Composites Joining and Repair Signature Initiative Update

Transcription

1 Composites Joining and Repair Signature Initiative Update Chuck Zhang School of Industrial & Systems Engineering and Georgia Tech Manufacturing Institute April 10, 2018

2 Outline Significance of composite joining and repair CAIIAC project progress since GTMI EAB meeting in September 2017 Update on NSF IUCRC proposal for D-CJAR EAB feedback

3 Why Composite Joining and Repair (CJAR)? - Increasing Usage and Aging of Composite Structures 2015 backlog for commercial composite (>50%) aircraft: 787: 850 units A350: 750 units Breakdown of materials used in the 787 Dreamliner Source: Boeing Breakdown of materials used in the A350 Source: Airbus ,000 units/year BMW 7 s hybrid roof frame construction Source: BMW, SGL A large number of legacy military aircraft requiring CJAR: UH-60: >4,000 units since 1974 C-130: >2,500 units since and beyond: high volume production of CFRP cars/trucks 2017 Honda Ridgeline Source: Honda BMWi3 Electric CFRP Car and Life Module (passenger cell) Source: BMW

4 CJAR Significance: National Security and Societal Impact National Security: Improved military equipment readiness Reduce cost for maintenance Societal: Increase in flight and other transportation safety Significant increase in on-time rate and quality of public transportation services (~60% of flight delay is related to aircraft maintenance*) Emission reduction by supporting more energy efficient aircraft and cars * U.S. Department of Transportation Bureau of Transportation Statistics

5 Financial Impact of CJAR for Aircraft and Air Lines Industries Lifecycle airframe MRO cost (mainly composite repairs) is estimated at 7.7% of the initial aircraft purchase cost Total airframe lifecycle MRO cost for all A350 and B787 aircraft delivered by Year 2021 is estimated to be at ~$34.1B. Large scale composite repair: Nacelle reskin and re-core repair Courtesy of Delta TechOps Repair cost = 1/3 of Replacement cost Grounding an Airbus A350 for one entire day could cost over $1M to air line companies (over $40,000 per hour)

6 CAIIAC Proposed Transformation for Composite Repairs: Digital Composite Joining and Repairs (D-CJAR) Current: Slow, unreliable, unrepeatable manual repairs Future D-CJAR: Automated, rapid, and reliable repairs (AR3) CAIIAC D-CJAR Goal: Reduce composite joining and repair operations cycle time and cost by 50% by the end of the CAIIAC roadmap period (10-15 years)

7 CAIIAC Consortium Partners > 50 industry companies and organizations spanning the entire composites supply chain Including a large number of SMEs Involving major composites trade associations: ACC, ACMA, GAMA, SAMPE, etc. Air Force Research Laboratory LMCO Solvay International Partners: - A*STAR/SIMTech, Singapore - Airbus, France - BCT, Germany - Fraunhofer Institute, Germany

8 CAIIAC CJAR Technology Roadmaps Book

9 CAIIAC Industry Critical Demonstration Projects Large-Scale, Long-Term Advanced quantitative NDI techniques for weak bonds ( kissing bonds ) Rapid, field-deployable NDI techniques for large structures Large area inspection with NDI and/or structural health monitoring Development and assessment of CJAR techniques involving heterogeneous materials CJAR databases and simplified design tools/software Fast curing resins for rapid on-site repairs Integrated and automated/robotic preparation, bonding and NDI processes Medium-Scale, Short to Medium-Term Rapid, field-deployable pre-bonding inspection of surface treatment In-situ monitoring of bonding process using advanced sensing Rapid tooling for repair using advanced materials and manufacturing techniques (such as 3D printing) NDI techniques for heat damages Remote controlled drone/robot operations for CJAR Improvement of CJAR operations and training with augmented reality Time study on composite repair

10 Our Vision: Digital Composite Joining and Repair Structure damage evaluation with quantitative damage assessment tools (e.g., digital AR/NDI techniques) Computational tools for joining and repair analysis, design and planning Materials and structures preparation and inspection with digital, automated and controlled tools (such as plasma surface treatment and FTIR surface inspection) Robotic/automated scuffing/bonding/joining processes with in-situ monitoring and control for repeatability and reliability Quantitative NDI techniques for bonded/repaired structures D-CJAR informatics with advanced sensing, IoT and AI techniques

11 D-CJAR Laboratory at GTMI Raw materials storage Composite fabrication stations Surface treatment system Surface measurement and characterization devices Bonding/joining process setup with in-situ sensing Materials testing and NDI equipment Room 224 of Callaway Manufacturing Research Center Building

12 CAIIAC Project Progress Since GTMI EAB Meeting in September 2017 Continue to engage industry/government partners for D-CJAR R&D projects, research facilities development, and workforce training Promoted CAIIAC work at 2017 CAMX Conference (Special AMTech Roadmapping Session and CJAR Panel) Submitted pre- and full-proposals for planning grant to establish an NSF IUCRC on D-JCAR

13 Outcomes of Industry Partners Engagement Activities Conduct joint R&D projects on CJAR Delta Air Lines: Advanced Sensing, Non-Destructive Evaluation and Materials Quantification for Composite Aircraft Repair $497,500, 3/6/2017-3/5/2019 Lockheed Martin Corp.: Comprehensive Investigation of Nondestructive Inspection of Weak ( Kissing ) Bonds in Composite Joints $200,000, 12/12/ /11/2018 (Phase II) - ongoing $200,000, 12/12/ /11/2019 (Phase III) - proposed Develop demonstration facilities Delta Air Lines and LMCO: GTMI D-CJAR Lab development and improvement

