Element Materials Technology
Element Materials Technology
Agency: European Commission | Branch: FP7 | Program: CP-FP | Phase: AAT.2013.4-4.;AAT.2013.1-2. | Award Amount: 3.78M | Year: 2013
A composite aero-structure with self-repair capabilities will offer durability, extend its service life and prolong maintenance protocols leading to lower aircraft operational costs. Despite the extensive research activities in the area of self-healing resins applied to composite materials, the research for aeronautical applications is currently very limited. To this end, the main objective of HIPOCRATES is the development of self-repair composite materials by transforming widely used resins within aeronautical industry to self-healing materials, facilitating this way the subsequent certification and its related cost. Taking into account the current technological maturity of self-repair, secondary structural composites shall be targeted. The transformation will be done through the epoxy enrichment with appropriate chemical agents, following three main strategies: a) The nano-encapsulation strategy that involves incorporation of nano-encapsulated healing agents and a dispersed catalyst within a polymer matrix, b) The reversible polymers strategy where remediable polymer matrices follow the Diels-Alder chemical reaction rendering damage repairable through triggered reversible cross-linking. c) A combination for the first time of a) and b). For all strategies the current progress of nano-technology will be utilized towards either better facilitation of self-healing process (e.g. nano-carriers) or enhancement of the self-healing performance or integration of other functionalities (e.g. monitoring of the self-healing performance, activation of DA reaction). Impact, fracture and fatigue mechanical tests are envisioned to assess the self-healing efficiency. Manufacturing challenges that arise from incorporating such self-healing thermosetting systems into fibrous composites (pre-preg, infusion/RTM) shall be closely investigated at the early stages of development to ensure the effective transfer of the desired properties to the large scale as required by the industry.
Agency: European Commission | Branch: FP7 | Program: CP-IP | Phase: AAT.2011.4.4-4. | Award Amount: 37.57M | Year: 2011
The ESPOSA project will develop and integrate novel design and manufacture technologies for a range of small gas turbine engines up to approx. 1000 kW to provide aircraft manufacturers with better choice of modern propulsion units. It will also deal with engine related systems which contribute to the overall propulsion unit efficiency, safety and pilot workload reduction. Through the newly developed design tools and methodologies for the engine/aircraft integration the project will also contribute to the improved readiness for new turbine engines installation into aircraft. New technologies and knowledge gained through the ESPOSA project will provide European general aviation industry with substantially improved ability to develop and use affordable and environmentally acceptable propulsion units and reliable aircraft systems minimizing operating costs, while increasing the level of safety. The new engine systems and engine technologies gained from ESPOSA should deliver 10-14% reduction in direct operating costs (DOC) and reduce significantly the pilot workload. The ESPOSA project is oriented on turbine engine technologies tailored for a small aircraft up to 19 seats (under CS-23/FAR23) operated on the scheduled and non-scheduled flights. The research work comprises performance improvements of key engine components, their improved manufacture in terms of costs and quality. New engine component technologies will be backed by novel modern electronic engine control based on COTS, pioneering the engine health monitoring for small engines and providing new more electric solutions for fuel and propeller control systems. Project activities will include extensive validation on the test rigs. The most appropriate technologies according to value/cost benefit will be selected and integrated into functional complexes and further evaluated on the engine test beds. The functionality of certain project outcomes will also be demonstrated and validated in-flight conditions.
