Materials used in products are subjected to mechanical, chemical and physical loads, hence, materials properties must be tested in complex and relevant loading situations. Reliable models that can predict properties or reduce test complexity are essential to reduce validation costs and increase reliability so that the final product can meet customer demands.
Clearly, this R&D platform will be necessary for all solutions developed in the R&D and Fast Track activities, and might be thought of as a service provider. The purpose of the R&D platform is to strengthen these activities and create a national service for testing, modelling and validation in connection with the Advanced Materials Portal.
This will benefit partners in the consortium as well as the Danish Industry in general.
The motivation for modelling materials is basically to generalize and simplify observations from optimal test configurations. A model can be capable of predicting properties based on information of materials structure, or based on data from simple tests to predict the behaviour outside the tested parameter space. For example, it is possible from mechanical tests at different strain rates to predict long-term creep behaviour, from mechanical tests to predict diffusion or from tests at low strain rate to predict high deformation rate behaviour. The industry would like to use materials to their limits in sophisticated engineering structures subjected to complex 3D loading with time-dependent loads in combination with the environment induced changes in properties involving chemical and physical ageing, thermal and UV degradation, corrosion, etc. Only a few models are available for predicting the effects of environmental factors on the mechanical behaviour under short- and long-term deformations. This urgently calls for development of new models incorporating environmental-induced changes in the visco-elasto-plastic response of a wide class of materials, and which remain sufficiently simple to be applied for the analysis of strength and fracture of the engineered structures.
For many traditional manufacturing processes, fairly accurate models have been developed and implemented in CFD- and FEM-codes modelling internal structure and evolution of physical properties of materials at the manufacturing stage. However, linking development of structures and changes in physical and mechanical properties is still a challenge for novel manufacturing techniques like 3D printing, laser welding, etc., where predicted properties are still far from optimal.
Validation is key to ensure the necessary quality of a product. Today validation is often seen as a legal exercise where an external testing center might certify products conform to an accepted standard. Fulfilling the standards is, however, not enough for a responsible company, which requires a high level of confidence that products will meet the expectations of the customers. This calls for a close integration of the former sub tasks with validation.
The goal of this R&D platform is to develop reliable mathematical methods and simulation techniques capable of replacing, at least partially, expensive and time-consuming real experiments with tests that provide additional information about performance of their products under extreme conditions.
National Service Portal
The Technical University of Denmark, Aalborg University, Danish Technological Institute and FORCE Technology are very well equipped and together they hold almost every industrially relevant characterization and testing techniques. However, there is a great need for a portal to map availability, for easy industrial access and for information about capability of the methods and the results generated.