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
16.02.2011 3AAC Presentation
Company Organisation
Competences and Services
16.02.2011 4AAC Presentation
Polymer Composites
16.02.2011 5AAC Presentation
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
16.02.2011 6AAC Presentation
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
16.02.2011 7AAC Presentation
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
16.02.2011 8AAC Presentation
���� CTE reduction
Polymer Composite
Bulky paper
Re-inforced nano-composites - application for structures
Polymer Composites - Nano Composites
16.02.2011 9AAC Presentation
Inorganic Composites
16.02.2011 10AAC Presentation
Materials & Components Testhouse
16.02.2011 11AAC Presentation
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 Testhouse
16.02.2011 AAC Presentation 13
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
Materials & Components Testhouse
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
W: www.aac-research.at
16.02.2011 AAC Presentation 18