Agency: European Commission | Branch: H2020 | Program: MSCA-ITN-ETN | Phase: MSCA-ITN-2014-ETN | Award Amount: 3.88M | Year: 2015
The aim of CoACH (Advanced glasses, Composites And Ceramics for High growth Industries) is to offer a multidisciplinary training in the field of high-tech GLASSES, CERAMICS and COMPOSITES based on effective and proven industry-academia cooperation. Our scientific goals are to develop advanced knowledge on glass and ceramic based materials and to develop innovative, cost-competitive, and environmentally acceptable materials and processing technologies. The inter/multi-disciplinary and -sectorial characteristic is guaranteed by the presence of 5 academic partners and 10 companies having top class expertise in glass, ceramic and composite science and technology, modelling, design, characterization and commercialization. Advanced materials fall within the KEY ENABLING TECHNOLOGIES (KETs) and are themselves an emerging supra-disciplinary field; expertise on these new materials brings competitiveness in the strategic thematic areas of: HEALTH-innovative glass and composite for biomedical applications, ENERGY-innovative glass, ceramic and composite materials for energy harvesting/scavenging, solid oxide electrolysis cells and oil, gas and petrochemical industries, ICT-new glass fibre sensors embedded in smart coatings for harsh environment, ENVIRONMENT-new and low cost glass, ceramic and composite materials from waste. The originality of the research programme is to be seen in the supra-disciplinary approach to new glass- and ceramic- based materials and their applications: recruited researchers will benefit from a complete set of equipment and expertise enabling them to develop advanced knowledge in KETs and strategic thematic areas for the EU and to convert it into products for economic and social benefit. The effective research methodology used by the partners and the mutual exploitation of their complementary competences have been successfully experienced in the past in long term common research cooperation and in on-going common projects, including a Marie Curie ITN
Agency: European Commission | Branch: FP7 | Program: CP-SICA | Phase: NMP.2012.2.2-3 | Award Amount: 4.10M | Year: 2013
This project is focused to advance considerably the efficiency of power generation in gas turbine processes by the development of improved thermal barrier coated parts or components of significantly improved performance as well as software products providing optimized process parameters. The proposed project addresses the following scientific and technological issues: New TBC formulations with long-term stability, more resistant under extremely severe operating conditions (e.g. creep, fatigue, thermal-mechanical fatigue, oxidation and their interactions, at high service temperatures) thus the maximum application temperature will be higher (e.g.1450-1500oC) and so performance during energy generation. Flexible and cost effective production systems based mainly on thermal spray (SPS/SPPS, APS, HVOF) but also EB-PVD in order to realize patterned functional TBCs with improved properties. Application of structural analysis and fluid simulation software, including radiation, combustion, heat transfer, fluid-structure interactions and conjugate heat transfer models for the development of detailed models for the operational performance and prediction of spallation phenomena and failure. Environmentally friendly process using chemical formulations free of hazardous and toxic solvents. The aim of this project is the development of materials, methods and models suitable to fabricate, monitor, evaluate and predict the performance and overall energy efficiency of novel thermal barrier coatings for energy generative systems. By the radical improvement of the performance (working temperature, lifetime etc) of materials in service, by the application of novel thermal barrier coatings, structural design and computational fluid simulations a significant improvement in energy efficiency and cost effectiveness will be achieved.
Agency: European Commission | Branch: FP7 | Program: CP-FP | Phase: AAT.2010.1.1-2.;AAT.2010.4.1-2. | Award Amount: 4.34M | Year: 2011
Aeronautics is a key asset for the future of Europe, but nowadays the industry has to face the challenge of More Affordable, Safer, Cleaner and Quieter while at the same time accounting for a demand that will triple over the next 20 years. WASIS project aims to rise to this challenge with the development of a composite fuselage structure based on the lattice stiffening concept, optimizing geometrical and mass properties of transition zones of fuselage structural joints. Project overall concept is focused on simultaneous meeting environmental demands and rising safety coupled with design and manufacturing cost-efficiency improvement. The lattice approach allows composites to obtain more efficient mechanical behaviour, reducing weight and optimizing structure performance, which will be proved by comparative simulations against other approaches. This will be combined with specially designed semi-loop and micro-pin joining elements to provide the ability of innovative non-regular lattice structure manufacturing, save aircraft weight, avoid fuselage section weakening due to cutting reinforcement fibres. Furthermore, the structure will also be developed to better withstand worst situation loadings, assessing safety through the large adoption of simulation and virtual testing from the very first design stages to analyze explosions and material damping. Developed innovative fuselage section design will be merged with high-productive filament winding technology to reduce manufacturing costs and time, and samples will be manufactured in order to prove how the different concepts fit together. Complete testing of the samples will be applied to prove the wafer approach. As a result of this project integrated approach sufficient fuselage weight savings, manufacturing cost/time efficiency and safety increasing are to be achieved.
