IMS&CPS

Innovative Material Synergies & Composite Processing Strategies

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 Obiettivo del progetto (Objective)

'Mutation of transport industry to carbon fibre reinforced polymer (CFRC) is now ineluctable in order to reduce our mobility environmental imprint. This sector is at a turn of its conversion from metal to composite, which should impose a radical rethinking of the whole supply chain. Combined developments of materials and matched processes is the main strategy of IMS&CPS project, only such a concerted effort may favor best synergies in the final part within a cost-effective process. The Main challenges for definitive conversion of transport sector to CFRC remains: (1) improvement of mechanical properties (mainly impact properties and interlaminar failure) (2) development of cost-effective manufacturing processes. IMS&CPS will address both challenges: - by positioning of CNT at specific locations (in the reinforcing fibre, at the fibre surface and/or in the matrix) and with specific orientations (random or 1D, 2D-orientated) as predicted by advanced engineering and innovative modeling tools for optimized properties. - by manufacturing CFRC by closed mould technologies : adapted RTM, SQRTM(RTM with prepreg) and Quickset processes, the today most competitive processing alternatives to autoclaves. Cheap and/or automated 3D-preform will be also developed for offering highest and easiest part integration in order to reduce at maximum assembly costs, which counts for one third of a CFRC part costs. CNT offers other opportunities to the designers: electrical, thermal conductivities, fire- and wear-resistance as well as sensing capabilities. Such performance improvements will be studied in IMS&CPS. A special effort will be focused on CFRC electrical conductivity enhancement by CNT insertions for lightning degradation prevention, for EMI shielding, which are today aerospace important issues. Sensing properties offered by CNT insertion will be also investigated. One highly-integrated part will be finally elected in order to demonstrate all IMS&CPS achievements.'

Introduzione (Teaser)

Novel ways of manufacturing aircraft parts could decrease pollution and enhance the aviation manufacturing industry in Europe.

Descrizione progetto (Article)

The number of passengers travelling by aeroplane in 2010 has almost quadrupled in the last 30 years, reaching from around 260 million to 1 billion passengers. With increased pollution and greenhouse gases, researchers worldwide are looking for newer technologies to decrease aeroplane weight and save on fuel. In this context, the EU-funded project 'Innovative material synergies & composite processing strategies' (IMS&CPS) investigated new nanotechnologies and processes to make lighter planes.

Taking advantage of a process called same-qualified-resin-transfer-moulding (SQRTM) to produce a one-shot complex structure, the team sought to reduce metal parts. It also studied pre-impregnated fabrics and advanced fabric preforms, including materials based on carbon nanotubes, to improve electrical conductivity. This led to the successful development of two typical aircraft parts, namely a part of fuselage and a re-engineered nose landing gear door.

The project team then conducted a life-cycle analysis that showed to what extent these parts could decrease both manufacturing costs and an aircraft's environmental footprint. In addition, the team looked into ways of integrating carbon nanotubes into composite materials not only in the aviation sector but also in the rail sector.

Importantly, IMS&CPS has granted access to all its valuable research based on SQRTM and nanotechnology, potentially enabling greener manufacture of doors, flaps, spoilers, ailerons, slats and other aircraft parts. A more robust aviation manufacturing industry and a decrease in carbon emissions could result from these new innovations, helping European manufacturers lead in making better aircraft parts. The competitiveness of the European air transport industry will certainly benefit from such an endeavour.