HELIOS

The overall project "HELIOS" aims at the development and validation of novel design principles and technologies for weight-optimized and high-rate capable CFRP fuselage shells. The core of the project is the design of a fuselage shell architecture based on rivet-free joining technologies such as the bonding of longitudinal seams and the hybrid welding of frame-to-skin connections. By the end of the project duration, technological feasibility is to be demonstrated. Furthermore the process chains shall be evaluated regarding their lightweight potential, high-rate capability, and cost-efficiency.

Tasks performed by Wölfel

The subproject HELIOS-Wölfel focuses on the further development and validation of a simulation-based verification methodology for the damage tolerance of rivet-free fiber composite joints. The main objective is the creation of a continuous simulation chain covering the phases of initial damage (impact), fatigue, and residual strength, thereby largely complementing or replacing physical tests. Wölfel is particularly responsible for the advancement of the impact module, the integration of the individual modules into a robust process chain, and their transfer to larger structures such as longitudinal joint designs or wide single-lap shear (WSLS) specimens. Through experimental validations, the applicability of the methodology will be demonstrated and its integration into industrial design processes prepared. In doing so, Wölfel contributes to more efficient and resource-saving development and manufacturing processes in the aviation industry.