Slc lab opening

Welcome tothe official opening

of the SLC-LabApril 26, 2012

Program of the day

13h30 SLC-Lab and beyond - trends and insights Hans Vercammen, Sirris ; Ignaas Verpoest, KU Leuven ; and Joris Degrieck, UGent

14h00 Basalt fiber composites Pauline Koslowski, Basaltex

14h30 Collaborative innovation for high volume composites John Hobdell, Huntsman Polyurethanes

15h00 Specification for industrial robots in CFK-machining Otto Kellenberger, KUKA Robotics

15h30 Composites: great opportunities with tough challenges Jan-Anders Månson, EPFL

16h30 Official opening of the SLC-Lab Guided tours and demonstrations

18h00 Networking / cocktail buffet

Welcome tothe official opening

of the SLC-LabApril 26, 2012

Why an application lab? Why composites? Why here?

Hans Vercammen

Business unit manager at Sirris

Results Survey

Survey(*) with 400 companies from the technological industry in Belgium showed that

Industry seeks: Capacity for product development

New ideas for new product development

Infrastructure for new product development

Sirris answer Application Labs

(*) Net Promotor Score survey, jan 2011

A multidisciplinary lab where companies can test theirinnovations at an almost industrial scale using newtechnologies in take off, without having to make investments

Many unconnected stakeholders

Material Processing Product

Lab

Prot

otyp

ing

Indu

stria

l

Fabricatorand itsvaluechain

OEM

UGent MMSKU Leuven Associatie

lack of application lab

Engineering Offices

Materialproducers

Many connected stakeholders – application driven

Material Processing Product

Lab

Prot

otyp

ing

Indu

stria

l

Fabricatorand itsvaluechain

OEM

UGent MMSKU Leuven Associatie

Engineering Offices

Materialproducers

An open initiative by KU Leuven, UGent and Sirris

Application Lab inspired by …

industrial (but private) application labs Closed-shops: Umicore (solar cells), Bekaert (tires), CTC (EADS), and

many others

Semi-open: Agfa-Labs

the “Fablab” initiatives world wide, prof. Neil Gershenfeld, MIT E.g. FabLab Leuven

public-private initiatives CFK valley, Pôle Plasturgie de l’Est, Carbon Composites ev, ...

An application lab brings technology to companies

Focused on products/services & their industrial value chain

• Enabling:

• Players in the value chain to see the effect of their product/contribution on the end product

• Interaction between players in the value chain with the OEM

• Stimulate innovation outside the typical client-supplier relationship

• Create technology awareness with OEMs

• Targeting industrial time to market: 0 to 18 months


Strongly application oriented

Working on a test sample?

Or would you prefer working on a real world or close-toreal world product?


Low entrance level

Value proposition of Sirris

Find appropriate funding or research partners

Think together with entrepreneurs, speak the same language

Bridge between R&D and industrial applications

Hands-on engineers experienced with new technology …

And the equipment to prototype it …

And the facilities to evaluate it.

Mission

Create composite innovations for:a. Material producers

b. Composite part fabricators

c. Designers of composite parts, OEMs

Provide the industry with tangible solutions

Low-threshold development center

Short term innovation trajectories

competitivecompositeproducts

SLC-Lab Partners

...2007

2012

Launch 2009

From your idea to a tangible product

Conceptual designmaterial, process

tooling, series, cost

Structural design Virtual prototype

Process development

Validationprototyping, testingproduction planning,

cost estimation

ProductFeasibility study

SLC-Lab Equipment Fontijne press with preheating station (1):

thermoplastic and thermoset

Resin infusion systems (2)

Curing oven (3)

Vacuum pumps and oven

Mould heating systems

Paint booth

Chemistry laboratory

Workshop

(1)

(2)

(3)

SLC-Team

- Markus Kaufmann

Lab Manager

- Aart Van Vuure

Project Engineer

- Linde De Vriese

Project Engineer

- Bart Waeyenbergh

Project Engineer

- Guy Lambert

Technician

- Jonas Van De Winkel

Technician

- Open position

Project Engineer

Celebrating over 30 years research in composites

at KU Leuven

Prof. Dr. Ignaas VerpoestKU Leuven

Composite Materials Group @ KU Leuven

The Composite Materials Group at KU Leuven: achievements over 30 years

The research approach at CMG: From materials to processing and products

From nano- to macro-scale

Some examples of research in the four focus areas

CMG-KU Leuven in 2012 and beyond…

CMG-KULeuven achievements: 1981- 1990

Research: Learning the job: interaction with

Tsai&Springer (Stanford University)

Fatigue and damage of composites

First steps into textile composites

• Innovations:– Installing composites lab

– Damage detection & NDT

– Invention 2.5D and 3D-woven sandwich materials


Research: Fibre-matrix interfaces

Experimental work on 2D/3D textilecomposites

Start of Texcomp conferences

Start of textile modelling work

Start of natural fibres research

• Innovations:– Applications of 3D-woven

sandwich panels

– Patent on 3D-knitted sandwich

– First patents on foldedhoneycombs

– Start of EUPOCO


Research: Full expansion of meso-modelling (textile)

research

Fundamental & applied research on natural fibres

Re-focus on process & applicationdevelopment

Start of nano-engineered composites

• Innovations:– Wisetex software suite

– Patent on silk fibre composites

– Start of spin-off Econcore

– Samsonite suitcase

– Patent on bicycle helmet

– Patent on CNT sizing

PROCESSINGMACRO-

mechanicsMATERIALS

Micro-mechanics

Our approach: from constituent materials to products

A materials based view on composites…

Integrated with multiscale mechanics … towards processing and applicationdevelopment

