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Projects

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3D printer constructing a medical device prototype, emphasizing the application of 3D printing in healthcare innovation.

Gallery
Hydrofoil manufacture Day 2
Fibre Sensor AFP
Compression test of coupon specimen
Tensile test for coupon specimen
Tensile-shear test of coupon specimen
Strain gauge mounting and installation

PhD Projects

  • Automated Fibre Placement (AFP) offers fully automated manufacturing process and excellent tailoring capability at the expense of creating many process-induced defects which significantly increase the modeling complexity. Traditional AFP modeling techniques based on the ply-wise model are very limited in the global elastic stiffness prediction with the assumption that all the tows in-plane are uniform and continuous. However, the effect of these process-induced defects such as gaps, overlaps or tow drops, etc on the performance of the final product is significant. This project primarily targets to develop a more detailed and robust simulation tool for various mechanical performance prediction for AFP composites with the inclusion of physical defects.

  • This project will develop a production-viable AFP process for reinforcement of metallic components with automated placement of unidirectional TPCs. The research will include investigation of surface texturing of metal substrates for optimal laser absorption and metal composite bond quality; metalcomposite interaction with possible adhesive inclusion and/or treatments; thermal modelling and measurements of the bond line temperature history to understand the effects of process parameter settings; and analysis of process constraints, limits of geometrical complexity for automotive part manufacture and cycle times.

  • The project will develop a near damage free machining of polymer based composites using abrasive waterjet (AWJ). AWJ machining have shown great advantages in machining composites than traditional mechanical machining. However, AWJ machining induced material damage, especially delamination, is a huge concern. The research will study the machining process and optimise the parameters. Material removal mechanism, mechanics and delamination mechanism during AWJ impact will also be investigated. The research aims to understand the interaction between AWJ and composites and to improve the AWJ machining process.

  • This research will focus on the certification process of bonded patch repair for aircraft primary structures. This study will involve design and development of defect or damage tolerant; assess the suitability along with support to slow damage growth management approach for both standard and taper geometries; satisfy the certification requirement for certification of bonded repairs in primary aircraft structures together with damage tolerance in the safe-life region. The research will support the overall aim of the Centre to integrate certification process of bonded patch repairs through generic specimen designs called the Double Overlap Fatigue Specimen (DOFS) and the Skin Doubler Specimen (SDS) along with the application of composite materials.

  • The research will focus on developing and characterizing nano-scale functional coatings for high performance composites applicable to several industry sectors, such as aerospace, automotive and elite sport. It will include, for example, the integration of graphene into polymer matrices to enhance electrical, thermal and mechanical properties; and coatings for controlled surface wetting such, as ultra/super-hydrophobic and super-hydrophilic films, for self-cleaning, anti-icing , and anti-fogging application, and water droplet manipulation. The research will support the overall aim for the Centre to integrate carbon composite tapes with enhanced functionality into the automated manufacturing chain.

  • The focus of this investigation will be the integration of nano-materials into polymer matrices to enhance, electrical thermal and mechanical properties of next-generation composites for applications in aerospace, automotive and elite sports. Bulk and nano-material interactions will be examined to consolidate fundamental knowledge to apply to current and future undertakings.

  • This research will focus on the development of optical fibre sensor (OFS) for introduced new possibilities to monitor the mechanical health of the structure. Strain, temperature and pressure are the most widely studied measurands and the fibre grating sensor represents the most widely studied technology for OFS. In the past decade, several R& D studies have been performed with the goal of improving the knowledge and developing new techniques associated with the application of distributed optical fibre sensors (DOFS) in order to widen the range of applications of these sensors and also to obtain more correct and reliable data. Their great advantage is the possibility of monitoring variations of one-dimensional structural physical fields along the entire optical fibre in a truly distributed way. The aim of this research project is to develop a smart structural health monitoring (SHM) application using DOFS and embedded the sensors network into the composite structure for real-time structural assessment and damage detection during manufacturing and in operation.

