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This project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement N° 685842.

EIROS project Advanced ice and erosion resistant composite materials International Workshop on Surface Icing and Assessment of De-Icing/Anti-Icing technologies Fraunhofer IFAM, Bremen (Germany) 24th and 25th of January 2017

09/02/2017

Marta Alvarez, TWI Ltd (UK)


Outline

• Project overview

• The ice challenge

• Fundamentals

• Materials-by-design approach

• Conclusions

09/02/2017 2

This project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement N° 685842. 09/02/2017 3

From an industrial driver to a project www.eirosproject.com

Overview of EIROS

http://www.eirosproject.com/


EIROS project concept

09/02/2017 4

Development of a high performance composite material by incorporating innovative additives into the composite bulk matrix for operation in extreme environments

Increased erosion resistance

Anti-icing characteristics

Self-healing properties


EIROS in numbers

09/02/2017 5

“Advanced ice and erosion resistant composite materials for diverse applications”

EIROS

o Competition: NMP19 – 2015 ‘Materials for severe operating conditions, including added-value functionalities’

o Duration: 3 years

o Total budget: EUR 8 millions

o Consortium: 18 partners from 9 European countries

o Starting date: March 2016


Project partners

09/02/2017 6

http://www.google.co.uk/url?sa=i&rct=j&q=&esrc=s&source=images&cd=&cad=rja&uact=8&ved=0ahUKEwitlbHCpsPLAhVLtBoKHWHXCLQQjRwIBw&url=http://www.ofir.dk/Resultat/Jobannonce.aspx?jobId%3D329568288&bvm=bv.116636494,d.ZWU&psig=AFQjCNEfWyZVqCPpG-NWnsOgtO-e6cPpiA&ust=1458152231068169

http://www.google.co.uk/url?sa=i&rct=j&q=&esrc=s&source=images&cd=&cad=rja&uact=8&ved=0ahUKEwjdqq2ZpcPLAhVCUhQKHYR-CskQjRwIBw&url=http://www.euroc-project.eu/index.php?id%3Dair00&bvm=bv.116636494,d.ZWU&psig=AFQjCNFBX6CJZq2QfhsuLwuUZU6N0c1_xA&ust=1458151880788649

http://www.google.co.uk/url?sa=i&rct=j&q=&esrc=s&source=images&cd=&cad=rja&uact=8&ved=&url=http://www.bohs.org/BOHSOHSI/Exposurecontainment/exhibitors/&bvm=bv.116636494,d.ZWU&psig=AFQjCNGTIJrXJfgXik1esyAAXSj0ZM2njw&ust=1458152177424848

http://www.google.co.uk/url?sa=i&rct=j&q=&esrc=s&source=images&cd=&cad=rja&uact=8&ved=0ahUKEwij_4LGpcPLAhVK6xQKHeYlBEYQjRwIBw&url=http://www.sikemia.com/&bvm=bv.116636494,d.ZWU&psig=AFQjCNHjLPeZ1zjTrPGzUBkTcAO3vMc87g&ust=1458151973563124

http://www.google.co.uk/url?sa=i&rct=j&q=&esrc=s&source=images&cd=&cad=rja&uact=8&ved=&url=http://www.sonaca.com/&bvm=bv.116636494,d.ZWU&psig=AFQjCNGf-w_h82t23cGBkU67F7uCqNdhPA&ust=1458152287173622

http://www.google.co.uk/url?sa=i&rct=j&q=&esrc=s&source=images&cd=&cad=rja&uact=8&ved=0ahUKEwjU4s6KpsPLAhWDbhQKHYUyA6YQjRwIBw&url=http://www.eitcpshii.eu/partners.html&bvm=bv.116636494,d.ZWU&psig=AFQjCNH2jxtp9a7HzUhD1rbaS-ZrunCwTw&ust=1458152117505944

http://www.google.co.uk/url?sa=i&rct=j&q=&esrc=s&source=images&cd=&cad=rja&uact=8&ved=0ahUKEwjousG0pcPLAhUD1hQKHQ9yB94QjRwIBw&url=http://www.roketsan.com.tr/en/&bvm=bv.116636494,d.ZWU&psig=AFQjCNHxOYtEhIt0lm_nq2zIGEa7gbR7rQ&ust=1458151933523146


Scientific and Technological objectives

09/02/2017 7

• To develop new functional materials:

• To optimise the processing parameters (loading levels of >50% of additives)

• Scaling-up process methodology

• Materials-by-design approach

• Advanced resin suitable for fibre reinforced composite manufacturing process

• To develop advanced composite structures:

• Functional properties: self-healing, ice repellency, erosion resistance, thermal and UV exposure resistance,

• Retention of functionalities: compressive strength, tensile strength, impact, water absorption

• To establish a multiscale modelling approach

1

2

3


Project structure

09/02/2017 8

WP5:

Multi-scale

Modelling

WP6:

Up-scaling

&

Validation

WP3:

Composites

Processing

WP2:

Development

of Nanoscale

Components

Processing

WP1:

Specification

KO

6

12 18 24

30

36

WP4:

Materials

Performance

Test

WP

7:

Ex

plo

itati

on

& D

iss

em

inati

on

WP

8:

Ma

nag

em

en

t


• Ice issues and impacts

• Industrial context

The ice challenge


Ice .. Is it a real problem?

09/02/2017 10


Industrial context

09/02/2017 11


Types of icing

09/02/2017 12

Ice and

snow type

Density

(kg/m3)

Description

Glaze ice 700-900 Pure solid ice - The density may vary with the content of air

bubbles

Very strong adhesion and difficult to knock off.

Hard rime 300-700 Homogenous structure with inclusions of air bubbles.

Strong adhesion and more or less difficult to knock off, even

with a hammer.

Soft rime 150-300 Granular structure, “feather-like” or “cauliflower-like”.

Can be removed by hand.

Wet snow 100-850 Various shapes and structures are possible

When T is close to zero it may have a high content of liquid

water, and slip off easily. If the temperature drops after the

accretion, the adhesion strength may be very strong.

Dry snow 50-100 Very light pack of regular snow.

Various shapes and structures are possible, very easy to

remove by shaking of wires.

Hoar frost <100 Crystal structure (needle like).

Low adhesion, can be blown off.

Source: Cigré Working Group B2.16. Report 291. April 2006


Impacts of icing Case study – Aerospace

09/02/2017 13

Main impacts of icing on aircrafts Structural integrity of the aircraft – Safety

Aerodynamic performance reduction: fuel consumption and safety

Delays (on-ground): de-icing, added costs

Large commercial

airplanes

Small commercial

airplanes

Non-commercial

airplanes

Icing-related accidents, including in-

flight and runway 6 49 510

Fatalities in icing-related accidents 0 27 202

Icing-related incidents in FAA’s database 120 86 319

Icing-related incidents in NASA’s ASRS

database 628 102 422

Lynch F T and Khodadoust A, 2001: ‘Effects of ice accretions on aircraft aerodynamics’. Progress in Aerospace Sciences, 37, 669–767.


De-icing methods in numbers Case study – Aerospace

09/02/2017 14

Chemical de-icing

Use of chemical (current volume of glycol for de-icing a Boeing-747 (BBC, 2007)= 1545 L/ aircraft.

Cost: Current cost of the de-icing of an Airbus A380: €19.795,54 (source EFM list Munich airport)

Infrared Ground De-icing System

Alternative to de-icing chemicals: using IR can save between €5-10k per aircraft

Capital costs: $12M IR de-icing facility at JFK

http://www.iasa.com.au

A Boeing 747 in the IR de-icing hangar at JFK

http://www.ainonline.com/sites/default/files/uploads/2013/10/jfk-b747-radiant1_web.jpg


Impacts of icing Case study – Power distribution

09/02/2017 15

http://www.iasa.com.au

China 2008 : $22.3Bn US/Canada 1998: $4.4Bn

US/Canada 1949-2000: 87 storms causing >$1M damage


Impacts of icing Case study – Wind Power in Cold Climates

09/02/2017 16


• Approach to anti-ice or de-icing problems • Repellent materials – State-of-the-art • Wetting

Fundamentals


Approaches to icing problems

09/02/2017 18

Energy transfer

Directly to the ice Via the substrate

Active

Thermal Freezing point depressant

fluids

Joule effect

Radiation Electrical tracers and

heaters Hot gases

Mechanical

Scraping SM alloys

Impacting Torsion devices

Abrasive particles Pneumatic expulsive boots

Automated robots Electro-impulsive devices

Vibrating devices

Passive Thermal Heat absorbing surfaces

Mechanical

Rings

Anti-torsion devices

Aeolian devices

One-time coatings

Icephobic coatings

Chemical Chemically reactive coatings

Adapted from: Laforte C & Laforte JL, 2012. “Deicing strains and stress of iced substrates” J. Adhesion Science and Technology 26 603-620


