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UK Public Sector Funded Projects
MERL conducts a range of UK government funded projects either as the project lead or as a partner or subcontractor. Typically projects are funded via the Technology Strategy Board (TSB), The Department for Innovation, Universities and Skills' Grant for Research and Development, and the Waste and Resources Action Programme (WRAP). For further information on funding opportunites contact Dr Rod Martin.

CURRENT PROJECTS:

  1. CQCC: Continuous Quality Control for Composites for the Next Generation Flexible Pipe
  2. NDT2DT: New ICT Approach to Automate Non-destructive Testing and Inspections with Evaluation of Damage Tolerance in Composite Structures
  3. i-composites: Inspirational Composite Technologies
  4. BMAX: Tidal Turbine Blades - Maximising Reliability and Performance and Reducing Cost
  5. DURASTOR: Low Cost, Durable Thermoplastic Hydrogen Storage Tanks

COMPLETED PROJECTS:

  1. NEW-MMEETT: New Materials and Methods for Energy Efficient Tidal Turbines
  2. YORKSHIRE FORWARD: Critical interfaces for new generation of offshore bonded flexible hoses
  3. THERMOPIPE: Thermoplastic composite pipelines versus corrosion resistant alloys.
  4. PEOR: Polymers for Use in Enhanced Oil Recovery
  5. MSI-SPAR: Maintaining Structural Integrity of yacht and wind turbine Spars
  6. FETLEC: Fuel Emission Testing for Low Emmision Components
  7. COMPOSITE FRICTION MATERIALS
  8. INCREASED DEMAND FOR RECYCLED PLASTICS
  9. TOOLKIT FOR ADHESIVE BONDING
  10. VIRCON: Virtual consultant for composite materials
  11. EPSRC: Thermoplastics in high pressure gas environments
  12. CURIGHT: Computer controlled curing of rubber.
  13. MMS DEFECTS: Effect of defects in composites
  14. FARADAY PLASTICS: Polymer networking.

CURRENT PROJECTS:

  CQCC:Continuous Quality Control for Composites for the Next Generation Flexible Pipe
Aims:
The project aims to design and develop an NDT phased array inspection module to detect defects resulting from manufacturing anomalies as well as damage from handling in fibre-reinforced plastic pipes used in the oil and gas industry. The latter half of the project will focus on the design and development of a module to repair the damaged composite armour used in the pipe’s manufacture. Both modules should be suitable for continuous quality control during the manufacturing process of fibre-reinforced plastic pipes when incorporated into the production line.
Application:   Fibre-reinforced plastic pipe manufacture for the oil and gas industry
Duration: 2011 – 2013
Participants:   MERL Ltd. (Lead Partner), Wavelength NDT Ltd., Wellstream International Ltd.
Contact:

Dr Morris Roseman

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  NDT2DT: New ICT Approach to Automate Non-destructive Testing and Inspections with Evaluation of Damage Tolerance in Composite Structures
Aims:
The NDT2DT project aims to develop software tools to bring together two state of the art technologies for composite material structures, the Non-Destructive Testing (NDT) and the evaluation of the Damage Tolerance (DT). These software tools will enable the transfer of NDT information obtained on composite material structures directly into Finite Element (FE) procedures for subsequent analysis, with minimal user input. By joining these two technologies together, the non-destructive testing (NDT) inspection method will rapidly give a qualitative (go/repair/no-go) decision to the operator of the composite material asset being inspected. The proposed techniques can apply to quality control (manufacturing), maintenance or in-service inspections. Currently, the inspection methods used may detect damage but any assessment relies on the engineering judgement of the asset owner.
Application:   Composites
Duration: 2011-2013
Participants:   MERL (Lead Partner), Spirit Aerosystems, Samtech UK, Wavelength NDT
Contact:

