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Case Study
Leinfelden-Echterdingen,
May 6, 2025

CFRP reliably tested

Condition assessment of CFRP structures before and after racing use.
The use of carbon-fiber-reinforced plastics (CFRP) is indispensable in professional racing to push vehicle performance to its limits. Maximum weight reduction while maintaining full functionality is the guiding principle in design and product development. Alongside aerodynamically optimized components, structural parts such as complete chassis (monocoques), suspension elements, and transmission or powertrain carriers are primarily manufactured from CFRP. These are often hybrid components that combine the specific advantages of different materials to enhance mechanical properties.

Project Description

Applications

Non-destructive evaluation using active thermography plays a crucial role in quality assurance for CFRP components. Due to their complex structure, CFRP hybrid components such as monocoques are prone to a range of material defects, including delaminations, air pockets (porosity), or impact damage. In racing, particular attention is given to metallic inserts embedded within the CFRP structure, which are used to mount suspension parts, transmissions, and powertrain carriers. It is vital that these inserts form a strong and durable adhesive bond with the surrounding CFRP laminate. Active thermography provides valuable insights into the integrity of these connections.

Challenge

In racing, quality assurance of CFRP structural components is complicated not only by their complex geometries and tight timeframes. Damage to components is often barely visible on the surface, if at all. Nevertheless, internal structural integrity may already be significantly compromised.

Solution

Active thermography methods provide an efficient means of characterizing CFRP structures. These imaging techniques allow even large component areas to be inspected quickly, contact-free, and with high depth resolution. Complex geometries and subsurface interfaces can be reliably assessed within minutes. Our powerful OTvis/PTvis test systems, equipped with intelligent excitation and evaluation technology, are designed specifically for this purpose.

Implementation

Before installation in the vehicle, newly manufactured components undergo a baseline test to ensure structural integrity and to document their initial condition. After use—whether during approval processes or following accidents in a racing series—the components are re-tested under identical conditions. Comparing the baseline with the latest results provides a fast and reliable assessment of any changes in the component’s condition. Our experienced ISO 9712-certified inspectors support manufacturers and users in deciding how to proceed with stressed components.

FAQ

Our frequently asked questions — answered quickly and easily.

All questions/answers

How deep can active thermography 'look' into a component?

Is the evaluation of the thermograms complicated?

What is the difference between passive and active thermography?

When is active thermography more sensible than passive?

Which materials can be tested with active thermography?