Strongwell Looking at Green Composite Materials

The demand for environmentally friendly materials is growing and will continue to grow. Strongwell, perhaps the world's largest pultruder, recently announced their Green Initiative. This is a fantastic move in the correct direction. Products made with composite materials are in fact environmentally friendly. Composites are inherently lightweight and non-corrosive, which is why they are used in wind blades, automotive, and aerospace.

The life cycle of composites needs to be closely analysed. For example, although a steel structure can be recycled at the end of life, the life span may be shorter, and thus, the overall environmental impact could be greater over time. This all needs to be measured on a analytical and straight forward level.

This being said, FRP composites must figure out a recycling solution. Yes composites are "recyclable", but no company is doing it on a large practical scale... Yet...

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JEC Composites 2010

Today is the last day of the JEC composites show in Paris. This is probably the largest composites show in the world, and has become the annual meeting place for composite material companies from all corners of the globe.

However, this years show may be lasting a little longer; volcanic ash from Iceland is about to shut down all the airports in Paris. The ash can damage airplane engines and could even cause failure. Hopefully this will clear soon, as the global composites industry will be on hold until it does...

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Lockheed Martin F-35 Joint Strike Fighter

The clip above demonstrates why the new Joint Strike Fighter needs to be as lightweight as possible. Carbon fiber is undoubtedly playing a role in reducing the weight. I caught a fascinating NOVA episode on the competition between Lockheed and Boeing in designing the F-35. It goes into a surprising amount of detail of the composite construction and even discusses how Boeing attempted to use a thermoplastic matrix. If you have Netflix, you can watch it instantly for free, or you can get the episode from Amazon below:


I highly recommended anyone interested in aerospace composites or this military program to check it out.

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Shape Memory Composite

Photo Credit: Technology Review

Imagine an airplane wing that could change shape when it hits a certain speed and become more aerodynamic. Perhaps one day this will become a reality. Technology Review reports on some polymers that have multiple shape memories. Meaning, when the polymer reachers a certain temperature, it will change into a preset shape...

Pretty awesome if you ask me.

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Photo Credit: Dave Sizer via flicker

The recent Christmas day "Underwear Bomber" failed, but what if he was successful? The folks at the Discovery Channel and the BBC put this to the test, setting off a similar explosive in a retired airframe. (You can watch the preview here.)

Not only would the airframe survive, but it is thought that a next-generation aircraft built with composite materials such as the 787 Dreamliner would do better:

"The BBC also used a decommissioned Boeing 747 and not a newer Airbus A330 for the test. An actual test would be necessary to prove this, but Wyatt and Joseph think that the newer plane, which was made with lighter and stronger composite materials instead of aluminum, would have performed even better.

The newest commercial passenger jet, the Boeing 747 or Dreamliner, which has even more composite materials, would likely perform even better, said Wyatt, although he doesn't know for sure."

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Recycling Composite Materials

For many reasons, composite material products need to have a better solution for their end of life. Thermoset composites have difficulties in reprocessing, however thermoplastic composites are showing some promise. Technology Review discusses some breakthroughs in recycling PET, which may provide some foundation for recycling fiber reinforced PET in the future. Essentially, researchers at IBM have figured out how to chemically break down PET to their original parts, which then can be used again. Traditional recycling of PET uses heat and pressure to melt down the plastic.

Although recycling composite materials is necessary, composites still provide valuable environmental savings during their life. In composite transportation products such as marine, rail, aerospace, and automotive, the fuel saving and carbon reduction benefits can outweigh the downside of not being able to recycle. Here is a Swedish study of a Life Cycle Analysis (LCA for short, and likely an acronym we hear often) of fiber reinforced composites.

In the study, the researched compared the LCA of a steel ship with composite sandwich structures. Even though steel is recycled in the end, the emission reductions and corrosion benefits of using composite materials outweigh the recycling benefit.

Now, imagine the LCA comparison when fully recyclable composites are used...