Compositematerial

Fibrous preform (textile)

Plastics

Bio-plastics

Man-made fibres

Natural fibres

Polymer matrix

Fibre reinforcementCompositeprocessing - TS

Composite processing - TP Automotive

Aerospace

Sporting goods

Machinery

Biomedical

… leading to four focus groups in 2012

Composites on macro & meso level

Natural and bio-composites

Composites on micro&nano level

Process &applicationdevelopment

Prof. Stepan Lomov*

Dr. Aart van Vuure

Dr. Larissa Gorbatikh

Prof. Jan Ivens**

Textile composites andtextilesRandom fibre compositesPorous materials and biomaterials

Nano-engineered fibre reinforced composites (also prof. Lomov)Cellular nanocompositesMechanics of hierarchical materials (incl. biological composites)

Flax fibres (Dr Joris Baets)Exotic fibres (bamboo, jute, coconut, silk…)Interface scienceBio-based polymers

Novel matrix systemsSandwich materials and foamsAdvanced processing methodsProduct development

* pt ZAP

** Lessius

Hierarchy of scales: nano – µicro

Molecular dynamics: interaction CNT -polymer

CNT bending

CNT on the surface of a carbon fibre

10 µm

1 µm

100 nm

10 nm

1 nm

Hierarchy of scales: µicro – meso

100 mm

10 mm

1 mm

100 µm

10 µm FE: fibre failure

Goyal 2008

plastic zone in an impregnated yarn

FE model of 3D fabric

Hierarchy of scales: meso–Macro–Mega

1 km

100 m

10 m

1 m

100 mm FE model of a composite aeronautic part

A350 wing

Composites in constructions

Windmill blade






Prof. Stepan Lomov*

Dr. Aart van Vuure


Prof. Jan Ivens**





WiseTex model for 3D angle interlock composites

WiseTex model: excellent predictions of the stiffness

1 m

Structurally stitched reinforcements

internal geometry and WiseTexmodel

correlation between damage

and stitching

sites

WiseTex worldwide

licences:industrial (6)university (30)

Composites on micro and nano level





Prof. Stepan Lomov*

Dr. Aart van Vuure


Prof. Jan Ivens**





Toughening strategies @ KU Leuven

Nano-modification of matrices, fiber/matrix interfaces, fibers

Ductile fibers(steel, CNT fibers, silk, …)

Hybridization(self-reinforced polymers, ductile fibers, …)

Intelligent use of structure(self-assembly, …)

Steel fibers

Carbon nanotube

fibers

Glass Fibers sized with CNTs

Bamboo vascular bundle, Liese 1998

0.25 wt% MWCNTs in the matrixDe Greef et al, Carbon (2011), De Greef et al, Composites Part A (2011)

• Carbon nanotubes hinder damage development in CF /epoxy composite.

Toughening composites by nano-modifications

• Position of CNTs in a composite depends on the dispersion state

Small isolated agglomerates

Network-like structure

Localization in resin rich zones






Prof. Stepan Lomov*

Dr. Aart van Vuure


Prof. Jan Ivens**





* pt ZAP** Lessius

Bamboo wallLiese, W., 1998

4

3

Fibres are distributeddensely in the outer regionof the wall and sparsely inthe inner region

Vascular bundleTechnical fibre

Bamboo culm Cross section

Elementary fibres

5

The elementary fibre in the bamboo wall

Bio-based Composites: bamboo fibre extraction

150

250

350

450

550

650

750

850

0 100 200 300 400 500 600

Extraction method

Stre

ngth

(MPa

)

Mechanical(rolling mill machine)

Chemical extraction(in some cases

mechanical process is required)

Steam explosion

Mechanical process(in some cases chemical process is required)

KULeuven process

Loop test

Typical stress-strain curve for treated and untreated

bamboo/epoxy composites

Strain (mm/mm)

Flex

ural

Str

ess

(MPa

)

3%

5%

0%

1%

Bamboo fibre composites

Process and application development





Prof. Stepan Lomov*

Dr. Aart van Vuure


Prof. Jan Ivens**





Application developmentof a (self-reinforced PP) composite suitcase

Characterisation of different material types

(impact, stiffness, strength, thermoformability related aspects…)

Selection of best performing one0

5

10

15

20

25

30

Silk - PBSa Curv Twintex Carbon Fibre / epoxy

30

1411

6

Rat

io o

f Abs

orbe

d en

ergy

by

pene

trat

ion

(J/m

m) a

nd d

ensi

ty

(ρ)

Fast and efficient tooling for RTM and thermoforming

• Incremental forming to produce complex metal sheet based tools (SPIF, TPIF)

