by cidaut | Feb 5, 2016 | Materials
The 30 months Metalmorphosis Project is really close to its end. In order to show and demonstrate the results achieved a final seminar is going to be held in the headquarters of the Belgian Welding Institute in Gant on the 24th of February 2016.
The admission to this event is free subjected to registration: http://goo.gl/forms/H0qr2ud0zY
The project has been focused on the development and optimization of hybrid joints between metal and composite hybrid parts in order to obtain enhanced automotive components with integrated functions. The joints are obtained thanks to the application of electromagnetic forces. This technology allows joining composite materials that are not weldable, eliminates the heat affected zone, is a clean process and reduces the cost of the joints. In the first half of the project, important innovations have been introduced in tubular and flat joints working with laboratory specimens, while in the second half, the knowledge generated has been applied to the development of automotive components.
The consortium is formed by nine partners. BWI, Centimfe (leader), Cidaut and Cidaut have focused their effort in the research and development activities. STAM is the responsible of the LCA analysis. Poynting is an SME specialized in the development of electromagnetic joining devices. Regeneracija, Tenneco and Toolpresse are the industrial partners of the project; each of them has developed, with the support of the consortium, a demonstrator to apply the knowledge and demonstrate the advantages of the electromagnetic joining.
Regeneracija has designed a bumper, where the crash box is designed in CFRP, and the cross beam is a sandwich of CFRP and aluminum. All the parts have been assembled attending to the technology developed for flat joints.
Tenneco has improved the design of its shock absorber reducing the number of components and simplifying the assembly process thanks to the integration of functions through electromagnetic tubular joints.
Toolpresse has created a new concept of hybrid pedal brake where both ends are manufactured by plastic injection to fulfill the geometric requirements and the central part is extruded in aluminum obtaining a stiff light component.
by cidaut | Feb 5, 2016 | Sin categoría
The REMAGHIC project continues its journey. On the 1st of February started the sixth month of work. Work packages 1 and 2, are in full swing, with the analysis of the main sources of waste, and at the same time preliminary work with the life-cycle assessment (WP5) has begun. All these tasks have been accompanied by the management and dissemination and communication works (WP6 and Wp7).
On 24th– 25th of February 2016 the general meeting of all the consortium will be held at CIDAUT Foundation facilities, CIDAUT is the project coordinator. The meeting will focus on reviewing the status of the work performed and planning tasks for the next 6 months including an overview of next year.
Complementing all these activities, this meeting will be used to perform two workshops, one about LCCA and other about risk management.
In addition, attendees will have the opportunity to visit the facilities of CIDAUT Foundation.
by cidaut | Nov 16, 2015 | Sin categoría
Last September 10th, the REMAGIHC consortium met in Brussels to kick-off the project. All partners gathered at Covenant Building, headquarters of DG RTD, to present the working plan and the tasks to be carried out during the first year of the project.
REMAGHIC, New Recovery Processes to produce Rare Earth-Magnesium Alloys of High Performance and Low Cost, aims at contributing to Europe’s rare earth recovery and magnesium recycling technologies, improving the efficiencies of these processes and advancing the technology readiness levels for a new generation of industrial processes that will produce new low cost competitive alloys for a wide variety of sectors across Europe’s manufacturing value chain.
All partners introduced their companies to the EC Project Officer, highlighting their respective role in the project: Fraunhofer ICT, Fundación TECNALIA, Catholic University of Leuven, Grupo Antolin, Relight, ITRB, Piaggio Aero, Pininfarina and Meotec are coordinated by Fundación CIDAUT.
During the meeting, all work package leaders presented their work plan for the first year of the project. REMAGHIC will start by defining the best way to recover the rare earth elements from industrial wastes, and the magnesium alloy from the scrap, dross & slug. The specific REE will be then used to alloy with recycled magnesium in order to obtain cheaper alloys to be used by Grupo Antolin in their casting facilities and tested to check they achieve with the end users request.
At the same time, the dissemination activities started by defining the project logo and the contents on the public website. This work package is also responsible for setting the Advisory Board; this is formed by industries interested in REMAGHIC results, and will act as test ground for the application of the developed framework and specific applications.