Photo Credit: jsbarrie via flicker

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Boeing 787 Dreamliner - Composite Materials

The composite industry as a whole is interested in the success of Boeing's new 787; it is one more step towards mass acceptance of composite materials. Despite all the problems and the current 28 month delay in production, in the end, the weight savings on the 787 will help contribute to a 20% fuel efficiency.

Here is a great post by MIT's Technology Review on the problems and the future of the Dreamliner. A worthwhile quick read for anyone following the 787 saga.

Photo Credit: Dave Sizer via flicker

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Composite Materials in the Winter Olympics

It's no secret, technology can help win gold medals at the Olympics. During this coming winter Olympics composite materials will play a large roll. Composites will be used in skis, snowboards, bobsleds, luges, lightweight aerodynamic helmets, ski poles, hockey sticks, and perhaps even curling equipment.

In racing events where seconds can be the difference between a gold medal and not placing at all, a technology equipment advantage could be the deciding factor. Here is an article about a small composites company in Canada which has designed a snowboard for the giant slalom out of carbon fiber. By dialing in the weight, shape, flex pattern, and balance, they are hoping their snowboards will be that difference to when a medal at home.

Not only will composite materials be used during competition, but Canadian aerospace company Bombardier has manufactured the torches out of composites (I'm guessing carbon fiber). In all, they manufactured 12,000 torches, you can see it here.

Photo Credit: Webdevil666 via flicker

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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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Composite Material vs Metal

Perhaps the first driving factor for replacing metal components with composite materials was the resistance fiber reinforced polymers have to corrosion. The marine industry began to embrace composite materials shortly after WWII, manufacturing boats impervious to the corrosive salt environment.

Today, modern metal alloys such as aluminum, titanium, and even stainless steel are used in industries, such as aerospace, where corrosion in unacceptable. Although these metals are not "prone" to corrosion, there is still the risk of galvanic corrosion, which occurs when two dissimilar metals are in contact with one another.

In fact, due to the conductive properties of carbon fiber reinforced composites, there is a growing concern in cases where metal components are interacting with carbon fiber components. This is perhaps a major issue on designing the new generation of Boeing and Airbus airframes.

Corrosion will continue to be an issue for metal products, and corrosion will continue to be a driving factor for the integration of composite materials. For a good illustration of this, here is an interesting blog post discussing how the household cleaner Simple Green can corrode aluminum.

Photo Credit: Nomads: will create via flicker

Critical National Need: Advanced Composites Manufacturing

The Technology Innovation Program (TIP) at the National Institute of Standards and Technology (NIST) was set up to "support, promote, and accelerate innovation in the U.S. through high-risk, high-reward research in areas of critical national need." The institute helps fund (through 50% cost sharing grants) R&D projects that may be too risky for the traditional investment community.

The 2010 NIST TIP program has identified 4 areas of "critical national need," they are:

• Civil Infrastructure
• Healthcare
• Energy
• Manufacturing

Manufacturing was identified as a highly important aspect of our economy because as of 2007, manufacturing represented 11.7% of the total GDP and 14 million US jobs. (This number has likely dropped in the last two years.) In order for the US to maintain global leadership in manufacturing technology, new and revolutionary innovations are required. In this recent NIST White Paper, the following 3 materials in particular are sited as in need of continued technology advancement:

• Nanomaterials
• Composite Materials
• Super/Specialty Alloys and Smart Materials

Additionally, the paper identified the following problems and promises of composite materials:

• Aerospace industry’s emphasis on fuel efficiency favors the use of polymer-matrix composites instead of aluminum
• Automotive industry recognizes advantages of weight reduction, parts consolidation and increased cost-effective design options for polymer-matrix composites;
• Energy sector’s growing use of wind energy has led to increased demand for polymer-matrix composite turbine blades;
• Better processes and tools needed to recognize special properties such as the anisotropic nature of these materials (strength and stiffness greatest in direction parallel to axis of the embedded reinforcements);
• Need to overcome cost barriers to use such as expensive starting materials, time-consuming fabrication processes, and autoclaves and expensive tooling;
• Multiple industries require accommodation of production of large, structurally complex parts; and
• Increased application of recyclable composites can reduce carbon footprint.