Dr Stefanos Giannis

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  i-composites: Inspirational Composite Technologies
Aims:
This programme aims to target the two critical requirements needed to transform the UK composites industry and so develop a wide range of new market opportunities:
1. Cost reduction technologies.
2. Enhancing the capabilities and performance of composite structures.
This programme aims to provide the basis for reducing energy consumption and wastage in manufacturing whilst simultaneously improving the functionality of composite materials.
MERL is participating with project in close collaboration with Rolls-Royce aiming to address the effect of manufacturing defects on composite structural parts
Application: Inspirational Composite Technologies
Duration: 2010– 2011
Participants: Led by GKN Aerospace and with participation of 22 companies including MERL
Contact:

Dr Stefanos Giannis
i-composites website

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  BMAX: Tidal Turbine Blades - Maximising Reliability and Performance and Reducing Cost
Aims:
This project addresses the requirement to reduce cost and improve the performance of existing tidal stream devices. Building on previous work under TSB and Carbon Trust funded programmes this project aims to develop further an innovative root blade attachment design through the development of more suitable composite and adhesive materials, design methodologies and modelling techniques. The project will research and develop new adhesive and composite materials able to perform in hostile environments throughout the service life of a tidal turbine blade. Using state of the art modelling blade structures will be optimized for performance and reliability.
Application: Tidal turbine blades
Duration: 2010– 2013
Participants: MERL, Aviation Enterprises Ltd. (Lead Partner), Advanced Composites Group, University of Bristol
Contact: Dr Stefanos Giannis

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  DURASTOR: Low Cost, Durable Thermoplastic Hydrogen Storage Tanks
Aims:
The objective of the project is to develop a novel, low cost, high pressure (700bar) gaseous hydrogen storage vessel for the automotive market that will offer improved fatigue performance at a lower cost than current solutions with the added benefit of being fully recyclable at the end of life. This step change in cost and performance will be achieved by the development of monolithic thermoplastic composite pressure tanks. The project will research and develop new formulations of low cost engineering thermoplastic polymers and co-polymers that have excellent hydrogen barrier properties, are low density (resulting in a lighter weight structure) and are inherently recyclable so the product can be broken down and re-used at the end of its service.
Application: Hydrogen storage in automotive applications
Duration: 2009 – 2012
Participants: MERL, EPL Composite Solutions (Lead Partner), Crompton Technology Group Ltd, Ticona UK Ltd, Delta Motorsport Ltd, Crompton Mouldings Limited, Oxford Brookes University
Contact: Peter Hansen

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COMPLETED PROJECTS:

  New Materials and Methods for Energy Efficient Tidal Turbines (NEW-MMEETT)
Aims:
NEW-MMEETT focuses on the investigation and improvement of the fatigue properties of composite materials used in tidal turbine energy generation through the design of a matrix resin system specifically for this particular application. The improvement of the fatigue resistance of thick composite components would offer the potential to extend the life and increase the usage of such components for long-term use in hostile environments. It would also allow for improved efficiency in manufacture, reduction in component mass simplifying installation and maintenance of large generators and reducing inspection requirements.
Application: Renewable Energy
Duration: 2008 - 2010
Participants: MERL, Advanced Composites Group (Lead Partner), Aviation Enterprises Ltd., University of Bristol
Contact: Dr Stefanos Giannis

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  YORKSHIRE FORWARD: Critical interfaces for new generation of offshore bonded flexible hoses
Aims: This project aims to develop technology that will allow novel bonded flexible hoses to be designed with high axial strength. This potential new market for bonded flexible hoses requires a new generation of designs with enhanced capability and long-term performance especially in the UK continental shelf. In order to achieve these new designs, a greater understanding is required of the interfacial failure modes in the composite layers of hoses alongside the ability to predict hose performance using FEA.
Application: Oil & Gas: Bonded hoses for offshore applications
Duration: 2009 – 2011
Participants: MERL, Dunlop Oil and Marine Ltd
Contact: Dr Salim Mirza

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  THERMOPIPE
Aims: To research and develop a cost effective thermoplastic composite pipeline with increased durability and reduced maintenance over expensive corrosion resistant alloy
Application: Oil & Gas
Duration: 3½ years
Participants: EPL, MERL, Acergy, Chevron, Hess, PERA, Ticona
Contact: Dr Morris Roseman

