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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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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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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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 Shipping Container

Since the advent of composite materials, and in particular, strong lightweight composite sandwich panels, engineers have been trying to replace the commonly used steel sea-land ISO shipping containers with composite materials.

It seems logical, steel shipping containers are extremely heavy, they spend a good deal of their life in a highly corrosive environment, and they don't last very long. However, the main barrier to entry is the fact that steel cargo containers are dirt cheap, especially as the majority of these containers are manufactured in low labor Asian markets.

As the raw material costs of steel rise, composite materials will have more of a realistic chance. In particular, niche composite containers such as refrigerated containers will likely be the first to be introduced.

Here is an article discussing a development program through the Department of Homeland Security for the design of composite tamper-proof containers. Besides the need for containers to be tamper proof for homeland security reasons, containers that are x-ray transparent will be easier to inspect at ports. Composite material is the viable long-term solution.

It is likely the use of composite shipping containers is inevitable. One aspect that must be kept in the forefront during the design process, is the containers' end of life. Current steel containers are easily recyclable, and the same will need to be true of composite replacements. Perhaps reinforced thermoplastic composites will be the design winner...

Photo Credit: Marc oh! 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 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

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

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...

London City Bus / Freight Bus Design

A new design for London bus that will follow the double decker tour bus style, but will have the ability to transport freight when not needed for transporting passengers. The design would utilize lightweight composites for maximization of fuel efficiency..

Read the Article: SAE