• Advantages

• light-weight mold

• Heating-cooling cycle

• Multiple insert tooling

Preparation in metal plateshell

(primer - preform)

Curing (p, T)

DemoldingCured parts

Cleaning & preparationMetal shell

Injection

Productivity2 - 3 times

higher

Collaboration network in KU Leuven Association




Dr. Aart van Vuure


Prof. Stepan Lomov*


Prof. Jan Ivens**

PMAprof. VandepitteComputer Scienceprof. Roose

NDT-groupprof. Wevers

MTM-Physicsprof. SeoChemistryprof. Nies, Smet

Chemistryprof. Goderis, SmetChemical Eng.prof. VanpuyveldeBio-engineeringprof. Delcour

PMAprof. Duflou

CMG coordinators and

post-docsPhD students

Visiting andaffiliated

researchers

Technical staff (pt)

LarissaGorbatikh

IgnaasVerpoest

Stepan Lomov

Yasmine Abdin

Jan Ivens

Aart Van Vuure

Michaël Callens Manuël Adams

Marc Peeters

Bart Pelgrims

Kris Van de Staey

Aniko Lantos

Sergey Ivanov

Katleen Vallons

MarcinBarburski

Joris Baets

FaridaBensadoun

SvetlanaOrlova

Ngoc Le Quan Tran

Bart Buffel

Yentl Swolfs

Mohammadali Aravand

Niels De Greef CarlosFuentes

YasmineMosleh

Atul Jain

DieterPerremans

ValentinRomanov

OksanaShishkina

AhmadTabataba

eiEduardoTrujillo

Lina Osorio

Kelly Vanden Bosche

Bart Van Mieghem

Nhan Vo Hong Mireia Olave

Carmen TolaPerez

TomHouthoofdt

Marcel Bruijn

Frederik Desplentere

IonutDumitrascu

Jan Bens

MarjetkaConradi

MalikaKersani

ImenNasrallah

RashnalHossain

Maarten Fabré

4 senior postdocs4 junior postdocs24 PhD-students3 research enginee3 research affiliate4 visiting research4 technicians (pt)

~15 masters’ stude

CMG @ KU Leuven: a strong growth…

0

5

10

15

20

25

30

35

40

45

50

1981 1985 1990 1995 2000 2005 2010 2012

CMG-researchers

Osaka UniversityUCLA

St-Petersburg Polytechnic U

TorayHanoi UCantho U

Stanford MIT

Boeing

3Tex

… and a wide network of research collaborations

[universities and industrial partners with established long-term collaboration]

industrial university UGent

Nanocyl

HuntsmanDeceuninck SirrisUCL

Bekaert

Samsonite

Recticel

INSASnecma

Poly.Milano

EPFLRTWH

U Munich

U Valladolid

AirbusImp College

U Bristol

KTH

VolkswagenDaimler

CELC

Composites research at Ghent University

Reinforcing your composites activities!

Prof. Dr. Joris Degrieck

Who are we?

The research group “Mechanics of Materials and Structures” at Ghent University is doing research for more than 25 years on the mechanics of composite materials. The composites group is lead by Prof. Joris DEGRIECK and Prof. Wim VAN PAEPEGEM, and counts almost 20 doctoral students

Mission statement

“To study the mechanical behaviour of composite materials by a combined approach of instrumented experimental testing and adequate numerical modelling, in close collaboration with the composites industry and its suppliers”

Metals Science and Technology

• physical materials science• steel technology• durable/sustainable

materials

Mechanics of Materials and

Structures

• mechanical behaviour of materials and structures

• modeling and experimental characterization

Department of Materials Science and Engineering

Our research areas Our industrial services

Aerospace composites

Composites for wind energy

Composites for wave energy

Composites for bicycles

Crash performantcomposites

Blast proof composites

Composite joints

Next generation composites

Mechanical characterization

Dynamic testing

Inspection and monitoring

Outdoor field testing

Numerical simulation and design

Advanced finite element modelling

large-scale slamming tests at the canal in Ghent

FO3 platform (courtesy of Fred Olsen Ltd.)

filament winding simulation of

composite buoy

survivability design of composite buoys for

storm conditions

simulation of breaking wave slamming

Composites for wave energy(European FP6 project in collaboration with Dept. of Coastal Engineering and Dept. of Hydraulics (UGent),

Spiromatic, Standfast Yachts, Fred Olsen, ABB, Brevik, NTNU, Marintek, IST, Chalmers)

UGent test for bracket stiffness

UGent test for torsion stiffness

instrumented racing bicycle for field testing of comfort and

vibration levels

kinematic model of racing bicyle with applied road

accelerations

UGent all-in-one test set-up for fatigue testing of

racing bicycles

finite element simulation of the free body vibration

modes of a racing bicycle frame

Composites for bicycles(IWT R&D project; in collaboration with Museeuw Bikes and Merckx)

12

3 47

6

5

9

8

10

1 2

659

8

UGent bird impact testing facility

computer simulation of composite tube crushing

upon blast loading

high-speed imaging of drop weight impact of circular

pultruded composite tubes

Impact and crash performant composites