Carbon Fiber Technology Center - Oak Ridge National Laboratory

In order for the full utilization of carbon fiber in automotive applications. (Which is necessary to lower weight.) The cost of raw carbon fiber needs to decrease. Oak Ridge National Laboratory (ORNL) is taking on this challenge using $34.7 million in DOE ARPA funding; they are establishing a Carbon Fiber Technology Center. According to their website:

The center will be capable of producing up to 80 tons per year of low-cost carbon fiber for evaluation and use by industry and government partners. Primary equipment will include a thermal (conventional) carbon fiber conversion line and a melt-spun precursor fiber production line. Space and utility provisions are planned to add an advanced technology conversion line.

The overall goal of this technology center is to lower the cost of carbon fiber 50%. This could be a major breakthrough not only to the automotive industry in gaining better fuel efficiency, but many other applications of carbon fiber where high-strength and lightweight is crucial.

Photo Credit: ORNL

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Defense Armor Funding - 2011 Requests

2010 was a fantastic year for defense appropriations for composite companies, in particular, composite armor received substantial funding. Even though it is only April, Senators are beginning to announce their 2011 requests. Senator Jim Bunning of Kentucky announced some of his requests, and looks like 2011 will be another stellar year for composite armor funding. Below are Bunning's related requests:

Project: De-Weighting Military Vehicles through Advanced Composites Manufacturing Technology

Amount Requested: $3,200,000

Recipient: MAG Industrial Automation Systems

Location: Boone County, KY

Description:  This is a research and development project for manufacturing of a machine to produce lighter-weight parts for military vehicles.  The project is a valuable use of taxpayer funds because it advances technology that delivers light-weight materials that improve fuel efficiency, cost savings, and enhanced combat readiness.

Project: Enabling Optimization of Reactive Armor 

Amount Requested: $5,000,000

Recipient: Ensign-Bickford Aerospace and Dynamics

Location: Muhlenberg County, KY

Description: These funds will be used to develop a replacement for current reactive armor used by the Army which will be reduced in weight, meet new threats, and increase overall safety. 

Project:  New Specialty Resins for Advanced Composite Armor

Amount Requested: $2,000,000

Recipient: Hexion Specialty Chemicals, Inc.

Location: Jefferson County, KY

Description: Funds will help develop a new range of matrix resins that address shortcomings in existing composite ballistic armor systems.  Achieving a better balance of properties will advance composite toughness, enhance fire, smoke, and toxicity performance to help our servicemen and women. 

Project: Tactical Mobility Consortium (TMC)

Amount Requested: $8,000,000

Recipient: University of Kentucky Research Foundation and M2 Technologies

Location: Fayette County, KY

Description:  The requested funding will advance years of aggressive research and development with the Marine Corps to deliver a critical force protection capability to the warfighter, allowing our military to provide the technical expertise required to assess the intended and unintended impacts of emerging technologies within the context of expeditionary warfare.  

Hopefully the military is actually requesting this research...

Source and Photo Credit: Senator Jim Bunning

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Biomimicry Adhesives

Composites, which are often structurally bonded with adhesives, are always looking for a better product. So when adhesive researchers need inspiration, what better place to look then nature (Biomimicry). Some researchers have looked at shellfish, such as how mussels are able to adhere so well to wet rocks in a turbulent environment.

However, recent research is looking into the sandcastle worm. This little guy builds his home on the ocean floor by gluing grains of sand together. Not only is this adhesive extremely strong, but it is cured underwater, a feat humans are yet to accomplish. Most adhesives cure requiring a drying process, and if scientists can better understand how the sandcastle worm works, a whole new generation of sythetic adhesive products could be developed.

Beyond creating a better adhesive for composites, a structural adhesive able to cure underwater has numerous uses in marine applications and medical uses...

Photo Credit: Philippe Guilluime via flicker

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Advanced Mechanics of Composite Materials

 

This came up on a web search, some good information...

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Aluminum Bats vs Composite Bats

Composite baseball bats are gaining popularity in softball and little leagues world wide. Using carbon fiber and epoxy, these composite bats are said to have such good performance, that they are now banned for use in NCAA play. Much like other composite products, the big draw to the bats is their lightweight yet powerful capabilities.

What is interesting though, is that while most composite products dread delamination and fiber-breakage, composite bats desire it. It is said that composite bats get better with use. The theory goes, as fiber breaks and delaminates in the bat barrel, the bat becomes more flexible producing more power when you hit the ball.

In 2008, the University of Massachusetts at Lowell put this to the test. Although their sample size was relatively small, they concluded:

"A set of six “high-performance” composite baseball bats and one aluminium baseball bat were tested to see how their respective batted-ball performances would evolve with use. None of the bats showed a significant change in the resulting batted-ball-speed performance using the NCAA BESR performance testing protocol. Three of the six baseball bats failed with less than 100 hits—implying that some of the composite bat designs are not durable."

A high-end composite bat, weighing less the 30oz, can retail for over $300... Not too shabby.

