AIT Austrian Institute of TechnologyLight Metals Technologies Ranshofen
LKR Leichtmetallkompetenzzentrum Ranshofen GmbH
Mobility Department
Dipl.-Ing. Rudolf Gradinger
Head of Business Deveolpment LKR
JTI Workshop, BMVIT, Vienna, 3. Feb. 2011
Blindtext auf einer PPT-Folie, ein Text without weitere Bedeutung, allein
der Visualisierung eines grafischen Konzeptesdienend. (16pt)
Blindtext auf einer PPT-Folie, ein Text without weitere Bedeutung,
allein der Visualisierung dienend.
Ranshofen
LKRVienna
AITSeibersdorf
General Company Information
LKR Leichtmetallkompetenzzentrum Ranshofen GmbH
� LKR� Number of employees: 34
� Location: Ranshofen, Austria
� Turnover: about 5 million euros
� 100% subsidiary of the AIT
� Non-university research establishment
� Certificates� ISO 9001:2008
� ÖNORM EN ISO/IEC 17025
Positioningof AIT (Austrian Institute of Technology)
LKR Leichtmetallkompetenzzentrum Ranshofen GmbH
Mobility Department
LKR Leichtmetallkompetenzzentrum Ranshofen GmbH
* LKR Leichtmetallkompetenzzentrum Ranshofen GmbH
AIT is one of Europe’s leading mobilityresearch centres
� through efficient, safe and green mobilitysolutions
� through extensive expertise in simulationcoupled with a highly-developed researchinfrastructure
� through networking with science andindustry on a national and international level
Key Research Topics
� Materials development
� Development and optimisation of alloys
� Optimisation of heat-treatment parameters
� Improvement of mechanical and dynamic characteristics
� Optimisation of the microstructures of alloys
� Process development and optimisation
� Development and improvement of casting processes
� Evaluation and optimisation of metal forming processes
� Simulation of process technologies
� Evaluation and optimisation of processes in external production lines� Validation and prototyping
� Materials-based design
� Design of lightweight structures
� Crash simulation of vehicle components and structures
� Optimisation of topology and structure
� Joining technologies� Demonstration and prototyping
LKR Leichtmetallkompetenzzentrum Ranshofen GmbH
GmbH
GmbH
Research Focus Interlinked methods enabling customised lightweight design with light metals
� WHAT:
� Material
� Process
� Design
Pre-product Forming Heat treatment Operation
LKR Leichtmetallkompetenzzentrum Ranshofen GmbH
BlockSmart Materials
LKR Leichtmetallkompetenzzentrum Ranshofen GmbH
LKR Leichtmetallkompetenzzentrum Ranshofen GmbH
Motivation
� Development: Innovative hybrid design joints � Combination: friction, form and material closure� Low preliminary damage to joined elements� Improved interface efficiency
Basic idea
� 3D modification of metal surface (steel, aluminium, titanium)� CMT welding process� Creation of fine structures (pins)� Metal part connected to second part through pins
Objective
� Max. load potential � Energy absorption capacity� => Safety reserves� => Design limits� => Reduction of mass at the joint location
See Project IGEL² in www.bmvit.gv.at/innovation/downloads/takeoff.pdf /http://www.bmvit.gv.at/innovation/downloads/takeoff_broschuere_2.pdf
Joining Technique (IGEL)
Work topics
� Sample geometries(development, design, production)
� Test methods (tensile, peel and bending tests)
� Determination of static and dynamic behaviour
� Influence of geometry parameters
� Corrosion issue
� Non-destructive testing
� Failure mechanisms and characterisation
� Finite element simulations, sensitivity analyses
Material pairing
� Metal – wood
� Metal – textile
� Metal – metal
� Metal – plastic
� Metal – fibre-reinforced plastic
LKR Leichtmetallkompetenzzentrum Ranshofen GmbH
Joining Technique(IGEL)
LKR Leichtmetallkompetenzzentrum Ranshofen GmbH
Anti-icing & de-icing technologies
