AIT Austrian Institute of Technology Light Metals Technologies Ranshofen LKR Leichtmetallkompetenzzentrum Ranshofen GmbH Mobility Department

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1 AIT Austrian Institute of Technology Light Metals Technologies Ranshofen Mobility Department Dipl.-Ing. Rudolf Gradinger Head of Business Deveolpment LKR JTI Workshop, BMVIT, Vienna, 3. Feb. 2011

2 General Company Information LKR Number of employees: 34 Location: Ranshofen, Austria Turnover: about 5 million euros 100% subsidiary of the AIT Non-university research establishment Certificates ISO 9001:2008 ÖNORM EN ISO/IEC Blin dtext auf einer PPT-Folie, ein Text without Ranshofen weitere Bedeutung, allein Vienna der Visualisierung LKR eines grafischen AIT Konzeptesdienend. (16pt) Seibersdorf Blindtext auf einer PPT-Folie, ein Text without weitere Bedeutung, allein der Visualisierung dienend.

3 Positioningof AIT (Austrian Institute of Technology)

4 Mobility Department AIT is one of Europe s leading mobility research centres through efficient, safe and green mobility solutions through extensive expertise in simulation coupled with a highly-developed research infrastructure through networking with science and industry on a national and international level *

5 Key Research Topics Materials development Development and optimisation of alloys Optimisation of heat-treatment parameters Improvement of mechanical and dynamic characteristics Optimisation of the microstructures of alloys Process development and optimisation Development and improvement of casting processes Evaluation and optimisation of metal forming processes Simulation of process technologies Evaluation and optimisation of processes in external production lines Validation and prototyping Materials-based design Design of lightweight structures Crash simulation of vehicle components and structures Optimisation of topology and structure Joining technologies Demonstration and prototyping GmbH GmbH

6 Research Focus Interlinked methods enabling customised lightweight design with light metals WHAT: Pre-product Forming Heat treatment Operation Material Process Design

7 Block Smart Materials

8 Joining Technique (IGEL) Motivation Development: Innovative hybrid design joints Combination: friction, form and material closure Low preliminary damage to joined elements Improved interface efficiency Basic idea 3D modification of metal surface (steel, aluminium, titanium) CMT welding process Creation of fine structures (pins) Metal part connected to second part through pins Objective Max. load potential Energy absorption capacity => Safety reserves => Design limits => Reduction of mass at the joint location See Project IGEL² in /

9 Joining Technique(IGEL) Work topics Sample geometries (development, design, production) Test methods (tensile, peel and bending tests) Determination of static and dynamic behaviour Influence of geometry parameters Corrosion issue Non-destructive testing Failure mechanisms and characterisation Finite element simulations, sensitivity analyses Material pairing Metal wood Metal textile Metal metal Metal plastic Metal fibre-reinforced plastic

10 Anti-icing & de-icing technologies Active de-icing by heating structures using semi-conductive coatings These coatings can be applied like paint and have intrinsic adjustable Ohmic resistance. They feature a positive temperature coefficient of the electrical resistivity (PTC) providing additional safety issue and auto-regulation of temperature gradients See Project HEAT in / See also

11 Anti-icing & de-icing technologies Active de-icing by vibrating structures near/at the natural frequency of the structure Principal laboratory results successful Numerical simulation in good accordance with experimental findings New icephobic coatings show improvements over base technology regarding reduced bonding of accreted ice See Project ANTI-ICE in /

12 Active vibration damping Active vibration damping by countering structural deformations with piezo actuators Full scale tests successful: > -8dB achieved See Project Vibe-less in See

13 Technologies for Aero-Engines

14 Reducing the machining costs by process simulation Lamellar chip formation: numerical description of material damage Description of friction state through improved friction modelling Determination of friction parameters under forming conditions with the forming tribometer Model with thermo-physical material properties Flow curves for high forming speeds described by Johnson-Cook material model applicable on many hard to machine materials like Titanium Ti5553, γ-tial, Superalloys, UHSS steels etc. Lamellar chip formation in circumferential milling of Ti6Al4V Micro and macro tool geometry Material properties of substrate and coating Process parameters See Project TiZ, TiZ² in /

15 Optimization of Aluminium alloys Increasing the strength and durability at elevated temperatures by metallurgical achievements at microstructural level Investigating new alloy concepts like AlMgScZr (in close partnership with EADS, also for airframe application) Further development of metal matrix composites for specific specifications See Projects ALUSTAN and ScaLA in /

16 Electric Tail Drive / More Electric Aircraft Main innovation development of an electrically driven and controlled tail rotor antitorque device, replacing the conventional, mechanically driven and hydraulically controlled state of the art systems according to the Green Rotorcraft (GRC) Programme. The aim is to maximise the efficiency of power usage for rotorcraft and eliminate the use of environmentally unfriendly materials, including hydraulic fluid. A further aspect is the decoupling of the tail rotor speed from the main rotor speed, therefore allowing for a lower tail rotor rpm in forward flight, potentially leading to a reduced noise footprint. JTI-CS-Proposal EliTE (Electric Tail Drive Modelling, Simulation and Rig Prototype Development) JTI-CS GRC

17 AIT Austrian Institute of Technology your ingenious partner Dipl.-Ing. Rudolf Gradinger Head of Business Deveolpment LKR JTI Workshop, BMVIT, Vienna, 3. Feb. 2011