Aerospace & Advanced Composites GmbH...Aerospace & Advanced Composites GmbH c/o Forschungszentrum...

GF Dipl.-Ing. Dr. Norbert Gamsjäger

GF Dipl.-Ing. Dr. Reinhard Polak

Aerospace & Advanced Composites GmbH

AAC is positioning itself as the only commercial provider of research, development and testing in the field of composite materials for

aerospace and terrestrial applications in Austria

Company Profile

Company data

� Founded 19.8.2010, operational start on 1.10.2010

� Headquarters: Wiener Neustadt, Viktor-Kaplan-Straße 2(business location „Technology park Seibersdorf“ until end 2011, then TFZ Wiener Neustadt)

� Shareholders: Staff members, AC2T research GmbH, other experts

� 28 scientific und technical staff members, 6 freelancers, 4 new employees, managing directors und administration

Mission statement

16.02.2011 2AAC Presentation

� Reorganisation by product linesCalard

Pönninger

Simon

Stelzer

Wendrinsky

Steiner

Schindel

Acquisition/Marketing

Stelzer/Pönninger

Inorganic Composites

Merstallinger

Office: Nussbaumer

Controlling: N.N.

Accounting: Ac²T subcontract

QM: N.N.

Polymer Composites

Gamsjäger

Materials & Components

Testhouse

Scheerer

Liedtke

Macho

Baca

Merstallinger

Sales

Nier

Uschan

Hahn

Jogl

Fink

Karlovsky

Goss

Fabing

Cabelka

Henzel

Mozdzen

Costin

Schorn

Scheerer

Wagner

Marischler

Composites

Materials

SHM

Composites

Materials

Mech./

Thermal

Testing

SEM

Tribology

Managing Directors

Gamsjägercommercial/organisational

Polakscientific/strategic

Consulting: Semerad

+6 freelancers for project specific tasks


Company Organisation

Competences and Services


Polymer Composites


Polymer Composites - Composite Development Loop

Development of Composites

LFI ProcessRTM Process

Control with

US ScanningCharacterisationResin Modification

Autoclave Process

Altern.:

warm press

VARTM

Mix with 7.43 w% of Al2O3 nano-powder


Process Modelling

• resin flow through the fiber bed

• thermal analysis part and mold

• chemical reaction of the resin

Experimental validation

• resin flow through fiber bed

• shrinkage

• micro defect analyses

Polymer Composites - Modelling


Process modelling and verification of resin infusion

Re-inforced nano-composites - application for structures

�� Mechanical properties: Re-inforced nano-composites with good nano-particle

dispersion exhibit significant E modulus improvement under bending.

The addition of nano-particles to epoxy resin

increases the E modulus under bending

Re-inforced nano-composites: Mechanical tests results E Modulus (Gpa)

0.0

0.5

1.0

1.5

2.0

2.5

3.0

3.5

4.0

A297:

Refe

ren

ce

A271:

Al2

O3 5

%

A284:

Al2

O3

7.4

3%

A272:

Al2

O3 1

0%

A290:

ZrO

2

1%

A291:

ZrO

2

5%

A292:

ZrO

2

10%

A295:

Al2

O3 s

m

2.5

%A

294:

Al2

O3 s

m

5%

A293:

Al2

O3 s

m

7.6

3%

A306:

YS

Z

3.8

%

A305:

YS

Z

7.5

%

A304:

YS

Z

10%

+17%

Polymer Composites - Nano Composites


�� CTE reduction

Polymer Composite

Bulky paper

Re-inforced nano-composites - application for structures

Polymer Composites - Nano Composites


Inorganic Composites


Materials & Components Testhouse



16.02.2011 AAC Presentation 12

Microstructure – material analysis and support

• Light Microscopy - LIMI

• Electron- and Ion Microscopy

High Resolution Scanning Electron Microscopy – HRSEM

Energy Dispersive Spectroscopy – EDS

Electron Back-Scattered Diffraction – EBSD

CrossBeam Workstation - HRSEM/FIB

• 3D Analysis - FIB Tomographie

• 3D Nano-Metrologie

• Surface topograhy

• Qualitative & Quantitative characterisation of structures

• micro and nano scale

• Interface characterisation

• Chemical & cristallographic analysis

•Ultramicro-, Micro- and hardness analysis

• Vickers ( 0,005 bis 294N)

