Mathematical insights into disassembly and separation of highly stressed CFRP structures

Abstract In the current effort towards sustainability, the aviation industry faces challenges in repurposing carbon fibre-reinforced plastic (CFRP) components effectively. Traditional “downcycling” methods fail to maintain CFRP integrity, as they involve cutting load-bearing fibres and re-embedding them with new polymers, which leads to fragmentation and loss of properties. Innovative solutions like non-destructive disassembly or dismantling offer precise separation without compromising fibre integrity. This method allows for the direct reuse of materials in similar or new applications and highlights the importance of advanced recycling technologies for fibre-reinforced plastics. In this work, an approach for disassembly based on the mechanism of wedge separation is developed. For this purpose, the mathematical fundamentals are first derived analytically and their applicability is demonstrated. Subsequently, the non-destructive disassembly of a stringer-stiffened CFRP structure is demonstrated using a Finite Element model in combination with a Cohesive Zone Approach. In summary, the wedge separation approach proves to be suitable for application in the non-destructive disassembly of stiffening elements, offering a promising method for future non-destructive disassembly within the scope of sustainable recycling.