14 Sponsored Research: Materials Preparation and Bonding Process Monitoring for Composite Aircraft Repair and Maintenance Upper layer surface Printed electrodes Dielectric layer Lower layer surface Printed electrodes Investigation of materials and repair processes for efficient and reliable composite structures joining

15 Sponsored Project: Comprehensive Investigation of Nondestructive Inspection of Weak ( Kissing ) Bonds in Composite Joints Task 1: Controlled Fabrication Investigation of kissing bond mechanism Study of effects of surface and process parameters on bonding strength Fabrication of test panels Task 2: Testing and Characterization Mechanical testing Linear and nonlinear ultrasound testing Experiments for models validation and calibration Task 3: Modeling Cohesive zone modeling (CZM) for bonded joints Wave propagation modeling Model validation and calibration Bonded joints with various strengths Panel fabrication knowledge and database Bonding strength vs surface and process parameters Bonding failure modes Calibrated models CZM model for bonding strength estimation Wave propagation model Improved reliability and confidence of bonded structures through precise control of bonding process and effective NDI

16 NSF Industry/University Cooperative Research Center on D-CJAR Goal: create a sustainable center of excellence on CJAR with strong industry collaboration and commitment How: through NSF Industry-University Cooperative Research Center (IUCRC) competition When: planned start date - Summer 2019 (see detailed schedule later) Partners: University partners: University of Tennessee/Knoxville (Auto/Energy Applications) and Wichita State University (Testing/Certification) Oakland University (Auto/Ground Vehicles) Industry partners: CAIIAC members and industry companies collaborating with partnering universities Conditions and limitations: membership requirements

17 Overview of NSF IUCRC Program The NSF IUCRC program develops long-term partnerships among industry, academe, and government. The Centers are primarily supported by industry members, with NSF taking a supporting role. A multi-university center is encouraged, with each university constituting a Site of the Center. An IUCRC can be supported up to 3 phases with 5 years for each phase. Application starts with a preliminary proposal, followed by a planning grant proposal (for $15,000 for a 12-month period) and the Site full proposal. NSF support/site (annual): Phase I - $150,000; Phase II - $100,000; Phase III - $50,000. Industry membership (annual): Phase I -$150,000 and 3 distinct full members; Phase II -$200,000 and 4 distinct full members; Phase III - $250,000 and 5 distinct full members.

18 University Partners Selection University of Oakland Research strength in materials joining Strong partnership with auto and defense industries University of Tennessee/Knoxville Research strength in composites Connection/partnership with IACMI Full Proposal: December 20, 2018 Wichita State University (initially) Research strength in composite testing and certification Strong partnership with FAA and aero industry Quit after planning grant due to IP concerns

19 D-CJAR IUCRC Timeline NSF IUCRC Deadlines Preliminary Proposal: October 18, 2017 (submitted and invited) Planning Grant Proposal: December 20, 2017 (submitted and under review) Planning grant workshop in August 2018 Full Proposal: December 20, 2018 Planned Starting Date of D-CJAR IUCRC: Summer 2019

20 NSF Industry/University Cooperative Research Center on D-CJAR Aircraft Automobile Infrastructure Protective Eq. Design, Analysis & Standardization for D-CJAR D-CJAR Materials and Processing Engineering Testing and NDI/NDE Advanced Data Analytics for D-CJAR

21 Proposed D-CJAR IUCRC Research Thrusts and Topics Design and Analysis for D-CJAR D-CJAR Materials and Process Engineering - ICME and design for CJAR - Advanced materials for CJAR - Damage tolerance for CJAR - Joining process sensing, monitoring and control - Database, standards and qualification - Multi-/hybrid-materials joining - Robotics and process automation Testing and Non-destructive Evaluation Advanced Data Analytics for D-CJAR - Advanced testing/characterization - IoT for CJAR - NDI for weak/ kissing bonds detection - Diagnostics and prognostics for CJAR - Fast large-area structural inspection - Data analytics and machine learning tools for CJAR

22 D-CJAR IUCRC Measurable Metrics Measurable metrics per IUCRC site: Number of consortium members: > 10 (5 full and 5 associate, with $30,000 for full- and $10,000 for associate-members) Amount of funding per year: > $350,000 Number of projects: 5 or more Number of faculty involved: 8-10 Number of graduate students supported: 5 or more Number of publications and patents/licenses: 5/1

23 Industry Partners Which Provided Letters of Support to GT Site Abaris Training AFSC-Robins AFB Boeing Chomarat Delta Air Lines Fiat Chrysler Automobiles Fokker Aerostructures Henkel Lockheed Martin Lockheed Martin - Sikorsky Optomec Owens Corning Siemens Solvay

24 Potential Challenges and Hurdles Membership requirements It may not be easy for some companies, particularly SMEs, to provide memberships (cash) Retention of industry members IP and NDA issues IUCRC is for pre-competitive R&D; some industry members may prefer different models (WSU case) Different partners may have their own policies; reaching to agreement may cause long delays Space Centralized space for D-CJAR labs and offices is preferred; but not easy to obtain

25 How Can EAB Help? Advice/suggestions for D-CJAR IUCRC Recruitment of industry/government members for D-CJAR IUCRC Funding/funding opportunities and referrals

26 Questions/Suggestions/Comments