2_Polymer Nanocomposite Coatings for Aerospace Composite Components - Dr. Hua-Xin Peng, ACCIS, United Kingdom

7/29/2019 2_Polymer Nanocomposite Coatings for Aerospace Composite Components - Dr. Hua-Xin Peng, ACCIS, United Kingdom

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www.bris.ac.uk/composites

Polymer Nanocomposite Coatings foraerospace composite components

Hua-Xin Peng ( )

Advanced Composites Centre for Innovation and Science ACCIS)

&

NanoScience and Quantum Information (NSQI)


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13 staff members ~20RAs ~50 PhDs

25m National Composites Centre

7.2m Centre for Doctor Training (CDT)

Rolls Royce UTC (4.35m)

Industrial Doctorate Centre (3.8m)

GE Aviation UTSP (1.25m)

Vestas UTC (1.3m) Extensive links to aerospace companies

Advanced Composites Centre for

Innovation and Science(ACCIS)


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ACCIS research themes

Multifunctional Composites

and Novel Microstructures

Design, Analysis and Failure

Intelligent Structures

Composites Processing andCharacterisation

HierarchicalMicrostructures

Scaling effectson strength

Multistablemorphingcomposites

Simulating drapeon complexparts


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National Composites Centre (GBP 25m)


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Carbon laminate

Carbon sandwich

Fiberglass

Aluminum

Aluminum/steel/titanium pylons

Carbon laminate

Carbon sandwich

Fiberglass

Aluminum


Carbon laminate

Carbon sandwich

Fiberglass

Aluminum


Applications ofCarbon Fibre Composites (CFC)

National Composites Centre


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AgustaWestland

AirmanJamesR.Evans,U.S.Navy

Aeronautical applications focus

Report2009


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HH60 Kuwait Landing

AgustaWestland


The Challenges


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HH60 Kuwait Landing

AgustaWestland


The Challenges


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The Challenges

Erosion

- particle abrasion

- sharp object cut

- water erosion

Lightning protection

De-icing

Solution Nano-enabledCoatings


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Nano-particle(s) Polymeric matrix

Particles functionalization & matrix compatibility

Dispersion & Formulation

(Bead milling system)

Spray coatings

(Dowty)

Tape applications

(3M, WHL)

Erosion performance:---Sand, Water, Cutting

Physical properties

---Lightning effects

Mechanical properties

Paints

(PPG, AUK, WHL)

Propellers (DP), rotor blade (WHL, 3M), Paint (WHL,

Airbus, PPG), wind turbines (3M), automobiles (3M).

ACCIS nano-Roadmap

Fundamentals

Routes toApplication

Characteristics

Applications


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Erosion & Impact Damage


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Erosion & Impact Damage

Development erosion and cut resistant polymer nano-composite coatings for rotor & propeller blades

Comparison of PU tape (left) & sprayed PU (right) to 1%nano-diamond coating (middle) in sand erosion tests

PUtape 1%ND SprayedPU


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Sand Erosion Mechanism

Soft/ductilecoating

Hard/brittlecoating

Nanocomposite

coating


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Nanocomposite Scratch Resistance

Scratch-resistance performance of nano-alumina particleswith various loading in UV curable coatingsNanophase Technologies Corp.


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Nano-diamond reinforcement

Why nano-diamond?

Driven by potential erosion/cut

protection:

Hard

Mass produced (and cheap)

Potential for surface functionality

And coincidentally >5x greaterthermal conduction than silver

MaterialThermal

Conduction

(W/mK)Epoxy 0.59

Polyurethane 0.16

Alumina 40

SiC 120

Aluminum 220

Gold 310

Nickel 90

Silver 429

St. Steel 16

Titanium 22

Diamond >2000

d l


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Key to reap the full benefits of the nanoparticles

Provides the low cost and high performance

Large-scale production.