Current ice-phobic coatings

09/02/2017 19

Company name

Location Markets Website

Lotus Leaf Coatings

USA Biomedical http://www.lotusleafcoatings.com/

NeverWet USA Consumer http://www.neverwet.com/

HiRec USA Telecoms http://www.ntt-at.com/product/hirec/

Isurguard USA Biomedical http://www.isurtec.com/products/isurguard/

Tecnan Spain Construction http://www.tecnanshop.com/

Shun Technology

USA Solar http://www.c-voltaics.com/

3M USA Solar http://multimedia.3m.com/mws/media/818346O/3mtm-anti-soiling-liquid-600.pdf

http://www.lotusleafcoatings.com/







http://www.neverwet.com/







http://www.ntt-at.com/product/hirec/









http://www.isurtec.com/products/isurguard/







http://www.tecnanshop.com/







http://www.c-voltaics.com/









http://multimedia.3m.com/mws/media/818346O/3mtm-anti-soiling-liquid-600.pdf























Repellency OR/AND durability with current commercial materials?

09/02/2017 20

0.0

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

0.9

1.0

0.0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0

Figure of Merit

Durability– abrasion resistance index

Commercial repellent products

Current commercial repellent and durable products

Rep

ellen

cy i

nd

ex

Next generation of materials


Fundamentals of wetting

09/02/2017 21

Surface energy measurements

Wa ≈ γw(1+ cos θ)

0.00

0.50

1.00

1.50

2.00

0 100 200

Wa/

γw

Contact angle (θ)

Makkonen L: J Adhesion Sci. Technol. 26 (2012) 413-445

γs = γw . cos θ + γsw

Young Equation

Liquid-solid interactions • Polar • Dispersive • Hydrogen bonding

Low WCA – High Adhesion

High WCA – Low Adhesion

As the wettability decreases, surface contamination is easier to remove

PTFE - 120˚ (water)


High repellency fundamentals

09/02/2017 22

Super-hydrophobic properties result from dual-scale roughness and low surface energy

Lotus Leaf (Nelumbo Nucifara) Naturally superhydrophobic and self-cleaning

EIROS aims to replicate the natural super-repellency of the Lotus leafs via the use of functional repellent nano-additives

These need to be design to achieve minimum surface energy and dual-scale roughness


EIROS project

Materials-by-design approach


ADDITIVES • Development &

Synthesis • Optimisation • Lab scaled up • Characterisation

Functional nano-encapsulated phase

change materials

Functionalised Silica nanoparticles for hydrophobicity

Self-healing additive

Modified bulk resins

BULK RESINS • Incorporation &

Dispersion • Performance evaluation • Characterisation • Small batch

manufacture

Prepreg Materials

EIROS – Materials development approach

H&S Risks associated to

nanomaterials

BULK RESINS & FIBRES

1

2

3


ADDITIVES • Development &

Synthesis • Optimisation • Lab scaled up • Characterisation

Self-healing additive

Functionalised Silica nanoparticles for hydrophobicity

EIROS – Materials development approach

1

2

3

Additives development

1) Functional silica nanoparticles (TWI)

2) Functional encapsulated PCMs (TEK)

3) Self – healing additives (LEI)

Functional nano-encapsulated phase

change materials



09/02/2017 26

Repellent functionality

Crosslinking with polymer matrix

(Epoxy)

Inorganic core that can enhance

mechanical and thermal properties

of the polymer matrix

Underpinning technology:

• Use of additives to enhance resin properties

• Additives at nano and micro scale level

• Tech background: methodology that allows multiple functional groups on the same surface of a single particle

1



09/02/2017 27

Mono or dual functional additives size /type /shape

Resin formulation

Durable functional systems

Micro-scale roughness

Development of high performance composite materials by incorporating novel additives into the composite resin



09/02/2017 28

Building blocks • Chemistry • nm

Characterisation • Porosity • Surface area • Surface chemistry • Size • Dispersity

Functional additives • Materials chemistry • nm microns

Characterisation • Particle size distribution • Bonding • Chemical sequence • Functional groups selection • Surface coverage

Functional resins • Materials science • Microns bulk

Characterisation • Integration into resin • Dispersion techniques

• Initial functional

performance


Conclusions


Conclusions

09/02/2017 30

• Icing is a real problem in the majority of industrial sectors: it induces extra costs, reduces process efficiencies, and has an impact on human lives

• Anti-icing /de-icing methods are generally classified in active and passive systems

• There are not durable passive anti-icing systems

• The EIROS projects aims at reducing the use of active de/anti-icing systems via the use of durable and repellent materials

• A materials-by-design approach is being followed


Thank you!

[email protected] [email protected] [email protected]

Have a look at www.eirosproject.com !

mailto:[email protected]



http://www.eirosproject.com/

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