Photo Credit: ertemplin via flicker

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Wind Turbine Interference on Radar

Wind farm development has seen resistance from a variety of people/groups. Some environmentalists fear the safety of bats and birds caught in the path of the blades. Local residents of potential developments fear blocked views, noise, and even flickering of shadows.

Another concern, is the disruption wind turbines can have on radar. Here is a recent ABC News article discussing the Pentagon's concern that wind farms may disrupt radar systems, and could be a homeland security threat.

If wind turbines stood still, there would be no problem. Modern radar is programed to ignore stationary objects. However, with tip speeds over 200 mph, large wind turbines create a signature that can be reported on radar. Above is an image from the NOAA, the star represents a Doppler radar tower, and the circled area is the disruption from a local wind farm. Looks like a thunder storm is moving in right? According to the NOAA:

"The rotating turbines also impact the velocity base data as you can see from the below image.  This velocity data is used by radar operators and by a variety of algorithms in the radar's data processors to detect certain storm characteristics such as mesocyclones, tornado vortex signatures, and relative storm motion."

With the National Weather Service, there is a concern as a severe weather event such as a flash flood could roll through undetected as it is passed off as wind turbine interference. Here are a couple more interesting images.

Photo Credits: NOAA National Weather Forecast Office Buffalo, NY

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Composites vs Metal

Above is a helpful material property comparison of composites and metals. Below is an interesting graph comparing the fatigue strength of composites vs metal. Enjoy...

Source: Advanced Composite Materials Technology Research Centre at The Hong Kong University of Science and Technology.


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Why we need composite materials?

The continued integration of lightweight composites into automotive and transportation will help alleviate the United Sates dependence on foreign oil. In particular, the US dependence on foreign oil supplied by unstable nations (as seen in the map above.)

Composite materials integrated into aerospace, automotive, trucking, and mass transit will all have fuel saving benefits. Additionally, products manufactured with composites will require less energy to transport or ship then traditional materials.

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Natural Fiber Composites - Abaca

With consumers, manufacturers, and governments all desiring more environmentally friendly products, composite companies are beginning to look seriously at bio-based materials. Bio-based resins, reinforcing fibers, and core materials are all potential replacements for traditional products.

When looking at reinforcing fibers, for some time people have been using hemp, flax, bamboo, etc as a polymer reinforcement. Products or parts made with these natural fibers do not have nearly the structural characteristics of traditional composite fibers such as fiberglass. However, for many non-structural components such as interior car panels, these reinforcements are an ideal fit.

One natural fiber that is gaining momentum is Abaca. A relative of the banana family, abaca is primarily grown in the Philippines and more recently in Ecuador. The major use currently is in speciality paper products, such as coffee filters, but abaca is slowly gaining traction in automotive composite applications. As of 2008, abaca was cultivated on 140,000 hectares (345,000 acres) in the Philippines, representing about $80 million in annual revenue.

In years to come I imagine abaca and other bio-based composite components will become more prevalent... as they should.

Source:
Businessmirror.com
Wigglesworthfibers.com

Photo Credit: ripplestone garden via flicker

Dyneema in Composite Armor

Dyneema is an ultra high molecular weight polyethylene fiber manufactured by Dutch company DSM Dyneema. The properties of Dyneema, which include high tensile strength, allow it to be one of the best performing reinforcements used in composite armor. Composite armor manufactured with Dyneema is often lighter-weight then other material options; which is why Dyneema is used on military vehicles across the globe.

Here is an interesting interview with Ivo Oerlemans, Marketing Manager Vehicle Protection at DSM Dyneema from defpro.com. It worth the read if you are following the composite armor industry.

Photo Credit ob1left via flicker

Advanced Thermal Composite Materials

Here is an interesting technical presentation on advanced thermal materials.

Advanced Thermal Materials Overview Slides C Zweben

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Composite Waste water Pipes

Photo Credit: Roantrum via flicker

Composite waste water pipes are becoming increasingly popular as traditional steel and concrete pipes are due for replacement around the world. Concrete, being a porous material allows moisture to penetrate and corrode the steel reinforcement. This can damage the structural integrity of the pipes, and ultimately will require retrofitting.

Here is an article from WaterWorld on the increasing use of FRP composites in waste water pump stations, the article states:

"Many companies in the wastewater treatment industry make their products out of steel and concrete. But steel is highly susceptible to corrosion caused by various chemicals in the wastewater stream. This tendency for corrosion is often accelerated by chloride-rich environments, such as areas with natural salt water concentrations – ultimately shortening the life spans of these lift stations Concrete stations tend to crack as they settle, resulting in leakage and typically higher maintenance costs. Both steel and concrete stations also are extremely heavy, making them difficult to transport and install."

What are Composite Materials?

Here is an interesting introduction to composite materials from a more technical point of view.
Introduction To Composite Materials C Zweben

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More Biomimicry and Composite Materials

Here are some more great examples of materials in development derived from nature.

Photo Credit: Ryan Somma via flicker

Composite Material Industry Has a Voice in Congress

Every major material industry has representation in congress (aluminum, wood, steel, etc). Thanks to the American Composites Manufacturers Association (ACMA), the composite material industry now has a voice as well.

