Polymers & Composites Projects

Current projects portfolio

Bruce Duncan

Materials Characterisation Programme 2006-2009

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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

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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

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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

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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

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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

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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

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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

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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

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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

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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

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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

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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

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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

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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+

Project proposals in development/formulation