Structures and Materials Performance Laboratory

Dany ParaschivoiuManager, Operations

e-mail: Dany.Paraschivoiu@nrc.ca

A few words on the Canadian Industry

• Canada’s sales are $23B, mainly civilian (83%)• 5th worldwide• 80% exported mainly to the US (60%), • 80,000 employees, • Profile: 16% Eng & science, 12% Tech, 47% production, 24% O/H • Locations: 52% Quebec, 29% Ontario• CDN, has a 6% market share of the global aerospace industry • 6% market share in aircraft & parts (Bombardier’s position)• 5% market share of engine & parts (Pratt & Whitney Canada)

leading small propulsion + engine module supplier Magellan Aerospace

• 5% market share in MRO world-class firms including Aveos, CAE, Cascade Aerospace, L3 MAS, IMP Aerospace, and Standard Aero.

A few words on the Canadian Industry

NRC: A National Institution• Federal government

agency

• Provides essential elements of national S&T infrastructure

• Labs and facilities across the country • 20 research institutes

• Industrial Research Assistance Program or NRC-IRAP

• Industrial Partnership Facilities

• CISTI

Staff: Approx. 4,300 employees; 1,500 visiting / guest workers, Total expenditures 2009-10: $840 M Total Income 2009-10: $160 M.

NRC Aerospace Players

President

Finance SecretaryLegal ServicesHuman Resources

VP Physical Sciences

Aerospace (IAR)

Manufacturing Technology (IFCI, IMI)

Marine Sector (IOT)

Construction (IRC)

Hydraulics (CHC)

Surface Transportation (CSTT)

Design and Fabrication

Biotechnology Research (BRI)

Biodiagnostics (IBD)

Biological Sciences (IBS)

Marine Biosciences (IMB)

Plant Biotechnology (PBI)

VP Life Sciences

General

VP Corporate Services

VP Technology & Industry SupportVP Engineering

Astronomy (HIA)

Chemical Process & Env. Tech. (ICPET)

Information & Telecommunications

(IIT, IMS)

Nat’l Measurement Standards (INMS)

Nanotech. (NINT)

Molecular Sciences (SIMS)

Administrative Services & Property

Mgmt (ASPM)

Information Mgmt Services (MSB)

Strategy & Development (SDB)

Information Services (CISTI)

Industry Support (IRAP)

Business Relations

Renewal Implementation

NRC ClusterSecretariat

NRC Aerospace IAR major facilities

• 15 buildings (>50,000 m2)• Major facilities:

– 8 wind tunnels– 9 research aircraft– Full-scale structural test rigs– Engine and combustion test cells– Materials characterization and testing equipment– Aeroacoustic reverberant chambers– Lubrication/tribology test rigs– Flight Recorder Playback Centre– Manufacturing research facilities

Institute for Aerospace Research (IAR)

Director General

Aerospace Manufacturing

Technology Centre

Automation & Intelligent Manufacturing

Forming & Joining of Metallic Products

Fabrication & Joining of Composite Structures

Material Removal

Structures & MaterialsPerformance Laboratory

Aeroacoustics & Structural Dynamics

Aerospace Structures

Composite and Novel Airframe Materials

Materials & Component Technologies

Non-Destructive Evaluation

Flight Research Laboratory

Airborne Research

Flight Mechanics & Avionics

Flight Recorder Playback Centre

Aerodynamics Laboratory

Fixed-wing Aerodynamics

Rotary-wing Aerodynamics

Bluff-body Aerodynamics

Wind Tunnel Facilities

Computational Facilities

Gas TurbineLaboratory

Combustion test & evaluation

Performance & operability assessment

Tribology

Office of Collaborative Technology Management Support Office

SMPL MissionSurface Mountable

Crack System

• Our mission is to perform innovative research and technology development in the areas of design, analysis, processing, testing, performanceassessment and qualification of aerospace structures and materials. We work in collaboration with industry, academia and government, nationally and internationally.

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D.I.C results showing buckling behaviour of Aluminum cylinder .

Principal Dimensions

• 87 full time employees• 22 visiting workers • 12 graduate students• 9 students/co-op

• $11M annual budget of which $6.4M is earned income

• Approx. 58% dependent on external income.

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50µm50µm

Characterization of intrinsic particles for inclusion into the new life prediction methodology (HOLSIP).

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Buildings and Facilities

• 4 buildings• Major facilities:

– Full scale structural test rigs– State-of-the-art nondestructive

evaluation equipment– Materials characterization

equipment– Aeroacoustic reverberant

chambers– Large mechanical shaker– New materials and coating

research facilities– Broad spectrum of test frames

(-100oC to 1200oC)– Burner Rigs

Structures & Materials Performance Laboratory

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Technological expertise and facilities for research in aerospace structures and materialsDirector: Dr. Prakash Patnaik• Aeroacoustics & Structural Dynamics

– Dr. David Zimcik • Aerospace Structures

– Mr. Nick Bellinger• Composites and Novel Airframe Materials

– Dr. Andrew Johnston• Materials and Component Technologies

– Dr. Peter Au• Non-Destructive Evaluation

– Dr. Abbas Fahr

Aeroacoustics & Structural Dynamics

12Ground vibration test

Impact simulation

• Adaptive Control of Structures– Reduce vibration and noise in

aerospace structures through active control means including adaptive smart structures systems.

