Industry-University Crosstalk Andrew George Brigham Young - - PowerPoint PPT Presentation

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Industry-University Crosstalk Andrew George Brigham Young - - PowerPoint PPT Presentation

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Industry-University Crosstalk Andrew George Brigham Young University Andy_George@byu.edu / 801-422-7878 1 Nov 2017 Production challenge - aero composites Commercial Airplanes Manufacture Backlogs Boeing/Airbus all models = 9K

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Industry-University Crosstalk

Andrew George Brigham Young University

Andy_George@byu.edu / 801-422-7878

1 Nov 2017

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  • Commercial Airplanes Manufacture

✓Backlogs

  • Boeing/Airbus – all models = 9K (2/’13), 12K (6/’15 and 9/’17)
  • ~8-10 years of production
  • Boeing 787 = 683 (Sept 2017)
  • Airbus A350 = 744 (Oct 2017)
  • Producing planes at 10-12/month (ATL/AFP/autoclave)

✓20 year forecast (to 2036, by Boeing) = 47K airliners / $6T

  • Trend towards higher composites content
  • Need to produce high performance composites faster
  • Global competition (JBRIC) = need to reduce costs

BRIGHAM YOUNG UNIVERSITY

Production challenge - aero composites

2

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OoA

Out-of-Autoclave (OoA)

✓Conventional oven instead of autoclave:

  • Lower costs: capital investment / energy / nitrogen

pressurization

  • Lower cycle time
  • Higher propensity for voids, but recent R+D has

helped (minimize amount and effect of voids)

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LCM

Liquid composite molding e.g. resin transfer molding (RTM) and vacuum infusion (VI)

✓ Dry fabrics instead of prepreg:

  • Lower material costs / scrap
  • Less freezer storage requirements (less energy)
  • Greater flexibility in geometry and preforming (less post-processing)
  • Adds engineering challenge of infusion

– Optimization of LCM process with simulation tools

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LCM

PAM-RTM; Mesh provided by ESI

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“Effects of defects” - voids

  • S. Sisodia, et al. J. Comp Mat

LCM = never homogeneous void distribution, so total void content in part is inadequate

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NDI for void content (ultrasound)

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Void Characterization: xCT imaging

  • S. Sisodia, et al.

ICCM20 Copenhagen

x y z

1 mm Voids Collection of voids in 90 ply

−45º 45º z x = 0º y = 90º direction of production

Biaxial yarns

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Void Characterization: xCT imaging

How processing and reinforcement affect voids in LCM

Low-velocity through- thickness impact damage in UD weave. Damage propagates from voids that accumulate by the weft roving cross-over points

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  • S. Sisodia, manuscript

in preparation

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Void Characterization: xCT imaging

  • S. Sisodia, et al.

quasi-static indentation damage, manuscript in preparation

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Voids: Properties Correlation

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Void (bubble) Formation

Size/location of voids is dependent on flowrate Optimal = when flowrate is equal between, and within the tows

Ruiz, et al, Comp Sci Tech, 66 (2006)

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Void Measurement: photography

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Void measurement methods – macro lens photography and automated image analysis

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Bubble photography during infusion

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Carbon Weave

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Bubble photography during infusion

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Carbon Biax NCF

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Filling Simulation: Void Formation

  • Void formation coupled to filling simulation

✓ Optimize for lowest formation, or least detrimental shape/location

BRIGHAM YOUNG UNIVERSITY 17

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Filling Simulation: gate location opt.

  • Gate Optimization

✓ Optimize resin inlets and vacuum vents to prevent dry spots / reduce filling time

Inlet Vent

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VI thickness gradient simulation

  • Simulate vacuum bag’s thickness gradient
  • Determine how long vacuum on inlet required to to reduce the gradient
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Resin kinetics / viscosity modeling

  • Model the rate and

extent of cure

✓Rheometry and DSC testing

200 C 180 C 160 C 200 C 180 C 160 C Red = full model Black = experiment Green = model in literature Blue = simplified model Cure rate vs time Cure extent vs time

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Cure and fill simulation / optimization

  • Temperature gradient, exotherm, viscosity

✓ Following Hexcel advice: infuse at 80°C into 120°C tool; what if 200°C tool?

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Industry-Academia in Europe

  • Students are inexpensive R+D sources for all large

companies

✓Industrial thesis – time at both school and work ✓Workforce development

  • Less of an IP barrier to publication

✓Companies looking for publications more than patents

  • Co-authored by school and company
  • Thesis can be restricted to closed audience, as long as

some of it is published

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Industry-Academia in Europe

  • Cross-industry collaboration

✓Seed-investment by government to bring multiple companies and universities together into a project ✓Generic “demonstrator” part used to solve an industry-wide problem ✓e.g. FP7-Infucomp

  • companies: Daher, ESI, Hexcel, Short Brothers, Israel

Aerospace, INASCO, Piaggio

  • Institutes: ARMINES, SICOMP
  • Uni’s: Cranfield, Patras, KUL, Stuttgart

BRIGHAM YOUNG UNIVERSITY

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THANK YOU

BRIGHAM YOUNG UNIVERSITY