Cooperative Research Centre (CRC) for Advanced Composite Structures Ltd

Profile

Ian Crouch Business Development Manager Cooperative Research Centre (CRC) for Advanced Composite Structures Ltd http://www.crc-acs.com.au/ http://www.crc.gov.au/centres/man/acs.htm

A career in aerospace, creating new products for aircraft, cars, trains, buildings. Important for maintenance and creation of lighter, stronger materials.

Ian’s background is in metallurgy and he calls himself a material scientist. His initial area of expertise was in steel and aluminium, however, over years his knowledge diversified and the use of other, more appropriate materials for construction of products also gained his interest.

The CRC obtains its funding from a range of sources, from government, the participating members and from individual research projects commissioned by private industry. Ian’s role is to ensure that there is enough funding from private industry as the government contribution gradually reduces. Initially, all of the CRC’s work was in the aerospace sector, however, they have undertaken work in the automotive, building and they now cover work for low tech back yard companies.

In the CRC, scientists have the opportunity to progress into roles such as Ian’s or to maintain a strictly hands on scientific role, undertaking projects and leading teams of scientists to undertake jobs.

The organisation consists of 25 engineers (aeronautical, materials, mechanical, polymer), scientists (materials) and mathematicians, as well as 8-10 technical officers (with diploma’s in engineering, aerospace, a B. Tech in manufacturing or fitting and machining trade qualifications).

In addition to this, the partners (http://www.crc-acs.com.au/link.html) often fund the CRC to undertake a particular project. As part of this project, the partners second a young engineer or scientist to work with the CRC for the duration of the project, often with the opportunity of a Masters qualification being undertaken over this time. At any one time 3-4 scientists and engineers from the partners are seconded to the CRC for advanced composite structures.

Often graduates who come to work with the CRC stay to undertake postgraduate work for three years and then move on to other organisations. Work can vary from design, to manufacture, testing and operating of the products.

The following universities are partners with the CRC for Advanced Composites Structures and provide courses, which can lead to careers in materials science. They are not the only Universities that offer these courses in Australia, see your careers teacher.

Courses and careers RMIT http://www.rmit.edu.au/browse/Our%20Organisation%2FFaculties%2FEngineering %2FResearch%20and%20Development%2FAerospace%20&%2338%3B %20Manufacturing%2FAerospace,%20Maritime%20and%20Automotive %2FAdvanced%20Composite%20Structures/ http://www.aero.rmit.edu.au/ http://www.rmit.edu.au/browse/Our%20Organisation%2FResearch%20and %20Development%2FResearch%20Centres/?STATUS=A University of Newcastle http://www.newcastle.edu.au/research/centres/composite.html Monash University http://www.eng.monash.edu.au/mecheng/ University of New South Wales http://www.mech.unsw.edu.au/mech/ http://www.materials.unsw.edu.au/ University of Sydney http://www.aero.usyd.edu.au/ http://www.mech.eng.usyd.edu.au/ Each of the members has employment opportunities, see http://www.crc- acs.com.au/link.html for a list.

A recent project As an example, the CRC was involved in the research for the construction of carbon fibre I-beams suitable for use in the new Airbus. Ian’s role was to secure the contract between the CRC and Hawker De Haviland to undertake this research. Hawker De Haviland were bidding for this project, and needed to produce a product that met the specifications. Hawker De Haviland did not win the project, primarily due to price.

Other projects

Minesweeper: The CRC has worked with the DSTO and other defence department personnel to build a minesweeper made largely from composite materials.

Carbon Fibre Aileron Section Developed as a replacement. The CRC has also worked on other replacement parts for the RAAF fleet. A prototype for replacement of panels on the F1-11 has been produced as these aircraft begin to age. The panels are to be trialled soon to see how they behave. The challenge has been to produce a panel similar to the one existing, in weight and in surface finish, cheaply and with a short production time.

What does a team do on a project? All members of the CRC’s team work closely together, communicating at all stages of the process, to ensure the project is completed efficiently and with the best outcome. In the design process, the designer needs to assess which materials will be used in which location in the structure, as different parts of the structure have different requirements. Although they have a good knowledge of construction, they must consult others in the team, to assess feasibility, before a test prototype is produced. Through testing of the product is then undertaken. Composites fail in a complex manner and they are still being investigated. This failure mode means that these materials are fatigue resistant to a degree.

The I beams were produced using a process called pulltrusion. The fibres are arranged at one end of the dye in the order they are required in, then an apoxy is injected and the material is pulled through the dye, where it is cured to the correct specifications.

What are composite materials being used for? Although there are significant gains in using composite products, they have not been adopted in civilian aircraft, due in part to confidence. Boeing is proposing that all new aircraft by 2007 will be 80% composite, this will include such things as the fuselage and the wings of the aircraft. http://www.boeing.com/news/releases/2003/q2/nr_030612g.html

The CRC has been involved in work for the automotive industry and for the building industry. The use of the materials in the automotive industry is limited as the cost of conventional materials is less expensive, even though the advantage of composites is great.

The CRC has been involved in repairing cracks in metal using composites also.