Workpackage 6 - Innovative materials & processes

This workpackage aims to develop smart and functional materials and structures. It will take advantage of the extended properties of intelligent materials, integrated by using the self-sensing abilities of materials. Versatility, advanced characterization, modelling tools and optimal design methods will be combined in order to find the best micro- meso- and macro-scale arrangements in a top-down approach. The manufacturing of parts has to rely on agile and automated processes with real-time control to ensure product reliability and reduce costs through a link with the workpackages 1 and 2.

In this way, this workpackage feeds BEST by developing a top-down design approach, from functional specifications to the creation of structured materials and associated processes (leading to work with workpackage 2). Concerning product life, reliable and cost-effective smart structures provide the possibility of rising to the challenge of predictive maintenance based on continuous health monitoring (in collaboration with workpackage 1).

The objective is focused on polymers and reinforced polymers and a proof of concept is planned to be developed in order to validate this objective. Methodologies will be developed and assessed for specific technologies in the short term. In a longer term, an impulsion will be given to generalize these methodologies through other applications, such as smart ceramic composites for Structural Health Monitoring (SHM), polymer or metamaterial with graded properties for acoustics. The durability of materials will be studied in severe conditions combining cyclic, dynamic mechanical loadings and aggressive environments in order to be representative of actual conditions applied to industrial systems. The workpackage 6 will feed workpackage 1 in terms of new SHM hardware technologies in order to evaluate new SHM methods for predictive maintenance. In return, workpackage 1 will adjust design requirements for smart structures. It will propose predictive models for optimization procedures developed in workpackage 2. In return, workpackage 1 will propose enhanced design that will be manufactured and tested in industrial conditions.

 Priority topics and actions

• Development of multi-stage processes manufacturing units for smart structures
• Evaluation and improvement of the performance of smart features on-board of the host structure under in-service conditions

Examples of other topics and actions of interest

• Evaluation and prediction of the invasive nature of smart components regarding the host structure under in-service conditions
• Process analysis and control based on in-situ measurements and multi-physical modelling - Application to additive manufacturing of metal, polymer, composite and hybrid materials
• Taking into account the gradient of microstructure and effective properties to predict the service life of structured parts
• Manufacturing strategies for the control of post-processing effect on the durability of metallic parts made by additive manufacturing