A team from Khalifa University has developed a technique to repair aerospace parts using autohesion, or ‘self-healing.’��

A composite material is a combination of materials designed to achieve specific structural or performance properties. Fiber-reinforced polymer composite materials (FRPCs) are one such type of composite used in aerospace applications. FRPCs can enhance structural performance in an aircraft while reducing weight. Their high strength, load-bearing capability, high corrosion resistance, and enhanced durability makes FRPCs state-of-the-art materials in aerospace applications.��

However, no material is perfect, and one of the biggest challenges faced in the aerospace industry is dealing with damaged composite parts. Damaged composite structures tend to be replaced because repairing them is expensive and labor-intense.

A KU research team has found a way to repair these damaged parts using a technique called crack healing.

The team comprised Tayyab Khan, PhD student, Dr. Muhammad Irfan, Postdoctoral Fellow, Prof. Wesley Cantwell, Director of the Advanced Research and Innovation Center (ARIC), and Dr. Rehan Umer, Associate Professor, Aerospace Engineering Department. Their results were published in a leading journal in the field of composites,

In the aerospace industry, FRPCs are employed in both structural and non-structural aircraft components. Most complex aerostructures are formed by joining multiple small parts, with the joint often representing the weakest part. Introducing complexity into large composite parts is often a challenge, and one of the most cost-effective methods to achieve complex structures involves joining smaller parts together.

To test their technique, the team fabricated carbon-fiber reinforced composite material with pre-existing cracks introduced in a novel infusible thermoplastic matrix. These faults were then ‘repaired’ using hot press, by melting them back together again.

“Self-bonding, also known as autohesion, through interdiffusion is an interesting joining approach that has the potential to provide strong bonds between two polymer surfaces,” Dr. Umer said. “Two polymer surfaces in contact with each other can interdiffuse if the polymer chains are mobile enough—if the temperature is high enough.”

Fusion bonding techniques can be used to both join and repair thermoplastic composites. It is the material itself that can be readily melted and consolidated: The heat introduces mobility to the polymer chains that make up the material. These chains can then move and interlink with each other, mixing together and creating a strong seal between the two parts without any need for an adhesive.

“Strong bonds are formed through interdiffusion and the subsequent entanglement of the polymer chains across the interface,” Dr. Umer said. “The initial boundary gradually disappears—the crack vanishes—and mechanical strength builds up at the interface.”

Fusion bonding can’t be used with just any material, such as traditionally used thermosets in aerospace industry. Many thermoplastics have high melt viscosities and high processing temperatures, limiting their widespread use in many sectors, including the aerospace industry. New materials have been developed, including Elium, a novel infusible thermoplastic resin. Arkema Industries China provided the Elium material for the KU team’s research.

The team fabricated pre-cracked laminates from the Elium material and then ‘healed’ the laminates at different temperatures for various time periods and under a range of pressures. They found that pressure had a negligible effect on the results, with the temperature used having the most influence. The laminates bonded at higher temperatures for longer showed the highest strength at the repaired area, with these repaired composites testing at strengths near to those of new or undamaged laminates.

said Dr. Umer.

Jade Sterling
Science Writer
20 June 2022

The post ‘Self-Healing’ Composite Materials for Aerospace Applications appeared first on Khalifa University.

Khalifa University is collaborating with Sanad Aero Tech (a Mubadala Company) to leverage the Additive Manufacturing capability at KU. Together, they are utilizing state-of-the-art equipment to research and develop solutions to some of the world’s most pressing problems. One of these projects involves repairing compressor blades.

A jet engine is powered by constantly spinning compressor blades, but when in service, the blades rub against the housing of the engine and get worn down. When they become too small, the engine’s efficiency is compromised. Taking the engine off wing and repairing these blades is necessary.

Current repair techniques involve tip welding the worn blade to restore its length. However, the current process is lengthy as it involves shipping blades to vendors where they can be placed on the maintenance queue, affecting the overall turn-around time of the engine.

Instead, the joint research team from Sanad and Khalifa University are looking into repairing the blades using additive manufacturing. If the technology is qualified, which is the final stage of development, the blades can be directly repaired using titanium powder, which builds the blade back up to its original shape.