• Structural Dynamics and Impact– Develop modern methods of

analysis and test to analyze, predict and improve the structural responsedue to dynamic loading.

• Noise and Vibration Test & Analysis– Develop and apply engineering

capability and knowledge, particularly in Space Systems Technology, in support of Canadian industry.

Aerospace Structures

• Risk/Reliability based Life Assessment– To develop a new physics-based lifing

paradigm to augment both the safe-life and damage-tolerant approaches.

– To develop new repair technologies to extend the life of legacy aircraft as well as anticipate the repair requirements for new generation aircraft.

• Experimental Stress Analysis– Using existing technologies develop

techniques to model and simulate structural damage from the micro-scale to macro-scale.

Patching of SCC

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Entrance

Exit

Effect of residual stress on fatigue

Simulation of limit load case

Aerospace Structures

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• Structural Health Monitoring– Expand the technical competency

within the Structures Group to address the future requirements for structural health monitoring with the goal of developing technologies for use in fixed and rotary wing aircraft.

• Full-Scale Structural Testing– Carry out Structural Testing, Full-

Scale (e.g. F-18) or large Components by applying complex spectrum loads in both fatigue and/or high static cases (RST).

Full-scale test using SOFFT

ISG sensor

Composites and Novel Airframe Materials

• Composite Materials and Process Development– Explore innovative technologies to reduce

the manufacturing costs of composite components while improving the quality of the parts.

• Novel Metallic and Hybrid Structures and Materials for Airframes and Other Applications– Develop and qualify novel metallic and

non-metallic materials for aerospace and non-aerospace structural applications.

• Conductive Heating Technology for Composite Processing Applications– Developed a low-cost out-of-autoclave

Conductive Heating System for composites processing including mould heating, bonded repair, and secondary bonding.

Heater cellsHeat transfer tile

Bondline

Coupling agent

Composite structure

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Materials and Component Technologies

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• Aerospace Protective Coatings and Testing– To develop, fabricate and

characterize advanced materials and coatings for aerospace applications.

– To develop non-standard materials performance tests, as well as use standard test procedures, to evaluate various material systems for gas turbine applications.

• Gas Turbine High Temperature Materials– To offer unique expertise and

comprehensive state-of-the-art facilities for evaluation and qualification testing of new or repaired engine materials and components.

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Materials and Component Technologies

• Gas Turbine Component Life Cycle Management– To develop new repair technologies and

procedures to extend the life of engine components.

– To develop new physics-based life methodologies to augment the safe-life and damage tolerance approaches.

– To develop advanced gas turbine component repair technologies.

Oxidation cracking

Weld nugget

Distribution of plastic strain

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Non-Destructive Evaluation

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• NDE Technology Development– To address inspection requirements

of new or unique materials, components, manufacturing or repair processes.

– To define optimal inspection parameters, conditions, outcome and reliability.

• Inspection Reliability Assessment– To generate inspection reliability

data in support of aircraft life cycle management.

Pulsed eddy current

0.026 0.028 0.03 0.032 0.034 0.036 0.038 0.04 0.042 0.044

Data fusion (thickness loss due to corrosion in lap joint)

Manufactured defects Pulsed

thermographic image of patch

Collaborators and Clients

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OGD31%

OTHER7%

OEM35%

SME27%

OGD56%

OEM32%OTHER

2%

SME10%

Distribution: Total number of projects

Distribution: Total value

• SMPL collaborates with a variety of clients ranging from Small to Medium Enterprises (SMEs) to Original Equipment Manufactures (OEMs).

• Our largest client is Other Government Departments (ODGs), since our mandate includes supports R&TD for the DND fleet of aircraft, both fixed and rotary wing.

Most of SMPL’s work is TRL 5-6: Tech Demos

Tech Level (TRL) by Projected Revenue

9%

8%

15%

54%

14%0%

Basic Research (1-2)

Feasibility (2-3-4)

Tech Development (3-4-5)

Tech Demo (5-6)

System Development (6-7-8)

Sys Test, Launch & Operations (8-9)

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Benefits of doing Business with NRC

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IMAGE & COMPETENCIES• Reputable Canadian Government Research and Testing Organization• Highly regarded internationally for its innovative research and facilities• World leaders in some R&D niches (corrosion, deicing, lifing methods…)• Sate-of-the art Testing facilitiesCND MARKETS• Accessibility to the Canadian Military market (our relation with DND)• IRB multipliers for R&D (foreign OEMs)• Facilitation for Certification (our relationship with Transport Canada/FAA)• Enhanced credibility for TIERs 1, 2, 3 in face of Canadian OEMsFLEXIBLE BUSINESS ARRANGEMENTS• Collaboration projects w/ high R&D content, NRC contribution, shared IP• Fees For Services, Technical and Consulting Services, IP given to client

Questions?

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