Involves the following:

Particle/polymer interface modification

Dispersion

Incorporation into spraying apparatus

Fundamental aspects Process 1

F d t l t P 2


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Preploymer Curing AgentNanoparticles

Add particles to solvent whilemixing with HSD

Highly loaded, but de-agglomerated and dispersed

slurry

Recirculate in bead mill withdispersant

Mix with solvent Heat to 70C

Mill Base

Add Mill base toparticle slurry

slowly but withrapid stirring using

HSD/Bead mill

Mix with solvent Heat to 70C

1 2 1 2

1 spray coating

2 moulding(heated mould)

Fundamental aspects Process 2

F d t l t F ti li i


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Chlorine stage 1: Free radical attack of surface hydrogen

ND

H

+ Cl2

ND

Cl

+ HCl

Functionalising nano- diamond particles:

Chlorine stage 2: Chlorine substitution reaction

ND

Cl

+ NH3 or H2O

UV

ND

NH2

ND

OH

+ H2O

or

Fundamental aspects Functionalizing

F d t l t Rh t


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Fundamental aspects - Rheometry

0.10

1.00

10.00

100.00

0.10 1.00 10.00 100.00 1000.00

Shear rate (1/s)

Viscosity(Pa.s

)

0% ND 1% ND

3% ND 5% ND

25C, Malvern Gemini Rheometer

Particular importance to sprayed coatings

Large increase in viscosity at 5% weight

Departure from Newtonian behaviour Large increases in solvents needed to maintain

processing ability

HVLP 2k spray system

T i S d i i


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Testing: Sand erosion resistance

ACCIS produced PU and 1wt% nanodiamond / PU

tested using grit blaster at extreme close range (


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Testing: Thermal Conduction

0.0000

0.0400

0.0800

0.1200

0.1600

0.2000

0.2400

0 1 3 5 8% weight of filler in PU

Therm

alConduction(W/mK)

Batch ABatch B

21.1% increase at 1%

29.5% increase at 5%

Conduction plateau reached?


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Lightning and de-icing

Li ht i t ik


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Protecting the 787

Lightning strike

Li ht i t ik


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Lightning strike

Li ht i t ik


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Lightning strike

Aircraft Blade De-icing


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Small quantities of ice buildup on aerofoil sections leads

to rapid & significantchanges blade lift & pitchingmoments

Icing is not just a problem

encountered in cold climates

Inflatable boots or spraychemical solutions simply

not as versatile or robust asheat based systems

Ice build up on a Wessex rotor blade



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10mm 10mm

Awareness that current polymer coatings inhibit thermalde-icing systems.

Modern helicoptersneed as much as6kW which istransferred through

slip rings at therotor hub

Due to insulationeffect much of thiswill go backwards

into the carbon fibrestructure

Copper heaterelements embedded

in composite rotorstructure


Lightning strike & De icing


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Lightning strike & De-icing

What properties?

- electrical conductivity

- thermal

- dielectric

CNT, ACCIS buckypaper andcomposites

Fundamental aspects


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Fundamental aspects

Decorating MWCNTs with Agnanoparticles

X-ray EDX of Ag/MWNTs

Fundamental aspects


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Fundamental aspects

Decorated CNTs and ACCIS Buckypapers

Fundamental aspects


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Fundamental aspects

Buckypapers and Composites

ACCIS buckypaper


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Materials(monolayer)

Electricalconductivity

(S/cm)

Thickness/(m)

EMI shieldingeffectiveness

(dB)

MWNT/ NPs 40 110 38.47

MWNT 27.7 120 36.07

Electrical conductivity and EMI:

ACCIS buckypaper

ACCIS buckypaper


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ACCIS buckypaper

5 Volts

6V

7V

Temperature(oC)

Heating Stabilising Cooling

Time, (s)Thermal imaging ofMax Temp. @ volts

Joule heating under various electric voltages:

Thermalresponse:

Concluding remarks


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g

Nanotechnology affords the opportunity to create a range

of advanced materials & composites

Challenges facing the Aerospace engineering:

Hardness, Radiation, solar absorption, infrad emission Heat pipes, antenna reflector & systems

Electrical housing/bond

Space craft structures

Solar array substructures

Documents

2_Polymer Nanocomposite Coatings for Aerospace Composite Components - Dr. Hua-Xin Peng, ACCIS, United Kingdom