Structural Materials for Innovation (SM 4 I)

Transcription

1 Second SIP Caravan Structural Materials for Innovation (SM 4 I) - Tough, Light and Heat Resistant Materials for Aircrafts - Strategic Innovation Promotion Program Prof. Teruo KISHI Program Director, CAO 1

2 billion US$ billion US$ billion US$ Background: Aviation Industry in Japan and World Industries in Japan Data in 2012 Comparison to other countries (119) Data in aerospace industry (aviation industry) (11) USA UK FRA GER CAN JPN BRA Ref) Report by The Society of Japanese Aerospace Companies. Aerospace Industries Association of Brazil 20 Aviation industry in Japan 17.9 Total Japanese aviation industry is small because of historical reason Civil aviation However, Japanese materials science and industry are strong (2015) 4.7 Defense Japanese aviation industry has a big potential to develop more.

3 Structural Materials for Innovation (SM 4 I) Program Director Teruo KISHI Professor Emeritus, The University of Tokyo; Former President, NIMS; Advisor to the Ministry of Foreign Affairs of Japan Development of tough, light-weight and heat-resistant structural materials applicable to aircraft and power generator Encouraging Japanese aviation industry Improvement of the energy efficiencies for saving energy and reducing CO 2 emission Duration Five years ( ) Composition of SM 4 I (2016) Budget FY Total (US$) million million million Industry: 31 University: 37 National/Public Institutes: 10 Total: 78

4 Specific strength (MPa/(Mg/m 3 )) Properties of Heat Resistant Materials Heat and impact resistant high performance FRP Cost saving FRP for low environmental impact Domain A Carbon fiber reinforced plastics CFRP (specific strength ~450) Innovative large-scale and practical forging technology using computer simulation and materials data base Domain B Domain B Material design, casting and forging technologies. 100 Ti alloys TiAl intermetallic compounds Domain C Coating technology to achieve excellent environmental shielding and thermal cycling resistance 50 Mg alloys Al alloys Ni-base alloys Ceramics Single crystal Ni-base alloys Matrix composite Intermetallic compounds Pt group metals Temperature (ºC)

5 Temp. Structural Materials for Innovation (A) Polymers and FRP A02 A11 Main structure Out-of-Autoclave CFRP Tail skin (Main structure) A01 Fan blade Thermo-plastic resin CFRTP (C) Ceramics coatings Thermal shock absorbing layer Binder layer Oxygen shielding layer Water vapor shielding layer Heat-resistant & light-weight Ceramics substrate Combustion chamber High pressure turbine C41-43 Ti Alloys Ti and Ni-Based Alloys B22 Fan case Laser power metal deposition TiAl intermetallic compounds Low pressure turbine B29-31 High pressure compressor (LP) (HP) (HP)(LP) Fan Combustion Compressor Turbine B23 Compressor Turbine stator vane B21 Compressor Turbine disk (B) Heat resistant alloys and intermetallic compounds

6 Materials Integration (MI) Aims Reducing R & D time and cost, reducing diagnosis and maintenance cost, application for certification (virtual testing). (A) Polymers & FRP (B) Hear resistant alloys & Intermetallic compounds (C) Ceramics coating (D) Materials Integration (MI) Integration of Theory Experiments Instrumental analysis Simulation Database Informatics Structure Phase fraction, Grain size, Orientation Performance Processing Time dependent property Fatigue, Corrosion, Creep Property Strength, Toughness, Rolling, Forging, Welding

7 Materials Integration System for Materials Microstructure System for Materials Performance INPUT Prediction of structure, hardness, residual stress, etc. Prediction of fatigue, creep, brittle fracture, hydrogen embrittlement, etc. OUTPUT Conditions of materials, processing and utilization Numerical modeling Experiments & DB Theory & exp. data Utilization of big data Numerical simulation System for Data Assimilation Assimilation by data processing, analytical functions, etc. Integrated System Estimation of life-time, probability of destruction, factors of embrittlement Numerical modeling Experiments & DB Theory & exp. data Utilization of big data Numerical simulation Processing Structure Property Performance Casting Phase fraction Stress-strain Fatigue Rolling Precipitation & growth High temperature strength Creep Forging Grain size distribution Fracture toughness Hydrogen embrittlement Welding Hardness distribution Hydrogen diffusion Brittle fracture

8 Representative Results (A) Out-of-autoclave CFRP Sample in 2014 Sample in 2014 Sample in 2015 (B) Forging simulator (1.5 kt) (Working at NIMS from May 2016) Clear midterm target values (Void ratio < 1%, CAI > 40ksi). Same performance as sample prepared using autoclave. Develop low-cost CFRP manufacturing technology CAI: Compression after impact (C) Environmental barrier coating (EBC) High-quality EBC coating technology was established. Preparation of materials database for forging process. High damage tolerance at 1400⁰C EBC layer Optimization of forging process condition before utilizing 50 kt-press machine. (Japan Aeroforge, Kurashiki). Development of more efficient jet engine Substrate Layer A Layer B Saving time and cost of R & D.