Erica Solomon
Publication Senior Specialist
14 March 2022

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Project to Offer Numerous Advantages in Performance, Productivity, Efficiency, and Safety, in Line with UAE’s 4th IR and ‘Operation 300bn’ Strategies ��

Khalifa University today announced researchers at its are exploring the deployment of industrial robots guided by computer vision to perform high-precision manufacturing tasks for Strata Manufacturing, in line with the UAE’s 4th IR and the ‘Operation 300bn’ strategies.��

These industrial robots, also called vision-guided cobots or collaborative robots, will be used in automated cyber-physical manufacturing and machining processes that will offer numerous advantages in terms of performance, productivity, efficiency, and safety. The aim of this project is to develop things at the lab then deploy them at Strata. These cobots will be used for solving real-world industrial challenges, especially through Khalifa University’s collaboration with the Al Ain-based composite aero-structures manufacturer Strata, which is wholly-owned by Mubadala Investments. ARIC is jointly funded by Khalifa University, Strata, and Mubadala.

At the same time, the project is also building industrial know-how and expanding knowledge base locally through providing students with learning at different stages of their campus life. Two graduate students and four UAE national undergraduate students are also involved in this project. Ameera Al Shehhi, Nouf Al Mesafri, Bushra Al Dhanhani, Mouza Al Zaabi and Anoud Al Zahmi are senior engineering students from Khalifa University who have conducted their summer internship program with Strata. They are currently working on automating repetitive and labor-intensive tasks with advanced computer vision-based technologies that enable robots to operate smarter and safer in the factory.

Dr. Arif Sultan Al Hammadi, Executive Vice-President, Khalifa University, said: “This vision-guided collaborative robots project is another stellar example of Khalifa University’s research projects that are not only industrially-relevant but also economically and financially significant. The outcome of this project will prove beneficial to our partners Strata, through technology enhancements. This project is also in line with the UAE’s 4th IR strategy that aims to work towards advancing the national economy, while making the industrial sector the driving force that contributes to sustainable development.”��

This project is among several projects currently being executed at ARIC where researchers from Khalifa University and Engineers at Strata work hand-in-hand to develop groundbreaking solutions for practical problems in advanced manufacturing.��

Mr. Ismail Ali Abdulla, CEO of Strata said: “ARIC has a unique model for joint R&D between industry and academia in the whole region. It provides an innovative environment for integrating science and engineering to develop practical solutions in addition to developing human capital know-how that is critical for the growth of the advanced manufacturing industry in UAE.”��

The Principal Investigator of the project is Dr. Yahya Zweiri, Associate Professor, Aerospace Engineering, and the Co-PI is Dr. Cesare Stefanini, Professor, Biomedical Engineering, while the lead researcher is Abdulla Ayyad, Research Associate. Strata Engineers Dewald Swart, and Gordon Ferguson are also involved in this project.

Researchers at ARIC use artificial intelligence and computer vision to develop guidance and control strategies for these industrial robots to perform manufacturing tasks quicker with higher reliability for a wide range of shop-floor applications. In addition, the collaboration with Strata allows validation of these technologies in natural living environments that capture the complexity of the end-use applications.��

Concurrently, researchers are also laying the groundwork for the use of vision-based tactile sensing in robotic machining. Tactile sensing is crucial for the success of precise and sensitive machining operations to guarantee repeatability and to avoid damaging delicate work-pieces. It brings advantages in bandwidth, resolution, and cost-efficiency, compared to conventional tactile sensing approaches.

Clarence Michael
English Editor Specialist
11 December 2021

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Partners Agree on Sponsorship of Students, Internships, and Capacity Building and Development ��

Khalifa University of Science and Technology and global aerospace leader Dassault Aviation today announced they have signed a memorandum of understanding (MoU) to establish academic cooperation in developing aeronautical education and related research in the UAE, involving industrial experience as well as advanced technologies.