� Active de-icing by heating structures using semi-conductive coatings� These coatings can be applied like paint and have intrinsic adjustable Ohmic resistance.� They feature a positive temperature coefficient of the electrical resistivity (PTC) providing
additional safety issue and auto-regulation of temperature gradients
See Project HEAT in www.bmvit.gv.at/innovation/downloads/takeoff.pdf / http://www.bmvit.gv.at/innovation/downloads/takeoff_broschuere_2.pdfSee also www.villinger.com
LKR Leichtmetallkompetenzzentrum Ranshofen GmbH
Anti-icing & de-icing technologies
� Active de-icing by vibrating structures near/at the natural frequency of the structure� Principal laboratory results successful� Numerical simulation in good accordance with experimental findings� New icephobic coatings show improvements over base technology regarding reduced
bonding of accreted ice
See Project ANTI-ICE in www.bmvit.gv.at/innovation/downloads/takeoff.pdf / http://www.bmvit.gv.at/innovation/downloads/takeoff_broschuere_2.pdf
LKR Leichtmetallkompetenzzentrum Ranshofen GmbH
Active vibration damping
� Active vibration damping by countering structural deformations with piezo actuators� Full scale tests successful: > -8dB achieved
See Project Vibe-less in http://www.fit-it.at/downloads/FIT-IT-GefoerderteProjekte_2002-2006.pdfSee http://www.vibe-less.org/
Technologies forAero-Engines
LKR Leichtmetallkompetenzzentrum Ranshofen GmbH
� Model with thermo-physical material properties
� Flow curves for high forming speeds described by Johnson-Cook material model applicable on many hard to machine materials like Titanium Ti5553, γ-TiAl, Superalloys, UHSS steels etc.
� Lamellar chip formation: numerical description of material damage
� Description of friction state through improved friction modelling
� Determination of friction parameters under forming conditions with the forming tribometer
� Micro and macro tool geometry
� Material properties of substrate and coating
� Process parameters
Lamellar chip formation in circumferential milling of Ti6Al4V
LKR Leichtmetallkompetenzzentrum Ranshofen GmbH
Reducing the machining costs by process simulation
See Project TiZ, TiZ² in www.bmvit.gv.at/innovation/downloads/takeoff.pdf / http://www.bmvit.gv.at/innovation/downloads/takeoff_broschuere_2.pdf
LKR Leichtmetallkompetenzzentrum Ranshofen GmbH
Optimization of Aluminium alloys
� Increasing the strength and durability at elevated temperatures by metallurgical achievements at microstructural level
� Investigating new alloy concepts like AlMgScZr (in close partnership with EADS, also for airframe application)
� Further development of metal matrix composites for specific specifications
See Projects ALUSTAN and ScaLA in www.bmvit.gv.at/innovation/downloads/takeoff.pdf /http://www.bmvit.gv.at/innovation/downloads/takeoff_broschuere_2.pdf
LKR Leichtmetallkompetenzzentrum Ranshofen GmbH
Electric Tail Drive / More Electric Aircraft
� Main innovation � development of an electrically driven and controlled tail rotor anti-torque device, replacing the conventional, mechanically driven and hydraulically controlled state of the art systems according to the Green Rotorcraft (GRC) Programme.
� The aim is to maximise the efficiency of power usage for rotorcraft and eliminate the use of environmentally unfriendly materials, including hydraulic fluid. A further aspect is the decoupling of the tail rotor speed from the main rotor speed, therefore allowing for a lower tail rotor rpm in forward flight, potentially leading to a reduced noise footprint.
JTI-CS-Proposal EliTE (Electric Tail Drive – Modelling, Simulation and Rig Prototype Development)
JTI-CS-2009-2-GRC-03-001
AIT Austrian Institute of Technologyyour ingenious partner
Dipl.-Ing. Rudolf Gradinger
Head of Business Deveolpment LKR
JTI Workshop, BMVIT, Vienna, 3. Feb. 2011
LKR Leichtmetallkompetenzzentrum Ranshofen GmbH
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