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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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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Life Cycle Assessment

We have talked before about life cycle assessment (LCA) of products manufactured with composite materials. Here is a paper discussing the life cycle of a surfboard. A surfboard is more or less a composite sandwich structure. The core is either a polyurethane foam core or eps foam core. A wood stringer is added down the center for stiffness. The skins are generally woven 4oz fiberglass, often 2 layers on top and one on the bottom. Resin is epoxy or more commonly polyester.

In the life cycle analysis paper, the author cites more carbon emissions are created driving to and from the beach then the life of the surfboard will ever produce. Recently, companies have been experimenting with greener surfboard materials. In particular, bio-based resins, fabric, and foam. However, at least from a greenhouse emissions point of view, the composite construction of the board is a moot point in comparison to the emissions surfers generate driving to the beach.

I imagine similar studies for other products manufactured with composite materials will find similar statistics. It also exemplifies that we need greener transportation, and composites will play a role in reducing automotive weight and increasing fuel efficiency.

Photo Credit: Hot Tamale Surfboards

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Composite Material: Shape Memory Composite

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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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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Composite Armor at the Superbowl

I don't usually find composite material information from gossip web sites, but TMZ is reporting that celebratory Kim Kardashian, girlfriend of Saints running back Reggie Bush, will be riding to the big game in an "Armor Horse" limo as seen above. Supposedly this limo is protected with "composite ballistic panels."


Photo Credit: Armorhorse.net 

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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

Competition for Better Composites

Throughout time, competitions have led way to some of the greatest innovations. Like the recent x-prize and now the automotive x-prize, there comes a new UK based competition.

In search for better processing of composite materials, a competition is being held where the winner will receive 5 million British pounds. More info: Reinforced Plastics

Photo Credit: Eric Charlton via flicker

Aptera and Composite Materials

Any start-up composite material company is likely having a hard time finding funding right now. As the federal government seems to be the best source for early seed money, electric car companies such as Fisker, Tesla, and Aptera are all waiting and hoping for loans from the Department of Energy.

Meanwhile, a company like Aptera, who's production is on hold until additional funding rolls through, is in a tough situation as they need to remain ready for production, but need to conserve cash. In a recent Wired Article, two of the original Aptera founders have been let go in addition to other Aptera employees.

The article also states that they are redesigning some of the features. Currently, the windows do not roll down, and if you want to go through a drive through or talk to a friend outside, you must open the door. So to correct this, they are changing the design. Like most molded composite products, Apteria likely will have to redesign the door structure, build new molds, and manufacture/test new composite panels.

Let us all hope success for Aptera, automotive companies utilizing composites, and all other start-ups who work with composite materials.

Photo Credit: Kevin Marks 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

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?

Car Companies Looking at Lightweight Composites... Thermoplastics?

This recent Plastics news article (read it here), discusses how the major auto manufacturers are researching advanced composite materials. In an attempt to stay with the times, the Michigan Economic Development Corporation is investigating new materials being researched at universities, government laboratories, and R&D companies. It was also noted,

"Michigan is not alone in investing in lightweight materials: Toyota Motor Corp. of Toyota City, Japan, is “progressing” in its research into using thermoplastic composites in structural parts, said Justin Ward, advanced powertrain program manager at the Toyota Technical Center in Gardena, Calif. The center is part of the research and development division of Toyota Motor Engineering & Manufacturing North America Inc., Toyota’s U.S. subsidiary based in Erlanger, Ky."

Weight savings (fuel efficiency) will continue the push towards the increased use of composite materials in transportation. For car manufacturers, composites processing has traditionally been seen as a new and big investment in tooling and equipment. Material costs, surface finish, end of life recyclability, and other issues must all be solved prior to acceptance.

Thermoplastic composites will be a natural candidate with the ability to post mold, ability for automotive quality surface finish, impact resistance, and recyclable features. European car manufacturers are already playing around with continuous fiber thermoplastic components, as I believe the new BMW M series bumpers are manufactured with a carbon reinforced thermoplastic bumper. (will look into this further)

Photo Credit: WilVision Photography via flicker

Plastic's and the Auto Market

Composites and plastics play a large role in each automobile. In fact, the American Chemistry Council (ACC) estimates that each automobile contains $2,200 dollars worth of chemistry. (ie composite resins, plastics, adhesives, rubber hoses, coatings, etc.) With the "Big 3" reporting 2008 demand dropped by 3 million vehicles, my calculations say that $6.6 BILLION less dollars of chemical based auto components were used in '08... Thats nothing to shake a stick at.

But, with darkness comes the hope of light. The demand for fuel efficiency only increasing, there is hope that more and more composite materials, plastics, and other lightweight chemical based products will replace steel and metal components in the future. And then there is hope, that the economny will turn around.

More info: Article by ICIS.com

Photo Credit: dougww via Flicker

Riversimple Urban Car - 300 mpg - (Composite Body)

An entrepreneur/engineer out of the UK has released the first version of a new efficient car. Above is the Riversimple Urban Car, it is part Smart Car, part Bat-Mobile, and it claims to get 300 miles per gallon of hydrogen.

The man behind this car, Hugo Spowers, has raised 5 million British pounds thus far, and is looking to raise another 20 million to build ten additional prototypes.

The body, which is "lightweight composites" is likely carbon fiber, and I imagine it saves a good deal of weight.

Here's to seeing more cars like this...

Great Use of Composites: Robot Costumes

Here is a niche company that makes massive robot costumes. These are not costumes your mother made for you, these are legit, molded fiberglass and painted with high quality automotive paint...

Check em out:

Robot Costumes USA