Some of the best and brightest minds of our nation who work for NIST identified the above as the future of composite materials. If you are a composite material company, I would suggest reading the entire white paper as it may inspire innovation. In particular, I like that NIST identified recyclable composites as a future component of composite material manufacturing. I imagine thermoplastic composites will play a major role in the recycalability of composites, as post consumer plastic (such as the PET bottles in the picture at the top) can be used as a replacement for thermoset resin.

Photo Credit: ThreadedThoughts via flicker

Boron Fiber - Superior to Carbon

There are those who think carbon fiber is the strongest reinforcing fiber available, but they are mistaken. Boron fiber, a far superior fiber to carbon, is underutilized due to being 6 times more expensive. Here is an interesting article discussing the manufacturing of Boron Fibers in the USA. The article states:

"Aerospace applications built this business. Boron fiber is used for structural reinforcement or repair of the F-15 fighter, B-1 bomber, Black Hawk helicopter, space shuttle and Predator.

The material also found its way into high-end golf clubs, skis, hockey sticks, fishing rods and Tour de France bike frames. Formula One, for competitive reasons, largely banned its use, says Treasure. Only the wealthiest teams could afford it."

Photo Credit: orphanjones via flicker

Latest with Boeing and the 787

Many who follow composite materials like to keep an extremely close eye on Boeing, and in particular, the development of the new 787 Dreamliner. Randy Tinseth, the vice president of marketing for Boeing Commercial Airplanes in Seattle has a great blog (Randy's Journal), which is a must read for staying up to date with all things Boeing.

Photo Credit: markjhandel via flicker

Reducing Aviation Emissions

Interesting article by MITs Technology Review on how the aviation industry can reduce global warming emissions. Obviously, using lightweight composite materials is a start; further carbon reductions can come from improved logistics, improved wing/airplane design, and using bio-fuels.

Read the article here.

Photo Credit: Rob Shenk via flicker

Composite Material Definition

According to NASA's Dictionary of Technical Terms for Aerospace Use, composite materials are defined as:

"Structural materials of metals, ceramics, or plastics with built-in strengthening agents which may be in the form of filaments, foils, powders, or flakes of a different compatible material."

NASA's interest in composite materials is as follows:

Exhaustive Interest : Physical and mechanical properties, production, handling, testing, and evaluation of composite materials for use in aircraft, rockets, launch vehicles, space vehicles, reentry vehicles, aircraft and spacecraft propulsion systems, and supporting facilities.

Selective Interest : Research and development on composite materials having potential aerospace applications.

Negative Interest : Routine developments of structural composite materials for use in housing, heavy industry, and earthbound transportation, unless a potential exists for aerospace use.

That right, NASA is not interested in composite materials used in "eathbound transportation..." Who knew? Perhaps they would be interested in a $150 edge-of-space camera?

Source: nasa.gov

Photo Credit: NASA Aug 2007

Biomimicry of Composite Materials

Biomimicry is known as "the process of understanding and applying biological principles to human designs". It is a method of understanding why something works so well in nature, and then applying the reasoning to something man made.

Here is an example, researchers are trying to develop a robot to climb walls, instead of reinventing the wheel, researchers will study a gecko, to learn how it is able to climb walls so well, and then try to copy those features. (Geckos have a hard time filing patents)

Above is a video describing this exact example.

In composite structures and composite materials, there is much researchers and scientists could learn by first looking at nature. US News reports here:

To help wind turbines advance further, scientists are looking into morphing blades, which can rapidly change their aerodynamic profile to best suit the prevailing wind conditions.

"The idea was born from a simple observation of a fish in an aquarium," said researcher Asfaw Beyene, a mechanical engineer at San Diego State University. "Many flying and swimming animals have superior efficiencies than manmade devices. The primary difference between natural motion and motion of manmade devices is lack of geometric adaptability to varying flow conditions."

In another current study, which can be read here, researchers are trying to determine how a naturally occurring composite, teeth, can be so well adjusted to high impact and abrasion. They hope that what they discover will lead to better composite materials for aircraft and automotive components.

What other composite products or composite materials could benefit from biomimicry?

