AIT Austrian Institute of Technology - FFG · AIT Austrian Institute of Technology Light Metals Technologies Ranshofen LKR Leichtmetallkompetenzzentrum Ranshofen GmbH Mobility Department

AIT Austrian Institute of TechnologyLight Metals Technologies Ranshofen

LKR Leichtmetallkompetenzzentrum Ranshofen GmbH

Mobility Department

Dipl.-Ing. Rudolf Gradinger

Head of Business Deveolpment LKR

[email protected]

JTI Workshop, BMVIT, Vienna, 3. Feb. 2011

Blindtext auf einer PPT-Folie, ein Text without weitere Bedeutung, allein

der Visualisierung eines grafischen Konzeptesdienend. (16pt)

Blindtext auf einer PPT-Folie, ein Text without weitere Bedeutung,

allein der Visualisierung dienend.

Ranshofen

LKRVienna

AITSeibersdorf

General Company Information


� LKR� Number of employees: 34

� Location: Ranshofen, Austria

� Turnover: about 5 million euros

� 100% subsidiary of the AIT

� Non-university research establishment

� Certificates� ISO 9001:2008

� ÖNORM EN ISO/IEC 17025

Positioningof AIT (Austrian Institute of Technology)


Mobility Department


* LKR Leichtmetallkompetenzzentrum Ranshofen GmbH

AIT is one of Europe’s leading mobilityresearch centres

� through efficient, safe and green mobilitysolutions

� through extensive expertise in simulationcoupled with a highly-developed researchinfrastructure

� through networking with science andindustry on a national and international level

Key Research Topics

� Materials development

� Development and optimisation of alloys

� Optimisation of heat-treatment parameters

� Improvement of mechanical and dynamic characteristics

� Optimisation of the microstructures of alloys

� Process development and optimisation

� Development and improvement of casting processes

� Evaluation and optimisation of metal forming processes

� Simulation of process technologies

� Evaluation and optimisation of processes in external production lines� Validation and prototyping

� Materials-based design

� Design of lightweight structures

� Crash simulation of vehicle components and structures

� Optimisation of topology and structure

� Joining technologies� Demonstration and prototyping


GmbH

GmbH

Research Focus Interlinked methods enabling customised lightweight design with light metals

� WHAT:

� Material

� Process

� Design

Pre-product Forming Heat treatment Operation


BlockSmart Materials



Motivation

� Development: Innovative hybrid design joints � Combination: friction, form and material closure� Low preliminary damage to joined elements� Improved interface efficiency

Basic idea

� 3D modification of metal surface (steel, aluminium, titanium)� CMT welding process� Creation of fine structures (pins)� Metal part connected to second part through pins

Objective

� Max. load potential � Energy absorption capacity� => Safety reserves� => Design limits� => Reduction of mass at the joint location

See Project IGEL² in www.bmvit.gv.at/innovation/downloads/takeoff.pdf /http://www.bmvit.gv.at/innovation/downloads/takeoff_broschuere_2.pdf

Joining Technique (IGEL)

Work topics

� Sample geometries(development, design, production)

� Test methods (tensile, peel and bending tests)

� Determination of static and dynamic behaviour

� Influence of geometry parameters

� Corrosion issue

� Non-destructive testing

� Failure mechanisms and characterisation

� Finite element simulations, sensitivity analyses

Material pairing

� Metal – wood

� Metal – textile

� Metal – metal

� Metal – plastic

� Metal – fibre-reinforced plastic


Joining Technique(IGEL)


Anti-icing & de-icing technologies

� Active de-icing by heating structures using semi-conductive coatings� These coatings can be applied like paint and have intrinsic adjustable Ohmic resistance.� They feature a positive temperature coefficient of the electrical resistivity (PTC) providing

additional safety issue and auto-regulation of temperature gradients

See Project HEAT in www.bmvit.gv.at/innovation/downloads/takeoff.pdf / http://www.bmvit.gv.at/innovation/downloads/takeoff_broschuere_2.pdfSee also www.villinger.com


Anti-icing & de-icing technologies

� Active de-icing by vibrating structures near/at the natural frequency of the structure� Principal laboratory results successful� Numerical simulation in good accordance with experimental findings� New icephobic coatings show improvements over base technology regarding reduced

bonding of accreted ice

See Project ANTI-ICE in www.bmvit.gv.at/innovation/downloads/takeoff.pdf / http://www.bmvit.gv.at/innovation/downloads/takeoff_broschuere_2.pdf


Active vibration damping

� Active vibration damping by countering structural deformations with piezo actuators� Full scale tests successful: > -8dB achieved

See Project Vibe-less in http://www.fit-it.at/downloads/FIT-IT-GefoerderteProjekte_2002-2006.pdfSee http://www.vibe-less.org/

Technologies forAero-Engines


� Model with thermo-physical material properties

� Flow curves for high forming speeds described by Johnson-Cook material model applicable on many hard to machine materials like Titanium Ti5553, γ-TiAl, Superalloys, UHSS steels etc.

� Lamellar chip formation: numerical description of material damage

� Description of friction state through improved friction modelling

� Determination of friction parameters under forming conditions with the forming tribometer

� Micro and macro tool geometry

� Material properties of substrate and coating

� Process parameters

Lamellar chip formation in circumferential milling of Ti6Al4V


Reducing the machining costs by process simulation

See Project TiZ, TiZ² in www.bmvit.gv.at/innovation/downloads/takeoff.pdf / http://www.bmvit.gv.at/innovation/downloads/takeoff_broschuere_2.pdf


Optimization of Aluminium alloys

� Increasing the strength and durability at elevated temperatures by metallurgical achievements at microstructural level

� Investigating new alloy concepts like AlMgScZr (in close partnership with EADS, also for airframe application)

� Further development of metal matrix composites for specific specifications

See Projects ALUSTAN and ScaLA in www.bmvit.gv.at/innovation/downloads/takeoff.pdf /http://www.bmvit.gv.at/innovation/downloads/takeoff_broschuere_2.pdf


Electric Tail Drive / More Electric Aircraft

� Main innovation � development of an electrically driven and controlled tail rotor anti-torque device, replacing the conventional, mechanically driven and hydraulically controlled state of the art systems according to the Green Rotorcraft (GRC) Programme.

� The aim is to maximise the efficiency of power usage for rotorcraft and eliminate the use of environmentally unfriendly materials, including hydraulic fluid. A further aspect is the decoupling of the tail rotor speed from the main rotor speed, therefore allowing for a lower tail rotor rpm in forward flight, potentially leading to a reduced noise footprint.

JTI-CS-Proposal EliTE (Electric Tail Drive – Modelling, Simulation and Rig Prototype Development)

JTI-CS-2009-2-GRC-03-001

AIT Austrian Institute of Technologyyour ingenious partner

Dipl.-Ing. Rudolf Gradinger

Head of Business Deveolpment LKR

[email protected]

JTI Workshop, BMVIT, Vienna, 3. Feb. 2011


Documents

AIT Austrian Institute of Technology - FFG · AIT Austrian Institute of Technology Light Metals Technologies Ranshofen LKR Leichtmetallkompetenzzentrum Ranshofen GmbH Mobility Department