9 Number of airplanes Growth of Aviation Industry driven by SM 4 I We are developing innovative structural materials applicable to narrow body jet (volume zone) developed after Number of narrow body jet 13,084 (2015) 21,839 (2035) Fleet development of passenger jet 40k 30k 20k 10k 7,616 0 Actual 12,977 19, Year Forecast 28,183 Retained New 38,901 Wide body jet 230 seats Narrow body jet 100 seats Regional jet Ref) Worldwide market forecast Japan Aircraft Development Corp. Domain (A) FRP (B) Metals (C) Ceramics Projects (module) Out of autoclave (Tail skin etc.) Thermoplastic resin (Fan Case) CFRP (Main body) Ti, Ni-based alloy (Turbine stator vane) TiAl intermetallic comp.(hpc etc.) CMC (HPT etc.) Production in billon $ 1.6 billion $ 13 billion $ 4.8 billion $ 3.1 billion $ 2.2 billion $ Total 26 billion $ Ref) Report on business strategy of structural materials for innovation (2015)

10 Establishment of Centers of Excellence for Sustainable Structural Materials R&D in Japan Domain A: CFRP Univ. of Tokyo & JAXA (Japan Aerospace Exploration Agency) - Monitoring, modeling & simulation - Performance evaluation Domain B: Alloys NIMS (National Institute for Materials Science) & TITECH (Tokyo Institute of Technology) - Alloy design - Processing - Performance evaluation Prof. N. Takeda, U. Tokyo Capacity building R&D COE International collaboration Domain C: Ceramics Coatings JFCC (Japan Fine Ceramics Center) - Coating design & processing - Performance evaluation Researcher networking Dr. Y. Mitarai, NIMS Domain D: Materials Integration Univ. of Tokyo & NIMS - Computational materials science - Database - Informatics - MI system Prof. M. Takeyama, TITECH Prof. M. Takata, JFCC Prof. T. Koseki, U. Tokyo

11 Peer Review of Project Advisory board gives comments and suggestions for new theme assignment and evaluation of the results. Domestic advisory board International advisory board House of Japan, Tokyo Meeting frequency: Three times in 2015 Two times in 2016 Board member: Akira AZUSHIMA (Chair) Sector Number Affiliation Academic 5 Industry 5 Nippon Steel & Sumitomo Metal Toyota Mitsubishi Heavy Industry Japan Airlines All Nippon Airways Government 1 Japan Aerospace Exploration Agency (JAXA) Total 11 Bristol Vienna Prof. M. Van de Voorde (EC) Institute for Materials Research and Testing (BAM), Berlin Prof. T. Boellinghaus (Germany), Dr. A. Laukkanen (Finland), Prof. L. Schalpbahch (Switzerland), Prof. K. Potter (UK) 11

12 Outreach Activities SM 4 I made brochures to introduce our mission. We regularly publish magazines to report our recent activities. We utilize internet and SNS to post the latest news. Brochures and magazines Japanese Science and Technology Policy toward Innovation First overseas outreach Caravan Japan-Germany Rectors Conference Time: June 28, 2016, 17:30~18:00 Venue: Japanese-German Center Berlin Japanese science and technology policy toward innovation Cabinet office Counselor Jun IWAMATSU Short version for all domains (JPN ENG) Full version for each domain (JPN ENG) SIP-SM 4 I MAGAZINE (JPN) SIP project Structural materials for Innovation Science and technology advisor to the Ministry for foreign affairs of Japan Prof. Teruo KISHI CAO MOFA Internet & SNS Open original HP of SM 4 I Introduction of young researchers via Facebook. 12

13 National Projects for Structural Materials in Japan MEXT Basic research Pure science Elements Strategy Initiative for Structural Materials ( ) Innovative R & D Materials Informatics MI 2 I ( ) CAO: Cabinet office METI: Ministry of Economy, Trade and Industry MEXT: Ministry of Education, Culture, Sports, Science and Technology MOE: Ministry of Environment ISMA: Innovative Structural Materials Association Polymers FRP METI Carbon fiber MOE CFRP Steels CAO Heat resistant alloys & intermetallic compounds Materials Integration (MI) ISMA Joining Non-ferrous metals (Al, Ti, Mg) Cellulose Nano-Fiber ( ) Ceramics Coatings ( ) Target Power generator Aircrafts Railway vehicle Automobiles Industrial equipment

14 Thank you very much for your kind attention! 革新的構造材料 Structural Materials for Innovation (SM 4 I)