Silvio Pappadà, Ph.D.
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1 Silvio Pappadà, Ph.D. Technologies and Processes Area Manager Materials and Structures Technology Department s.s. 7 Appia Km Brindisi ITALY c/o Cittadella della Ricerca phone: +39 (0) , mobile:
2 What is CETMA Departments: Materials and Structure Engineering TEC - Technologies and Processes SIM - Modelling and Simulation DCE - Diagnostics and Civil Engineering Computer Science and Engineering Industrial Design 70 people a multidisciplinary center
3 TEC - Technologies and Processes Development and testing of polymer and composite materials and components Modelling and simulation for designing of materials, components and processes Scaling-up, process technologies, prototyping what we do
4 TEC - Technologies and Processes Material developers Equipment producers Component/products manufactures Software developers CUSTOMERS / PARTNERS University / Research center FIELDS Aeronautics 60% of the activities Automotive Nautical field Sport and leisure Furniture Plastic recycling
5 TEC - Technologies and Processes Compression moulding lines - lab and pilot scale RTM Industrial induction welding equipment Autoclave Rotational moulding Extrusion Dynamometers DSC, TGA, DMA Thermographic camera HDT e VICAT temperature MFI Chromatography (GPC - HPLC) Certified supplier for aeronautic companies equipment
6 SIM - Modelling & Simulation Numerical modelling LS DYNA Modelling of Ceramic Matrix Composite for Aerospace Applications Woven ceramic Fabric Al2O3- Al2O3 RVE RVE Stress-strain curves in different loading conditions, as input for the macro f.e. model Application: impact simulation of the leading Edge of a turbine vane 4 points-bending test: experimental-numerical calibration Structural analysis 6
7 SIM - Modelling & Simulation CFD and Discrete Element modelling - FLUENT Heat Exchange Fluid-Dynamics and Hydrodynamics Gas Dispersion Fluid-Structure Interaction Industrial particle handling Fluid-Dynamic Analysis of Wind Turbines HVAC system analysis of a passenger coach Hydrodynamic behavior analysis of a Fast Ship and its T-Foil system (Pressure contour (Pa)) DE simulation results of a vibrating screen Multiphase analysis of an high performance Water Nozzle Computational Fluid Dynamic analysis
8 SIM - Modelling & Simulation Thermo-structural and reliability analysis of a ceramic vane for aeronautic turbine - ANSYS European Patent : Numerical-experimental methodology to study the viscous behavior of materials Ceramic characterization & simulation Numerical modelling of ceramic core for turbine vane
9 DCE - Diagnostics and Civil Engineering NON DESTRUCTIVE EVALUATION OF COMPONENTS Structural integrity evaluation and quality control Impact Fault Delamination Honeycomb Hybrid GFRP sample with SMA Void/detachment CFRP CFRP InfraRed Thermography
10 DCE - Diagnostics and Civil Engineering STRUCTURAL HEALTH MONITORING FRP materials with embedded optical fiber sensors for both reinforcing and real time monitoring functionalities smart patch smart textile smart rebar Smart patch for composite repairing and real time monitoring Smart materials
11 Development of Out of Autoclave processes for the Aerospace sector Autoclave process High cycle times High production costs Low production volumes Processing of recycled fibers Compression moulding of thermoplastic composites and thermoset composites (PCM) Fiber placement and tape winding Bladder Moulding Out of autoclave technologies Induction welding of thermoplastic and thermoset composites Sheet moulding compound Vacuum bag of out of autoclave prepregs Advanced liquid moulding technologies (hybrid RTM and SQRTM) CETMA is a leader at European level in the development of OOA processes optimized for aeronautical components
12 RTM..Advanced components for Aerospace sector Advanced design methodology Process optimization Tools Parts manufacturing and validation
13 RTM..Advanced components for Aerospace sector
14 RTM Experimental activities for materials properties evaluation..advanced components for Aerospace sector Matrices RTM6 epoxy resin by Hexcel RTM6-2 epoxy resin by Hexcel BZ9110 benzoxazine resin by Henkel BZ9130 benzoxazine resin by Henkel EP2004 Epoxy resin by Cytec Elium 150 acrilic resin by Arkema Elium C1 acrilic resin by Arkema EC114W340 epoxy resin by Elantas Allowables definition (RTD HTW) Fatigue properties evaluation Physical and chemical properties Reinforcements G0926 carbon fabric by Hexcel G0803 carbon fabric by Hexcel G0947 UD carbon by Hexcel
15 Draping analysis RTM..Advanced components for Aerospace sector Structural analysis Process simulation Dynamic analysis FEM TOOLS
16 RTM..Advanced components for Aerospace sector Experimental activities Physical and mechanical tests for allowables generation Requirementss KO factors 0.9 Geometries, loads, boundary conditions Materials Resins, Reinforcements, Binders, Inserts Preliminary component design Process costs Mechanical properties Experimental activities Tests on fabrics Experimental activities Reinforcement permeability Resin properties NDI inspections Modelling Structural FEM analysis Modelling Draping analysis Resin Physical properties Final component design Void content <1.5% Modelling Fluydodinamic process analysis Mould design Preform design Process design process knowledge ensures performances. Component manufacturing and validation Fatigue behaviour Fiber volume fraction: 57±1%
17 Compression Moulding..Advanced components for Aerospace sector Advanced design methodology Process optimization Tools Parts manufacturing and validation
18 Integrated Approach to composite component development Compression Moulding..Advanced components for Aerospace sector Requirements Geometries, loads, boundary conditions Experimental activities Physical and mechanical tests for allowables generation Materials Matrices, Reinforcements Preliminary component design Experimental activities Physical and mechanical tests for preform characterization (shear tests, friction, locking angle ) Modelling Structural FEM analysis Modelling Draping analysis Modelling Process Optimization (contact pressure distribution, temperature gradients, multiphisics analysis) Final component design Mould design Preform design Process design Component manufacturing and validation
19 Isothermal compression molding Compression Moulding..Advanced components for Aerospace sector T ( C) P T P (bar) Tmax= 450 C Max force=1000 tonn
20 Compression Moulding..Advanced components for Aerospace sector Non-Isothermal compression molding Rubber forming compression molding Match-die compression molding <5 sec <5 min <5 min
21 Weldability (e.g. Induction Welding) Compression Moulding..Advanced components for Aerospace sector High temperature service Process costs Repairability Mechanical properties Fiber volume fraction 60% NDI inspections FST properties Low Void content process knowledge ensures performances.