New Composite Research Center for medical Products... Perhaps

Scientists in Wichita, KS applied for $15 million dollars of stimulus money to create a research center to help integrate composite materials into medical and orthopedic products. The city of Wichita has already donated 43 acres of land worth $1.2 million, and are hoping to build a 50,000 sqft building next to the current National Center for Aviation Training.

Much of the new composite aerospace materials, especally FDA approved thermoplastic resins, have a bright future for use in orthopedics. For example, if you look closely at the x-ray above, you can spot a metal bone screw holding together a fracture. If that orthopedic insert could be composite, it would not appear on the x-ray, and the doctor could more easily determine the healing of the injury. Other advantages of composite medical inserts include higher lubricity (less pain/discomfort) and less risk of allergies (a surprisingly large population is allergic to nickle).

With the nearby National Institute for Aviation Research (NIAR), a leading composite material research institute, there is ample space for sharing of ideas and technology.

More info:

The Wichita Eagle

Aerospace Composites


Photo Credit: joebeone via flicker

Latest Word on Composite with Boeing and Airbus

Nobody like wrinkles, especally composite manufacturers. Wrinkles in composite laminates can lead to delamination and premature failure. Apparently, Alenia Aeronautica out of Italy supplied Boeing with some fuselage sections, where the carbon fiber had some wrinkling. Boeing filed a stop work with Alenia as of June 23rd, and as of last Friday, Boeing has delayed the first 787 flight test until further notice (other issues involving joining the wings). Read a NY Times article here.

Meanwhile, Airbus has received £340 million in loans from the UK government to help stimulate domestic manufacturing, much of which will undoubtedly be composite related. This comes on top of a recent £60 million loan to GKN Aerospace for the manufacturing of rear spar and trailing edge for the A350 XWB. Read about it all here.

Photo Credit: markjhandel via flicker

Best to come out of NASA: Composite Materials

Interesting article about some of the best technology advances to come out of NASA... Including composite materials...

Also included: solar energy, forest management, environmental controls, oil spill control, water purification, home insulation, smoke detectors, water reduction technology, energy storage systems, structural analysis, air quality monitors, virtual reality, green building, advanced lubricants, and more.

So lets hear it for more funding for space exploration... How about Mars?

Read the article: examiner.com

Photo Credit: buglugs via Flicker

Composite Carabiners & the Dollar per Pound Ratio

A common goal for manufacturers of composites is to create and sell products that have the highest dollar per pound ratio possible. The higher the dollar per pound ratio is, the more margin the product will likely have. Lets look at some products/industry and examine their $/lb ratio.

At the low end, are commodity type composite products, typically made with e-glass and vinyl ester, are readily available, and have no significant variations between one manufacturer to the next. An example of this are common pultruded profiles such as I-beams, tubes, rods, etc. Obviously pricing will depend on quantity, but margins are very low and the dollar per pound sales prices can be in the $3/lb range...

At the other end of the spectrum are aerospace composites and recreational composite products. These products, often have a proprietary design, are carbon fiber epoxy, are specialty products, and often carry a brand name. The premium received is often due to the extra weight savings, durability, and extra labor involved in the product.

In recreational equipment, a constantly growing segment of composites and an early adapter of new materials and processes, the price per pound is often extremely high. Bicycles, golf shafts, tennis rackets, even ping pong paddles, all demand a premium. For example, take a surfboard that costs $500 dollars, and weighs 6lbs. The surfboard, constructed from polyurethane foam, woven 14oz e-glass, and vinyl ester resin retails for $83 a lb. (Most of this margin goes to manufacturing...)

One interesting recreational sporting product, not yet composite, is the carabiner used in rock climbing. As of now there is no composite counterpart, this study states that although a lighter weight carabiner would be desirable, it is currently not feasible. (I do not believe this is the case...)

This particular carabiner here, weighs 36 grams, and sells for $23 dollars. By my calculations, this is over $300 per pound for aluminum. A lightweight composite version could absolutely command a premium over this.

These are the type of products composite manufacturers are beginning to look at, niche markets with opportunity.

Photo Credit: Phil Hawksworth via Flicker