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
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
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
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
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
Experimental validation of the strain invariant failure theory for carbon/epoxy composites. The project will be of national and international benefit, through providing a validated, enhanced design capability for advanced composite materials. Greater depth of understanding of such materials will allow more efficient structures to be designed in applications requiring high strength and stiffness, low weight, and resistance to corrosion and fatigue. Such applications include the aerospace, offshor ....Experimental validation of the strain invariant failure theory for carbon/epoxy composites. The project will be of national and international benefit, through providing a validated, enhanced design capability for advanced composite materials. Greater depth of understanding of such materials will allow more efficient structures to be designed in applications requiring high strength and stiffness, low weight, and resistance to corrosion and fatigue. Such applications include the aerospace, offshore and mining industries. There are, therefore, far-reaching benefits in industries important to Australia. In addition, the reputation of the Australian aerospace research industry will be promoted through a collaborative association with Boeing, a world leader in development of commercial aircraft.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.
De-consolidation and Re-consolidation of Advanced Thermoplastic Matrix Composites. The project provides a comprehensive physical understanding on thermal de-consolidation and re-consolidation processes in advanced thermoplastic composites during re-heating/cooling processes, such as thermoforming and joining. Mechanistic models based on theoretical analysis, experimental studies and computational modelling will be established to provide a unified approach to predict de-consolidation and re-conso ....De-consolidation and Re-consolidation of Advanced Thermoplastic Matrix Composites. The project provides a comprehensive physical understanding on thermal de-consolidation and re-consolidation processes in advanced thermoplastic composites during re-heating/cooling processes, such as thermoforming and joining. Mechanistic models based on theoretical analysis, experimental studies and computational modelling will be established to provide a unified approach to predict de-consolidation and re-consolidation processes. Optimum processing-windows will be established, with which the undesired deterioration in material meso-structures and mechanical performance due to de-consolidation is effectively minimised. The outcomes of the project will fill the gap in the knowledge for thermoplastic composite processing and will improve the integrity of thermoplastic composite structures in practical applications.Read moreRead less
On-line structural integrity assessment of advanced composite airframe with senor network. The project addresses frontier technologies that lead to solutions to one of the critical key issues forming the Australian community - online integrity/safety assessment of structures or asset including aircraft, ships, buildings and bridges. The community benefits significantly if potential disaster due to occurrence of damage associated with those structures can be prevented - the ultimate aim of resear ....On-line structural integrity assessment of advanced composite airframe with senor network. The project addresses frontier technologies that lead to solutions to one of the critical key issues forming the Australian community - online integrity/safety assessment of structures or asset including aircraft, ships, buildings and bridges. The community benefits significantly if potential disaster due to occurrence of damage associated with those structures can be prevented - the ultimate aim of researchers for decades. It is imperative that Australian industries remain technologically ahead of international competitors. Outcomes of the project will lead to novel technologies for real-time structural health monitoring and integrity assessment, bringing significant improvement in operation safety and driving down maintenance cost.Read moreRead less