On November 7, 2007, a full-size locomotive traversed the first composite railroad bridge in the world with John Hillman, inventor of the unique hybrid-composite beam that formed the structure of the bridge, on board. Hillman, Senior Associate with Teng & Associates in Chicago, patented the technology in 2000 under the name “Plasticon-Optimized Composite Beam System.”  Now known as the Hillman-Composite Beam, or HCB, the material was designed to be stronger, lighter, and more corrosion resistant than the standard concrete and steel used in infrastructure applications.

After patenting the concept, Hillman turned to UD-CCM several years ago for support in fabricating and testing the beam.   The Center’s expertise in composites manufacturing, augmented by Prof. Dennis Mertz’s knowledge of bridge design and the Department of Civil and Environmental Engineering’s large-scale testing capabilities, helped Hillman turn his dream into a reality.

For Hillman, the successful load test was evidence that the beam has a future beyond the lab.  The test was conducted on the FAST (Facility for Accelerated Service Testing) Loop at the Transportation Technology Center, Inc. (TTCI) near Pueblo, Colorado, a transportation research and testing organization operated by the Association of American Railroads. 

Hillman gives a “thumbs-up” from the train as it passes the load test.

In addition to the commercial potential of the HCB, Michael Chajes, Interim Dean in the UD College of Engineering, is pleased that the project provided a learning opportunity for students.  Two civil engineering undergraduates spent 10 weeks in the summer of 2005 working on fabrication, testing, and design of the HCB in the Composites Manufacturing Lab and the civil engineering structures lab. Hillman spent time on site at UD to co-advise the two juniors.

“Thanks to all the work that has been done with CCM on the composites manufacturing process since then, the beams can now be manufactured in a day,” Chajes points out. “But two years ago, the team was facing a number of fabrication challenges, which turned out to be a great experience for our students because it provided them with insights into the research process that they wouldn’t have gained if everything had gone smoothly.”

For CCM Director Jack Gillespie, the project is a perfect example of how the contributions of many partners can take an innovative idea from concept to field application.  “It also demonstrates successful interdisciplinary research,” he says. “The beams are intended for structural applications, which meant that the involvement of civil engineers was critical to complement our knowledge and expertise in composites manufacturing.”

While Hillman is eager to recognize the contributions of the many partners involved in the project, he was also willing to accept the blame had the load test failed. “I don't mind telling you I was nervous,” he says, “given there was only one direction to point the finger.” 

Fortunately, there will be no finger pointing or looking back on this project—only looking ahead to more widespread use of a technology that shows great promise as a replacement for traditional civil infrastructure materials.

In the 1980s, there was a considerable research effort on 3D fabrics, including involvement by CCM.  I came to Delaware as Distinguished Visiting Professor of Mechanical Engineering and worked with Tsu-Wei Chou, Guang-wu Du, Peter Popper, and others on 3D fabrics for composites.  There were developments in braiding at DuPont, Albany International, North Carolina State University, and Drexel University.  3D weaving was developed at NCSU and by specialist companies in Pennsylvania.  Most of this work used specially designed machinery.  The commercial uptake was limited.

Twenty years later, there is increasing interest.  At a recent conference, Alan Prichard of Boeing said that for the next-but-one generation of aircraft (design of the next generation is well under way), use of 3D fabrics could reduce weight by 30%.  This would give an immense advantage in reducing fuel consumption, with a saving that makes the cost of the composites almost immaterial and an environmental benefit in reducing emissions.  He also contrasted companies that were “engineers trying to be weavers” with companies that were “weavers trying to be engineers.”  The skills of these two different traditions are needed, and the successful companies are those who, in cooperation with academic researchers and user companies, integrate their activities.

One of the reasons for the current optimism is the development of ways to make 3D fabrics on standard weaving machinery with minimal modifications.  Xiaogang Chen and other researchers in the University of Manchester have pioneered this approach and made fabrics for composites and impact protection.  There are many other potential areas for the use of 3D woven fabrics, such as civil engineering and tissue growing. In weft knitting, computer control of machines has enabled integrated 3D garments to be made, thus eliminating the need for sewing pieces together.  This technology also has technical applications.  In nonwovens, 3D forms have been made by Hugh Gong at the University of Manchester by aerodynamic deposition on perforated molds.

First World Conference on 3D Fabrics and Their Applications
April 10 - 11, 2008
Weston Conference Centre,
University of Manchester
Click here to view
conference program

Simulation Seminar Held at CCM

By Diane Kukich

On Wednesday, December 5, 2007, CCM hosted a free seminar, “Simulating Realistic Performance of Composite Materials.”  Offered by SIMULIA, the Dassault Systèmes brand for realistic simulation solutions, the seminar covered issues relevant to applications ranging from automotive, aerospace, and defense to energy, industrial, and consumer products. 

Some 35 participants, including faculty, staff, and students, as well as employees from CCM’s Army and industrial sponsors, attended the day-long class.

One of SIMULIA’s most widely used products is the Abaqus suite for unified finite element analysis.  The software enables both process and product simulation including advanced nonlinear physics (e.g., contact, material nonlinearity, damage and failure) and coupling effects.  Its functionality can be extended through user-defined physics and automated simulation processes as well as integration with complementary products offered by the company and its partners for specific applications.

“This was one of our most successful seminars ever,” says Mike Sasdelli, Manager of Business Development for SIMULIA’s Mid-Atlantic region. “We’ve added a lot of composites-related functionality to recent releases of Abaqus, and we’re working to raise awareness and gather feedback on the new capabilities.  It was great to have CCM, as a center of excellence in composites, host the seminar.  There’s a synergy between what’s going on at CCM and what we’re trying to accomplish.”

“Having CCM host the seminar was a win-win situation,” Sasdelli continues. “We provided Center researchers with information about tools that can be valuable to them, and they can provide us with composites expertise that will enable us to continually upgrade and improve those tools to better meet the needs of the user community.”

Sasdelli earned his master’s degree in mechanical engineering at UD in 1995. Working through the Center, he was advised by Drs. Jack Gillespie, Dick Wilkins, and Vistasp Karbhari and completed his thesis on “A Design Methodology for RTM Composites with Molded-in Metal Inserts”.

CCM is pleased to announce the 9th International Conference on Textile Composites (TEXCOMP9), to be held at the University of Delaware John M. Clayton Hall from October 13 through 15, 2008. The goal of TEXCOMP is to promote knowledge in the field of textile composites

By bringing together scientists and engineers active in a variety of disciplines, the conference provides a dedicated forum for discussions and reports on recent advances in textiles and their composites.

Please visit the TEXCOMP9 Website for more information.