This will be especially critical for Rhode-Barbarigos’ project, which hopes to make buildings along the coast less vulnerable with the possibility of more intense hurricanes and tropical storms on the horizon. Currently, engineers design structures using separate load models for wind, waves, and storm surge that they later combine, Rhode-Barbarigos said. However, during a storm, wind, waves, and storm surge are always linked. Therefore, as part of this research, he wants to create new load models for structural engineers that account for combined action of wind, storm surge, and waves.
“We want to develop an understanding of how wind, storm surge, and waves interact at high wind speeds, to assess their combined effect on the structures,” said Rhode-Barbarigos.
Suraneni, an expert in cement chemistry, is looking forward to testing the performance of glass-fiber-polymer-reinforced, ultra-high-performance concrete. This is an alternative to the traditional steel-reinforced concrete, but one that aims to avoid corrosion that often causes concrete structures in saltwater environments to degrade. His team will also be evaluating the ability of these materials to create more sustainable seawalls, which could prove extremely useful in coastal communities. The team includes Rhode-Barbarigos; Antonio Nanni, professor and chair of the Department of Civil and Architectural Engineering; Esber Andiroglu, engineering associate professor of practice; and Haus.
Both projects will offer insight about how South Florida and other coastal communities can better protect themselves for future storms, noted Haus, a physical oceanographer and coastal engineer who directs the SUSTAIN facility.
“These projects will be important for a lot of applications in the field, where you can use these new loads to revamp building codes. Or in the case of the materials, they could be used to improve coastal construction,” said Haus, who leads the University’s Department of Ocean Sciences and is a co-investigator on both projects.
Photo: From left, assistant professor of engineering Landolf Rhode-Barbarigos, along with associate professor of practice Esber Andiroglu, and assistant professor Prannoy Suraneni display some of their coastal resilience research project at the eMerge Americas conference in April. Photo: Mike Montero/University of Miami
#composites #UltraHighPerformanceConcrete #GlassfiberReinforcedPolymers
> source
“We want to develop an understanding of how wind, storm surge, and waves interact at high wind speeds, to assess their combined effect on the structures,” said Rhode-Barbarigos.
Suraneni, an expert in cement chemistry, is looking forward to testing the performance of glass-fiber-polymer-reinforced, ultra-high-performance concrete. This is an alternative to the traditional steel-reinforced concrete, but one that aims to avoid corrosion that often causes concrete structures in saltwater environments to degrade. His team will also be evaluating the ability of these materials to create more sustainable seawalls, which could prove extremely useful in coastal communities. The team includes Rhode-Barbarigos; Antonio Nanni, professor and chair of the Department of Civil and Architectural Engineering; Esber Andiroglu, engineering associate professor of practice; and Haus.
Both projects will offer insight about how South Florida and other coastal communities can better protect themselves for future storms, noted Haus, a physical oceanographer and coastal engineer who directs the SUSTAIN facility.
“These projects will be important for a lot of applications in the field, where you can use these new loads to revamp building codes. Or in the case of the materials, they could be used to improve coastal construction,” said Haus, who leads the University’s Department of Ocean Sciences and is a co-investigator on both projects.
Photo: From left, assistant professor of engineering Landolf Rhode-Barbarigos, along with associate professor of practice Esber Andiroglu, and assistant professor Prannoy Suraneni display some of their coastal resilience research project at the eMerge Americas conference in April. Photo: Mike Montero/University of Miami
#composites #UltraHighPerformanceConcrete #GlassfiberReinforcedPolymers
> source
Composites
Photo
The Gill Corporation announces new Gillcore® HF fiberglass honeycomb core
The Gill Corporation (TGC) announces new Gillcore® HF fiberglass honeycomb core meeting all requirements of AMS 3715. TGC began developing fiberglass honeycomb in response to industry demand from aerospace customers around the world.
The core is produced with a substrate consisting of woven fiberglass cloth reinforced with heat resistant phenolic resin for improved moisture resistance over traditional aramid fiber substrates. It is suitable for high temperature applications requiring a high degree of forming and high moisture areas. TGC processes rolls of fiberglass cloth through the same manufacturing equipment as aramid honeycomb cores. TGC successfully completed all AMS 3715 test requirements. TGC is working with other customers to meet their qualification requirements.
Testing performed includes:
– Plate shear strength and modulus, Ribbon and Transverse
– Stabilized compression strength and modulus
– Flatwise tension
– 65F, RTA, 180F, 250F, 350F
– Wet – RTA, 180F, 250F, 350F
#composites #FiberglassHoneycombCore #fiberglass
> source
The Gill Corporation (TGC) announces new Gillcore® HF fiberglass honeycomb core meeting all requirements of AMS 3715. TGC began developing fiberglass honeycomb in response to industry demand from aerospace customers around the world.
The core is produced with a substrate consisting of woven fiberglass cloth reinforced with heat resistant phenolic resin for improved moisture resistance over traditional aramid fiber substrates. It is suitable for high temperature applications requiring a high degree of forming and high moisture areas. TGC processes rolls of fiberglass cloth through the same manufacturing equipment as aramid honeycomb cores. TGC successfully completed all AMS 3715 test requirements. TGC is working with other customers to meet their qualification requirements.
Testing performed includes:
– Plate shear strength and modulus, Ribbon and Transverse
– Stabilized compression strength and modulus
– Flatwise tension
– 65F, RTA, 180F, 250F, 350F
– Wet – RTA, 180F, 250F, 350F
#composites #FiberglassHoneycombCore #fiberglass
> source
Composites
Photo
New recycling process for polyester fishing nets helps to reduce environmental burden
Fishing nets are mainly made from chemical fibers such as nylon and polyester to prevent rot as well as to ensure excellent strength and easy maintenance. Whereas common nylon fishing nets are generally easy to recycle with an established process, recycling polyester fishing nets has been technically difficult and also costly due to the lack of a dedicated process. In recent years, discarded polyester fishing nets in Japan have accounted for about 1,300 tons of landfill waste annually.
But in April 2021, a breakthrough solution was launched by Teijin Limited and four additional enterprises specialized in fields including fishing net manufacturing, plastic molding, fiber processing and resin processing. Under the new system, it is now possible to collect polyester fishing nets and recycle them into resin that can be used to make commercially marketable trays and stationery.
Initially, the partners faced two major tasks. First was the challenge of developing a technology capable of cleaning smelly, waterlogged fishing nets and stripping the polyester of coatings applied to improve durability. Teijin and the other partners eventually identified organic solvents that can be used in an environmentally friendly cleaning process to produce virtually odorless resin that can be recycled repeatedly.
The second big challenge was profitability. Raw polyester costs less than many other materials, so the companies knew that its resin would not be price-competitive if the cleaning and drying processes incurred prohibitive costs. The companies’ solution was to devise a method for manufacturing high-quality resin pellets containing a mixture of other recycled resins added to improve durability and heat resistance.
Thanks to this project’s success, commercially viable resin recycled from fishing nets is now being used to produce food trays for a restaurant chain in Japan. Teijin is responsible for collecting and cleaning the nets and selling the final products.
Going forward, Teijin aims to promote the new recycling system for the global production and sale of various practical products. The hope is to realize locally produced and locally consumed products in efficient circular economies that incur little energy loss. Along with strengthening the traceability of fishing nets, Teijin initially aims to recycle 1,000 tons of polyester fishing nets annually by 2030.
Teijin, a people-focused company that develops innovative solutions for enhanced quality of life, is committed to minimizing any negative impact on the environment or society through its business in order to support the society of the future.
#composites #RecyclingProcess #polyester
> source
Fishing nets are mainly made from chemical fibers such as nylon and polyester to prevent rot as well as to ensure excellent strength and easy maintenance. Whereas common nylon fishing nets are generally easy to recycle with an established process, recycling polyester fishing nets has been technically difficult and also costly due to the lack of a dedicated process. In recent years, discarded polyester fishing nets in Japan have accounted for about 1,300 tons of landfill waste annually.
But in April 2021, a breakthrough solution was launched by Teijin Limited and four additional enterprises specialized in fields including fishing net manufacturing, plastic molding, fiber processing and resin processing. Under the new system, it is now possible to collect polyester fishing nets and recycle them into resin that can be used to make commercially marketable trays and stationery.
Initially, the partners faced two major tasks. First was the challenge of developing a technology capable of cleaning smelly, waterlogged fishing nets and stripping the polyester of coatings applied to improve durability. Teijin and the other partners eventually identified organic solvents that can be used in an environmentally friendly cleaning process to produce virtually odorless resin that can be recycled repeatedly.
The second big challenge was profitability. Raw polyester costs less than many other materials, so the companies knew that its resin would not be price-competitive if the cleaning and drying processes incurred prohibitive costs. The companies’ solution was to devise a method for manufacturing high-quality resin pellets containing a mixture of other recycled resins added to improve durability and heat resistance.
Thanks to this project’s success, commercially viable resin recycled from fishing nets is now being used to produce food trays for a restaurant chain in Japan. Teijin is responsible for collecting and cleaning the nets and selling the final products.
Going forward, Teijin aims to promote the new recycling system for the global production and sale of various practical products. The hope is to realize locally produced and locally consumed products in efficient circular economies that incur little energy loss. Along with strengthening the traceability of fishing nets, Teijin initially aims to recycle 1,000 tons of polyester fishing nets annually by 2030.
Teijin, a people-focused company that develops innovative solutions for enhanced quality of life, is committed to minimizing any negative impact on the environment or society through its business in order to support the society of the future.
#composites #RecyclingProcess #polyester
> source
Brazilian consumption of composites fell 4.2% in the first half of 2022
For the year as a whole, the sector represented by ALMACO expects a reduction of 2.5%.
In the first half of 2022, Brazilian consumption of composites fell by 4.2%, totalling 117 thousand tons. Total revenue was US$ 359 million, 17% higher than that recorded between January and June 2021. The mismatch between consumption and revenue is due to successive increases in raw material prices. The data are part of a survey carried out by the Latin American Composite Materials Association (ALMACO).
“This result means much more an accommodation of demand, after the explosion in 2020 and 2021, than a fall itself,” evaluates Erika Bernardino Aprá, president of ALMACO.
According to ALMACO survey, in the first half of 2022, civil construction accounted for 30.9% of Brazilian consumption of composites, ahead of transport (24.7%), corrosion/sanitation (17.5%), leisure/pools (12.4%), electric energy (5.2%), wind energy (3.1%), marine (2.1%) and clothing (1%), among others. When only the consumption of epoxy resin-based composites is separated, the generation of wind energy led with 90.5%, ahead of oil (3.8%) and electronics (2.7%).
“The drop in demand from the construction and leisure market, the latter represented mainly by swimming pools, was partially mitigated by the good phase of the transport industry, especially road buses, whose sales increased after the resumption of post-pandemic tourism,” comments Erika.
For 2022 as a whole, ALMACO study points to a retraction in consumption of around 2.5%, which will total 239 thousand tons. In terms of revenue, the Brazilian composites sector should register US$ 922 million this year, a figure 20% higher than that recorded in 2021.
“The second half of the year is historically better for our industry than the first. Added to this is the start of major projects in the area of corrosion, a movement that will positively impact many companies in the composites production chain,” adds the president of ALMACO.
#composites #BrazilianConsumption #ALMACO
> source
For the year as a whole, the sector represented by ALMACO expects a reduction of 2.5%.
In the first half of 2022, Brazilian consumption of composites fell by 4.2%, totalling 117 thousand tons. Total revenue was US$ 359 million, 17% higher than that recorded between January and June 2021. The mismatch between consumption and revenue is due to successive increases in raw material prices. The data are part of a survey carried out by the Latin American Composite Materials Association (ALMACO).
“This result means much more an accommodation of demand, after the explosion in 2020 and 2021, than a fall itself,” evaluates Erika Bernardino Aprá, president of ALMACO.
According to ALMACO survey, in the first half of 2022, civil construction accounted for 30.9% of Brazilian consumption of composites, ahead of transport (24.7%), corrosion/sanitation (17.5%), leisure/pools (12.4%), electric energy (5.2%), wind energy (3.1%), marine (2.1%) and clothing (1%), among others. When only the consumption of epoxy resin-based composites is separated, the generation of wind energy led with 90.5%, ahead of oil (3.8%) and electronics (2.7%).
“The drop in demand from the construction and leisure market, the latter represented mainly by swimming pools, was partially mitigated by the good phase of the transport industry, especially road buses, whose sales increased after the resumption of post-pandemic tourism,” comments Erika.
For 2022 as a whole, ALMACO study points to a retraction in consumption of around 2.5%, which will total 239 thousand tons. In terms of revenue, the Brazilian composites sector should register US$ 922 million this year, a figure 20% higher than that recorded in 2021.
“The second half of the year is historically better for our industry than the first. Added to this is the start of major projects in the area of corrosion, a movement that will positively impact many companies in the composites production chain,” adds the president of ALMACO.
#composites #BrazilianConsumption #ALMACO
> source
Composites
Photo
Russian scientists suggest using a cryptozoic mineral to create new lightweight carbon composites
Scientists at MISIS University and Skoltech have developed a technology for the production of a new composite material based on shungite and carbon fibers in a graphite matrix. Due to the combination of low density, high strength and chemical stability at elevated temperatures, it can be used to produce fuel cells, super-capacitors, and next-generation aircraft engine components. The work was published in Polymers.
Composites with carbon fillers are widely used in modern industry. They can be used for the production of units and equipment operating in extreme conditions, due to their unique properties — high chemical and temperature resistance. Unlike heavy refractory metals that are readily oxidized at elevated temperatures, carbon materials have exceptional high temperature resistance and low weight. At the same time, properties of different carbon materials vary a lot — from diamond to graphite.
Materials scientists are now developing a new class of composites consisting of various carbon reinforcing fillers in a graphite matrix obtained by carbonization, i.e. transformation of a polymer into a carbon material.
Scientists from MISIS University and Skoltech have presented the technology of fast and economical production of such composite and identified the optimal parameters for heat treatment to achieve the best performance in terms of “crack resistance” — that is, resistance to the initiation and propagation of cracks that largely determines the strength for brittle and quasi-fragile materials.
The composite synthesis process is similar to “baking” a “dough” made from an elastomer (a soft rubber-type polymer) reinforced with a “filling” at several temperatures above 180ºC. The short carbon fibre often used as a “filling” is however quite expensive and its available volume is limited. Therefore, in the new material the short carbon fibers were partially import-substituted with shungite. Shungite is a unique Precambrian rock consisting of almost 100% carbon that was first discovered in Russia.
The result of processing is the enrichment of the initial product with carbon accompanied by simultaneous restructuring. The easily shaped polymer is thereby turned into one of the most stable carbon compounds, such as graphite or diamond. Given the unique rigidity of these materials it is almost impossible to machine necessary part shapes from graphite or diamond.
“The purpose of this study was to optimize the carbonization process to increase the crack resistance depending on the processing temperature and the initial mixture composition, namely, the volume fraction of the reinforcing phases. A careful selection of conditions was undertaken to obtain the highest values of the critical stress intensity factor in samples carbonized at the temperature of 280°C,” says Alexey Salimon, Ph.D, co-author and Head of the Department of Physical Chemistry.
The researchers expect the obtained materials to find use for the manufacture of key parts of fuel cells (devices for direct conversion of the fuel chemical energy into electrical energy without combustion), components of chemically resistant equipment, complex pumping equipment for oil production at record depths and in the harshest conditions (sand, hydrogen sulfide, temperature over 200 °C). Another promising area for the use of new materials will be to create a new generation of aircraft engine components.
#composites #MISIS #shungite #CarbonComposites
> source
Scientists at MISIS University and Skoltech have developed a technology for the production of a new composite material based on shungite and carbon fibers in a graphite matrix. Due to the combination of low density, high strength and chemical stability at elevated temperatures, it can be used to produce fuel cells, super-capacitors, and next-generation aircraft engine components. The work was published in Polymers.
Composites with carbon fillers are widely used in modern industry. They can be used for the production of units and equipment operating in extreme conditions, due to their unique properties — high chemical and temperature resistance. Unlike heavy refractory metals that are readily oxidized at elevated temperatures, carbon materials have exceptional high temperature resistance and low weight. At the same time, properties of different carbon materials vary a lot — from diamond to graphite.
Materials scientists are now developing a new class of composites consisting of various carbon reinforcing fillers in a graphite matrix obtained by carbonization, i.e. transformation of a polymer into a carbon material.
Scientists from MISIS University and Skoltech have presented the technology of fast and economical production of such composite and identified the optimal parameters for heat treatment to achieve the best performance in terms of “crack resistance” — that is, resistance to the initiation and propagation of cracks that largely determines the strength for brittle and quasi-fragile materials.
The composite synthesis process is similar to “baking” a “dough” made from an elastomer (a soft rubber-type polymer) reinforced with a “filling” at several temperatures above 180ºC. The short carbon fibre often used as a “filling” is however quite expensive and its available volume is limited. Therefore, in the new material the short carbon fibers were partially import-substituted with shungite. Shungite is a unique Precambrian rock consisting of almost 100% carbon that was first discovered in Russia.
The result of processing is the enrichment of the initial product with carbon accompanied by simultaneous restructuring. The easily shaped polymer is thereby turned into one of the most stable carbon compounds, such as graphite or diamond. Given the unique rigidity of these materials it is almost impossible to machine necessary part shapes from graphite or diamond.
“The purpose of this study was to optimize the carbonization process to increase the crack resistance depending on the processing temperature and the initial mixture composition, namely, the volume fraction of the reinforcing phases. A careful selection of conditions was undertaken to obtain the highest values of the critical stress intensity factor in samples carbonized at the temperature of 280°C,” says Alexey Salimon, Ph.D, co-author and Head of the Department of Physical Chemistry.
The researchers expect the obtained materials to find use for the manufacture of key parts of fuel cells (devices for direct conversion of the fuel chemical energy into electrical energy without combustion), components of chemically resistant equipment, complex pumping equipment for oil production at record depths and in the harshest conditions (sand, hydrogen sulfide, temperature over 200 °C). Another promising area for the use of new materials will be to create a new generation of aircraft engine components.
#composites #MISIS #shungite #CarbonComposites
> source
Composites
Photo
Velocity Composites launches digital manufacturing cell
Velocity Composites has launched a new digital manufacturing cell – located at its headquarters in Burnley, Lancashire – which has been designed to help improve traceability and efficiency for customers.
The cell creates a process where all composite plies can be scanned, logged and sequenced efficiently to improve traceability and reduce costs.
Matthew Fisher, Product and Process Manager at Velocity Composites, said: “We aim to be at the forefront of Industry 4.0 technologies to improve the aerospace supply chain, helping customers to cut waste, become more efficient and save money.
“Our Digital Manufacturing Cell is the next step in our journey to improve even further. Our bespoke AVISoCS technology can help customers to fully trace each individual piece of ply within a job, as it is nested, cut and sequenced ready to be delivered.
“Within our own processes, we pride ourselves on minimal waste and ultimate efficiency and the Digital Manufacturing Cell allows us to optimise our workflow so each job is managed flexibly and can provide greater value to the customer.”
The cell is the latest in a range of data-driven technology advances at Velocity Composites, aimed at fully tracking and tracing the aerospace supply chain for customers, improving efficiencies and making savings on material and operational costs.
Velocity’s own VRP technology has been designed to manage the entire value stream, from customer demand management, raw material management, batch traceability, complex nesting, kit manufacture and kit logistics, with all areas being connected and sharing real time data to drive maximum efficiencies.
Matthew Fisher added: “The software allows clients to benefit from real-time data which helps with Enterprise Resource Planning to optimise operations, cut down on waste and provide sound information upon which to make decisions.
“Customers can have a real time view of jobs from their initial acceptance and planning, through every step before it is delivered. The basic technology is similar to what people would experience when tracking a postage delivery or ordering a takeaway, but we have specifically tailored it to our processes in composite manufacturing to add that value to the aerospace and related sectors.”
As a result of the company’s proprietary software, Velocity’s customers have been able to reduce material waste by up to 20%, while also creating operational, stock and process efficiencies in a way which supports staff to be more effective.
The savings not only help companies to become more efficient and competitive but can help mitigate the impact of rising material costs while closing the gap on achieving environmental targets for the aerospace sector which stand at 15% by 2030, 40% by 2040, and achieving net zero by 2050.
Velocity Composites plc is the leading supplier of advanced composite material kits to the aerospace market. Through its development of proprietary digital technologies, Velocity offers a bespoke, fully managed supply chain and manufacturing service, targeting cost efficiencies for a global customer base. The company has its headquarters in Burnley, Lancashire, with a second site at Fareham, Hampshire.
#composites #VelocityComposites #cells
> source
Velocity Composites has launched a new digital manufacturing cell – located at its headquarters in Burnley, Lancashire – which has been designed to help improve traceability and efficiency for customers.
The cell creates a process where all composite plies can be scanned, logged and sequenced efficiently to improve traceability and reduce costs.
Matthew Fisher, Product and Process Manager at Velocity Composites, said: “We aim to be at the forefront of Industry 4.0 technologies to improve the aerospace supply chain, helping customers to cut waste, become more efficient and save money.
“Our Digital Manufacturing Cell is the next step in our journey to improve even further. Our bespoke AVISoCS technology can help customers to fully trace each individual piece of ply within a job, as it is nested, cut and sequenced ready to be delivered.
“Within our own processes, we pride ourselves on minimal waste and ultimate efficiency and the Digital Manufacturing Cell allows us to optimise our workflow so each job is managed flexibly and can provide greater value to the customer.”
The cell is the latest in a range of data-driven technology advances at Velocity Composites, aimed at fully tracking and tracing the aerospace supply chain for customers, improving efficiencies and making savings on material and operational costs.
Velocity’s own VRP technology has been designed to manage the entire value stream, from customer demand management, raw material management, batch traceability, complex nesting, kit manufacture and kit logistics, with all areas being connected and sharing real time data to drive maximum efficiencies.
Matthew Fisher added: “The software allows clients to benefit from real-time data which helps with Enterprise Resource Planning to optimise operations, cut down on waste and provide sound information upon which to make decisions.
“Customers can have a real time view of jobs from their initial acceptance and planning, through every step before it is delivered. The basic technology is similar to what people would experience when tracking a postage delivery or ordering a takeaway, but we have specifically tailored it to our processes in composite manufacturing to add that value to the aerospace and related sectors.”
As a result of the company’s proprietary software, Velocity’s customers have been able to reduce material waste by up to 20%, while also creating operational, stock and process efficiencies in a way which supports staff to be more effective.
The savings not only help companies to become more efficient and competitive but can help mitigate the impact of rising material costs while closing the gap on achieving environmental targets for the aerospace sector which stand at 15% by 2030, 40% by 2040, and achieving net zero by 2050.
Velocity Composites plc is the leading supplier of advanced composite material kits to the aerospace market. Through its development of proprietary digital technologies, Velocity offers a bespoke, fully managed supply chain and manufacturing service, targeting cost efficiencies for a global customer base. The company has its headquarters in Burnley, Lancashire, with a second site at Fareham, Hampshire.
#composites #VelocityComposites #cells
> source
Composites
Photo
Advanced Engineering: High-tension filament winding to be showcased
Fibre processing and converting machinery manufacturer Cygnet Texkimp will use this year’s Advanced Engineering show to highlight its high-tension filament winding and composites recycling solutions.
The company specialises in the design and manufacture of downstream processing equipment including filament winding, prepreg, coating and slitting machines. Its high-tension winding solution is the latest development in its filament winding product range which also includes high-speed, multi-axis and 3D winding machines.
Visitors will be able to find out more about the company’s approach to winding fibre at extremely high tension to create composite parts that perform well under intense forces, such as pressure, speed and rotation.
“We developed our high-tension winding technology in response to a number of enquiries from manufacturers looking for ways to increase the strength and resistance of their composite parts without adding weight or compromising fibre integrity,” explained Cygnet Texkimp CEO Luke Vardy. “We’ve designed a system that is particularly relevant in the manufacture of high-performance parts such as pressure vessels and motors that are subject to intense energetic forces such as pressure, speed and rotation.”
The company will also showcase the fibre reclaiming and recycling solution, DEECOM, which it is developing specifically for the composites market. DEECOM is an innovative technology that uses superheated steam to reclaim composite fibres and resins from wound parts and offers the potential for them to be reused in the manufacture of new parts.
“The quality, length and consistency of fibres we’re able to reclaim make DEECOM a truly game-changing solution for composites manufacturers and end users working to address the major challenges of sustainability, supply and waste reduction,” said Vardy. “Through the processes of reclaiming and reusing, DEECOM provides the possibility of using every carbon fibre multiple times. Giving composite fibres multiple lifecycles means massively reducing their lifetime cost and environmental footprint and create a more abundant and consistent supply of carbon fibre.”
#composites #prepreg #FilamentWinding
> source
Fibre processing and converting machinery manufacturer Cygnet Texkimp will use this year’s Advanced Engineering show to highlight its high-tension filament winding and composites recycling solutions.
The company specialises in the design and manufacture of downstream processing equipment including filament winding, prepreg, coating and slitting machines. Its high-tension winding solution is the latest development in its filament winding product range which also includes high-speed, multi-axis and 3D winding machines.
Visitors will be able to find out more about the company’s approach to winding fibre at extremely high tension to create composite parts that perform well under intense forces, such as pressure, speed and rotation.
“We developed our high-tension winding technology in response to a number of enquiries from manufacturers looking for ways to increase the strength and resistance of their composite parts without adding weight or compromising fibre integrity,” explained Cygnet Texkimp CEO Luke Vardy. “We’ve designed a system that is particularly relevant in the manufacture of high-performance parts such as pressure vessels and motors that are subject to intense energetic forces such as pressure, speed and rotation.”
The company will also showcase the fibre reclaiming and recycling solution, DEECOM, which it is developing specifically for the composites market. DEECOM is an innovative technology that uses superheated steam to reclaim composite fibres and resins from wound parts and offers the potential for them to be reused in the manufacture of new parts.
“The quality, length and consistency of fibres we’re able to reclaim make DEECOM a truly game-changing solution for composites manufacturers and end users working to address the major challenges of sustainability, supply and waste reduction,” said Vardy. “Through the processes of reclaiming and reusing, DEECOM provides the possibility of using every carbon fibre multiple times. Giving composite fibres multiple lifecycles means massively reducing their lifetime cost and environmental footprint and create a more abundant and consistent supply of carbon fibre.”
#composites #prepreg #FilamentWinding
> source
Composites
PCS Coated Carbon and Aramid Fibers. SEM micrographs of raw carbon fibers (A), PCS coated carbon fibers (B), raw aramid fibers (C), and PCS coated aramid fibers (D).
Mussel Polymers announces new multi-functional carbon and aramid fiber coating for stronger lighter reinforced composites
Carbon fiber reinforced materials are widely used in products from golf clubs to the world’s most advanced aircraft due to their high strength, stability, and light weight. Mussel Polymers, Inc., a specialty materials and coatings company, announced that it has successfully coated carbon and aramid fibers with its Poly(catechol-styrene) (PCS), which is a step forward in producing lighter, stronger fiber reinforced composites.
PCS coatings improve bonding for a wide range of adhesive and composite chemistries while functionalizing material surfaces. This application of PCS is likely to significantly increase the strength and impact energy of fiber reinforced materials and improve the use of coatings and adhesives with carbon fiber parts and materials.
While carbon and aramid fibers possess many positive attributes, they are notoriously difficult to bond with because they are smooth and chemically inert. Previous work coating carbon and aramid fibers with Polydopamine (PDA), a catechol containing research agent like PCS, showed that the shear strength of a single coated fiber pulled from its matrix increased over 200% compared to that of a raw fiber. Further, the flexural strength and impact energy of reinforced composites made with the catechol coated fibers increased over 200%.
PCS is the first commercially available catechol compound used to coat carbon fibers, among its many other uses.
Jason Stieg – Chief Commercial Officer of Mussel Polymers – “The MPI team successfully coated carbon and aramid fibers with PCS using a simple one-step, room temperature process. These coated fibers were examined under the scanning electron microscope at Lehigh University. The resulting images were striking and showed complete coverage of the fibers. The ability of our polymer to bond to these surfaces has applicability in both advanced composite materials and the assembly and coating of carbon fiber parts.”
George Boyajian – CEO of Mussel Polymers – “We are excited to have expanded the uses of our Poly(catechol-styrene). With this development allowing for stronger, lightweight materials, we will expand our partnerships with new materials and products companies. The simplicity of this coating process may accelerate its adoption and allow for safer and more environmentally sound materials.”
Mussel Polymers is currently in discussions to jointly develop new composite materials with its PCS.
Mussel Polymers, Inc. (MPI) is a specialty materials company commercializing a range of products based on its biomimetic Poly(catechol-styrene). PCS is the first commercially available catechol containing polymer. PCS effectively bonds with many materials, providing enhanced adhesion and other surface functionalizing benefits. MPI is developing products for applications in the dental, biomedical, defense, specialty coatings, industrial and marine industries. Founded in 2020, MPI is based at the Ben Franklin Technology Facility in Bethlehem Pennsylvania.
#composites #AramidFiberCoating #ReinforcedComposites
> source
Carbon fiber reinforced materials are widely used in products from golf clubs to the world’s most advanced aircraft due to their high strength, stability, and light weight. Mussel Polymers, Inc., a specialty materials and coatings company, announced that it has successfully coated carbon and aramid fibers with its Poly(catechol-styrene) (PCS), which is a step forward in producing lighter, stronger fiber reinforced composites.
PCS coatings improve bonding for a wide range of adhesive and composite chemistries while functionalizing material surfaces. This application of PCS is likely to significantly increase the strength and impact energy of fiber reinforced materials and improve the use of coatings and adhesives with carbon fiber parts and materials.
While carbon and aramid fibers possess many positive attributes, they are notoriously difficult to bond with because they are smooth and chemically inert. Previous work coating carbon and aramid fibers with Polydopamine (PDA), a catechol containing research agent like PCS, showed that the shear strength of a single coated fiber pulled from its matrix increased over 200% compared to that of a raw fiber. Further, the flexural strength and impact energy of reinforced composites made with the catechol coated fibers increased over 200%.
PCS is the first commercially available catechol compound used to coat carbon fibers, among its many other uses.
Jason Stieg – Chief Commercial Officer of Mussel Polymers – “The MPI team successfully coated carbon and aramid fibers with PCS using a simple one-step, room temperature process. These coated fibers were examined under the scanning electron microscope at Lehigh University. The resulting images were striking and showed complete coverage of the fibers. The ability of our polymer to bond to these surfaces has applicability in both advanced composite materials and the assembly and coating of carbon fiber parts.”
George Boyajian – CEO of Mussel Polymers – “We are excited to have expanded the uses of our Poly(catechol-styrene). With this development allowing for stronger, lightweight materials, we will expand our partnerships with new materials and products companies. The simplicity of this coating process may accelerate its adoption and allow for safer and more environmentally sound materials.”
Mussel Polymers is currently in discussions to jointly develop new composite materials with its PCS.
Mussel Polymers, Inc. (MPI) is a specialty materials company commercializing a range of products based on its biomimetic Poly(catechol-styrene). PCS is the first commercially available catechol containing polymer. PCS effectively bonds with many materials, providing enhanced adhesion and other surface functionalizing benefits. MPI is developing products for applications in the dental, biomedical, defense, specialty coatings, industrial and marine industries. Founded in 2020, MPI is based at the Ben Franklin Technology Facility in Bethlehem Pennsylvania.
#composites #AramidFiberCoating #ReinforcedComposites
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Composites
Printing is the fastest way to go from CAD file to near-net shape for moulds and support structures
Added dimensions for composite parts
In this Q&A session Gregory Haye, director of additive manufacturing at Airtech, discusses the company’s development of 3D printing processes and materials for moulds used in composite part production.
Airtech, has been at the forefront of composites technology for nearly 50 years, playing a key role in pioneering industry innovations. Today, it has over 800 employees worldwide and is the largest privately-owned manufacturer of vacuum bagging and composite tooling materials in the world.
The company supplies composite manufacturers worldwide in many sectors. Its comprehensive range of goods and services includes vacuum bagging films, release films, pressure-sensitive tapes, mould releases (non-liquid), peel plies, breathers and bleeders, sealant tapes, connectors and hoses, rubber, PTFE release fabrics, tooling prepregs and resins, carbon and glass reinforcements, 3D Print resins, and 3D Printed tooling.
At its Centres of Innovation in Springfield, Tennessee and Differdange, Luxembourg, the company uses additive manufacturing to develop its Print-Tech large-scale 3D printed composited tool service and Dahltram additive manufacturing resins.
Q) When did Airtech first start exploring the use of 3D printing as an additional manufacturing solution to the composite mould-making and tooling production?
Airtech officially launched its activities in additive manufacturing in the autumn of 2019. The concept was to use our company-wide knowledge and expertise in composites processing, auxiliary materials, tooling, and thermoplastic extrusion to bring a new technology to the commercial market in a way no one else could.
With our industry experience, plus the addition of key subject matter experts from the additive manufacturing world, we were able to quickly establish an internal ecosystem that supported our ability to offer printing services that were attractive to composite tooling customers as well as develop relevant resins for printing in a rapid way. We are unique in that we are the only resin manufacturer that can also develop materials and trial them internally to ensure their performance in printing and in the end use application. In this way, every resin or auxiliary product we offer the market has been evaluated internally to conform or exceed industry expectations before it is ever printed by a customer or machine manufacturer.
Our goal is to use our capabilities to support customer adoption of additive manufacturing using our qualified resin and other products either with us, with others or on their own printing equipment.
Q) What are the major benefits? More rapid production and turnaround? Design flexibility? Cost/material savings?
3D printed tooling can most commonly benefit the customer by offering a faster lead-time than conventional technologies. There’s no faster way to go from a CAD file to a near-net shape than printing the near-net form and its support structure in one step. In many applications where metallics would be used, the weight of the tool can be significantly less making transport or handling easier and safer for the workforce. Support structures, lifting and rigging points, air passages and mounting flanges for hardware can be designed and printed reducing part count and touch labour saving the customer time and money.
Q) What sectors are seeing the most demand for these services and products? Is there a growing awareness about the capabilities and applications of additive manufacturing?
Aerospace is Airtech’s largest global market segment. It is no surprise that aerospace tends to be the leader in technology development and adoption. We see this same trend in the additive tooling and resins we offer. Automotive interest is rapidly growing pushing development in multi-piece tooling and cost reduction. The other markets are still testing the waters, but typically are using low-tech old tooling products and processes that minimally meet their requirements.
#composites #CompositeParts #Airtech
> source
In this Q&A session Gregory Haye, director of additive manufacturing at Airtech, discusses the company’s development of 3D printing processes and materials for moulds used in composite part production.
Airtech, has been at the forefront of composites technology for nearly 50 years, playing a key role in pioneering industry innovations. Today, it has over 800 employees worldwide and is the largest privately-owned manufacturer of vacuum bagging and composite tooling materials in the world.
The company supplies composite manufacturers worldwide in many sectors. Its comprehensive range of goods and services includes vacuum bagging films, release films, pressure-sensitive tapes, mould releases (non-liquid), peel plies, breathers and bleeders, sealant tapes, connectors and hoses, rubber, PTFE release fabrics, tooling prepregs and resins, carbon and glass reinforcements, 3D Print resins, and 3D Printed tooling.
At its Centres of Innovation in Springfield, Tennessee and Differdange, Luxembourg, the company uses additive manufacturing to develop its Print-Tech large-scale 3D printed composited tool service and Dahltram additive manufacturing resins.
Q) When did Airtech first start exploring the use of 3D printing as an additional manufacturing solution to the composite mould-making and tooling production?
Airtech officially launched its activities in additive manufacturing in the autumn of 2019. The concept was to use our company-wide knowledge and expertise in composites processing, auxiliary materials, tooling, and thermoplastic extrusion to bring a new technology to the commercial market in a way no one else could.
With our industry experience, plus the addition of key subject matter experts from the additive manufacturing world, we were able to quickly establish an internal ecosystem that supported our ability to offer printing services that were attractive to composite tooling customers as well as develop relevant resins for printing in a rapid way. We are unique in that we are the only resin manufacturer that can also develop materials and trial them internally to ensure their performance in printing and in the end use application. In this way, every resin or auxiliary product we offer the market has been evaluated internally to conform or exceed industry expectations before it is ever printed by a customer or machine manufacturer.
Our goal is to use our capabilities to support customer adoption of additive manufacturing using our qualified resin and other products either with us, with others or on their own printing equipment.
Q) What are the major benefits? More rapid production and turnaround? Design flexibility? Cost/material savings?
3D printed tooling can most commonly benefit the customer by offering a faster lead-time than conventional technologies. There’s no faster way to go from a CAD file to a near-net shape than printing the near-net form and its support structure in one step. In many applications where metallics would be used, the weight of the tool can be significantly less making transport or handling easier and safer for the workforce. Support structures, lifting and rigging points, air passages and mounting flanges for hardware can be designed and printed reducing part count and touch labour saving the customer time and money.
Q) What sectors are seeing the most demand for these services and products? Is there a growing awareness about the capabilities and applications of additive manufacturing?
Aerospace is Airtech’s largest global market segment. It is no surprise that aerospace tends to be the leader in technology development and adoption. We see this same trend in the additive tooling and resins we offer. Automotive interest is rapidly growing pushing development in multi-piece tooling and cost reduction. The other markets are still testing the waters, but typically are using low-tech old tooling products and processes that minimally meet their requirements.
#composites #CompositeParts #Airtech
> source
Composites
World-first drone to save lives in dangerous water rescues
World-first drone to save lives in dangerous water rescues
A new world-first drone will help save lives and reduce human risk in dangerous water rescues.
Designed and created by Brisbane aerospace company Aeromech, the “drone” – known as SARGOTM (Search and Rescue Go) – is an unmanned surface vehicle (USV) that is set to revolutionise the way search and rescue operations are performed in life-threatening conditions.
Aeromech Director and the Australian inventor of SARGOTM, Joe Bryant, says there’s nothing else like it on the world stage.
“The difference with SARGOTM is that it is a USV designed specifically to be dropped from search and rescue aircraft to land safely on top of the ocean’s surface using a parachute. It can then be operated remotely to transport a payload of life-saving cargo to a stricken vessel or to people stranded in the water,” said Joe, an aerospace engineer.
“The overall design and capabilities of SARGOTM are different to anything else on the market currently deployed by Marine SAR and Coast Guard aircraft. Existing products delivered by a fixed winged aircraft must be dropped directly to a target and cannot be navigated remotely, which makes their delivery method limited and inaccurate.
“That’s why SARGOTM is a very exciting development for the rescue services.”
In 2021, Aeromech responded to an Expression of Interest from the Australian Maritime Safety Authority (AMSA) looking for a remotely operated vehicle that could be dropped from an aircraft and land on water – and so the idea for SARGOTM was born.
Noakes Group CEO Sean Langman said the vessel maintenance company, located in Sydney, was impressed by SARGOTM, in particular its design, capability and potential.
“We believe SARGOTM has the potential to change the way we address search and rescue operations, both domestically and internationally,” he said.
“SARGOTM is a product that can fill the gap that currently exists within the search and rescue market. We will continue to support Joe wherever possible, supporting young Australian companies that show initiative and innovation to ensure the lives of those at sea have access to technology such as SARGOTM,” he said. Aeromech was one of the successful recipients of the Queensland State Government Ignite 8 commercialisation fund announced in April 2022 to support the commercialisation and export of SARGOTM. Aeromech designs and builds SARGOTM in Brisbane, and is looking to continue to test and develop it further to market and export the product overseas in 2023.
“The beauty of SARGOTM is that it will not only save lives and keep rescuers safe, but also puts Australian manufacturing on the world stage, while also creating new jobs,” said Joe. “We want to be part of the revival of Australian manufacturing of high-quality products that are used all over the world to better it – and SARGOTM is our first step in doing that.
The patented SARGOTM design makes way for Aeromech’s second Australianmanufactured product, SEEKER, a USV designed to provide above and underwater surveillance, which is due to be released in early 2023.
Joe’s engineering background, including 13 years in the aerospace industry and a decade with French manufacturing giant Airbus, has allowed him specialise in advanced composites manufacturing.
It’s with this experience that Aeromech will set up an aerospace capability and manufacturing facility in southeast Queensland in 2023 to support the evolving aerospace and space sectors.
#composites #drone #SARGOTM
> source
A new world-first drone will help save lives and reduce human risk in dangerous water rescues.
Designed and created by Brisbane aerospace company Aeromech, the “drone” – known as SARGOTM (Search and Rescue Go) – is an unmanned surface vehicle (USV) that is set to revolutionise the way search and rescue operations are performed in life-threatening conditions.
Aeromech Director and the Australian inventor of SARGOTM, Joe Bryant, says there’s nothing else like it on the world stage.
“The difference with SARGOTM is that it is a USV designed specifically to be dropped from search and rescue aircraft to land safely on top of the ocean’s surface using a parachute. It can then be operated remotely to transport a payload of life-saving cargo to a stricken vessel or to people stranded in the water,” said Joe, an aerospace engineer.
“The overall design and capabilities of SARGOTM are different to anything else on the market currently deployed by Marine SAR and Coast Guard aircraft. Existing products delivered by a fixed winged aircraft must be dropped directly to a target and cannot be navigated remotely, which makes their delivery method limited and inaccurate.
“That’s why SARGOTM is a very exciting development for the rescue services.”
In 2021, Aeromech responded to an Expression of Interest from the Australian Maritime Safety Authority (AMSA) looking for a remotely operated vehicle that could be dropped from an aircraft and land on water – and so the idea for SARGOTM was born.
Noakes Group CEO Sean Langman said the vessel maintenance company, located in Sydney, was impressed by SARGOTM, in particular its design, capability and potential.
“We believe SARGOTM has the potential to change the way we address search and rescue operations, both domestically and internationally,” he said.
“SARGOTM is a product that can fill the gap that currently exists within the search and rescue market. We will continue to support Joe wherever possible, supporting young Australian companies that show initiative and innovation to ensure the lives of those at sea have access to technology such as SARGOTM,” he said. Aeromech was one of the successful recipients of the Queensland State Government Ignite 8 commercialisation fund announced in April 2022 to support the commercialisation and export of SARGOTM. Aeromech designs and builds SARGOTM in Brisbane, and is looking to continue to test and develop it further to market and export the product overseas in 2023.
“The beauty of SARGOTM is that it will not only save lives and keep rescuers safe, but also puts Australian manufacturing on the world stage, while also creating new jobs,” said Joe. “We want to be part of the revival of Australian manufacturing of high-quality products that are used all over the world to better it – and SARGOTM is our first step in doing that.
The patented SARGOTM design makes way for Aeromech’s second Australianmanufactured product, SEEKER, a USV designed to provide above and underwater surveillance, which is due to be released in early 2023.
Joe’s engineering background, including 13 years in the aerospace industry and a decade with French manufacturing giant Airbus, has allowed him specialise in advanced composites manufacturing.
It’s with this experience that Aeromech will set up an aerospace capability and manufacturing facility in southeast Queensland in 2023 to support the evolving aerospace and space sectors.
#composites #drone #SARGOTM
> source
Composites
Photo
Japanese researchers tested the heat resistance of carbon fiber-reinforced UHTC matrix composites
Carbon fiber-reinforced ultra-high-temperature ceramic (UHTC) matrix composites are extensively used in space shuttles and high-speed vehicles. However, these composites suffer from a lack of oxidation resistance. Recently, researchers from Japan tested the heat resistance of these composites at very high temperatures, providing insight into the modifications needed to prevent UHTC degradation. Their findings could have huge implications for the manufacture of space shuttle orbiters.
Carbon fiber-reinforced carbon (C/C) is a composite material made of carbon fiber reinforced in a matrix of glassy carbon or graphite. It is best known as the material used in hypersonic vehicles and space shuttle orbiters, which cruise at speeds greater than Mach 5. Since the 1970s, it has also been used in the brake system in Formula One racing cars. Even though C/C has excellent mechanical properties at high temperatures and inert atmospheres, it lacks oxidation resistance in these conditions, making its widespread use limited.
Researchers have found that ultra-high-temperature ceramics (UHTCs), which include transition metal carbides and diborides, show good oxidation resistance. In previous studies, zirconium-titanium (Zr-Ti) alloy infiltration has shown promising results for improving the heat resistance of carbon fiber-reinforced UHTC matrix composites (C/UHTCMCs). However, their use at high temperatures (>2000 ℃) is not known.
Set against this backdrop, a group of researchers from Japan have evaluated the potential utility of Zr-Ti alloy-infiltrated C/UHTCMCs at temperatures above 2000 ℃. Their study, led by Junior Associate Professor Ryo Inoue from Tokyo University of Science (TUS), was published in the Journal of Materials Science and made available online on October 27, 2022. The research team consisted of Mr. Noriatsu Koide and Assistant Professor Yutaro Arai from TUS, Professor Makoto Hasegawa from Yokohama National University, and Dr. Toshiyuki Nishimura from the National Institute for Materials Science.
Speaking of the motivation behind their study, “The research is an extension of the research and development of ceramics and ceramics-based composite materials. In recent years, we have received inquiries from several manufacturers of heavy industries regarding materials that can be used at temperatures above 2000 °C. We have also started to work with these manufacturers to develop new materials,” says Prof. Inoue.
The C/UHTCMC was manufactured using melt infiltration, which is the most cost-effective way to fabricate these materials. To study the applicability of this material, three types of C/UHTCMCs were fabricated with three different alloy compositions. The three alloy compositions used had varying atomic ratios of Zr:Ti. To characterize the heat resistance, the team used a method called arc-wind tunnel testing. This method involves exposing the material to extremely high enthalpy airflow inside a tunnel, similar to conditions that spacecrafts experience while re-entering the atmosphere.
The team found that the amount of Zr in the alloy had a strong effect on the degradation of the composite for all temperatures. This is owing to the thermodynamic preference for the oxidation of Zr-rich carbides compared to Ti-rich carbides. Further, the Zr and Ti oxides formed on the composite surface prevented further oxidation, and the oxide composition depended on the composition of the infiltrated alloys. Thermodynamic analysis revealed that the oxides formed on the composite surface were composed of ZrO2, ZrTiO4, and TiO2 solid solutions.
Carbon fiber-reinforced ultra-high-temperature ceramic (UHTC) matrix composites are extensively used in space shuttles and high-speed vehicles. However, these composites suffer from a lack of oxidation resistance. Recently, researchers from Japan tested the heat resistance of these composites at very high temperatures, providing insight into the modifications needed to prevent UHTC degradation. Their findings could have huge implications for the manufacture of space shuttle orbiters.
Carbon fiber-reinforced carbon (C/C) is a composite material made of carbon fiber reinforced in a matrix of glassy carbon or graphite. It is best known as the material used in hypersonic vehicles and space shuttle orbiters, which cruise at speeds greater than Mach 5. Since the 1970s, it has also been used in the brake system in Formula One racing cars. Even though C/C has excellent mechanical properties at high temperatures and inert atmospheres, it lacks oxidation resistance in these conditions, making its widespread use limited.
Researchers have found that ultra-high-temperature ceramics (UHTCs), which include transition metal carbides and diborides, show good oxidation resistance. In previous studies, zirconium-titanium (Zr-Ti) alloy infiltration has shown promising results for improving the heat resistance of carbon fiber-reinforced UHTC matrix composites (C/UHTCMCs). However, their use at high temperatures (>2000 ℃) is not known.
Set against this backdrop, a group of researchers from Japan have evaluated the potential utility of Zr-Ti alloy-infiltrated C/UHTCMCs at temperatures above 2000 ℃. Their study, led by Junior Associate Professor Ryo Inoue from Tokyo University of Science (TUS), was published in the Journal of Materials Science and made available online on October 27, 2022. The research team consisted of Mr. Noriatsu Koide and Assistant Professor Yutaro Arai from TUS, Professor Makoto Hasegawa from Yokohama National University, and Dr. Toshiyuki Nishimura from the National Institute for Materials Science.
Speaking of the motivation behind their study, “The research is an extension of the research and development of ceramics and ceramics-based composite materials. In recent years, we have received inquiries from several manufacturers of heavy industries regarding materials that can be used at temperatures above 2000 °C. We have also started to work with these manufacturers to develop new materials,” says Prof. Inoue.
The C/UHTCMC was manufactured using melt infiltration, which is the most cost-effective way to fabricate these materials. To study the applicability of this material, three types of C/UHTCMCs were fabricated with three different alloy compositions. The three alloy compositions used had varying atomic ratios of Zr:Ti. To characterize the heat resistance, the team used a method called arc-wind tunnel testing. This method involves exposing the material to extremely high enthalpy airflow inside a tunnel, similar to conditions that spacecrafts experience while re-entering the atmosphere.
The team found that the amount of Zr in the alloy had a strong effect on the degradation of the composite for all temperatures. This is owing to the thermodynamic preference for the oxidation of Zr-rich carbides compared to Ti-rich carbides. Further, the Zr and Ti oxides formed on the composite surface prevented further oxidation, and the oxide composition depended on the composition of the infiltrated alloys. Thermodynamic analysis revealed that the oxides formed on the composite surface were composed of ZrO2, ZrTiO4, and TiO2 solid solutions.