The two partners will jointly promote and implement cooperation in areas including collaborative high-skilled research programs, student sponsorships and internships, support to academic programs as well as capacity building and development. The MoU will build on existing strengths within Khalifa University in the critical aviation, space, and defense systems sectors, covering aeronautics and astronautical engineering, as well as the Aerospace Research and�� Innovation Center (ARIC) that drives innovation in these areas.

The MoU was signed by Dr. Arif Sultan Al Hammadi, Executive Vice-President, Khalifa University, and Philippe Perrin, Executive Vice-President International, on behalf of Eric Trappier, Chairman and Chief Executive Officer, Dassault Aviation, at Dubai Airshow 2021.

Dr Arif Sultan Al Hammadi said: “The collaboration with France-based global aerospace leader Dassault Aviation reflects our internationalization efforts to collaborate with best partners around the world to bring great minds and expertise to the UAE and our strong commitment to developing human capital in the UAE’s strategic areas. The partnership will benefit our researchers and scientists to explore new frontiers in this industry, while helping students to augment their knowledge and understanding of this vital sector. Through this MoU, we believe we will be able to contribute to the UAE and the region with innovative technology solutions and skilled manpower, capable of handling challenges specific to aerospace and aviation.”

Eric Trappier stated : “Dassault Aviation, as a reliable partner of the UAE for over 45 years, is committed for more than 20 years in contributing to human capital development of the UAE through the development of local capabilities and the enhancement of knowledge, technologies and industrial know-how. Our products, from Rafale fighter as well as Mirage 2000-9 brilliantly operated by the United Arab Emirates Air Force & Air Defence (UAE AF & AD) to Falcon family jets demonstrate our expertise in research and development in the field of Aeronautics and Systems with innovative solutions and a pragmatic and dynamic approach to cooperation. Today this new agreement illustrates our determination to share our expertise providing Khalifa University’s students with the highest education standards within the ambitious projects developed by the UAE industry for the benefit of strategic sectors of the UAE economy.”

Among other initiatives, Dassault Aviation intends to sponsor a cooperative research program on Smart and Advanced materials for aeronautic applications to be jointly conducted at Khalifa University. This activity, benefiting from the skills and outstanding expertise developed at the university, is seen as an important stepping-stone for the maturation of disruptive technologies and future integration on aircraft.

Clarence Michael
English Editor Specialist
22 November 2021

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3D Printing Technologies Help Incorporate Various Design, Ergonomic and Suitability Aspects for Easy Manufacture and Repeated Use

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on Nov 2, 2020 at 2:30am PST

Khalifa University of Science and Technology today announced a team of researchers at its Aerospace Research and Innovation Center (ARIC) is in the process of developing the design of a ‘Reusable 3D Printed�� Mask’, as a potential replacement for standard N95 masks that are in short supply following the COVID-19 pandemic.

The team is currently developing various aspects of the design, taking into consideration requirements including filtration performance, geometry/fit, flexibility, material suitability for medical applications, and manufacturability. Medically graded materials were used in the manufacture of the components.

A prototype has already been printed and once completed, an assessment will be performed before it gets qualified and approved.

The N95 respirators and surgical masks (face masks) are personal protective equipment (PPE) that protect the wearer from airborne particles and from liquid contaminating the face. They are critical supplies for health care workers and other medical first responders.

Dr. Arif Sultan Al Hammadi, Executive Vice-President, Khalifa University of Science and Technology, said: “Community-relevant research has always remained a key pillar of our strategy and we are keen to offer our resources to support R&D in this area, especially during the COVID-19 pandemic. The current situation is unprecedented in history, and has created challenges that require smart scientific solutions through innovation. We believe through the research work at ARIC, we would be able to offer a suitable solution to tackle the challenges posed by the pandemic and protect our frontline defense with this mask.”

As a leading research center focused on advanced manufacturing and robotics, ARIC helps to develop efficient techniques for manufacturing advanced structures and novel procedures for the automated manufacturing and assembly of aerospace components.

Over the past five years, ARIC has completed nine main industry-focused projects, 28 student-led projects involving 65 UAE national students, several patented innovations, and more than 30 academic publications in reputed research journals.

Clarence Michael
English Editor Specialist
2 November 2020

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