Agency: European Commission | Branch: H2020 | Program: RIA | Phase: NMP-01-2014 | Award Amount: 7.80M | Year: 2015
Two FP7 European projects ELECTRICAL and SARISTU aim to develop methods to manufacture CNT reinforced multifunctional composites compatible with current industrial manufacturing processes. According to the results, three CNT integration strategies appear as promising methods to be driven towards an industrial scale manufacturing process: buckypapers, CNTtreated prepreg and CNT doped nonwoven veils. Although each of the technologies can act separately they can be combined synergistically in a way that a higher multifunctional level can be achieved according to the final requirements of the application. This project aims to develop open access pilot lines for the industrial production of buckypapers, CNT treated prepreg and CNT doped non-woven veils for composite applications in sectors such as Aeronautic and Automotive. The purpose is to efficiently and economically manufacture components using novel developed at a scale suitable for industrial uptake. The developed facilities will not only provide increased capabilities to the operating company but also offer a network of nanorelated manufacturing facilities suited to the needs of related SMEs. A European platform of nanobased pilot lines will be created to which companies, and more precisely SMEs, can gain access and make use of the facilities as well as the experience and knowledge of the operating RTO.The partners will work with existing EU clusters and initiatives aimed at the establishment of an EU nanosafety and regulatory strategy framework to ensure the safe use of these products particularly at an industrial scale. This will be achieved through collaboration with end users to ensure the developed products are accepted within existing health and safety procedures or through the introduction of new ones.PLATFORM proposes solutions that will generate new market opportunities for European Aeronautic and Automotive components manufacturing offering to OEMs new added-value products based on nano-enabled products
Agency: European Commission | Branch: FP7 | Program: MC-ITN | Phase: FP7-PEOPLE-2010-ITN | Award Amount: 3.89M | Year: 2011
The aim of this project is to offer a multidisciplinary training in the field of high-tech glasses and composites, in tight contact with companies and universities within this consortium. Our scientific goals are to develop advanced knowledge on glass based materials and to develop innovative, cost-competitive, and environmentally acceptable materials and processing technologies. The inter/multi-disciplinary characteristic is guaranteed by the presence, within this consortium, of five academic partners and five companies, from six countries, having top class expertise in glass science and technology, modelling, design, characterization and commercialization of glass and composite based products. Beside, new high-tech glass-based materials (glasses, glass-ceramics, glass- and glass-ceramic composites and fibers) are themselves an emerging supra-disciplinary field: expertise on these new materials bring competitiveness in strategic fields as medicine (bioactive glasses as bone replacement and drug delivery systems), telecommunications (glass devices for broad-band applications), photonics (glass based photonic sensors), clean energy (Solid Oxide Fuel Cells glass sealants), waste management (vitrification and re-use of wastes), The scientific quality of the research programme is guaranteed by the quality of the academic and industrial partners, as well as from their proven success stories in previous EU projects participation and international ranking. The originality of the research programme is to be seen in the supra-disciplinary approach to new glass-based materials and their applications: recruited researchers can benefit of a complete set of equipments and expertise able to develop advanced knowledge in highly strategic fields for EU, such as medicine, telecommunications, photonics, clean energy production and waste management.
Agency: GTR | Branch: Innovate UK | Program: | Phase: Collaborative Research & Development | Award Amount: 211.55K | Year: 2012
Cables need to cross rail lines at regular intervals as part of the signalling system & must be electrically isolating. There are major disadvantages with the current methods of cable crossings which cause significant disruption when they fail & are expensive to install. Futhermore, urban rail systems can generate unwanted noise and this is often due to the use of concrete or steel sleepers. This project will deliver a range of unique, reinforced thermoplastic sleepers to address the practical issues of cable management & emission of sound to the environment and will demonstrate their performance in field trials with London Underground and Moorland & City Railways. This project addresses aspects of cost, carbon, capacity & customer satisfaction for the rail infrastructure. The project is a partnership of MERL Ltd, Oxford Plastic Systems Ltd and Testsure Technology Ltd with the TSB.
Agency: European Commission | Branch: H2020 | Program: IA | Phase: FTIPilot-01-2016 | Award Amount: 2.61M | Year: 2016
The aim of the IntAir project is to refine the materials and upscale the manufacturing process for a new generation of aircraft interior composites that are cheaper, lighter and safer than the toxic, carcinogenic materials that are currently used. To meet the strict fire and weight requirements for aircraft interiors, the current solution is to use a fire-resistant composite made of phenolic resin with glass fibre reinforcement. However: - Phenolic parts are expensive due to long moulding times and need several hours of manual finishing. - The poor surface finish means that filler is needed, adding to the component weight - Phenolics have a poor health and safety footprint, as they emit toxic and carcinogenic materials during processing As a direct substitute for phenolic, this project focusses on a composite using polyfurfuryl alcohol (PFA), which gives cost, weight and safety benefits over phenolics: - A 34% reduction in moulding cycle time, and a 70% reduction in manual finishing, giving a 58% cost reduction over phenolics - PFA gives a significantly improved surface finish, reducing the use of filler by 70% and reducing average component weight by 4% - PFA composites are non-toxic, non-carcinogenic, eliminating health & safety concerns from the workplace Testing by prospective customers has shown that PFA composites can meet aircraft interior standards for mechanical and fire performance. However, the development has so far been limited to simple formulations on small-scale, prototype equipment which does not yet give the accuracy or scale needed. The overall objective of this project is therefore to improve the processability, optimise the properties and upscale the production process of PFA composites for aircraft interiors. Addressing these 3 issues will enable significant improvements in part cost, component weight and worker safety compared to phenolics, and will allow the material to be commercialised on aircraft manufacturing programmes.