IAMAT – Introduction of advanced materials technologies into new product development for the mobility industries Team Universities Companies Prof. Brian Wardle, MIT. Prof. Richard de Neufville, MIT. Prof. Lallit Anand, MIT. Prof. Elsa Olivetti, MIT. Ricardo Reis, Embraer. Prof. Pedro Camanho, FEUP. João Luís, Embraer. Prof. Francisco Pires, FEUP. Miguel Louro, Embraer Prof. Júlio Viana, U. Minho. Luís Antunes, Optimal. Prof. Elsa Henriques, IST. Prof. Ana Póvoa, IST. • Main Goal: develop an integrated framework for product development evaluation that can exploit the potential of the use of advanced materials, manufacturing technologies and structures in the aeronautical industry across the supply chain.

IAMAT – Introduction of advanced materials technologies into new product development for the mobility industries Overview: WP1 Computational materials morphologies Material systems development based on advanced computational and experimental techniques WP2 Sustainable multifunctional structures Manufacturing technologies; multi-functional structures. WP5 Testbed Embraer aerostructure WP3 Management of uncertainty Analytical tools and implementation methods to evaluate the economic impact of new materials and manufacturing processes. WP4 Supply chains towards sustainability Framework and tools for evaluating and quantifying the supply chain impacts of product design choices.

WP1 Computational Materials Morphologies Material systems under investigation: Thermoplastic-based composite materials Thin-ply, nano-reinforced thermoset-based composite materials Thermoplastic-based composite materials Work conducted: New constitutive model for semi-crystalline polymers.

WP1 Computational Materials Morphologies RVE of a thermoplastic-matrix composite material: Shear Loading - With the slip directions of the composite, develop a crystal plasticity equivalent model:

WP1 Computational Materials Morphologies Thin-ply, nano-reinforced thermoset-based composite materials Work conducted: Test plan, test procedures and manufacturing. Identification of the material properties. Identification of the cohesive laws for nano-reinforced interfaces . Test results at the structural detail level.

WP1 Computational Materials Morphologies Experimental tests at ESRF Phase-field model for thin ply composite laminates

WP2 Sustainable multifunctional structures Resin infusion preliminary studies Sample panel Resin infusion vs CAPRI Niggemann et al. J Compos Mater 2008;42(11):1049-1061. Experimental analysis Resin infusion (conventional) Controlled atmospheric pressure resin infusion (CAPRI) Apparent FVF measurements

WP3 Management of uncertainty in design

WP3 Management of uncertainty in design

WP3 Management of uncertainty in design

WP3 Management of uncertainty in design

WP4 Supply Chain Towards Sustainability

WP4 Supply Chain Towards Sustainability

WP4 Supply Chain Towards Sustainability

WP4 Supply Chain Towards Sustainability

WP4 Supply Chain Towards Sustainability

WP5 Testbed TP system selected: Cytec APC-2-PEEK Thermoset system selected as baseline: Hexcel T700/M21 RI system selected: RTM6, Hexcel 194gsm HiTape AS7 OOA Prepreg selected: Hexcel, HexPly M56, M56/35%/UD134/AS7-12K (funds allowing, waiting for Hexcel’s quotation) All manufacture protocols must be finalized by the end of 2017.

WP5 Testbed Test matrix (+45/-45/0/45/-45/90/0)$ laminate (23/62/16). Baseline reference material: Hexcel T700/M21. Level 1 and Level 2 tests conducted until the end of 2017.

WP5 Testbed Material constitutive models Ply modelling Longitudinal (fibre) loading Ply modelling Continuum damage mechanics model. Simulation of progressive intralaminar damage mechanisms (matrix cracking and fibre breakage). Applicable for unidirectional composite tapes (ply-by-ply modelling of multidirectional laminates). Material properties obtained from ply-based test methods. The in situ effect is accounted for based on analytical solutions. Automatic strength reduction (allowing the use of larger elements). In-plane shear loading Transverse (matrix) loading Interface modelling New frictional cohesive zone models Linear constitutive law Mixed-mode propagation (BK energy criterion)

WP5 Testbed Simplified approach for material screening Example of conventional material qualification based on open-hole tension UD [0] tension (modulus and strength) 100/0/0×5 Poisson’s ratio 50/0/50×5 UD [90] tension (modulus and strength) 0/0/100×5 In-plane shear (modulus and strength) 0/100/0×5 Laminate tension 25/50/25×5 10/80/10×5 50/40/10×5 OHT Alternative material qualification based on trace and FFMs Tension (trace and strain-to-failure) 50/0/50×5 Tension fracture toughness (e.g. 4 geometries) 50/0/50×20 The unnotched and notched strengths of general laminates can be determined using simple, but physically-based models For each material: 1 laminate sequence Total 25 specimens For each material: 7 laminate sequences Total 50 specimens Predicted Laminate tension 25/50/25 10/80/10 50/40/10 OHT If laminate sequence changes? Strength predictions based on empirical “characteristic distances” (e.g. average stress) Non-trivial extrapolation from the tested QI, soft and hard laminates

Outputs for Embraer and Optimal Summary WP1 Thermoplastic composites Ultra-thin laminates Nano-stitiching WP2 Manufacturing SHM WP3 Uncertainty/process based cost modeling WP4 Sustainable supply chain Outputs for Embraer and Optimal Lighter composite structures. Analysis tools leading to a reduction of certification costs. Improved robustness in the design. Less expensive out-of-autoclave manufacturing techniques. Process optimization. Change from schedule-based maintenance to condition based maintenance. Technologies economic evaluation under future scenarios uncertainty Technologies economic evaluation under process stochastic conditions Framework for flexible design of manufacturing systems - Framework to support Sustainable Supply Chain Strategy under NPD. - Decision tools to analyse & assess supply chain: Design and planning Performance Suppliers selection.

IAMAT – Introduction of advanced materials technologies into new product development for the mobility industries Team Universities Companies Prof. Brian Wardle, MIT. Prof. Richard de Neufville, MIT. Prof. Lallit Anand, MIT. Prof. Elsa Olivetti, MIT. Ricardo Reis, Embraer. Prof. Pedro Camanho, FEUP. João Luís, Embraer. Prof. Francisco Pires, FEUP. Miguel Louro, Embraer Prof. Júlio Viana, U. Minho. Luís Antunes, Optimal. Prof. Elsa Henriques, IST. Prof. Ana Póvoa, IST. OBRIGADA