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Waruna Seneviratne, Ph.D. 
ATLAS Director
Sr. Research Scientist (Composites & Structures)
(316) 978-5221

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Chris Boshers
Technical Director and Chief Engineer of Advanced Technologies Lab for Aerospace Systems (ATLAS)(316) 393-5178

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1845 Fairmount St.
Wichita, Kansas 67260

 

Capabilities & Equipment  Research Projects  Partnerships   

CAPABILITIES & EQUIPMENT

Automated Manufacturing

  • Automated Fiber Placement (AFP) and Automated Tape Laying (ATL) for thermoset, thermoplastic, CMC, and dry fiber material systems.
    • Electroimpact System 1 (¼” and ½” AFP with Laser| 6”, 9”, and 12” ATL) – 36’ X-Axis and 15,000 lb Rotator
    • Electroimpact System 2 (¼” and ½” AFP with Variable Spot Size Laser) – 72’ X-Axis, 30,000 lb Rotator, and Dual-Axis Rotator
    • Coriolis System (¼” AFP) – 26’ X-Axis
    • Mikrosam Dual Robot System (¼” AFP & 2” ATL) for Tool-less Manufacturing – 30’ X-Axis and Filament Winding
    • Laser and Humm3 heating options for thermoplastic materials
  • Integrated 6 x 20-feet Vacuum Table and Rotators for AFP
  • Mikrosam Slitter-Rewinder Machine with In-Process Laser Inspection System
  • Fiber Patch Placement (FPP) – Additive 3D Fiber Layup Technology for Complex Composite Parts
  • KraussMaffei 450 Ton Spin-Form with Dual 1400 Injection Units and Rotary Turn Table
    • Integrated Polyurethane ColorForm and High-Pressure Metering Systems
    • Integrated FiberForm IR Oven
  • ENGEL V-DUO 1900 Ton Industrial Press with Thermoplastic Capabilities
    • Integrated Robot, (IR) Oven, Injection Molding Unit, and HP-RTM System
  • Electroimpact Scalable Robotic Additive Manufacturing (SCRAM)
    • Additive (Polymer and Metals), Subtractive, and Thermoplastic AFP
    • 5’ Dia. Vertical Rotator & 5,000 lb Horizontal Rotator (7’ Dia. & 16’ Build Volume)
    • 5’ x 13’ Heated Build Table and 27’ X-Axis
  • Automated Thermoplastic Welding with Closed-Loop Controls and In-Process Inspections
    • Induction, Resistance, and Ultrasonic Welding
  • Autoclaves
    • 13 x 26-feet with 800 deg-F / 200 psi Capability
    • Integrated Wireless Temperature Sensors and Rheometer for Material State Monitoring

High-Fidelity Inspections

  • Dual Tube Dual Detector NSI X7000 X-Ray CT System
    • Micro-focus (up to 5µm resolution) & Mini-focus X-ray Tubes; X-ray Energies from 10kV- 450Kv; Flat Panel Detector & Linear Diode Array Detection Technology
    • In-Situ XCT Scanning with Load Fixture, Extensometer, and DIC
    • Capable of scanning large components up to 60 in diameter x 60 in tall nominal scan envelope
  • ZEISS Xradia 520 Versa Submicron 3D X-ray CT System
    • 160kV high-energy microfocus X-ray source & staging
  • Ultrasonic (MAUS): Pulse Echo testing, MIA Testing, Resonance Testing, Pitch Catch, Phased Array
  • Pulse Thermography
  • Shearography
  • Acoustic Emission (16 Channel System)
  • GOM and Vic 3D Digital Image Correlation Systems (Microscopic 5MP to 29 MP)

Structural Test & Evaluations

  • Electrodynamic Test Systems (670 lbf Max Capability at 200Hz)
  • Permanent Magnet Shakers for Modal & Structural Analysis
  • Planar Biaxial Testing (Axial: 55-kip / Torsion: ±10,000 in-lbf)
  • Large-Scale Test Rig (6’ x 38’ x 16’ test envelope)
    • Over 40 MTS Structural Actuators (Range: 10 – 110-kip)
    • MTS AeroPro™ Software and MTS FlexDAC™ 20 Data Acquisition System (40 Control Channels and 400+ Strain Channels)
  • DMG MORI 5-Axis High-Precision Machining
    • Ultrasonic 85 - Ultrasonic Superimposition of the Tool Rotation
    • DMU 340 Gantry

Computer-Aided Simulations & Analysis

  • High-Performance Computing
  • Manufacturing Simulations and Process Modeling
  • Residual Stress and Failure Analysis

Training

  • Composite Hands-on Training (Manufacturing, Inspections, Repair, and Testing)
  • Metals Hands-on Training
  • Ultrasonic 5-Axis CNC (DMG Mori Ultrasonic 85)

HIGHLIGHTED RESEARCH PROJECTS

  • AFRL – Advanced Material Characterization and Structural Certification (AMCSC)
  • AFRL – Modeling for Affordable Sustainable Composites (MASC)
  • AFRL/Boeing – Composite Airframe Life Extension (CALE)
  • AFRL/Lockheed – Quantification of Aging from Long-term Exposure (QALE)
  • AFRL/Northrop – Fail-Safe Technologies for Bonded Unitized Composite Structures (FASTBUCS)
  • Army – Combat Capabilities Development Command Aviation & Missile Center (CCDC) – Rotorcraft Inspection and Repair, Composites Training, and Adhesive Characterization
  • FAA – Joint Advanced Materials & Structures (JAMS)
    • Certification Efficiency and Safety, Damage Tolerance of Composites, Inspection and Teardown of Aged In-Service Bonded Repairs, Structural joints (Adhesive and Thermoplastic Welds), and Sandwich Damage Growth
  • NASA – Advanced Composite Consortium (ACC)
  • NASA – High Rate Composite Manufacturing (HiCAM)
  • Navy – Process Simulation Models and Noninvasive In-Situ Material State Monitoring for Detection of Process-Induced Damages in Polymer Composites
  • Navy – Fatigue Damage Initiation and Progression of Composites and Bonded Joints under Variable Amplitude Cyclic Loading
  • Navy – Electrodeposition of Nanocrystalline Coating on Additive Manufactured Parts for Enhanced Structural Performance
  • NTSB Composite Aircraft Crash Investigations

CONSORTIUM MEMBERSHIPS AND RESEARCH PARTNERSHIPS

  • Composite Materials Handbook (CMH-17)
  • FAA Joint Advanced Materials & Structures (JAMS)
  • Kansas Aviation Research & Technology (KART)
  • NASA Advanced Composite Consortium (ACC)
  • NASA High-Rate Composite Manufacturing (HiCAM)
  • Navy Composites Manufacturing Technology Consortium (CMTC) - The Composite Consortium
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