Florian Roeper
Visiting Research Fellow
Project Title: CT inspection of bonded composite repairs
Abstract: Florian is an exchange research student from the Polymer Competence Center Leoben located in Leoben, Austria. His main area of research is repair of composites by adhesive bonding, which is of high interest for the aircraft industry. This interest is related to the fact that an increasing amount of structural components used in modern civil aircraft are constructed using composite materials. The scope of the research activities performed during the exchange is the investigation of damage mechanisms in repaired composite specimens that were subjected to impact loads with well-defined energy levels. For this purpose, damaged as well as pristine specimens will be inspected using high resolution computed tomography.
University: Polymer Competence Center Leoben GmbH, Leoben, Austria
Supervisor: Professor Paul Compston
Duration of stay: 19/08/2019 - 03/10/2019
Abstract: Florian is an exchange research student from the Polymer Competence Center Leoben located in Leoben, Austria. His main area of research is repair of composites by adhesive bonding, which is of high interest for the aircraft industry. This interest is related to the fact that an increasing amount of structural components used in modern civil aircraft are constructed using composite materials. The scope of the research activities performed during the exchange is the investigation of damage mechanisms in repaired composite specimens that were subjected to impact loads with well-defined energy levels. For this purpose, damaged as well as pristine specimens will be inspected using high resolution computed tomography.
University: Polymer Competence Center Leoben GmbH, Leoben, Austria
Supervisor: Professor Paul Compston
Duration of stay: 19/08/2019 - 03/10/2019
Kevin Otiquer
Visiting Research Fellow
Project Title: Performance monitor and prediction of a biaxially loaded thin composite tube
Abstract: The objective of this project was to study the behaviour of composite drive shaft. Therefore, I have concentrated on cylindrical specimens, manufactured using the automated fibre placement technique (AFP), under combined loading. During this internship, I was involved in a range of analytical and experimental activities related to biaxial testing of composite cylindrical specimens with cut out. A FEA has been carried out for the prepared specimens to predict strain and failure under combined loading. Besides, some analytical calculation have been made, including dimensioning calculations of a conventional drive shaft in order to compare with the performance of a composite drive shaft. After the analytical step, the experimental investigation has been carried out using an Instron biaxial testing machine. Digital Image Correlation (DIC) and Distributed Fibre Optic Sensing (DFOS) has been used to acquire strain fields on cylindrical specimens.
Scholarship: Sigma Clermont foundation, affiliated school Institut Mines Telecom (IMT) - University of Clermont Auvergne (UCA)
Supervisor: Professor Gangadhara Prusty
Duration of stay: 25/02/2019 - 04/08/2019
Abstract: The objective of this project was to study the behaviour of composite drive shaft. Therefore, I have concentrated on cylindrical specimens, manufactured using the automated fibre placement technique (AFP), under combined loading. During this internship, I was involved in a range of analytical and experimental activities related to biaxial testing of composite cylindrical specimens with cut out. A FEA has been carried out for the prepared specimens to predict strain and failure under combined loading. Besides, some analytical calculation have been made, including dimensioning calculations of a conventional drive shaft in order to compare with the performance of a composite drive shaft. After the analytical step, the experimental investigation has been carried out using an Instron biaxial testing machine. Digital Image Correlation (DIC) and Distributed Fibre Optic Sensing (DFOS) has been used to acquire strain fields on cylindrical specimens.
Scholarship: Sigma Clermont foundation, affiliated school Institut Mines Telecom (IMT) - University of Clermont Auvergne (UCA)
Supervisor: Professor Gangadhara Prusty
Duration of stay: 25/02/2019 - 04/08/2019
Cong Zhao
Visiting Research Fellow
Project Title: Optimisation of Advanced Grid Structure Based on Automated Fibre Placement
Abstract: Advanced grid structure (AGS) has been regarded as one of the most common composite structures. This project aims at the optimisation design and automated manufacture of a novel grid structure with significantly improved structural efficiency. The deformation mechanism of fibres around intersection region of crossed grids will be analysed considering compaction of fibre bed and flowing of resin. Moreover, the relationship between fibre distribution and the mechanical properties of composite structure will be studied in theoretical and experimental method. A universal criterion will be proposed to reduce processing defects and optimise the intersection region of AGS, based on automated fibre placement process. The success of this research will provide theoretical foundation and technical reference for the design and manufacture of high performance advanced composite grid structures, to meet requirements of lightweight and extreme service conditions.
