Improving the process modelling capability for manufacturing large composite structures used on passenger aircraft. This proposal aims to reduce manufacturing costs by developing innovative simulation tools for the production of future lightweight composite aerostructures.The development of a reliable predictive tool to simulate the cost-effective production of resin-infused composite aerostructures, will represent a significant technical advance. The successful transfer of this technology to Bo ....Improving the process modelling capability for manufacturing large composite structures used on passenger aircraft. This proposal aims to reduce manufacturing costs by developing innovative simulation tools for the production of future lightweight composite aerostructures.The development of a reliable predictive tool to simulate the cost-effective production of resin-infused composite aerostructures, will represent a significant technical advance. The successful transfer of this technology to Boeing Aerostructures Australia would give it a distinct competitive edge when bidding for participation in future international development programmes and will yield substantial economic benefits whilst further strengthening and developing local expertise. Lightweight aircraft structures will also contribute towards reducing the environmental impact of aviation. Read moreRead less
Optimisation of self-healing repair systems in aerospace composite structures. Design and manufacture of composite structures for civilian and military aircraft is a multi-billion dollar export business for Boeing Aerostructures Australia and other Australian aerospace companies. To remain globally competitive, Australian industry must develop new expertise for next-generation composite aerostructures that are lighter, cheaper, more damage tolerant and easily repaired. Autonomic self-healing of ....Optimisation of self-healing repair systems in aerospace composite structures. Design and manufacture of composite structures for civilian and military aircraft is a multi-billion dollar export business for Boeing Aerostructures Australia and other Australian aerospace companies. To remain globally competitive, Australian industry must develop new expertise for next-generation composite aerostructures that are lighter, cheaper, more damage tolerant and easily repaired. Autonomic self-healing of composites is an innovative repair technology with many future potential applications for damaged aerostructures. This project will develop analytical tools and data to enable the Australian aerospace industry to take advantage of the economic benefits offered by self-healing repair systems in aircraft composite structures.Read moreRead less
Onset Theory: Pushing the design envelope for textile composite structures. This study aims to exploit an innovative physics-based approach to predict the strength of textile composites. This is particularly important in areas such as aircraft design, where drastic weight savings are needed to allow designers to remain competitive in a low-carbon future. Improved theory and design tools will remove conservatism and account for a large part of these weight savings. The new approach is the first t ....Onset Theory: Pushing the design envelope for textile composite structures. This study aims to exploit an innovative physics-based approach to predict the strength of textile composites. This is particularly important in areas such as aircraft design, where drastic weight savings are needed to allow designers to remain competitive in a low-carbon future. Improved theory and design tools will remove conservatism and account for a large part of these weight savings. The new approach is the first to be consistent at all length scales — from atoms to aeroplanes — ensuring relevance for new and evolving composite material systems. A novel understanding of crack initiation in textile laminates is intended to reduce design and certification effort for new aircraft and help to design more efficient airframes at a lower cost.Read moreRead less
Supersonic Particle Deposition Of Metal Matrix Composite/Aluminium Alloy For Ensuring The Continued Airworthiness Of Damaged Structures. The June 2007 Report to Congress by the US Under Secretary of the Department of Defence (Acquisition, Technology and Logistics) estimated the cost of corrosion associated with US DoD systems to be between $10 billion and $20 billion annually. It further stated that the US DoD has focused its life-cycle corrosion research and development efforts on four primary ....Supersonic Particle Deposition Of Metal Matrix Composite/Aluminium Alloy For Ensuring The Continued Airworthiness Of Damaged Structures. The June 2007 Report to Congress by the US Under Secretary of the Department of Defence (Acquisition, Technology and Logistics) estimated the cost of corrosion associated with US DoD systems to be between $10 billion and $20 billion annually. It further stated that the US DoD has focused its life-cycle corrosion research and development efforts on four primary areas one of which is repair processes that restore corroded materials to an acceptable level of structural integrity and functionality. This project specifically addresses that topic and as such will have a significant impact on Australia's Defence infrastructure.Read moreRead less
