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
Fundamental roles of nano-particles in composite-fibre/epoxy-polymer (CF/EP) composites. There is a significant demand for value-added, innovative epoxy resins for various applications. Australia has a well established aerospace industry and world-leading expertise in synthesising and processing inorganic nano-particles. The outputs of this project will be beneficial to both material manufacturers and design engineers. Understanding the fundamental roles of functional nano-fillers will stimulate ....Fundamental roles of nano-particles in composite-fibre/epoxy-polymer (CF/EP) composites. There is a significant demand for value-added, innovative epoxy resins for various applications. Australia has a well established aerospace industry and world-leading expertise in synthesising and processing inorganic nano-particles. The outputs of this project will be beneficial to both material manufacturers and design engineers. Understanding the fundamental roles of functional nano-fillers will stimulate scientific and technological interests for future research and development of multifunctional engineering materials with improved properties and structures designed in the nano-scale. The project will give Australian researchers a technological edge over their competitors in materials science and engineering.Read moreRead less
Micro-electromechanics and finite element analysis models for adaptive structures. Adaptive structures are becoming increasingly important due to their direct improvement of structural system performance. However, electroelastic behaviour and damage mechanism, which are primary concerns for adaptive structural design, are poorly understood. This project aims at developing micro-electromechanics and finite element analysis models to investigate the electroelastic properties and detect delaminatio ....Micro-electromechanics and finite element analysis models for adaptive structures. Adaptive structures are becoming increasingly important due to their direct improvement of structural system performance. However, electroelastic behaviour and damage mechanism, which are primary concerns for adaptive structural design, are poorly understood. This project aims at developing micro-electromechanics and finite element analysis models to investigate the electroelastic properties and detect delamination for adaptive structures. It combines the fields of micro-electromechanics and composite material analysis in a computational framework to provide a useful and cost-effective tool for modelling the response of adaptive structures. It is a challenging task and will have significant impact in the adaptive structure design community.Read moreRead less
Thermoforming Mechanisms for Cost-effective Manufacturing of Advanced Composite Structures. The cost barrier in thermoforming, due to the lack of understanding of shear deformation and wrinkling, has inhibited the large-scale application of fibre-reinforced composite structures in aerospace and automobile industries. This project aims to develop a cost-effective diaphragm thermoforming process through an in-depth understanding of the thermoforming mechanisms. The outcomes will include novel theo ....Thermoforming Mechanisms for Cost-effective Manufacturing of Advanced Composite Structures. The cost barrier in thermoforming, due to the lack of understanding of shear deformation and wrinkling, has inhibited the large-scale application of fibre-reinforced composite structures in aerospace and automobile industries. This project aims to develop a cost-effective diaphragm thermoforming process through an in-depth understanding of the thermoforming mechanisms. The outcomes will include novel theories for thermoforming, a standard method for material property characterization and new finite element models compatible with the most popular software available for industry. The project will form the basis for establishing the effective production window and enhance greatly the competitive edge of the Australian manufacturing industry.Read moreRead less
Temper Development Using Secondary Precipitation for Stress Corrosion Cracking Resistance in 7xxx Series Alumimium Alloys. The work has the potential for very substantial benefit to Australia. Novel stress corrosion cracking resistant tempers with improved strength have the potential for widespread application in the aircraft industry. Since the patent for the interrupted ageing process is held by CSIRO there is the potential for substantial economic benefit to Australia from the licensing of th ....Temper Development Using Secondary Precipitation for Stress Corrosion Cracking Resistance in 7xxx Series Alumimium Alloys. The work has the potential for very substantial benefit to Australia. Novel stress corrosion cracking resistant tempers with improved strength have the potential for widespread application in the aircraft industry. Since the patent for the interrupted ageing process is held by CSIRO there is the potential for substantial economic benefit to Australia from the licensing of the novel tempers world-wide. Additionally, it would be possible to develop the novel tempers in-situ on existing aircraft structures to improve their performance. This would be of particular benefit to the Royal Australian Airforce with its fleet of ageing aircraft.Read moreRead less
Meta-composites of high level thermal dimensional stability. This project aims to design and manufacture meta-composites of high level thermal dimensional stability for future space-based imagery applications. The project will develop the fundamentals of novel enabling technologies including: meta-composite material design, miniature fibre tow placement, optimal processing window and the high precision net-shape additive manufacturing of continuous fibre laminated composites without needs of fol ....Meta-composites of high level thermal dimensional stability. This project aims to design and manufacture meta-composites of high level thermal dimensional stability for future space-based imagery applications. The project will develop the fundamentals of novel enabling technologies including: meta-composite material design, miniature fibre tow placement, optimal processing window and the high precision net-shape additive manufacturing of continuous fibre laminated composites without needs of follow-up machining. This is expected to eliminate or minimise the current need to use a motorised adjustment system for space-based imagery applications. This project will develop the know-how for design and technology to manufacture meta-composites of high level thermal dimensional stability.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