Master's Thesis / Student (f/m/x) Joining Concepts for Ceramic Matrix Composites

German Aerospace Center (DLR); Stuttgart; On-site; EUR 60,000 - 80,000; Full time

Job summary

The German Aerospace Center (DLR) invites a candidate to join the Department of Ceramic Composites and Structures. You will research CMC–metal connections, derive solutions, and design several CAD concepts for a turbine-stage interface within a metallic engine environment.

We seek a degree holder in aerospace/mechanical materials with fluency in German or English, strong independent design skills in NX, and familiarity with structural analysis tools such as ANSYS.

Qualifications

• Degree in aerospace engineering, mechanical engineering, materials science or a comparable discipline.
• Fluency in spoken and written German or English.
• Strong ability to work independently on design tasks with Siemens NX (or similar).
• Knowledge of structural analysis using ANSYS or similar software.

Responsibilities

• Research connection and sealing concepts between CMC and metal components.
• Identify problems in CMC–metal connections and derive solutions.
• Evaluate published solutions from patents and literature for the stator geometry.
• Design two to three connection concepts in CAD for a CMC guide vane in the engine context.
• Evaluate the connection with an existing evaluation matrix and basic FE analysis.

Skills

Independent design work

German or English fluency

Education

Bachelor/Master in aerospace engineering, mechanical engineering, materials science or comparable

Tools

Siemens NX

ANSYS

Job description

The Institute of Structures and Design works on the development and optimization of materials and their processing and joining technologies, as well as new design approaches and the construction of full-scale demonstrators. Naturally, testing and validation in specialized test facilities and flight trials are also part of the daily work. The focus is on fiber-ceramic, polymer, and hybrid composite materials. The research of new multidisciplinary design tools and digital models forms the basis for hardware development.

What To Expect

The Department of Ceramic Composites and Structures optimises and develops manufacturing processes for high-performance materials, whilst also pursuing the goal of putting these materials into practical use. To this end, application-oriented prototypes are designed, manufactured, integrated and tested. The focus is on ceramic matrix composites (CMC) for high-temperature, short-term and long-term applications such as rocket nozzles and tips, as well as components for the hot gas section of aircraft engines.

Continuous-fibre-reinforced SiC/SiC (silicon carbide fibre reinforced silicon carbide) materials are promising candidates for the first and second stages of the high-pressure turbine in aircraft engines and are already in series production in the LEAP and GE9X engines. Their low density and high temperature resistance offer a number of advantages over nickel-based superalloys. A key challenge here is the integration of CMC components into the metallic environment of the engine, due to the differing thermal expansion coefficients of the individual components.

Your tasks

• Research into existing connection and sealing concepts between CMC and metal components, drawing on the literature and patents
• Identifying the specific problems associated with CMC–metal connections and deriving potential solutions
• Evaluation of published solutions from patents and the literature, and selection of a suitable concept or a combination of different concepts for the specified stator geometry
• Development and detailed design using CAD of two to three connection concepts based on a specific case study: connection of a CMC guide vane from the first stage of the high-pressure turbine to the metallic engine environment
• Evaluation of the developed connection using an existing evaluation matrix, as well, where applicable, initial structural analysis using the finite element method

Your profile

• A degree in aerospace engineering, mechanical engineering, materials science or a comparable discipline
• Fluency in spoken and written German or English
• Good knowledge of and enjoyment in working independently on design tasks using Siemens NX (or similar software)
• Knowledge of structural analysis using ANSYS or similar software
• Interest in engine structures, ceramic matrix composites, material properties and sealing systems

We look forward to getting to know you! If you have any questions about this position (Vacancy-ID 6411) please contact: Dr. Joel Schukraft Tel.: [phone]