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<p>This study is dedicated to enhance the efficiency of autoclave curing processes for composite components in the aerospace industry, focusing on reducing time and energy consumption along with improving part quality. Comprehensive flow field analyses were conducted in a large autoclave under industrial loading conditions. Lumped mass calorimeter were incorporated to measure the distribution of heat transfer coefficients and variations in the temperature field during the process. Additionaly, tuft flow visualization was employed to reveal airflow patterns. The results indicated significant spatial variations in heat transfer conditions due to a highly complex flow field, emphasizing the necessity for sophisticated optimization strategies. In this regard, a novel approach using supplementary fans in the loading chamber was introduced to actively manipulate the flow field and address the previously identified process limitations. An experimental proof of concept demonstrated that the fans offer significant potential for enhancing heat transfer and improving local gas mixing capability in areas with minimal airflow, especially during ambient pressure heating stages. A subsequent hypothetical performance estimate demonstrated that for a given test configuration (five-meter-long, 2200&#xa0;kg test tool), the employment of three fans could reduce the lead-time by 106&#xa0;min and decrease the temperature spread within the composite part by 48%. Consequently, this study provides fundamental insights into flow dynamics and heat transfer in an industrial scale autoclave, and it highlights a promising method to improve both process efficiency and part quality for mixed loading batches as well as for batches of large, integrated components.</p>

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Experimental Analysis of Autoclave Airflow Patterns and the Implementation of Active Flow Manipulation to Improve Manufacturing Efficiency

  • 期刊论文

  • 发表日期：

    2025年7月16日

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  • Markus Englhard,
  • Tobias A. Weber,
  • Raphael Strecker,
  • Benjamin Hailer,
  • Jan-Christoph Arent,
  • Peter Middendorf

摘要

This study is dedicated to enhance the efficiency of autoclave curing processes for composite components in the aerospace industry, focusing on reducing time and energy consumption along with improving part quality. Comprehensive flow field analyses were conducted in a large autoclave under industrial loading conditions. Lumped mass calorimeter were incorporated to measure the distribution of heat transfer coefficients and variations in the temperature field during the process. Additionaly, tuft flow visualization was employed to reveal airflow patterns. The results indicated significant spatial variations in heat transfer conditions due to a highly complex flow field, emphasizing the necessity for sophisticated optimization strategies. In this regard, a novel approach using supplementary fans in the loading chamber was introduced to actively manipulate the flow field and address the previously identified process limitations. An experimental proof of concept demonstrated that the fans offer significant potential for enhancing heat transfer and improving local gas mixing capability in areas with minimal airflow, especially during ambient pressure heating stages. A subsequent hypothetical performance estimate demonstrated that for a given test configuration (five-meter-long, 2200 kg test tool), the employment of three fans could reduce the lead-time by 106 min and decrease the temperature spread within the composite part by 48%. Consequently, this study provides fundamental insights into flow dynamics and heat transfer in an industrial scale autoclave, and it highlights a promising method to improve both process efficiency and part quality for mixed loading batches as well as for batches of large, integrated components.