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BIA-Brukerstyrt innovasjonsarena

DemAComp — Filament wound composite products for demanding applications

Alternative title: DemAComp — Filamentviklede komposittprodukter for krevende anvendelser

Awarded: NOK 8.9 mill.

Project Number:

282054

Project Period:

2018 - 2021

Funding received from:

The project "DemAComp ? Filament wound composite products for demanding applications" is an industrial innovation project involving two of the main Norwegian players in the field of filament wound composite structures: Hexagon Ragasco and Nammo. The industrial innovation is supported by R&D activities provided by SINTEF Industry and SINTEF Manufacturing. The primary goal with the project is to develop new products in light weight composite materials: (i) portable gas pressure vessels for storage of different environmental friendly gases, such as hydro-gen, refrigerant gases, CO2 or various industry gases, and (ii) composite structures for rocket motors for civilian applications, such as a carbon composite motor case for sounding rockets or satellite launchers and a Rocket Motor Igniter to be used in booster rocket motors in the next generation of Vega and Ariane 6 space launch vehicles. The main driving force behind developing these new products is the strong environmental focus on reducing greenhouse gas emissions in all sectors: (i) by a transition to use of more environmentally friendly gases and containers for these using little energy in production and (ii) composite structure which leads to reduced weight in propulsion systems and therefor being a contribution in developing green propulsion systems for space launch vehicles. To fulfil the project ambition, R&D work is required for the design, production, qualification and verification of innovative filament wound composite structures for these application areas. The R&D activities have mainly focused on three areas: (i) improvements and optimization of production processes and materials, (ii) advanced numerical product development tools and (iii) verification and documentation support. In the beginning of the project we have focused on optimisation of materials and the filament winding production process. Among the topics being investigated was how this affects residual stresses. A reduction in these can improve the performance of the composite laminate against impact forces. We has also been working on developing advanced numerical tools to help in product development. These tools are developed stepwise. These tools will include material models that can handle residual stresses and damage development. In addition to be a tool in product development, such a numerical model will also be useful for product verification and documentation. A method for fast-track modelling of advanced composite structures with use of scripted parameterized models has been developed. We have also worked on numerical models and design rules for bolted composite structures, and other geometrical stress risers. In the development work of a prototype for the new composite structures for rocket motors, the numerical modelling goes hand-in-hand with advanced mechanical characterisation in order to obtain necessary material data. Project demonstrator based on new composite solutions, has been tested with good results. Composite propulsion system based on Hydrogen Peroxide technologies, will reduce weight and emissions compared with solid propulsion solution systems based on metal structures.

Oppbygging av material-, modellering- og simulerings kompetanse for avanserte viklede kompositt produkter i instituttsektoren og ute i industrien er forventet å ha vesentlig betydning for enkelte andre etablerte virksomheter i tillegg til fremtidige nyetableringer. Kunnskap og erfaring rundt kompatibilitet av plast/kompositt mot ulike gasser er også forventet å ha stor interesse innen flere ulike bransjer i Norge, både i dag og i fremtiden.

DemAComp project is an industrial innovation project involving the main Norwegian players in the field of filament wound composite structures: Hexagon Ragasco and Nammo. The industrial innovation will be directly supported by specific R&D activity provided by SINTEF Industry and SINTEF Raufoss Manufacturing. The project goal is to design and develop optimized production processes, as well as numerical and analytical methodologies, required for the production, qualification and verification of innovative filament wound composite structures for future and more demanding application areas. Different R&D activities will be performed focusing mainly on three areas: (i) Improvements in production processes and related materials, (ii) advanced numerical product development tools and (iii) Verification and documentation support. The innovations listed are motivated by the ambition to develop completely new products in light weight composite materials for (i) portable gas pressure vessels for storage of different environmental friendly gases, such as hydro-gen, refrigerant gases, CO2 or various industry gases, and (ii) composite structures for rocket motors for civilian applications, such as a carbon composite motor case for sounding rockets or satellite launchers and the structure for the P120C Solid Rocket Motor Igniter to be used in booster rocket motors in the next generation of Vega and Ariane 6 space launch vehicles. As a spin-off, these innovations will also be used for improvement of current products and production processes as well as for the development of the next generation of existing products. The main driving force behind developing these new products is the strong environmental focus on reducing greenhouse gas emissions in all sectors: (i) by a transition to environmentally friendly gases and containers for these with redused energy consumtion in production and (ii) composite structure which leads to reduced weight in propulsion systems is one contribution in developing green propulsion systems for space launch vehicles.

Funding scheme:

BIA-Brukerstyrt innovasjonsarena