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For aerospace vehicles, the development of new materials and structural configurations are key tools in the relentless drive to reduce weight and increase performance (in terms of, for example, speed and flight characteristics). The economic drivers are clear — it is widely recognised that it is worth approximately $10k to save one pound of weight in a spacecraft per launch and $500 per pound for an aircraft over its lifetime. The environmental drivers (ACARE 2050) are also clear — reduced aircraft weight leads to lower fuel burn and, in turn, to lower CO2 and NOx emissions. With such high cost-to-weight ratios, there is intense industrial interest in the development of new structural configurations/concepts and enhanced structural models that allow better use of existing or new materials. Analytical structural mechanics models of novel anisotropic structures, developed at the University's Advanced Composites Centre for Innovation and Science (ACCIS), are now used in the industrial design of aircraft and spacecraft. Based on this research, a new, unique anisotropic composite blade, designed to meet an Urgent Operational Requirement for the MoD, is now flying on AgustaWestland EH101 helicopters that are deployed in Theatre. In addition, the new modelling tools and techniques have been adopted by Airbus, AgustaWestland, Cassidian and NASA and incorporated into LUSAS's finite element analysis software. These tools have, for example, been used to inform Airbus's decision to use a largely aluminium wing design rather than a hybrid CFRP/aluminium wing for the A380.
The key impact is in the definition of best practice for the design of joints, components and structures comprised of glass fibre reinforced polymers (GFRP, also known as fibreglass). The primary beneficiaries are (i) professional civil and structural engineering designers of GFRP structures; (ii) pultruders and composites fabricators due to continually expanding use of GFRPs in construction; and (iii) the general public through the provision of sustainable structures.
In particular, Lancaster's research on pultruded GFRP materials and structures has contributed to the EUROCOMP Design Code and Handbook (1996), the world's first limit state design code for GFRP structures. This code has influenced GFRP structural design globally ever since, both pre and post-2008. Additionally, post-2008, EUROCOMP has triggered and influenced development of new European and Japanese design codes, in turn impacting designers, fabricators and the public in those geographical regions. Lancaster's research has influenced the US Load and Resistance Factor (LRFD) Prestandard (2010) and ASCE's Manual No.102 on bolted and bonded joints (2011) two codes and guidelines that will accelerate the US's application of composites in construction.
Thus, the use of Lancaster's research in these codes and guidelines has supported the construction of fibreglass-based civil structures across the globe as well as the delivery of individuals with the analysis and design skills needed by the composites industry.
Research work in the University of Cambridge Department of Engineering (DoEng) created a formal methodology for eco-design, based on lifecycle thinking that can be implemented during product design. This methodology and supporting reference data have been commercialised by DoEng spin-off company, Granta Design Limited, within Granta's software solutions: for engineering and product design in industry, integrating with the CAD environment; and for materials education. These products are incorporated in software suites that have over 200,000 users. Industry case studies demonstrate their value to end customers.
The vulnerability of both military and civilian infrastructure to the threat of terrorist activity has highlighted the need to improve its survivability, and this poses a significant design challenge to engineers. Research work at Imperial has led to the development of novel constitutive relationships for polymeric materials coupled to novel analysis procedures; software algorithms for effective simulations of blast and impact events; and enhanced experimental testing methods allowing a fundamental understanding of the structures. According to Dstl, this body of research has `unquestionably improved the security and effectiveness of the UK armed forces operating in hostile environments abroad as well as the safety of citizens using metropolitan infrastructure within the UK'. The techniques have been applied to vehicles and UK infrastructure, including for high profile events, such as the 2012 Olympics.
Dr Richard Brooks and his team at the University of Nottingham have been investigating the high strain rate behaviour of composite materials since 2003. This has led to the development of two products that are being installed in streets in the UK and Ireland by East Midlands SME Frangible Safety Posts Ltd. The direct benefits to the company have been: the installation of 900 products in the UK and Ireland; saving of £17k capital cost and 2 months in terms of time to market per product developed and; raising of £1.8M investment to bring the products to market At least one life has already been saved in the Shetland Islands as a direct consequence of the product behaving in the way it was designed to.
The automotive and aerospace industries are keen to reduce their environmental impact and so have looked to move to lightweight materials. This creates issues in terms of joining, using and disposing of dissimilar materials. Oxford Brookes has therefore worked with national and multi-national companies in the adhesive, materials, automotive and aerospace industries to try to solve these problems. This has resulted in high quality research publications, innovative test equipment, improved numerical methods, novel designs, design guidelines, manufacturing procedures, British Standards, patents, commercial products and further funding. The impact of the work has global safety, environmental and economic benefits with multi-national aerospace and automotive companies implementing the results in current developments.
A significant body of research in ultrasonics at the University of Strathclyde led to the formation of Alba Ultrasound Limited in 2000. This successful UK engineering manufacturing company designs and manufactures high quality wideband ultrasonic array transducers for sonar applications to a worldwide client base, delivering benefits ranging from naval and maritime security through to safer ocean environments and informed exploitation of marine resources. Alba Ultrasound's unique array transducers constitute the sensor front-end in many leading sonar systems, and its innovative products are incorporated in a range of sonar devices used by the military and commercial companies. Through application of Strathclyde research, the company has experienced a significant period of growth during 2008-2013, with a three-fold increase in employees and turnover rising from £750k to £3.8M.
XeraCarb Ltd is a spin-out company formed in 2011 to exploit a class of ceramic composite materials co-invented by Jones. These materials were first devised in 2008 via a Materials and Engineering Research Institute (MERI) Knowledge Transfer activity and developed from 2009 onwards through a series of UK Ministry of Defence (UK MoD)-funded research projects. XeraCarb was spun out after the underpinning research won a national award in 2011 as the most promising UK materials system for commercialisation. The applications for XeraCarb's materials range from body- and vehicle-armour to kiln furniture and wear-resistant components. The company has attracted significant venture capital investment and is valued at over £1m. It has set up an independent production facility, has appointed employees, has been awarded a TSB grant, has materials undergoing trials in respect of a number of applications, and has delivered its first orders.
Since the mid-1990s, the Materials and Structures Research Group has been conducting research into materials-joining processes, including metal-ceramic joining for high-temperature applications. The group's research on metal-ceramic interfacial relationships and metal-ceramic joining subsequently assisted Cambridge-based C4 Carbides to optimise metal-to-diamond brazing and develop cutting tools with improved quality and longer lifetimes. Since 2010 the company has also [text removed for publication]
This continuing collaboration has helped C4 Carbides secure a TSB smart award and begin its strategic shift from niche SME to mainstream supplier.
The Centre for Numerical Modelling and Process Analysis (CNMPA) was asked in 2004 to apply its expertise in computational reliability engineering, usually used in high technology manufacturing, to help save the Cutty Sark ship and in 2010 to help restore the Medway Queen. This case study details how our computational expertise had impact and in particular: