molding Compound (SMC) parts make new material combinations necessary. One strategy is to reinforce SMC with unidirectional carbon fiber tapes to improve its mechanical properties. As quality assessment of cured parts is necessary, examination of semi-finished materials would be favorable. Two types of nondestructive testing methods, Thermography and Ultrasound, are compared to determine the best control method. These methods are examined on cured plates and semi-finished material to identify defects like air inclusions, delamination, misaligned fibers and microstructural changes. The focus of this paper is an assessment of the testing methods for the manufacturing process.

Durch die vielfältigen Anwendungsgebiete der faserverstärkten Kunststoffe entstehen individuelle Anforderungen an die Qualität der gefertigten Bauteile. Diese kann durch unterschiedliche Prüfverfahren unter Laborbedingungen bereits zuverlässig charakterisiert werden. Die Herausforderung für die Industrie besteht darin, diese Mess- und Prüftechniken in die Serienfertigung inline zu integrieren, um sowohl die Ausschussraten als auch die Wertschöpfung in der Fertigung optimieren zu können. The diversity of applications using Fibre Reinforced Plastics demands the detection of individual characteristics on manufactured parts by different methods of quality control. These methods offer a high reliability under laboratory conditions, but need to be adapted for the industrial use. Therefore, this article deals with the inline integration of these methods in serial production in order to reduce scrap and to maximise the added value of the process chain itself.

Lightweight material became more and more important during the last years. To ensure a defect-free production, effective measurement solutions for quality assurance are necessary. The Laser stripe sensors enable the evaluation of form deviations. For the detection of internal defects thermography provides a suitable solution. On this account the combination of these two non-destructive testing principles gives an opportunity to detect different kinds of defects regarding the outer geometry and the material within the parts. This paper deals with varied concepts to combine laser stripe sensor system and thermography and shows the potential of these methods.