Improving the process modelling capability for manufacturing large composite structures used on passenger aircraft. This proposal aims to reduce manufacturing costs by developing innovative simulation tools for the production of future lightweight composite aerostructures.The development of a reliable predictive tool to simulate the cost-effective production of resin-infused composite aerostructures, will represent a significant technical advance. The successful transfer of this technology to Bo ....Improving the process modelling capability for manufacturing large composite structures used on passenger aircraft. This proposal aims to reduce manufacturing costs by developing innovative simulation tools for the production of future lightweight composite aerostructures.The development of a reliable predictive tool to simulate the cost-effective production of resin-infused composite aerostructures, will represent a significant technical advance. The successful transfer of this technology to Boeing Aerostructures Australia would give it a distinct competitive edge when bidding for participation in future international development programmes and will yield substantial economic benefits whilst further strengthening and developing local expertise. Lightweight aircraft structures will also contribute towards reducing the environmental impact of aviation. Read moreRead less
Optimisation of self-healing repair systems in aerospace composite structures. Design and manufacture of composite structures for civilian and military aircraft is a multi-billion dollar export business for Boeing Aerostructures Australia and other Australian aerospace companies. To remain globally competitive, Australian industry must develop new expertise for next-generation composite aerostructures that are lighter, cheaper, more damage tolerant and easily repaired. Autonomic self-healing of ....Optimisation of self-healing repair systems in aerospace composite structures. Design and manufacture of composite structures for civilian and military aircraft is a multi-billion dollar export business for Boeing Aerostructures Australia and other Australian aerospace companies. To remain globally competitive, Australian industry must develop new expertise for next-generation composite aerostructures that are lighter, cheaper, more damage tolerant and easily repaired. Autonomic self-healing of composites is an innovative repair technology with many future potential applications for damaged aerostructures. This project will develop analytical tools and data to enable the Australian aerospace industry to take advantage of the economic benefits offered by self-healing repair systems in aircraft composite structures.Read moreRead less
Revival of silicon solar cells for space applications. Development of very thin silicon solar cells for space applications. These space cells will include many of the significant improvements in silicon cells of the last 20 years, which have allowed close to the maximum possible efficiencies and the order of magnitude decrease in cost of terrestrial solar cells. Space cells require good radiation resistance to give good end of life performance. This project will use photovoltaic architectures, p ....Revival of silicon solar cells for space applications. Development of very thin silicon solar cells for space applications. These space cells will include many of the significant improvements in silicon cells of the last 20 years, which have allowed close to the maximum possible efficiencies and the order of magnitude decrease in cost of terrestrial solar cells. Space cells require good radiation resistance to give good end of life performance. This project will use photovoltaic architectures, proven to give high performance for terrestrial cells, to develop ultrathin silicon cells with extreme light trapping and improved radiation tolerance to give high beginning and end of life efficiencies. These cells will be less than 5% of the cost of multijunction cells currently used in space.Read moreRead less
AM of MAX Phase parts for applications in extreme environments. This project aims to develop techniques to synthesize MAX Phase compound materials in-situ using laser additive manufacturing. The project expects to increase jet engine fuel efficiency and thrust, and to fabricate longer-lasting parts for supersonic speed applications. The expected outcomes include well-developed additive manufacturing processes to make high performance engineering components with shape complexity for extreme envir ....AM of MAX Phase parts for applications in extreme environments. This project aims to develop techniques to synthesize MAX Phase compound materials in-situ using laser additive manufacturing. The project expects to increase jet engine fuel efficiency and thrust, and to fabricate longer-lasting parts for supersonic speed applications. The expected outcomes include well-developed additive manufacturing processes to make high performance engineering components with shape complexity for extreme environment applications, and new methods to increase the 3D printability of brittle materials. This should provide significant benefits to aerospace and defense industries through solving their long standing bottleneck material and processing problems. The outcomes also enhance Australia’s manufacturing capacity.Read moreRead less
Development of novel high performance aluminium alloys containing scandium. Development of novel high performance aluminium alloys containing scandium. This project aims to develop a new generation of aerospace aluminium alloys containing scandium. Over 30 million tonnes of high performance aluminium alloys are produced annually. Early investigations showed many beneficial effects of scandium on alloy behaviour, but research was abandoned due to scandium’s high cost. Australia has the largest de ....Development of novel high performance aluminium alloys containing scandium. Development of novel high performance aluminium alloys containing scandium. This project aims to develop a new generation of aerospace aluminium alloys containing scandium. Over 30 million tonnes of high performance aluminium alloys are produced annually. Early investigations showed many beneficial effects of scandium on alloy behaviour, but research was abandoned due to scandium’s high cost. Australia has the largest deposit of scandium in the world, and Australian sustainable extraction technology will markedly lower the price. This project believes that now is an ideal time to capitalise scandium’s beneficial effects and be at the forefront of this new alloy development strategy. Anticipated outcomes are the creation of a new market with economic and sustainable opportunities for the Australian mining sector.Read moreRead less
Onset Theory: Pushing the design envelope for textile composite structures. This study aims to exploit an innovative physics-based approach to predict the strength of textile composites. This is particularly important in areas such as aircraft design, where drastic weight savings are needed to allow designers to remain competitive in a low-carbon future. Improved theory and design tools will remove conservatism and account for a large part of these weight savings. The new approach is the first t ....Onset Theory: Pushing the design envelope for textile composite structures. This study aims to exploit an innovative physics-based approach to predict the strength of textile composites. This is particularly important in areas such as aircraft design, where drastic weight savings are needed to allow designers to remain competitive in a low-carbon future. Improved theory and design tools will remove conservatism and account for a large part of these weight savings. The new approach is the first to be consistent at all length scales — from atoms to aeroplanes — ensuring relevance for new and evolving composite material systems. A novel understanding of crack initiation in textile laminates is intended to reduce design and certification effort for new aircraft and help to design more efficient airframes at a lower cost.Read moreRead less
Designer microstructures through cold spray powder deposition. Additive manufacturing routes are very attractive in terms of reduced material usage and shorter lead times. This project will look at opportunities for the expansion of one such process (cold spray) from surfacing using a single powder feedstock to three-dimensional construction of multi-powder mixtures into high performance components.