University: Nanjing University of Aeronautics and Astronautics, China
Supervisor: Professor Gangadhara Prusty
Duration of stay: 13/05/2019 - 12/05/2020
Abstract: Advanced grid structure (AGS) has been regarded as one of the most common composite structures. This project aims at the optimisation design and automated manufacture of a novel grid structure with significantly improved structural efficiency. The deformation mechanism of fibres around intersection region of crossed grids will be analysed considering compaction of fibre bed and flowing of resin. Moreover, the relationship between fibre distribution and the mechanical properties of composite structure will be studied in theoretical and experimental method. A universal criterion will be proposed to reduce processing defects and optimise the intersection region of AGS, based on automated fibre placement process. The success of this research will provide theoretical foundation and technical reference for the design and manufacture of high performance advanced composite grid structures, to meet requirements of lightweight and extreme service conditions.
University: Nanjing University of Aeronautics and Astronautics, China
Supervisor: Professor Gangadhara Prusty
Duration of stay: 13/05/2019 - 12/05/2020
Marco Sotelo
Exchange Research Student
Project Title: Automated Manufacture of a Shape-Adaptive Large Hydrofoils
Abstract: In this work was presented the design and manufacture of a shape-adaptive large hydrofoil of 1.5 m long using the automated fibre placement technique (AFP). To determine the optimum layup of the laminate, a coupled FEM code with a Genetic Algorithm was used. With this method, the goal was to obtain the different ply orientation to achieve the required bend/twist capability of the large hydrofoil. Once the optimization phase was completed, the resulting layup orientation was used in the development of the G-code and proceeded with the manufacturing of the laminate using the AFP technique. During the automated lamination, it was implanted an embedded optic fibre as a monitor control system. After the curing process, the laminate will be submitted to fatigue loads and measure the mechanical response. The results obtained will be compared to experiments made on laminates with similar characteristics built with classic manufacturing process (RTM).
University: University of Liege, Belgium
Scholarship: Erasmus Mundus Masters Course in Integrated Advanced Design and Offshore Structures (EMship)
Supervisor: Professor Gangadhara Prusty
Duration of stay: 02/07/2018 - 09/11/2018
Abstract: In this work was presented the design and manufacture of a shape-adaptive large hydrofoil of 1.5 m long using the automated fibre placement technique (AFP). To determine the optimum layup of the laminate, a coupled FEM code with a Genetic Algorithm was used. With this method, the goal was to obtain the different ply orientation to achieve the required bend/twist capability of the large hydrofoil. Once the optimization phase was completed, the resulting layup orientation was used in the development of the G-code and proceeded with the manufacturing of the laminate using the AFP technique. During the automated lamination, it was implanted an embedded optic fibre as a monitor control system. After the curing process, the laminate will be submitted to fatigue loads and measure the mechanical response. The results obtained will be compared to experiments made on laminates with similar characteristics built with classic manufacturing process (RTM).
University: University of Liege, Belgium
Scholarship: Erasmus Mundus Masters Course in Integrated Advanced Design and Offshore Structures (EMship)
Supervisor: Professor Gangadhara Prusty
Duration of stay: 02/07/2018 - 09/11/2018
Piotr Jabłoński
Exchange Research Student
Project Title: Development of computational system for MMC coatings.
Abstract: this research assumes development of system that would be useful in design and development of metal-matrix composite coatings. During study, finite element model for composite coatings concerning contact loads and thermal stresses will be developed and validated. What is more, independent computer software together with GUI will be developed for output data visualization and processing. Whole study is interdisciplinary, as it incorporates areas of computational mechanics and software development.
University: Poznan University of Technology (Poznań, Poland)
Scholarship: PANTHER - Pacific Atlantic Network for Technical Higher Education and Research
Supervisor: Professor Gangadhara Prusty
Duration of stay: 13/11/2017 - 12/05/2018
Abstract: this research assumes development of system that would be useful in design and development of metal-matrix composite coatings. During study, finite element model for composite coatings concerning contact loads and thermal stresses will be developed and validated. What is more, independent computer software together with GUI will be developed for output data visualization and processing. Whole study is interdisciplinary, as it incorporates areas of computational mechanics and software development.
