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