The ACMA has put together a 25-member Congressional Composites Caucus co-chaired by U.S. Rep. Joe Wilson (pictured above, and most famous for yelling "you lie"), a South Carolina Republican. The caucus held its first meeting in July.

The following is a list of current members of the Composite Caucus:

Joe Wilson (R-SC) – Caucus Chair
Rick Boucher (D-VA) Caucus Co-chair
Michael Arcuri – (D – NY)
Steve Austria (R-OH)
Tammy Baldwin (D-WI)
Gresham Barrett (R-SC)
Brian Bilbray (R-CA)
Earl Blumenauer (D-OR)
Vern Buchanan (R-FL)
Chris Carney (D-PA)
Howard Coble (R-NC)
Vern Ehlers (R-MI)
Jeff Fortenberry (R-NE)
Virginia Foxx (R-NC)
Doug Lamborn (R-CO)
Patrick McHenry (R-NC)
Buck McKeon (R-CA)
Cathy McMorris Rodgers (R-WA)
Michael H. Michaud (D-ME)
Bill Shuster (R-PA)
Mark Souder (R-IN)
Mike Thompson (D-CA)
Henry Waxman (D-CA)

Not listed is my local congressman, who I have already contacted and encouraged to join. (I suggest everyone reading this involved with composites do the same.)

Here is an interesting recent interview with Monty Felix, the current president of the ACMA. In the article, it states that the composites industry is a $42 billion industry with 3,000 makers of composites that employ more than 250,000.

In this letter attempting to rally support from other congressmen (which you can send to your congressman), dated June 22nd, 2009, and signed by Joe Wilson and Rick Boucher, it states the composites industry is a $70 billion dollar industry employing 550,000 nation wide.

So by calculations, either the congressmen puffed up their numbers or the composites industry has lost $28 billion in revenues and 300,000 employees since the end of June.

Photo Credit: www.joewilson.house.gov

New Humvee Door Design

Here is an article from Defense News talking about new BAE Systems armor kits for the Humvee and how they reduce weight by 500 lbs. (Which actually doesn't seem like that much). What I found most interesting in the article, is that they redesigned the doors which:

"feature front and rear doors that swing open like cabinet doors, providing combat troops front- and rear-armor protection."

Most all military vehicle doors open like conventional automobiles, in parallel. However, it makes perfect sense to reverse this. The doors, up armored with composites, act as shields and protect from the front and rear.

I am willing to bet money this will save more then one life, and it is often the simple ideas which can have a great impact. Perhaps in other military and composite applications designers and engineers should take a step back, and question why.

Photo Credit: US Army Military Command via flicker

BPA in Composite Materials

Bisphenol A (BPA) is an organic compound that is widely used in plastics. The majority of BPA is used as a monomer in the manufacturing of polycarbonate (think 5-gallon water bottles), but there is a large amount being used as an additive in epoxy resins. Recently, BPA has been shown to act much like the hormone estrogen; causing concern for consumer products containing BPA. (In particular baby bottles and water bottles.)

Concerns over BPA in the structural composites industry are yet to come to light as the majority of epoxy based composite products do not allow for human ingestion. However, one use of epoxy does, and this is causing some concern.

Many epoxy dental sealants commonly use BPA, in a recent survey among dentists, 25% reported being "very worried" about the use of BPA in dental sealants. Here is the American Dental Association's take on BPA.

It will be interesting to see the future of BPA in consumer products, plastics, and epoxy...

Photo Credit: ^@^ina via flicker

Lamborghini Sponsers University of Washignton Composites Center

Italian car manufacturer Lamborghini has donated $1 million to the University of Washington's: Automobili Lamborghini Advanced Composite Structures Laboratory. (Not a bad sponsor...)

Here is the research labs mission statement:

"Our mission is to provide research and education solutions in the field of composite materials and structures that are of particular relevance to ensuring the safety of current and future air and ground vehicles.

The research conducted in the group includes foreign object damage resistance and tolerance, crash worthiness, lightning strike protection, and certification by analysis supported by test evidence. "

More info: Seattle Times

Photo Credit: OmniNate via flicker

Composite Carabiner - Destructive Testing

I written before about composite carabiners, but here is a funny video of destructive testing of a metal carabiner. Why is it funny you ask? Skip to about 3:30 and watch the reaction of the tough-guy on the left...

U. Maine's Composite Bridge Technology

The University of Maine's AEWC Advanced Composites Center has been know to do some exciting things. Back in February of this year, they announced they were spinning off a company for a composites technology called, "Bridge in a Backpack." Not entirely sure how it works, but it seems they are using hollow tubes and inflating a sort of bladder, curing in place, and later filling with concrete, thus making a structural bridge. Time savings and shipping/logistics savings are a likely draw. Read some more info here.

This new company called, "Advanced Infrastructure Technologies," is planning to build bridges for the Maine Department of Transportation, and it seems the U.S. Transportation Secretary Ray LaHood is giving them a visit this week. Read the announcement here.

Photo Credit (not a composite bridge): Big D2112 via flicker