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UD-CCM Composites ResearchFrom Research to Applications:
A Model for Knowledge Based Partnershipsby
Stephen Andersen
April 25, 2008
Knowledge based university/industry partnerships
Entrepreneurship, economic development/incubator
International collaborations
A NEW ERA
CCM OVERVIEW
Founded in 1974, CCM is an internationally recognized interdisciplinary center of excellence for composites education and research
Three-Part Mission Conduct basic and applied research Educate scientists and engineers Transition technology to industry
Annual research expenditures (7/1/06 to 6/30/07): 21% college; 5% university) Currently 270 people participate representing 3 colleges and 7 departments 2000 alumni; 200 PhDs, 350 masters degrees; teaching at more than 30 universities World class – Brings international recognition to state and UD Host to 6 NSF/DoD Centers of Excellence since 1985
NSF Engineering Research Center (85); ARO URI (86) Composite Materials Research (ARL: 1996-2014) Composite Materials Technology (ARL: 2001-2007) Composites Applied Research and Technology (ARL: 2007-2012) Advanced Materials Intelligent Processing Center (ONR: 1997-2008) Participant in the FAA COE
Hosted more than 15,000 visitors More than 3500 small, medium and large companies have benefited
More than 270 Researchers Involved in CCM
During the past fiscal year:
• 45 affiliated faculty and 2 visiting faculty• 44 research professionals and support
staff• 54 visiting scholars and post-docs• 40 graduate students• 79 undergraduate research assistants• 15 member administrative staff
CCM Faculty Affiliation by Department
Chemical23%
Civil and Environmental
16%Electrical and
Computer23%
Materials Science
11%
Mechanical27%
UD-CCM’s CENTERS OF EXCELLENCE
PROCESSING
MATERIALS
PERFORMANCEARL Composite Materials Technology (CMT) Program:Composite Materials Technology for Transformation of the Army
2001-2012
ARL Materials Center of Excellence ProgramMicrostructural Design of Lightweight Multifunctional Materials
1996-2014
ONR Advanced Materials Intelligent Processing Center (AMIPC)1997-2008
2004-2008 Federal Aviation Administration’sCenter of Excellence for AdvancedMaterialsMember of University Consortium
TECHNOLOGY TRANSFER TO MEET NEEDS FOR LIGHTWEIGHT MULTIFUNCTIONAL COMPOSITES ENABLED BY UD-CCM’S UNIQUE APPROACH AND FACILITIES
Close ties with “end users” in industry and military allow: Rapid insertion of technology Understanding of needs and technology gaps
Multi-Scale Modeling and Building Block Approach Are Needed
Unit-CellUnit-Cell
LaminateLaminate
Structural Performance
Structural Performance
Fiber-MatrixFiber-Matrix
Macro-MechanicsModels
Macro-MechanicsModels
Meso-MechanicsModels
Meso-MechanicsModels
Micro-MechanicsModels
Micro-MechanicsModels
Resins/AdhesivesLevel 0: Materials
Level 1: CouponBonding/Joints
Level 2: Element
Level 3: Sub-component
Panels/Beams
Level 4: Component
Level 5: Full-Scale
Materials:Focus on Soldier Protection
© 2008 University of Delaware All rights reserved
Damage Tolerance of Novel Composite Materials for Lightweight Armors
Identify novel materials and combination candidates:durable resins, ultra high modulus fibers, 3-dimensional architectures,
advanced interphase designs and high performance adhesives
“Materials-by-Design” approach to damage tolerant materials insertion enablingdevelopment of next generation high performance lightweight armors
Establish fundamentalunderstanding of mode specific
failures and material requirements
Adopt building block methodologyfor “ballistic damage relevant”characterization and evaluation
Develop modeling andsimulation capabilities to
identify processing-structure-performance relationships
Integrate multi-scale models and materials database to establish a comprehensive "materials-by-design“software tool suite enabling rapid and efficient materials insertion for improved armor design
Nanoparticle sizings
3D architectures
analytical solutions
Unique FEA approaches
coupon levelpunch shear testing
time dependant loading
damage tolerantstructural testing
subcomponent testing
03/15
Processing:Focus on Cost, Quality & Automation
Using Simulation
Performance:Focus on Vehicle Applications, Generic
Software and Design Tools, Testing
03/15
Applications Examples:Technology Insertion
AUTOMATED THERMOPLASTIC FIBER PLACEMENT
Process developed to meet need for affordable non-autoclave processing of aerospace structures
Lab-scale workcell developed at CCM with neural-network-based control and IR camera for quality feedback
