Technological Laboratories for Advanced Materials and Processes

The Technological Laboratories for Advanced Materials and Processes are the experimental branch of the Structures and Materials Unit. They are able to carry out both study, test and characterization activities of innovative materials and prototyping of advanced aeronautical and space structures through the development and set up of advanced process technologies. They include three experimental units:

Innovative Materials Lab for the study and development of high performance structures under extreme conditions. The lab is able to perform basic thermal analysis on materials such as calorimetry, thermal expansion coefficient and their thermomechanical properties. It is also capable to execute mass loss measurement following thermal treatments, and to measure the viscosity of fluids and suspensions. In addition, the lab includes a microscopy section, containing some optical microscope for composite and metallographic analysis, and an Environmental Electron Scanning Microscope (ESEM-FEG). The laboratory also includes an in-house developed instrument for the measurement of the contact angle between a fluid and the surfaces it comes into contact with.

Metallic Materials Technology Lab for the study and development of advanced processes for the production of metallic structural components through additive manufacturing technology. The lab includes an additive layer manufacturing machine (ALM) with EBM (Electron Beam Melting) ARCAM A2X technology whose build envelope is 200x200x380 mm (W/D/H). The lab also includes a powder recovery system and a software able to set up the additive job (a CAD/3D printing interface).

Composite Materials Technology Lab for the study and development of innovative processes for the prototyping of composite structural components through automated technologies (FIG5). The lab includes environments and tools for hand-layup, automated deposition of thermoset and thermoplastic prepregs, Filament Winding (dry and wet) 6-dof, Parallel Robotic Winding (dry and we) 8-dof, Thermoplastic (single) Fiber Placement, Resin Transfer Moulding and Liquid Infusion, Autoclave curing and thermoplastic hot pressing.

The Technological Laboratories for Advanced Materials and Processes are equipped with:

Environmental SEM FEG  EDXS (Energy dispersive X-ray spectroscopy)

• Max Zoom: 600.000x

• Electron energy: up to 30KV

• Heating Stage fino a 1500°C

• Chamber pressure 10-4 torr ¸ 20 torr 

Modulated Differential Scanning Calorimeter (TA MDSC 2920)

• Temp. range: -180°C ¸ +725°C max heating rate 100°C/min

Scanning Differential Thermogravimetry (TA SDT 2960) – Mass Spectrometer

• Temp. range: RT ¸ +1500°C max heating rate 200°C/min

Dynamic Mechanical Analyser (TA DMA 2980)

• Temp. range: -150°C ¸  +600°C max heating rate 100°C/min

• Frequency range: 0.01 Hz ¸ 200 Hz

Thermo Mechanical Analyser (TA TMA 2940)

• Temp. range: -150°C ¸ +1000°C max heating rate 100°C/min

Rheometer (TA AR 1000)

• Temp. range: -100°C ¸ +300°C max heating rate 100°C/min

Stereo Microscope  (LEICA)

• Image Analysis

• Fracture Analysis

• Zoom  80x

Metallographic Microscope

• Image Analysis

• Max resolution  1000x

• Zoom 5000x

ALM Machine EBM-based (ARCAM A2X)

• Actual Build Envelope: 200 x 200 x 380 mm (W x D x H)

• Power: up to 3500 W

• Power density: 106 KW/cm2

• Vacuum Process Clean & controlled environment (10-4 mBar)

• Designed to process titanium alloys as well as materials that require elevated process temperatures

• Spot size 0.2-1.00mm

• Built rate 55/80 cm3/h

• EB scan speed 8000m/s

• Roughness 25/35micron

• Accuracy model-to-part: Long range (100mm)=+/-0.20mm Short range (10mm)=+/-0.13mm

Filament Winding Machine (CMC)

• Ø max 0.8 m x L=3.6 m

• D.o.f: 6 (x, y, z, yaw, rotating eye, mandrel)

• 10 spooling with controlled tension [ 7 ¸ 50 N]

• Control System: CMC1 Windows Based Machine Control

Robotic Cell (KUKA)

• Max arm lenght 1.6 m, max. load 45 kg

• D.o.f.: 8 (6 for the robotic arm and 2 for the swivel rotary positioner)

• Fiber tension control and head-injection system

Autoclave (IROP)

• Ø 0.8 m x 1.2 m,

• T=350 ºC, P=9,8 bar.

• Fluid air

Two components Resin Injection System (VENUS EP03)

• Injection pressure 2 ¸ 5.5 atm

• Injection ratio 1.1 ¸ 8.1