22 Examples of thermoplastic composite components developed at CETMA Compression Moulding Lower edge beam Customer: Alenia Thermoplastic rib Customer: AW Leading edge for bird impact tests - Customer: Alenia Stringers for stiffened panel Customer: AW
23 IW Parts welding and validation Process Optimization Allowables generation
24 IW Certification of induction welding process by building block approach Compression test on the upper panel Test on components Test on induction welded joinings (T-test and single lap shear test) Test on subcomponents Tensile and compression test Test on coupons
25 Properties Automation Possibility to weld complex shapes IW Possibility to weld thick laminates (> 4 mm) T joint strength 10N/mm Process costs optimization Single lap shear strength 30 MPa High mechanical properties Possibility to weld Thermoplastic and Thermoset composites Low void content (NDI OK)
26 Facilities IW Innovative continuous IW machine patented by CETMA 6-Axis Robot Possibility to install the welding head on a robotic arm (1 option) Possibility to move small components around the induction head (2 option)
27 IW The new induction welding machine is equipped with an innovative control & cooling system (PATENT PENDING) Optimal temperature distribution within the material! No edge effect! Traditional Induction welding technology: Temperature distribution in a single lap joint
28 IW The new induction welding machine is equipped with an innovative control & cooling system (PATENT PENDING) Optimal temperature distribution within the material! No edge effect! CETMA continuous IW technology
29 IW Welding of thermoset substrates by a suitable thermoplastic hybrid interlayer Thermoplastic film Welding surface Hybrid layer Consolidated composite Welding of thermoset components made according to the traditional cycles (autoclave, RTM), using a thermoplastic film in the area to be joined.
30 Materials IW Matrices PPS by Tencate (TenCate Cetex TC1100 ) PEEK by Toho Tenax (Vestakeep 2000) PEI PEKK PP PA6 by Tencate (TenCate Cetex TC910) PA12 by Griltex-EMS Epoxy/PVB (polyvinyl butyral) hybrid system Reinforcements 5HS Weave Carbon Fiber Fabric by Toho Tenax (Tenax -E HTA40 3K) UD Carbon Fibers by Toho Tenax (Tenax -E HTS45 12 K) 5HS Weave Carbon Fiber Fabric by Tencate (TenCate Cetex TC1100 ) UD Carbon Fibers by Tencate (TenCate Cetex TC910)
31 Static process simulations IW Numerical tools Dynamic process simulations
32 Prototypes IW
33 Vacuum bag of OoA prepregs Development of a process for complex shape components with OOA prepreg
34 Complex shape Very low cycle times Sheet and bulk moulding compound Development of prototypes with Sheet Bulk Compounds Sheet moulding compound Hexcel HEXMC 2000C R1A system (carbon epoxy) Sheet moulding compound Polynt S8010 (glass vinylester)
35 Pre-preg Bladder Moulding Development and optimization of the process for of non-rectilineal tube Bladder Lamination Overlapping
36 CETMA is the techincal partner for the value chain of recycled carbon fibers Processing of recycled fibers CF recycling RCF producer Semi-finished products producer Components producer Resin/plastics providers Equipment providers milled chopped mat BMC SMC prepreg Injection moulding Compression moulding Autoclave/vacuum bagging Infusion / RTM RCF components Final products producer End user CETMA s role: Techincal support for all the actors of the value chain Favouring of an efficient communication among all the actors of the value chain
37 Processing of recycled fibers Development of processes to impregnate recycled fibers RTM Reinforcement: Non-woven recycled carbon fibers (Carbiso M nonwoven mat, Karborek nonwoven mat); Resin: RTM6-2 (Hexcel) Compression Molding ELG- Carbiso TM-PP nonwoven mats (60% polypropylene / 40% recycled carbon fibre Vacuum bag infusion Reinforcement: Non-woven recycled carbon fibers (Carbiso M nonwoven mat, Karborek nonwoven mat) Resin:EC157 (Elantas)
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