1. 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.

2. 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.

3. 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.

4. 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:

5. 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.

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

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

8. WP3 Management of uncertainty in design

9. WP3 Management of uncertainty in design

10. WP3 Management of uncertainty in design

11. WP3 Management of uncertainty in design

12. WP4 Supply Chain Towards Sustainability

13. WP4 Supply Chain Towards Sustainability

14. WP4 Supply Chain Towards Sustainability

15. WP4 Supply Chain Towards Sustainability

16. WP4 Supply Chain Towards Sustainability

17. 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.

18. 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.

19. 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)

20. 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

21. 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.

22. 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