AM of MAX Phase parts for applications in extreme environments. This project aims to develop techniques to synthesize MAX Phase compound materials in-situ using laser additive manufacturing. The project expects to increase jet engine fuel efficiency and thrust, and to fabricate longer-lasting parts for supersonic speed applications. The expected outcomes include well-developed additive manufacturing processes to make high performance engineering components with shape complexity for extreme envir ....AM of MAX Phase parts for applications in extreme environments. This project aims to develop techniques to synthesize MAX Phase compound materials in-situ using laser additive manufacturing. The project expects to increase jet engine fuel efficiency and thrust, and to fabricate longer-lasting parts for supersonic speed applications. The expected outcomes include well-developed additive manufacturing processes to make high performance engineering components with shape complexity for extreme environment applications, and new methods to increase the 3D printability of brittle materials. This should provide significant benefits to aerospace and defense industries through solving their long standing bottleneck material and processing problems. The outcomes also enhance Australia’s manufacturing capacity.Read moreRead less
Aligning and Chaining Carbon Nanofillers in Fibre Composites: Synergistically Improving Damage Tolerance and Diagnosis. Recent studies reveal that alternating electric or magnetic fields can rotate conductive nanofillers in polymers. This project aims to advance a new concept of aligning nano-scale reinforcements (for example, graphene nano-sheets and carbon nanofibres) along the thickness direction of composite materials. The alignment of nano-sized reinforcement will address the perennial prob ....Aligning and Chaining Carbon Nanofillers in Fibre Composites: Synergistically Improving Damage Tolerance and Diagnosis. Recent studies reveal that alternating electric or magnetic fields can rotate conductive nanofillers in polymers. This project aims to advance a new concept of aligning nano-scale reinforcements (for example, graphene nano-sheets and carbon nanofibres) along the thickness direction of composite materials. The alignment of nano-sized reinforcement will address the perennial problem of through-thickness weaknesses of fibre-reinforced composites and, at the same time, improve the electrical conductivity of composites. The synergistic improvements in the mechanical and electrical properties will improve damage tolerance and diagnosis of composites, thus expanding their applications in transport and civil construction to help reduce carbon dioxide emission.Read moreRead less
Optimised flush repairs for dissimilar composite material systems. The outcome of this research project will overcome a major technological challenge when designing repairs for dissimilar composite material systems, which are being utilised at an increasing pace in a multitude of industries. This new technological capability will help to improve the competitiveness of the Australian aerospace industry.
Linkage Infrastructure, Equipment And Facilities - Grant ID: LE120100139
Funder
Australian Research Council
Funding Amount
$350,000.00
Summary
A Hot Isostatic Press (HIP) for aerospace and biomedical component processing. This facility will provide a hot isostatic press of sufficiently large capacity to maximise production efficiencies in aerospace and biomedical applications through net shape manufacturing. The facility will be able to process small components or prototypes which will behave in a manner similar to larger scale components.
Theoretical model that predicts the grain size of alloys inoculated with micro- and nano- particle master alloys and cast under an external field. The aim of this project is to develop a theoretical model that predicts grain size when components are cast under the influence of external fields (electromagnetic, ultrasonic, pulsed electric current and melt shearing treatments) and with the addition of nano-particle master alloys. Refining microstructures by available master alloys is reaching a li ....Theoretical model that predicts the grain size of alloys inoculated with micro- and nano- particle master alloys and cast under an external field. The aim of this project is to develop a theoretical model that predicts grain size when components are cast under the influence of external fields (electromagnetic, ultrasonic, pulsed electric current and melt shearing treatments) and with the addition of nano-particle master alloys. Refining microstructures by available master alloys is reaching a limit and this limits further improvement in mechanical properties to meet the challenge of new applications requiring, for example, high temperature properties or light weighting (for example, use of less material). The outcomes will be a new theoretical model, validated numerical models, new casting technologies and highly refined alloys with greater than 25 per cent improvement in mechanical properties. Read moreRead less