• Material structuring and 3D analysis

Thermal Cycling & Outgassing• Temperatures: -160 to +200 °C

• Pressure: <10E-6 mbar

Outcome:• CVCM (Collected Volatile Condensable Material)• RML (Recovered Mass Loss)

• TML (Total Mass Loss)

• WVR (Water Vapour Regained)



Materials & Components testing under extreme environment

Sublimation Chamber• Temperatures: up to +600 °C• Pressure: <10E-6 mbar

Outcome:• Quadrupol Mass Spectra Analysis

• Online Mass Loss

• Dynamic: Mass Loss vs. Temperature• Static (isotherm): Mass Loss vs. Time

Thermal Vacuum Chamber

• Structural Health Monitoring (SHM): Implementation of a NDE-System (Non-

Destructive Examination) in a component or structure for a continuous monitoring of

the structural status (health) of the component / structure in operation

• Development of diagnostic systems for aerospace components for on-line

monitoring of the health status during operation

• Improved lifetime models of composite materials leading to individual adaptable

inspection and maintenance strategies and advanced structural design


Structural Health Monitoring

2 Cleansky projects in 2010

• 2 Projects have been funded in 2010: Organocs (100Keuro) and Thermocs (60Keuro)

• Projects of Green Regional Aircraft topic: development of advanced resin systems for composites

• The objectives were the manufacturing of nanomodified epoxy resin systems with various nano-particles, various contents (from 0.1% to 15%) and various surface modifications.

• Nanoparticles has been selected among:

– 1D needle shape: Carbon Nanotubes (Baytube GmbH)

– 1D needle shape: Carbon Nanofibres (Showa Denko K.K.)

– 2D plate shape: Nanoclay (Southern Clay Products Inc. )

– 3D ball shape: Zircon Dioxide (Evonik Degussa GmbH), Boehmite (AlOOH, Sasol GmbH)

• Dispersion techniques developed at AAC have been used.

• The results demonstrated the specific influence of each nano-reinforcements, e.g.:

– Increase of the electrical conductivity with carbon nanofibres

– Increase of the impact resistance with carbon nanotubes

– Increase of the resin stiffness with ceramic nanoparticles

• The project also demonstrated the difficulties to combine them to obtain a „high performance“resin.

16.02.2011 15

Nanoparticles: 10-50 nanometers

16.02.2011 16

Carbon nanotubes: impact resistanceCarbon nanofibers: electrical conductivity

Alumina nanoparticles:

stiffness

Difficulties:•Fine structure!

•Dispersion !

•Stabilisation!

•De-agglomeration!

Open for further

developments:

The most

efficient

combination!

1 Cleansky project to be started in 2011

• 1 Project is currently under negotiation: FOS3D (ca. 590 k€) within the Smart Fixed Wing Aircraft topic: JTI-CS-2010-3-SFWA-01- 027

• The objective of FOS3D is the development and Testing of a Fiber Optic System for Deflection and Damage Detection in order to control actively actuated morphing wing structures

• Consortium:

– AAC – project leader

– IMA project partner

• FOS3D concept

16.02.2011 17

Opto-electronic device

Preamplifiers with

bandpass (20 – 400 kHz)

Low-pass (< 100 Hz)

AE –channels analog input channels

Acoustic Emission System

Fiber optic coil sensor

Fiber optic cable

Contact

Aerospace & Advanced Composites GmbH

c/o Forschungszentrum Seibersdorf

2444 Seibersdorf

Austria

T: +43-(0)2622-90550-0

F: +43-(0)2622-90550-99

E: [email protected]

W: www.aac-research.at


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