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  PEOR: Polymers for Use in Enhanced Oil Recovery
Aims: To identify, qualify and develop new polymeric materials used during EOR operations to ensure their longevity for safe operations during these potentially hostile applications.
Application: Oil & Gas
Duration: 2 years
Participants: MERL, Clwyd Compounders Ltd, Precision Polymer Engineering Ltd and Baker Oil Tools
Contact: Dr Morris Roseman

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  MSI-SPAR: Maintaining Structural Integrity of yacht and wind turbine Spars
Aims: To investigate the damage tolerance of composite large yacht spars, with the aim to deliver improvements in structural durability, design and quality control
Application: Marine
Duration: 2005-2007
Participants: MERL (lead partner), UK Maritime and Coastguard Agency, Energy Management Consultants Ltd, Formula Yacht Spars Ltd, High Modulus Europe Ltd, Insensys Ltd, NDT Solutions Ltd, SP Technologies Ltd and Testsure Technology Ltd.
Contact: Peter Hansen
MSI-SPAR website

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  FETLEC - DTI Technology Programme
Aims: To develop new and improved test methods and measurement techniques to enable fuel system components with reduced rates of emission to be more rapidly designed and validated.
Application: Automotive (fuel containment)
Duration: 2004-2005
Participants: MERL (lead partner), Roulundes-Codan, Visteon, GPS
Contact: Dr Nickie Smith

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  Composite Friction Materials - DTI Technology Programme
Aims: To develop the methodology and associated test methods to identify the factors that influence the tribological properties of the composite friction materials in high friction applications
Application: Transport (aircraft, trains, commercial vehicles etc.)
Duration: March 2002 - February 2005
Participants: MERL (project managers), Leeds University, MIRA
Contact: Dr Rod Martin

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  Increased Demand for Recycled Plastics - WRAP funded
Aims: To develop a life prediction methodology and more durable Biobeads™, a recycled plastic media used in residential and commercial filtration. The results will increase the tonnage of recycled plastic by increasing the markets for Biobeads™
Application: Utilities
Duration: March 1st 2002 - February 28th 2003
Participants: MERL, Brightwater Engineering Ltd.
Contact: Dr Nickie Smith

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  Toolkit for Adhesive Bonding - DTI Materials Metrology Programme
Aims: To develop a web site for dissemination of information on adhesive bonding
Application: General engineering
Duration: April 2002 - March 2004
Participants: TWI (lead partner), MERL, NPL, AEA
Contact: Dr John Harris
Adhesives Toolkit website

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  VIRCON - DTI Materials Metrology Dissemination Programme
Aims: An introduction to composite materials using a web based ‘virtual consultant’
Application: All engineering fields
Duration: April 2002-May 2004
Participants: NPL (lead partner), MERL, Rapra Technology, AEA, Trend 2000, Qinetiq
Contact: Dr Rod Martin
VIRCON website

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  EPSRC
Aims: Assess physical ageing of thermoplastics in HP gas environments
Application: Oil and gas hoses, seals
Duration: 2002 - 2004
Participants: MERL, University of Strathclyde, WMG
Contact: Dr Barry Thomson

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  CURIGHT
Aims: To demonstrate feasibility of computer controlled curing to improve the control and precision of curing rubber components, saving energy and reducing scrap
Application: Rubber components
Duration: 2003
Participants: MERL,Silvertown UK Ltd.
Contact: Dr Michael Lewan

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  MMS DEFECTS
Aims: To assess the effects of defects on composite materials
Application: General composite engineering
Duration: 2002 - 2005
Participants: AEA (lead partners), MERL, NPL
Contact: Dr Rod Martin

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  FARADAY PLASTICS
Aims: To improve the link between academia and industry for plastics research
Application: General plastics engineering
Duration: 2002-2005
Contact: Dr Nickie Smith

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