University: Poznan University of Technology (Poznań, Poland)
Scholarship: PANTHER - Pacific Atlantic Network for Technical Higher Education and Research
Supervisor: Professor Gangadhara Prusty
Duration of stay: 13/11/2017 - 12/05/2018
Grazyna Ryzinska
Visiting Senior Research Fellow
Project Title: Evaluation of the influence of hoop fiber to axial fiber ratio (H / A) on the amount of absorbed energy in the process of the axisymmetric tube compression in dynamic conditions.
Abstract: Recently, there has been considerable interest to incorporate composite crashworthy structures in the aerospace and automotive industries. Crashworthiness is typically defined as the ability of a structure to absorb energy in a collision or an impact, and survive; in the case of a passenger vehicle, this would be the ability to ensure the survivability of the occupants. Well-designed composite crush structures can absorb significantly more energy per unit mass than metals. The crushing tests of samples with use of various hoop fiber to axial fiber ratio in dynamic conditions are planned in this work. Unidirectional prepreg and plain carbon prepregs of various weights will be used in the study. Made research may allow for significantly increasing in transport safety.
University: Rzeszow University of Technology, Poland
Grant: Endeavour Scholarship and Fellowship, Australia Awards
Supervisor: Professor Gangadhara Prusty
Duration of stay: 1/2/2018 – 30/6/2018
Abstract: Recently, there has been considerable interest to incorporate composite crashworthy structures in the aerospace and automotive industries. Crashworthiness is typically defined as the ability of a structure to absorb energy in a collision or an impact, and survive; in the case of a passenger vehicle, this would be the ability to ensure the survivability of the occupants. Well-designed composite crush structures can absorb significantly more energy per unit mass than metals. The crushing tests of samples with use of various hoop fiber to axial fiber ratio in dynamic conditions are planned in this work. Unidirectional prepreg and plain carbon prepregs of various weights will be used in the study. Made research may allow for significantly increasing in transport safety.
University: Rzeszow University of Technology, Poland
Grant: Endeavour Scholarship and Fellowship, Australia Awards
Supervisor: Professor Gangadhara Prusty
Duration of stay: 1/2/2018 – 30/6/2018
Kamila Kustron
Visiting Senior Research Fellow
Project Title: Research on verification and validation of FEM modelling development of delamination resulted by low-speed impact for AFP fabricated C/PEEK composite shell.
Abstract: An initiation-propagation FEM model of the delamination with progressive damage phenomenon inclusion in a flat and curved laminate shells of carbon reinforced thermoset and thermoplastic polymer composites are under consideration in the research. Interlaminar and intralaminar, adhesive and cohesive bondings are included. The smart diagnostic technology based on AE&FBG-SHM system is used for an assessment of the progressive damage phenomenon.
University: Warsaw University of Technology (Warsaw, Poland)
Grant: Erasmus Mundus - Pacific Atlantic Network for Technical Higher Education and Research – PANTHER – programme
Supervisor: Professor Gangadhara Prusty
Duration of stay: 26/12/2017 – 16/07/2018
Abstract: An initiation-propagation FEM model of the delamination with progressive damage phenomenon inclusion in a flat and curved laminate shells of carbon reinforced thermoset and thermoplastic polymer composites are under consideration in the research. Interlaminar and intralaminar, adhesive and cohesive bondings are included. The smart diagnostic technology based on AE&FBG-SHM system is used for an assessment of the progressive damage phenomenon.
University: Warsaw University of Technology (Warsaw, Poland)
Grant: Erasmus Mundus - Pacific Atlantic Network for Technical Higher Education and Research – PANTHER – programme
Supervisor: Professor Gangadhara Prusty
Duration of stay: 26/12/2017 – 16/07/2018
Marina Plöckl
Exchange Research Student
Project Title: Characterization of the influence of placement rate on the mechanical properties of laser-assisted AFP composite laminates by means of in-situ mircoCT compression tests.
Abstract: Automated Fiber Placement (AFP) of composite materials has great potential to become an manufacturing technology for components of high volume applications. Parts of thermoplastic composites can be fully processed with this technology by in-situ consolidation of the material via laser heating. This ability to manufacture composite parts without an out-of-autoclave (OOA) process potentially saves high running and capital costs that are associated with autoclaves. However, to obtain autoclave-level mechanical properties via AFP is still challenging. In this study unidirectional carbon-fiber-reinforced PEEK laminates, manufactured by laser-assisted AFP with different placement rates, are compared. The mechanical behavior of the composite laminates are analyzed by means of in-situ microCT compression tests. The focus of these measurements is especially on the distribution and geometry of the voids within the material and the failure initiation under compression.
