EIROS project Advanced ice and erosion resistant composite materials

Transcription

1 EIROS project Advanced ice and erosion resistant composite materials International Workshop on Surface Icing and Assessment of De-Icing/Anti- Icing technologies Fraunhofer IFAM, Bremen (Germany) 24 th and 25 th of January 2017 Marta Alvarez, TWI Ltd (UK) 09/02/2017

2 Outline Project overview The ice challenge Fundamentals Materials-by-design approach Conclusions 09/02/2017 2

3 Overview of EIROS From an industrial driver to a project 09/02/2017 3

4 EIROS project concept Development of a high performance composite material by incorporating innovative additives into the composite bulk matrix for operation in extreme environments Increased erosion resistance Anti-icing characteristics Self-healing properties 09/02/2017 4

5 EIROS in numbers Advanced ice and erosion resistant composite materials for diverse applications EIROS o Competition: NMP Materials for severe operating conditions, including added-value functionalities o Duration: 3 years o Total budget: EUR 8 millions o Consortium: 18 partners from 9 European countries o Starting date: March /02/2017 5

6 Project partners 09/02/2017 6

7 Scientific and Technological objectives To develop new functional materials: To optimise the processing parameters (loading levels of >50% of additives) Scaling-up process methodology Materials-by-design approach Advanced resin suitable for fibre reinforced composite manufacturing process To develop advanced composite structures: Functional properties: self-healing, ice repellency, erosion resistance, thermal and UV exposure resistance, Retention of functionalities: compressive strength, tensile strength, impact, water absorption To establish a multiscale modelling approach 09/02/2017 7

8 WP7: Exploitation & Dissemination WP8: Management Project structure WP1: Specification KO 6 12 WP2: Development of Nanoscale Components Processing WP3: Composites Processing WP4: Materials Performance Test WP5: Multi-scale Modelling WP6: Up-scaling & Validation /02/2017 8

9 The ice challenge Ice issues and impacts Industrial context 09/02/2017 9

10 Ice.. Is it a real problem? 09/02/

11 Industrial context 09/02/

12 Types of icing Ice and snow type Density (kg/m 3 ) Description Glaze ice Pure solid ice - The density may vary with the content of air bubbles Very strong adhesion and difficult to knock off. Hard rime Homogenous structure with inclusions of air bubbles. Strong adhesion and more or less difficult to knock off, even with a hammer. Soft rime Granular structure, feather-like or cauliflower-like. Can be removed by hand. Wet snow Various shapes and structures are possible When T is close to zero it may have a high content of liquid water, and slip off easily. If the temperature drops after the accretion, the adhesion strength may be very strong. Dry snow Very light pack of regular snow. Various shapes and structures are possible, very easy to remove by shaking of wires. Hoar frost <100 Crystal structure (needle like). Low adhesion, can be blown off. Source: Cigré Working Group B2.16. Report 291. April /02/

13 Impacts of icing Case study Aerospace Main impacts of icing on aircrafts Structural integrity of the aircraft Safety Aerodynamic performance reduction: fuel consumption and safety Delays (on-ground): de-icing, added costs Large commercial airplanes Small commercial airplanes Non-commercial airplanes Icing-related accidents, including inflight and runway Fatalities in icing-related accidents Icing-related incidents in FAA s database Icing-related incidents in NASA s ASRS database Lynch F T and Khodadoust A, 2001: Effects of ice accretions on aircraft aerodynamics. Progress in Aerospace Sciences, 37, /02/

14 De-icing methods in numbers Case study Aerospace A Boeing 747 in the IR de-icing hangar at JFK Chemical de-icing Use of chemical (current volume of glycol for de-icing a Boeing-747 (BBC, 2007)= 1545 L/ aircraft. Cost: Current cost of the de-icing of an Airbus A380: ,54 (source EFM list Munich airport) Infrared Ground De-icing System Alternative to de-icing chemicals: using IR can save between 5-10k per aircraft Capital costs: $12M IR de-icing facility at JFK 09/02/

15 Impacts of icing Case study Power distribution China 2008 : $22.3Bn US/Canada 1998: $4.4Bn US/Canada : 87 storms causing >$1M damage 09/02/

