Consortium to develop composite liquid hydrogen fuel tank

Toray Advanced Composites, together with partners from industry and academia, has been awarded funding from the Dutch Ministry of Economic Affairs and Climate Policy’s Research and Development for Mobility scheme for the development of a long-life, fully composite liquid hydrogen tank for civil aviation.

Hydrogen has been identified by the European Commission (EC) as a key priority to achieve the European Green Deal for a sustainable economy. By converting the construction of the hydrogen tank from existing metallic solutions to composites, the liquid hydrogen (LH2) composite tank will achieve weight savings that enable the advancement of liquid hydrogen as a sustainable fuel source for civil aviation. This will lower the carbon footprint of air travel and increase and extend the flight range of aircraft fleet by reducing construction weight and cost.

The cross-sector research undertaken as part of this program aims to result in a lightweight composite tank that can withstand the incredibly low temperature of liquid hydrogen, minus 253°C. The project will focus on both composite tank construction, digital design strategies and production technologies.

The consortium comprises 13 partners across academia and industry: Aircraft Development and Systems Engineering (ADSE), Airborne, Bold Findings, Cryoworld, GKN Aerospace’s Fokker business, IT’S Engineering, KVE, NLR, PhotonFirst Technologies, Somni Solutions, TANIQ, and Technical University Delft together with SAM|XL.

Frank Meurs, managing director, Toray Advanced Composites, said: “We are delighted to have been granted this funding. By joining together the best of Dutch industries and institutes in a unique consortium, we will contribute to the acceleration of hydrogen technology into aerospace as a sustainable fuel source for the future. This project underlines the commitment across the supply chain to drive forward sustainable propulsion technologies and is conducted in full alignment with the major aircraft and engine manufacturers.”

#composites #CompositeLiquidHydrogenFuelTank #TorayAdvancedComposites

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Photo Credit: Solvay, PR018

Solvay collaborates with Trillium on bio-based acrylonitrile for carbon fiber applications

New agreement with Trillium Renewable Chemicals will enable Solvay's development of sustainable, bio-carbon fiber for use in various applications.

Solvay (Brussels, Belgium) and Trillium Renewable Chemicals (Birmingham, Ala., U.S.) have signed a letter of intent to develop the supply chain for bio-based acrylonitrile (bio-ACN). Trillium will supply Solvay with bio-ACN from Trillium’s planned commercial asset, and Solvay will evaluate bio-ACN for carbon fiber manufacturing as part of its long-term commitment to developing sustainable solutions from bio-based or recycled sources. The aim of this partnership is to produce carbon fiber for use in various applications such as aerospace, automotive, energy and consumer goods.

“Trillium’s bio-ACN process technology enables bio-carbon fiber,” explains Corey Tyree, CEO of Trillium. “We are excited to continue our partnership with Solvay, who have supported the bio-ACN process technology development since 2014. Solvay is a leader in the most rapidly-growing acrylonitrile segment [carbon fiber] and are market leaders in bio-carbon fiber and sustainable development.”

Acrylonitrile is a chemical intermediate typically made from petroleum-based feedstocks like propylene, and is the primary raw material used in the production of carbon fiber. Trillium’s Bio-ACN process delivers acrylonitrile from plant-based feedstocks, such as glycerol, with a lower carbon footprint.

“We are thrilled to be partnering with Trillium which aligns well with our Solvay One Planet commitment to more than double our revenue based on renewable or recycled materials by 2030,” comments Stephen Heinz, head of composite research and innovation, Solvay. “Innovation partnerships such as this are driven by a desire to make a real-world sustainability impact. Bio-based feedstocks are a key part of Solvay’s sustainability strategy, and we look forward to being a consumer of bio-ACN from Trillium’s first bio-based acrylonitrile plant.”

#composites #CarbonFiber #BioBased

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Automated inline process involves a high-resolution vision sensor, colored lights and machine learning.

Photo Credit: Diab

Full process, quality control brings Diab closer to Composites 4.0

Developed by 2550 Engineering, an automated inline system helps measures 100% of samples in real time, ensuring a complete quality control process.

Progressive technology consultancy 2550 Engineering (Gothenburg, Sweden), a Qamcom Group company, has collaborated with Diab (Laholm, Sweden), to optimize process and quality control in the production of the company’s sandwich composite solutions used in marine, wind, aerospace and automotive industries.

“Diab came to us with the ambition to perform inline quality control for every sample and provide an individual material property set for each produced sample. This would take Diab from occasionally checking samples manually, to measuring the quality of all material produced. Some would say that it sounds impossible. We said, challenge accepted,” says Magnus Janson, CEO at 2550 Engineering.

With the help of a high-resolution vision sensor, colored lights and machine learning (ML), 2550 Engineering developed an automated inline system that captures the samples’ structure in real time. The result was that Diab moved from measuring one out of 10,000 samples, to all of them.

#composites #SandwichCompositeSolutions #Diab

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JEC World 2022 postponed to May

Global composites event will now take place May 3-5, 2022 at the same venue, Paris Nord Villepinte Exhibition Centre, after consultation with exhibitors and event partners.

After thorough consultation with the exhibitors and partners of the event, JEC Group (Paris, France) has decided to postpone the 2022 edition of JEC World from its original March 8-10 date. The leading composites event will now take place May 3-5, 2022, at the same venue, the Paris Nord Villepinte Exhibition Centre in France, as well as online via the JEC World Connect digital platform.

JEC World is “the place to be” for composites professionals from all over the world. The event brings together major global companies, innovative startups in the field of composites and advanced materials, experts, academics, scientists and R&D leaders. The event also offers a unique showcase of what composites can offer to various application sectors, from aerospace and marine, to construction to automotive, and what event organizers say is an unlimited source of inspiration for participants from these industries.

“We are fully dedicated to supporting the composites industry and to fostering its development via our events and media activities,” says Eric Pierrejean, CEO of JEC Group. “Exhibitors and partners are strongly supporting JEC World, their leading event, and want to meet in person in 2022 to activate business, share knowledge and highlight innovations. Postponing from March to May is a way to offer improved conditions to satisfy the industry requirements for such a trade fair as JEC World.”

The JEC World team has decided to postpone the event after a conducted survey conducted of its exhibitors and partners, confirming that a large majority is in favor of the new dates in May. As already planned, the three-day event will offer a digital platform, JEC World Connect, in parallel to the in-person event in Paris for an augmented digital experience. Content will also be available via the JEC Web TV after the show, in order to extend event reach.

“Our main concern is to create the best possible conditions for our participants for successful networking, inspiration and business success. With a postponement of eight weeks we can enable this and offer to the industry the event it deserves. Taking the decision now, after consultation of all exhibitors, was necessary to give them planning and preparation visibility,” adds Thomas Lepretre, VP events, sales and operations.

#composites #JECWorld2022

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Toray develops novel analysis technology for multi-material structures incorporating UD tape

More precise prediction of properties for multi-material structures, particularly UD tape and injection molding materials, enables swifter part development.

Toray Industries Inc. (Tokyo, Japan) has developed a new analysis technology for multi-material structures consisting of both unidirectional (UD) continuous fiber-reinforced tape and injection molding materials. This breakthrough, says Toray, makes it possible to more precisely predict the properties of parts made up of multiple materials and more swiftly develop high-performance components.

The company looks to supply UD tape, injection molding resins and other materials, as well as structural design, molding support and other services while providing total solutions that incorporate its new technology. Toray says it will leverage the technology to expand the adoption of its materials in the urban air mobility (UAM), electric vehicle (EV) and other advanced mobility fields and in regular industrial sectors, thereby helping manufacturers create lighter, more energy-efficient products.

According to Toray, UD tape’s continuous, unidirectional aligned fibers provide optimal rigidity, strength and enable welding to other thermoplastics, making it ideal for use in injection-molded products. The resulting multi-material structures maximize weight savings while constraining costs.

The downside to this, however, makes its difficult to accurately analyze strength and impact properties, which is vital for multi-material structures.

Toray’s novel analysis technology improves 3D TIMON, the 3D injection molding CAE system developed by subsidiary Toray Engineering D solutions Co. Ltd. (Tokyo), accurately reflecting jointing strength between materials and materials fracture behavior. Toray has also created a coupled analysis technology for resin flow and impact properties that factors in the fiber orientiation of injection molding materials. It combines analyses of various phenomena and calculates their interactions. Together, says, the company, these two developments have resulted in the novel analysis technology offering for accelerating the structural design of multi-material structures.

#composites #Toray #UnidirectionalContinuousFiberReinforcedTape

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Photo Credit: The NCC

The NCC, Skanska trial low-carbon, basalt fiber-reinforced concrete

Study is critical to understanding the impact of low-carbon concrete and advanced composite reinforcement systems in the construction sector, and its contributions toward low-carbon emissions, structural performance and EOL recycling.

Under a £282 million (~$381 million) project, the National Composites Center (NCC, Bristol, U.K.) and construction company Skansa (Stockholm, Sweden) are trialing an “industry-first” low-carbon concrete with basalt fiber reinforcement, designed to alleviate congestion for motorists on National Highways M42 Junction 6, a temporary haul road for construction vehicles and a well-known bottleneck in the Midlands. While aiming to cut down on carbon emissions — a combination that is reported to reduce the carbon footprint by more than 50% — the project also serves to improve the structural performance of reinforced concrete and deliver better productivity, safety and cost outcomes.

The trial, led by Skanska, in partnership with the NCC and funded by National Highways (NH), compares traditional steel-reinforced concrete with a low-carbon concrete reinforced with basalt fiber.

Production of cement, a key ingredient in concrete, currently accounts for around 7% of the world’s CO2 emissions. In the U.K., this figure is less than 1.5% as a result of innovation and investment in efficient plant, fuel switching and the use of low-carbon cement substitutes that are byproducts from other industries.

Tarmac (Solihull, U.K.), a member of the project’s supply chain, provided two types of concrete for the trial: A mix comprising conventional blended cementitious material and a low-carbon alternative mix incorporating an Alkali Activated Cementitious Material (AACM) in place of the cement.

“Manufactured at a conventional concrete plant located close to the project and installed in exactly the same way as traditional materials, this new sustainable product delivers a carbon footprint up to 80% lower than a standard CEM I concrete,” claims Robert Gossling, head of commercial engineering for Tarmac. “We hope this demonstration will help to accelerate the development of innovative low-carbon materials.”

Basalt Technologies UK Ltd. (London, U.K.) supplied the basalt fiber reinforcement. “Basalt is a lightweight composite material consuming 62% less CO2 than steel during its manufacture,” says Malcolm Newton, director at Basalt Technologies. “It comprises a nonmetallic inert material that does not corrode, making it more durable than steel. Basalt fiber reinforcement is also up to four to five times lighter than steel, making it safer to handle, fix and transport with fewer lorry movements.”

Field and laboratory tests will be carried out over the coming months following the start of the trial, which began early Dec 2021. Four reinforced concrete slabs were cast at the M42 Junction 6 site as part of a temporary haul road that will be heavily used by construction vehicles and will be monitored over the works duration. The slabs comprise of:

Slab A: Conventional concrete + steel reinforcement
Slab B: Low-carbon concrete + steel reinforcement
Slab C: Conventional concrete + basalt reinforcement
Slab D: Low carbon concrete + basalt reinforcement

The team is now monitoring the slabs in-situ. Full-scale test slabs have been sent to a specialist laboratory for bending and shear testing. All collected test results will build knowledge of the curing process, ease of construction, safety benefits, functional properties and structural behavior of the various concrete and reinforcement combinations. This will provide insight into the future use of longer lasting materials in construction.

The trial will also provide a better understanding of the impact of the use of these materials ahead of the proposed revision to Eurocode 2 standards that will include use of composites in the design of concrete structures. This is currently being developed.

“This project, its learnings and test results, is critical to understanding the impact of low-carbon concrete and advanced composite reinforcement systems to reduce embodied carbon for the construction sector,” adds Carys Holloway, technology program manager, NCC. “I am eager to witness the expected ease of planing out of the basalt fiber-reinforced slabs for recycling and the potential that has for end-of-life [EOL] scenarios.”

The Skanska and NCC team will also be working with HS2 to further research and develop this innovative low-carbon solution. Work on the M42 junction upgrade is set to be complete 2024-2025.

#composites #BasaltFiberReinforcedConcrete #Concrete #LowCarbonConcrete

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Flagship center console boat model, H:CRAFT H44Z.
Photo Credit: Hayaari Marine

The resin infusion process.

Resin-infused center console boat configuration proves higher performance, speed, quality

Hayaari Marine employs a revised infusion setup using semi-permeable membranes to eliminate porosity and improve laminate consolidation, reducing about 450 kilograms of resin per boat, and offering 20% weight savings.

Motorboat builder Hayaari Marine (Abu Dhabi, United Arab Emirates) has recently launched a fully resin infused version of its flagship center console boat model, the H:CRAFT H44Z, with weight savings of more than 20% enabling a top speed in excess of 90 miles per hour.

Hayaari Marine says it has seen major benefits with the switch to infusion, saving approximately 450 kilograms (~992 pounds) of resin per boat and reducing the overall hull weight by more than 20%. The investment in infusion technology has also increased the laminate quality and consistency, as well as provided for cleaner, safer shop floor conditions with reduced volatile organic compound (VOC) emissions.

Working with a novel, in-house designed, glass-topped infusion test table, Hayaari’s engineering and production team evaluated flow speed and resin consumption for multiple laminate and consumable configurations. The optimum combination selected for series production uses Scott Bader’s (Wellingborough, U.K.) Lloyds-approved Crystic VE679-03PA infusion resin and Crystic gelcoat, glass fiber stitched multiaxial fabrics, PVC foam cores and what is said to be the latest in vacuum consumable technology.

Taking inspiration from the aerospace sector, Hayaari Marine also uses semi-permeable membranes to enhance the infusion process. By allowing air to pass, yet blocking the passage of resin, the semi-permeable membranes maintain the vacuum after the infusion is complete, eliminating porosity and improving the consolidation of the laminate.

Hayaari’s revised infusion setup requires only seven resin inlet points for the 44-foot hull, reducing the risk of air leaks and simplifying the resin management throughout the infusion. As well as the hull, Hayaari also uses the resin infusion process to manufacture the H44Z floor, cap deck, console, seats and roof.

According to Hayaari, the standard H44Z E-glass and infused vinyl ester construction delivers optimized performance. Further upgrades are also available, with Hayaari offering a carbon fiber and epoxy version of the H44Z for owners looking for the ultimate lightweight and high-performance center console boat.

“At Hayaari Marine, we have always focused on the highest quality raw materials,” comments Wassim El Zein, owner, Hayaari Marine. “With the H44Z switch to infusion, we created our own in-house testing tools to really understand how these materials interact with the vacuum consumables. The results speak for themselves. Exceptional laminate quality, a 20% weight reduction of unnecessary resin, and a 90-plus mile per hour top speed.”

#composites #ResinInfused #HayaariMarine

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Dear friends!

The main event in the composite industry, the Composite-Expo 2022 exhibition, will be held from March 29 to 31 in Pavilion 1 of the Expocentre Fairgrounds.

The entrance to the territory of the Expocentre Fairgrounds is carried out from three entrances: South, North and West.

Exhibition opening hours:
March 29 and 30 - from 10.00 to 18.00
March 31 - from 10.00 to 16.00

As part of the business program, on March 30, the 3nd R&D Conference «Practical use of composite materials in different industries» will be held.

• catalog of exhibitors

• conference program

• get an invitation

• venue

See you at the exhibition!

#composites #CompositeExpo2022 #CompositeExpoExhibition