  • The research focuses on identifying the interface failure of laminated composites using the advanced technique of Scaled Boundary Finite Element Method (SBFEM). SBFEM uses a semi-analytical approach and works appreciably faster than conventional FEM. The research aims to propose a one-stop solution from crack identification to propagation in polymer composite materials and will extend to identify possible avenues of design optimization in case of large hydrofoil structures. The research will support the overall aim for the Centre to integrate simulation findings with enhanced design improvements into the manufacturing of composite structures.

Dental-Composites

  • Novel combinations of mechanical and biological properties are required when developing new polymer-based restorative dental composites. This study reports a promising strategy to develop preventive and restorative dental materials by synthesizing multifunctional dental composites reinforced with short S-glass fibres and chitosan integrated halloysite nanotubes (HNTs). An enhanced interfacial bonding strength and a dispersion capability of the micro-/nao-fillers in the dental resin matrix are obtained by the newly developed surface modification process, resulting in increased mechanical and antibacterial properties.

    • Project 1 - A multifunctional dental composite reinforced with short S-glass fibres and chitosan integrated halloysite nanotubes (HNTs).
    • Project 2 – Molecular dynamics study on dental composites.
    • Project 3 – 3D printable dental and bio-composites.

  • Mechanical and physical characteristics such as strength, modulus, toughness, polymerization shrinkage and stress, and rheological properties, for a range of dental materials (ceramics, composites, and human tooth) can be determined using the various cutting-edge methodologies in experimental dental research.ÌýScientific findings and technologies would support dental industry ultimately dedicating to improving clinical practices of dentistry.

    • Project 1 – Mechanical, physical and handling characterisation of flowable and packable dental composites reinforced with micro-sized S-Glass fibres.
    • Project 2 – Progressive failure and fracture analysis of the dental materials using acoustic emission and photonics techniques.
    • Project 3 – Polymerisation stress and curing kinetics of photo-curable and self-curable dental composites.
    • Project 4 – Bimaterial interface analysis using experimental, numerical and analytical approaches.

  • An ideal tooth restorative material is required to possess mechanical/nanomechanical properties that are similar to natural enamel so that the major tooth function of mastication can be carried out without affecting the vertical dimension of occlusion, etc. This study focusses on the experimental investigation to optimize the composition of fibre reinforced dental composites which helps in increasing the tribological performance of high load-bearing posterior restoration

    • Project 1 - Development of material microstructure – nanomechanical/tribological property relations
    • Project 2 - Synthesis of novel dental materials with improved nanomechanical/tribological performance
    • Investigating coupled temperature-displacement in reinforced dental composites
    • analysing stress at the restoration-tooth Interface due to mechanical loadings
    • Evaluating fracture toughness of dental resin composites
    • Developing density–modulus relationship for enamel and dentine
    • Investigating biomechanical behaviour of functionally graded biomaterials dental implant
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    • Project 1: Structural optimization of dental restorations for reducing stress singularity andÌýcontrolling fracture
    • Project 2: Improvement of mechanical and thermal properties at the inlay-cement-tooth interface: reducing stress singularity andÌýcontrolling fractureÌý
    • Project 3: Optimizing mechanical properties flowable resin composites restorations using random S-glass fibres

Durability of Composite Propellers

  • Automated fibre placement (AFP) is an efficient and reliable manufacturing method for advanced composites. Further improvement in quality, accuracy and production rates can be achieved by the precise control of manufacturing process parameters. However, improper processing conditions can induce random defects within the laminate, which may compromise the structural integrity. The investigation includes the following:

    • Understanding the influence of AFP process parameters on the physical and mechanical characteristics thermoplastic composites.
    • Optimization of AFP process parameters for advanced manufacturing of composites.

  • Marine propellers may encounter several types of impact loadings including collision with floating debris. Experimental and simulation-based underwater impact investigation on marine composites is limited. Resistance to impact damage and residual structural properties are crucial to avoid potential loss of structural integrity and performance. The current project investigates the following:

    • Underwater impact performance of thin/thick marine composites.
    • Finite element based impact performance of composites involving fluid-structure interaction and material property manipulation.
    • Multi-scale modeling of impact damage development on thick composites with geometrical features of a marine propeller.

