polymers & composites projects bruce duncanresource.npl.co.uk/.../01projects_29march_06.pdf ·...
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Polymers & Composites Projects
Bruce Duncan
Materials Characterisation Programme 2006-2009
SM06: Knowledge based design for plastics
Develop and code a validated model for predicting the long term performance of plastics used in load bearing applications
Provide guidance / measurement protocols on the use of the model
Significant technical improvement to industry – current models are inaccurate for polymers
Predictive modelling is an underpinning technology for materialsdesign
Enables users to shorten design cycles, reduce over-engineered products and increase reliability
Increase UK capabilities in predictive modelling
SM07: Improved Composite Component Design Through Validated Measurement Techniques
Develop test methodologies to support design of composite components under multi-axial loading and comprising of thick material sections
Provide validated test methods for measuring thick section properties and multi-axial material/structural response
Significant technical improvement to industry – current test methods are uni-axial in scope and suitable for relatively thin coupons
Measurement infrastructure will allow key players (e.g. Airbus) to maintain market position and influence design codes
Will increase confidence of manufacturers and users in ability of structures to perform as required in service – representative test methods
Support VAMAS biaxial test activity
SM09: Improving Quality in Composite Materials Through Provision of Traceable Measurements
Develop tools for physical property measurements to assess quality of composite components during and after manufacture
Provision of accurate cure and residual stress assessment tools, together with optical techniques for post-manufacture microstructural characterisation
Significant benefits to industry through by relating chemical state of cure to mechanical performance – cure optimisation, shorter production times
Guidance on measurement of residual stress particularly for thick sections –significant need for industry expressed during orientation
New measurement services – thermal analysis and microstructural characterisation
SM10: Characterising Interfaces inContinuous and Dispersed Materials
Develop traceable methods for characterising interfacial properties
Develop methodologies based on new measurement techniques Improved capabilities for industry / greater confidence in materials
Provide more accurate methods for measuring and predicting interfacial and interphase properties
Enable users to tailor and optimise material performance.
Establish metrology in nanocomposites area
Note: Nanocomposites are a new emerging class of materials, with a predicted market of $1 billion by 2010, with claimed significantperformance advantages over traditional materials
Materials Processing Programme 2005-2008
H1: Measurement methods for heat transfer properties data for application to polymers
Develop methods for the measurement of heat transfer properties across surfaces (e.g. solid/air interface)
Validated method
Develop standards for measurement of thermal properties of plastics (ISO TC61 SC5/WG8),
Intercomparison of thermal conductivity methods
Assess uncertainties in heat transfer data and effect on modelling predictions
Industrial case study
H4: Flow properties of filled materials
Develop new or improved measurement methods/procedures for monitoring flow properties of filled materials,
Emphasis on mixing/compounding processes
Evaluate the use and capability of innovative piezoelectric devices
Improved process monitoring (e.g. for dispersion)
Melt Flow Rate method for moisture sensitive materials (e.g. PET, PBT, nylon)
Avoid the need for solvent-based testing
Melt Flow Rate precision and uncertainty statements in support of ISO standards
U4: Dynamic properties of solid/liquid materials systems at the nano and micro-scale
Develop a macro scale resonating piezoelectric cantilever device for fluid rheology
validate using a range of reference fluidsConcept design for MEMS-scale resonating cantilever device
micron scale rheological measurement small quantities of expensive / development materials in- process monitoring
Construct a nano-mechanical tester (NTM3D) based in an SEM for measurement of solids
Microcomponents, thin films, coatings and MEMS devices microstructural changes under loads nanotribology
Materials Performance Programme 2004-2007
F02: Sensing the Onset of Damage at Polymer Surfaces due to Environmental Exposure
Develop measurement techniques to identify the onset of damage on polymer surfaces due to hostile environments
information on environmental susceptibility of polymers assess weathering performanceevaluate novel techniques (e.g. nano-indentation)
Provide guidance to enable industry to correlate results obtained from onsite measurement techniques to the damage sustained by the polymer
improve understanding of damage mechanisms to help assess the likelihood of failureevaluate effects of reprocessing on durability
F04: Accelerated Ageing Protocol For Service in Hostile Conditions
Establish the availability and credibility of existing accelerated testing procedures
assess previous work including those from past DTI projects (MMS, CPD, PAJ) and current performance projects, identify preferred approaches
Evaluate procedures using an industrial case studyPublish recommended procedures via standards and guides,
living document with future editionsencompass findings of other performance projectssave costs through having a clear procedure for data generation & greater acceptance by designers, users & regulators
F07: Permeation, absorption and desorption of liquids and gases in polymer and multilayer systems
Develop methods for assessing the ingress of chemicals into polymeric materials
low permeability materialsmulti-layer coatings, laminates or adhesive jointsdevelop supporting modelling capability
Assist in the development of reliable accelerated ageing methodologies for polymers
improve understanding of the influence of environment (stress and temperature) on permeation rates assess the effect of interfaces on transport of chemicals in polymeric systems work with other performance projects
F09: Prediction of the lifetime of adhesive joints under sustained loading
Develop methods for characterising non-linear creep behaviour in structural adhesive joints
evaluate available test methods and modelsDevelop measurement techniques and predictive model for characterising cyclic fatigue behaviour of structural adhesives
improve understanding and prediction of fatigue failureCharacterise creep behaviour in welded thermoplastics
assess predictive models Produce design protocols
Better design – more reliable jointsSMART manual approach
F10: Adhesive Design Toolkit
Integrate three new modules into existing toolkitdesign and testing for bond durability, forensic analysistest methods and standards
Increase on-line advice and guidance resources for adhesives technology
maximise the availability of knowledge developed through DTI funded programmesintegrate with other websites (e.g. Materials Solutions)develop strategy for future sustainability and promotion of the system
www.adhesivestoolkit.com
F12: Development of test methods for determining the criticality of defects in composite materials systems under long-term loading
Development defect tolerance test methods for long-term loading
residual properties assessment, strength and design issues defect growth monitoring methods and protocols
International standardisation of candidate test methods round-robin for compression after impact test
case studies demonstrate the robustness and suitability of developed proceduresstructural health monitoring and assessment
B03: A Tool to Predict Lifetime for Composites Subjected to Environmental/Fatigue Damage
Develop generic SmartManual technology using lifetime prediction as the focus
make existing NPL micro-mechanics models more easily accessible develop new models for general symmetric laminatesheat and mass transfer models
A user-friendly tool to help design damage resistant composites
allow effective “what-if” scenarios to be investigated guidance on the process required to obtain the necessary material parameters interface that is suitable for different levels of users
Materials 2007+
Ideas and needs required