Polymers & Composites Projects. Current projects portfolio. Bruce Duncan

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1 Polymers & Composites Projects Current projects portfolio Bruce Duncan

2 Materials Characterisation Programme

3 SM06: Knowledge based design for plastics Develop and code a validated model for predicting the long term performance of plastics used in load bearing applications Provide guidance / measurement protocols on the use of the model Significant technical improvement to industry current models are inaccurate for polymers Predictive modelling is an underpinning technology for materials design Enables users to shorten design cycles, reduce over-engineered products and increase reliability Increase UK capabilities in predictive modelling 3

4 SM07: Improved Composite Component Design Through Validated Measurement Techniques Develop test methodologies to support design of composite components under multi-axial loading and comprising of thick material sections Provide validated test methods for measuring thick section properties and multi-axial material/structural response Significant technical improvement to industry current test methods are uniaxial in scope and suitable for relatively thin coupons Measurement infrastructure will allow key players (e.g. Airbus) to maintain market position and influence design codes Will increase confidence of manufacturers and users in ability of structures to perform as required in service representative test methods Support VAMAS biaxial test activity 4

5 SM09: Improving Quality in Composite Materials Through Provision of Traceable Measurements Develop tools for physical property measurements to assess quality of composite components during and after manufacture Provision of accurate cure and residual stress assessment tools, together with optical techniques for post-manufacture microstructural characterisation Significant benefits to industry through by relating chemical state of cure to mechanical performance cure optimisation, shorter production times Guidance on measurement of residual stress particularly for thick sections significant need for industry expressed during orientation New measurement services thermal analysis and microstructural characterisation 5

6 SM10: Characterising Interfaces in Continuous and Dispersed Materials Develop traceable methods for characterising interfacial properties Develop methodologies based on new measurement techniques Improved capabilities for industry / greater confidence in materials Provide more accurate methods for measuring and predicting interfacial and interphase properties Enable users to tailor and optimise material performance. Establish metrology in nanocomposites area Note: Nanocomposites are a new emerging class of materials, with a predicted market of $1 billion by 2010, with claimed significant performance advantages over traditional materials 6

7 Materials Processing Programme

8 H1: Measurement methods for heat transfer properties data for application to polymers Develop methods for the measurement of heat transfer properties across surfaces (e.g. solid/air interface) Validated method Develop standards for measurement of thermal properties of plastics (ISO TC61 SC5/WG8), Intercomparison of thermal conductivity methods Assess uncertainties in heat transfer data and effect on modelling predictions Industrial case study 8

9 H4: Flow properties of filled materials Develop new or improved measurement methods/procedures for monitoring flow properties of filled materials, Emphasis on mixing/compounding processes Evaluate the use and capability of innovative piezoelectric devices Improved process monitoring (e.g. for dispersion) Melt Flow Rate method for moisture sensitive materials (e.g. PET, PBT, nylon) Avoid the need for solvent-based testing Melt Flow Rate precision and uncertainty statements in support of ISO standards 9

10 U4: Dynamic properties of solid/liquid materials systems at the nano and micro-scale Develop a macro scale resonating piezoelectric cantilever device for fluid rheology validate using a range of reference fluids Concept design for MEMS-scale resonating cantilever device micron scale rheological measurement small quantities of expensive / development materials in- process monitoring Construct a nano-mechanical tester (NTM3D) based in an SEM for measurement of solids Microcomponents, thin films, coatings and MEMS devices microstructural changes under loads nanotribology 10

11 Materials Performance Programme

12 F02: Sensing the Onset of Damage at Polymer Surfaces due to Environmental Exposure Develop measurement techniques to identify the onset of damage on polymer surfaces due to hostile environments information on environmental susceptibility of polymers assess weathering performance evaluate novel techniques (e.g. nano-indentation) Provide guidance to enable industry to correlate results obtained from onsite measurement techniques to the damage sustained by the polymer improve understanding of damage mechanisms to help assess the likelihood of failure evaluate effects of reprocessing on durability 12

13 F04: Accelerated Ageing Protocol For Service in Hostile Conditions Establish the availability and credibility of existing accelerated testing procedures assess previous work including those from past DTI projects (MMS, CPD, PAJ) and current performance projects, identify preferred approaches Evaluate procedures using an industrial case study Publish recommended procedures via standards and guides, living document with future editions encompass findings of other performance projects save costs through having a clear procedure for data generation & greater acceptance by designers, users & regulators 13

14 F07: Permeation, absorption and desorption of liquids and gases in polymer and multilayer systems Develop methods for assessing the ingress of chemicals into polymeric materials low permeability materials multi-layer coatings, laminates or adhesive joints develop supporting modelling capability Assist in the development of reliable accelerated ageing methodologies for polymers improve understanding of the influence of environment (stress and temperature) on permeation rates assess the effect of interfaces on transport of chemicals in polymeric systems work with other performance projects 14

15 F09: Prediction of the lifetime of adhesive joints under sustained loading Develop methods for characterising non-linear creep behaviour in structural adhesive joints evaluate available test methods and models Develop measurement techniques and predictive model for characterising cyclic fatigue behaviour of structural adhesives improve understanding and prediction of fatigue failure Characterise creep behaviour in welded thermoplastics assess predictive models Produce design protocols Better design more reliable joints SMART manual approach 15

16 F10: Adhesive Design Toolkit Integrate three new modules into existing toolkit design and testing for bond durability, forensic analysis test methods and standards Increase on-line advice and guidance resources for adhesives technology maximise the availability of knowledge developed through DTI funded programmes integrate with other websites (e.g. Materials Solutions) develop strategy for future sustainability and promotion of the system 16

17 F12: Development of test methods for determining the criticality of defects in composite materials systems under long-term loading Development defect tolerance test methods for long-term loading residual properties assessment, strength and design issues defect growth monitoring methods and protocols International standardisation of candidate test methods round-robin for compression after impact test case studies demonstrate the robustness and suitability of developed procedures structural health monitoring and assessment 17

18 B03: A Tool to Predict Lifetime for Composites Subjected to Environmental/Fatigue Damage Develop generic SmartManual technology using lifetime prediction as the focus make existing NPL micro-mechanics models more easily accessible develop new models for general symmetric laminates heat and mass transfer models A user-friendly tool to help design damage resistant composites allow effective what-if scenarios to be investigated guidance on the process required to obtain the necessary material parameters interface that is suitable for different levels of users 18

19 Materials Project proposals in development/formulation