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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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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Selecting a Composite Decking Material

Composite decking products, such as Trex, are a different type of composite then we usually discuss here. Unlike traditional FRP composites consisting of a continuous fiber reinforcement such as fiberglass or carbon fiber and a polymer resin matrix, composite decking products, for the most part, are an extruded composite consisting of wood fiber (saw dust) and polyethylene (grocery bags). Composite decking is a replacement for traditional wood and has many advantages, including lower maintenance, no splinters, no termites, etc.

However, many of the composite decking products have downsides as well. From my experience, some composite decking products are susceptible to stains and mold. For example, if part of your deck is in the shade, this area could slowly grow mildew and require occasional power washing, not exactly zero maintenance. Also, BBQ stains and other spills can grab hold to a composite deck and be near impossible to remove.

The best thing to do before deciding on a type of composite deck material, is talk to professionals working with the various composite materials, also ask if you can talk to customers they have worked with.

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

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

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

Composite Armor Companies Get More Funding

Composite armor companies are making some recent headlines for receiving substantial funding support. This includes the following:

Armor Dynamics, out of Kingston, NY is set to receive $2 million from the fiscal year 2010 defense appropriations bill to develop advanced composite armor. You can read the announcement here and another one here.

In same 2010 defense bill, PPG Industries is set to receive $2 million in composite armor development. Press release here.

Additionally, CPS Technologies Corporation announced it has received an award of $1,473,509 from the Army Research Laboratory to continue the development of manufacturing technologies for large modules hybrid metal matrix composite armor. Read the press release here.

Not to mention the $3.3 million slated to AGY for ballistic fiber which was mentioned before here.

As long as troops are in conflict, force protection will be mandatory. Here is an interesting blog post about composite armor in the MRAP vehicle and the JLTV. The JLTV, Joint Light Tactical Vehicle, which is in development by some of the largest military contractors and will hopefully be the replacement for the older Hummer-type military vehicles.

Photo Credit: Army.mil via flicker

Thermoplastic Composites vs Thermoset Composites

Many unfamiliar with composite materials see all Fiber Reinforced Polymer (FRP) the same... However, this is not the case.

The common difference in composite materials is most often the structural fiber, be it carbon fiber, Kevlar, fiberglass (E-glass or S-Glass). A composite, by definition, is the combination of two or more materials. In FRP composites, the structural fiber is held together by a resin matrix, much the same how structural rebar is held in place by concrete.

In the advanced development of composite materials, the focus on the next generation has shifted from the structural fiber to the resin matrix. In the on going analysis, thermoplastic composites are beginning to show real potential. Main advantages include, recycle-ability, re-mold capabilities, no or low VOCs, long shelf life, and high impact resistance. For more information, here is a link to a good article by Sandwichpanels.org on the differences between thermoplastic composites and thermoset composites.

Increased impact resistance many thermoplastics display is a major attraction. Below is a video displaying a test on thermoplastic composites, and simulating an impact on a car door.