University: Technical University of Munich
Scholorship: TUM Graduate School and Faculty Graduate Center Mechanical Engineering, Technical University of Munich (TUM)
Supervisor: Professor Paul Compston
Duration of stay: 12/02/2018 – 06/04/2018
Abstract: Automated Fiber Placement (AFP) of composite materials has great potential to become an manufacturing technology for components of high volume applications. Parts of thermoplastic composites can be fully processed with this technology by in-situ consolidation of the material via laser heating. This ability to manufacture composite parts without an out-of-autoclave (OOA) process potentially saves high running and capital costs that are associated with autoclaves. However, to obtain autoclave-level mechanical properties via AFP is still challenging. In this study unidirectional carbon-fiber-reinforced PEEK laminates, manufactured by laser-assisted AFP with different placement rates, are compared. The mechanical behavior of the composite laminates are analyzed by means of in-situ microCT compression tests. The focus of these measurements is especially on the distribution and geometry of the voids within the material and the failure initiation under compression.
University: Technical University of Munich
Scholorship: TUM Graduate School and Faculty Graduate Center Mechanical Engineering, Technical University of Munich (TUM)
Supervisor: Professor Paul Compston
Duration of stay: 12/02/2018 – 06/04/2018
Ginu Rajan
Visiting Senior Research Fellow
Bio:
Dr. Rajan is a Senior Fellow/Lecturer at the University of Wollongong, Australia. He obtained a PhD degree in Engineering from Dublin Institute of Technology (DIT), Ireland in 2009. He was a Project Manager at the Photonics Research Centre of DIT during 2009-2012 and a VC Research Fellow at UNSW during 2012-2015. He has published over 135 articles in journals, conferences and as book chapters and two patents are also filed. He is also the editor of the books “Optical Fiber Sensors:- Advanced Techniques and Applications” and "Structural Health Monitoring of Composite Structures using Fiber Optic Methods", both published by CRC Press. He serves as a technical program committee chair and member of conferences in the area of optical fiber sensors and smart composite materials, editorial board member and reviewer of several journals, and reviewer for funding applications of several organizations. His research and teaching interests includes optical fibre sensing and its applications in a number of engineering areas. At AMAC he is leading the fibre optic structural health monitoring research and its applications in composite structures.
University: University of Wollongong, Australia
Supervisor: Professor Gangadhara Prusty
Duration of stay: 2018 – 2021
University: University of Wollongong, Australia
Supervisor: Professor Gangadhara Prusty
Duration of stay: 2018 – 2021
Andreas Kollmannsberger
Exchange Research Student
Project Title: Heating characteristics of laser assisted Thermoplastic-Automated Fiber Placement of 3D paths
Abstract: Thermoplastic Automated Fiber Placement (TP AFP) is a fully automated process to manufacture high performance composite parts. The thermoplastic matrix offers unique properties to the composite part, but also requires special manufacturing process knowledge. The ultimate goal of TP AFP process development is reaching sound in situ consolidation, as this reduces manufacturing steps and costs. However, today the TP AFP process is limited to flat parts or geometries with either constant or a very soft curvature. The work focuses on characterizing the laser heating characteristics of convex 3D geometries with a small corner radius. A thermal model of the process is accompanied by lay up trials with a state-of-the-art TP AFP machine on 3D geometry.
University: Technical University of Munich
Scholorship: TUM Graduate School and Faculty Graduate Center Mechanical Engineering, Technical University of Munich (TUM)
Supervisor: Professor Paul Compston
Duration of stay: 27/04/2018 – 04/06/2018
Abstract: Thermoplastic Automated Fiber Placement (TP AFP) is a fully automated process to manufacture high performance composite parts. The thermoplastic matrix offers unique properties to the composite part, but also requires special manufacturing process knowledge. The ultimate goal of TP AFP process development is reaching sound in situ consolidation, as this reduces manufacturing steps and costs. However, today the TP AFP process is limited to flat parts or geometries with either constant or a very soft curvature. The work focuses on characterizing the laser heating characteristics of convex 3D geometries with a small corner radius. A thermal model of the process is accompanied by lay up trials with a state-of-the-art TP AFP machine on 3D geometry.
University: Technical University of Munich
Scholorship: TUM Graduate School and Faculty Graduate Center Mechanical Engineering, Technical University of Munich (TUM)
Supervisor: Professor Paul Compston
Duration of stay: 27/04/2018 – 04/06/2018