16 Impacts of icing Case study Wind Power in Cold Climates 09/02/

17 Fundamentals Approach to anti-ice or de-icing problems Repellent materials State-of-the-art Wetting 09/02/

18 Approaches to icing problems Energy transfer Directly to the ice Active Thermal Freezing point depressant fluids Radiation Hot gases Via the substrate Joule effect Electrical tracers and heaters Mechanical Scraping SM alloys Impacting Torsion devices Abrasive particles Pneumatic expulsive boots Automated robots Electro-impulsive devices Vibrating devices Passive Thermal Heat absorbing surfaces Mechanical Chemical Rings Anti-torsion devices Aeolian devices One-time coatings Icephobic coatings Chemically reactive coatings Adapted from: Laforte C & Laforte JL, Deicing strains and stress of iced substrates J. Adhesion Science and Technology /02/

19 Current ice-phobic coatings Company name Lotus Coatings Leaf Location Markets Website USA Biomedical NeverWet USA Consumer HiRec USA Telecoms Isurguard USA Biomedical Tecnan Spain Construction Shun Technology USA Solar 3M USA Solar O/3mtm-anti-soiling-liquid-600.pdf 09/02/

20 Repellency index Repellency OR/AND durability with current commercial materials? Commercial repellent products 1.0 Figure of Merit Next generation of materials Durability abrasion resistance index Current commercial repellent and durable products 09/02/

21 Wa/γw Surface energy measurements Fundamentals of wetting W a γ w (1+ cos θ) γ s = γ w. cos θ + γ sw Young Equation Liquid-solid interactions Polar Dispersive Hydrogen bonding Low WCA High Adhesion PTFE (water) High WCA Low Adhesion Contact angle (θ) Makkonen L: J Adhesion Sci. Technol. 26 (2012) As the wettability decreases, surface contamination is easier to remove 09/02/

22 High repellency fundamentals Super-hydrophobic properties result from dual-scale roughness and low surface energy EIROS aims to replicate the natural superrepellency of the Lotus leafs via the use of functional repellent nanoadditives Lotus Leaf (Nelumbo Nucifara) Naturally superhydrophobic and self-cleaning These need to be design to achieve minimum surface energy and dualscale roughness 09/02/

23 Materials-by-design approach EIROS project 09/02/

24 EIROS Materials development approach 1 ADDITIVES Development & Synthesis Optimisation Lab scaled up Characterisation Functionalised Silica nanoparticles for hydrophobicity BULK RESINS Incorporation & Dispersion Performance evaluation Characterisation Small batch manufacture BULK RESINS & FIBRES H&S Risks associated to nanomaterials 2 Self-healing additive Modified bulk resins Prepreg Materials 3 Functional nanoencapsulated phase change materials 09/02/

25 EIROS Materials development approach 1 ADDITIVES Development & Synthesis Optimisation Lab scaled up Characterisation Functionalised Silica nanoparticles for hydrophobicity Additives development 1) Functional silica nanoparticles (TWI) 2) Functional encapsulated PCMs (TEK) 2 3 Functional nanoencapsulated phase change materials Self-healing additive 3) Self healing additives (LEI) 09/02/

26 Materials-by-design approach 1 Underpinning technology: Use of additives to enhance resin properties Additives at nano and micro scale level Tech background: methodology that allows multiple functional groups on the same surface of a single particle Repellent functionality Inorganic core that can enhance mechanical and thermal properties of the polymer matrix Crosslinking with polymer matrix (Epoxy) 09/02/

27 Materials-by-design approach Mono or dual functional additives size /type /shape Resin formulation Durable functional systems Development of high performance composite materials by incorporating novel additives into the composite resin Micro-scale roughness 09/02/

28 Materials-by-design approach Building blocks Chemistry nm Functional additives Materials chemistry nm microns Functional resins Materials science Microns bulk Characterisation Porosity Surface area Surface chemistry Size Dispersity Characterisation Particle size distribution Bonding Chemical sequence Functional groups selection Surface coverage Characterisation Integration into resin Dispersion techniques Initial functional performance 09/02/

29 Conclusions 09/02/

30 Conclusions Icing is a real problem in the majority of industrial sectors: it induces extra costs, reduces process efficiencies, and has an impact on human lives Anti-icing /de-icing methods are generally classified in active and passive systems There are not durable passive anti-icing systems The EIROS projects aims at reducing the use of active de/anti-icing systems via the use of durable and repellent materials A materials-by-design approach is being followed 09/02/

31 Have a look at Thank you! marta.alvarez@twi.co.uk info@eirosproject.com alan.taylor@twi.co.uk 09/02/