On the following month REMAGHIC consortium will start updating the public website with news related to REE recovery as well as the partial results achieved by the project. Once the public deliverables are approved by the EC, they will also be uploaded in the website. So do not forget to follow from December 2015 on our website in order to be updated on REMAGHIC!
by cidaut | Sep 18, 2015 | Materials
The XI Spanish National Congress on Composite Materials is organized by the Rey Juan Carlos University, AEMAC and FIDAMC, and its main sponsors are AIRBUS Group, ACITURRI, AERNNOVA, HEXCEL, ALESTIS Aerospace and TEAMS. CIDAUT participated presenting two different papers, one dedicated to development of material models for short fibre reinforced materials entitled “Implementación de una Metodología para considerar el Proceso de Inyección en el Diseño de Componentes Reforzados con Fibra Corta”, and a second one focused on the implementation of design methodologies for continuous carbon fibre composites for automotive safety components entitled “Procedimientos de Optimización para el Diseño de Componentes de Seguridad Activa en Materiales Compuestos”.
The MATCOMP series of National Congresses is one of the most important meetings between the academic, scientific and industrial communities within the composite materials field in Spain. The main objective was the establishment of a communication channel between the industry and the technical and scientific community to promote research, development, innovation
This year CIDAUT’s contribution was focused on the design of automotive components. Nowadays everything turn around weight reduction, new environmental standards, less emissions, therefore all this inputs are calling for sustainability in mobility, which will be achieved with less pollution power trains and light weight designs.
Short fibre reinforced components have considerably improved mechanical properties in terms of stiffness and structural strength thanks to the fibre contribution to their performance. Though used in the automotive industry for a long time, the influence of the manufacturing process is seldom taken into account because of the lack of an easy design methodology. CIDAUT research goes through combining complex material models with thermal and mechanical behavior in order to fulfill the OEM requirements and offer a light and high performance product.
If weight reduction is considered, then advanced composite materials, and especially those combining continuous fibre with plastic matrix are very well poised for growth. In this context our research carries out the development of a suspension arm, continuous fibre and plastic matrix is rarely found in active safety components. The most critical load cases have been selected from the most common maneuvers of the B segment vehicle. The packaging and manufacturing requirements have been taken account during the development. Besides, new joints have been developed between the control arm and the surrounding components, due to it has not been possible to apply the same solutions that in metallic parts.
Finally we have accomplished the objectives, developing a control arm with a mass reduction over 40% and the same performance of a metal predecessor.
If you want to know more about our researches in the field of composite materials, get in touch with us, we are always happy to share our experiences and find new collaboration opportunities. www.cidaut.es/en/contact
by cidaut | Sep 18, 2015 | Sin categoría
Since April 2013, CIDAUT has been coordinating REMART project, carrying out the technical tasks in collaboration with 3 partners, CIDETEC, ITRB and PBLH and under the direction of AGUSTA WESTLAND as Topic manager.
This project has been developed in the domain of the CLEAN SKY JTI – Green Rotorcraft which has the aim to improve the environmental impact of the components in aeronautic and air transport sectors. Along the project, the REMART consortium has been involved in the optimization of the use of existing recycling technologies, designing an efficient and environmental recycling protocol for each piece or set of pieces of the HTS (Helicopter Transmission System).
The first step in this work was the development of a comprehensive survey of market surrounding the recycling of HTS. In parallel with the market survey of recycling processes a study and analysis of all materials and coatings used in the manufacturing of HTS was developed.
Once all materials were identified, just like their main coatings and surface treatments, each piece and their most suitable recycling processes were combined.
The next stage of the project was the quantitative evaluation of the recycling processes. With all this information, the development of a tool for designing and developing recycling protocols (as the one of the next figure for chemical stripping) for each component of the HTS was possible.
Example of Recycling protocol for chemical stripping
Two different demonstrator components (one from AGUSTA and other from AIRBUS Helicopter) were tested during the project (tail gear box and intermediate gear box see below figures) to validate the recycling protocols developed.
Pictures of the demonstrators of the project
The validation of the recycling protocols was performed using quantitative parameters from the experimental tests, as for instance, time of each process, surface quality after stripping (see next figure) and the risks for the environment.
Microscope Surface quality after different stripping process
Finally, the last stage of the project consisted on the cost-effectiveness analysis of the recycling cycles for each material and coating (see example for zinc plated component in below figure).
As one of the conclusions of the project, the stripping stages during the recycling process are a good procedure to get the initial characteristics of metal base. Nevertheless, re-using components will not be a common solution for the aerospace industry due to the high cost of the stripping process. This limitation can always be overcame with stricter environmental policies or by breakthrough from others recycling processes.
Funded by the European Commission: FP7 – JTI – CS – Joint Technology Initiatives – Clean Sky
http://www.remartproject.com/