Scale-up in collaboration with industry
Now commercially available for dual-use applications such as civil transports and fighter aircraft
High Speed Civil Transport: High Temperature Materials and Non-Autoclave Processing
(Boeing, Nasa, Dupont, Hercules, Cincinnati Milacron)
INTELLIGENT RTM/VARTM:
ONR center of excellence for RTM and VARTM; science-based simulation software linked to hardware, enabling real-time control during mold filling
Transfer of automated systems to industry to decrease costs and improve quality; opportunity for companies to become beta test sites
Collaboration with industry and shipyardsfor demonstration on commercialprototypes—aircraft, ship topsidestructures
Affordable Processing for Helicopter and Aircraft Structures
UDLP York SMARTMolding Implementation
Scaleable Special Access Program (SAP) Capability
Controlled Access Facilities
Addressing the health / safety& environmental concernsof full-rate production
Tool & Material Preparation Area
Capitalizing on MANTECHTechnical Developments& Industry Partnerships
Climate Controlled & Crane Serviced EnvironmentAccommodating the Manufacturing Process & Material Stores
She ll mold to olTool des ign by T. PikeRe- us ab le s eal by AASC
D ual sta tion in ter fac e s tru ctu rea cco mmo da ting pi nch va lves & flo w se nso r c onn ec tion s. Colla bo ra tive de sign b y M. Boce k UD LPD . He ide r U niv D E CCM
In tel li gen t in fu sion co ntr ol s yste m De sign b y D. Heid er Un iv DE CCM
Resin Infusion
Oven Cure
M aterial Lay-U p Stati on C onfigurat ion Concept
Mat eria l la y-u p sta tionpro cess c ontr ol syste m / inter fac edes ig n an d p rovision byUniver sity of DE CCMRoll-ab ou t cabin et t o acco mm oda te sub -syste ms a nd p rovid e wor k heig ht su rfac e fo r co ntro l scre enand bar code , su pplied by G SD.
All oth er e lem ents in cluding car ts, m anip ulato r,m ater ial cut ting table , etc. by GSD.
Material Lay-up
15,000ft15,000ft22 Composite Composite Manufacturing AreaManufacturing Area
WORKSHOPS, SYMPOSIA, AND PUBLICATIONS
More than 30 workshops and symposia, attended by thousands of participants from industry, government, and academia
Targeted workshops on specific technologies
Publication of thousands of papers,dozens of books, DelawareComposites Design Encyclopedia
Composites 2000: An International Symposium on Composite Materialsheld to commemorate CCM’s 25th anniversary symposium; 300 attendees
R. L. McCullough Research Symposium-Held in May 2002 in honor of the Late Professor Roy L. McCullough; over 200 attendees
2009 35th anniversary of CCM to be celebrated with American Society for Composites Symposium
FACILITIES
• Composites Manufacturing Science Laboratory
• UD Departmental Facilities and Equipment
• Access to ARL Rodman Materials Lab in Aberdeen, Md.
© 2008 University of Delaware All rights reserved
New CCM-ATTL Facilities and Workcells Support Current Projects and Incubator Initiatives
How can the timescale to commercialize new materials be accelerated?
Innovation and discovery of new materials and innovative use of existing materials for new applications
Systems approach to develop products needed Design, processing, performance, manufacturing, test and evaluation,
affordability Interdisciplinary research, unique facilities and breadth of expertise Market needs
Modeling and simulation versus trial and error Small business can play a key role Role of University, government and industry partnerships?
What’s Missing?Vision: Establish a Collaborative Research and Development Partnership with Industry and Government to Promote Research and Innovation and Accelerate Technology Transition in Advanced Materials
• Co-location of scientists and engineers; Establish interdisciplinary teams.• Establish Incubator Space• Incorporation of business strategy and State Support• Foster Entrepreneurship (students, faculty and staff leading to new DE businesses,
new products, new jobs)
“Most notable is CCM’s ability to maintain a portfolio of programs and people that expertly walks the line between applied and basic research – simultaneously recognizing the needs of corporate and government sponsors to solve real-world engineering problems and the needs of students, faculty and the University to be at the forefront of the science of composite materials. CCM has excelled in this regard and her graduates are equally sought by industrial, government and academic employers.” -- VPI, MSU, UCLA, ARL and ONR
© 2008 University of Delaware All rights reserved
New Space
THE FUTURE IS COMPOSITES