  • omposite propellers undergo ageing while being submerged in the marine environment. Exposure to varying temperatures and water absorption may affect its mechanical and physical characteristics. The current project thus investigates the following:

    • Use of embedded sensors to detect moisture absorption and its effect on physical and mechanical characteristics due to seawater ageing.
    • Role of crystallinity on the variation of characteristics in thermoplastic composites due to seawater ageing.

  • Current trend in manufacturing is towards digitalization of technologies and processes. Focus has shifted from the performance of single machines and processes towards integration across the entire development chain. 3D printing (Automated Fibre Placement process), extensive digital monitoring framework (embedded sensors), digital twins (virtual simulation) and advanced algorithms (Machine Learning tools such as Artificial Neural Network) are part of major technology pillars towards emerging ‘Industry 4.0’. The project aims at integrating these technologies together for advanced manufacturing of marine composite propellers with enhanced performance.

    • Development of predictive models for performance assessment (including impact behavior) of marine composite propellers.

Advanced Manufacturing Growth Centre

  • Fundamental improvements to the performance of composite materials cascade through to more capable and higher value products. The greatest opportunities for innovation are currently in the area of nano-enhancement of existing materials to provide multi-functional capabilities. Carbon nano tubes (CNTs) and graphene have extraordinary potential to fundamentally change the electrical, thermal and mechanical properties of composite matrices IF they can be integrated into the production chain. ANU has recently invested in a pilot scale facility to produce up to 2 tons of graphene annually. AMAC has identified a key opportunity to integrate graphene treated polymers into the automated manufacturing chain by embedding them in tapes used by the AFP facilities.

    • Project A1 – Graphene enhanced prepreg tapes for thermal and electrical conductivity
    • Project A2 - Durable nano-scale surface treatments to improve wear and environmental resistance

  • Automated manufacture disrupts composites processing norms. Part quality is less of a function of cure cycles and infusion rates and more related to the mechanics of adding material to a mould: consolidation pressure, consolidation temperature, tape lay down rate, tape distortion, etc. This is still an immature area of research with huge potential for investigation and optimisation. Gains in this area will come from creating and optimising robust models for part performance and quality indicators by specifically addressing the complex thermal and mechanical environment at the point of material application onto the mould. Optimising the process parameters for multi-material interfaces, such as thermoplastic/thermoset or composite/alloy, unlocks new opportunities for industry.

    • Project B1 – Automated integration of process monitoring sensors
    • Project B2 – Thermoplastic AFP optimisation for metallic bonding
    • Project B3 - Post-forming of thermoplastic AFP composite tubes
    • Project B4 – Automation of the Thermoset Composite Welding (TCW) technology

  • AFP laminates can be manufactured in a greater variety of shapes than normal laminates, also with exotic mechanical properties, at the expense of including far more localised defects. The manufacturing process is, however, still constrained by the mechanics of the robot, tool and fibre tapes. It is critical that simulation tools are developed to: identify risks in the manufacturing process; identify likely defect locations; predict the as-manufactured properties; and predict the stiffness and strength of manufactured components.

    • Project C1 – Advanced microCT for in-situ defect and damage characterisation
    • Project C2 – Hybrid deterministic/stochastic failure models for AFP composites
    • Project C3 – Selective stiffness modification and performance prediction for composite components

  • One of the major obstacles to automated manufacturing of composites, and composite manufacturing in general, is the complexity of design, qualification, manufacture and testing. Automated manufacturing adds additional complexity to this system which imposes unacceptable risks for many businesses. This research theme aims to develop high-level tools (software, guidelines, etc.) that aid the integration of AFP into industry.

    • Project D1 – Robust composite design of thin-walled AFP composites
    • Project D2 – Stiffening regimes for maximum damage/impact resistance
    • Project D3 - Rapid minimum-damage automated machining of composites