R&D and Testing

Using equipment such as the Krautkramer USN60, is a very useful tool for verifying the evenness, thickness distribution and structural healthiness of a part without load case.

Acoustic emission testing is used extensively by Formtech Composites for the development of new composite parts, the subsequent monitoring of these parts during testing with different load cases and the validation of the parts against the finite element analysis model.

Of particular interest with spars are their torsional and bending stiffness. We have the capability to test spars up to 4.5m long on our test bench, meaning that early in an R&D project we can verify computational analyses for efficient design optimisation. 

Our 50kN Instron machine can be used for material characterisation using coupons.  It is also equipped with an environmental chamber, so we can fully characterise composite performance over a temperature range of -65°C to 250°C.  “Real world” physical characterisation data can be fed back to our designers to create accurate and efficient finite element analyses, improving the design and performance of composite components.

Using plasma treatment, laser ablation and hand abrasion. Plasma treatment is a method used to enhance the bond strength of bonded joints in composite materials. It involves the application of low temperature plasma to the surface of the composite, which alters its chemical properties and improves adhesion of glue to the surface. 

Laser abrasion is also an option available, with several different laser parameters than can be tuned to heat ablate the material surface and thus improve the bond strength. This technique requires careful calibration to ensure that the fibres are not damaged by the laser, which has been shown to limit the shear strength when tested.

NDT and inspection of bonded assemblies and composite panels can be done using our Bondmaster tool and probes.  This can detect areas of delamination or poor bonding within a structure (whether a full composite laminate panel or a sandwich style component), ensuring that only conforming components with the desired characteristics are delivered.

For some applications, thermal resistance of a structure can be of the upmost importance.  Formtech have testing facilities that can expose a composite component to high heat and fire, to establish its performance in extreme conditions. This has been used to design a fire retarding battery containment for heavy and light rail applications, using a lightweight composite sandwich structure that can withstand the temperatures seen during a battery thermal runaway event.