Composites and light weight metals - the best of two worlds
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1 nasjonalt senter for komposittkompetanse Composites and light weight metals - the best of two worlds Conference: Lettmetall 2010 Geilo 11th and 12th February 2010 Iver E. Jensen, General Manager, Norwegian Composite Center Nasjonalt senter for komposittkompetanse 1
2 Norwegian Composite Centre Mission: Promote Norwegian business development in the area of advanced composite materials through active coordination of knowledge transfer and technology development. Photo: Nasjonalt senter for komposittkompetanse 2
3 Norwegian Composite Centre Nasjonalt Senter for Komposittkompetanse (NSK) Foundation established by Innovation Norway 2007 Norwegian HUB- on advanced composite materials Co-located with NCE- Raufoss (light weight materials) and SINTEF Raufoss Manufacturing at Raufoss, Norway Mandate: Business development Technology management Technology services Support to SME s Coordination of competences International cooperation Organization: Manager: Iver E Jensen Project manager: Tomas Luksepp Project manager: Ragnar Sandmark Nasjonalt senter for komposittkompetanse 3
4 Definition Composite materials: A multiphase material in which the phase distribution is controlled so that properties are optimized Usually a continues phase or MATRIX and a distributed phase or REINFORCEMENT The material and the component are formed simultaneously Photo: Forumal 1 car; P. Stachel, Menzolite GmbH Photo: Boeing 787; Photo: Sailboat; P. Stachel, Menzolite GmbH Nasjonalt senter for komposittkompetanse 4
5 NSK shall focus on: Polymeric composites with: high performance and high content of continues fibers Other composite materials: -short fibers -nano particles -metallic based composites -ceramic based composites and the performance or the properties of the product is based on calculations and controlled processes to secure the products directional or its tailored properties Photo: Dr. Greogor Daun, BASF-SE Nasjonalt senter for komposittkompetanse 5
6 Composites vs. Metal Property Composites Metall Directional: Non Isotropic Isotropic Design properties: Directional design possibilities Isotropic Density: Low (2/3 of Al) Higher Corrosive resistance: High Lower Electric and thermal prop: Insulators (glassfibers) Production costs: High Low Cycle time: High Low Conductors Environmental prop: Not easy to recycle Easy to recycle Nasjonalt senter for komposittkompetanse 6
7 Reinforcement in Composites GRP: Glass fiber Reinforced Polymers CRP: Carbon Reinforced Polymers Other types of reinforcements: Aramid (e.g. Kevlar, Twaaron) Other types of polymers (e.g polyethylen, polyester) Ceramic reinforcements (e.g. silisium and carbide) Bio- composites (e.g. sisal, jute) Basalt (volcanic rock) Metals Photo: Basalt fiber; DBF Deutsche Basalt Faser GmbH Photo: Glass fiber; Nasjonalt senter for komposittkompetanse 7
8 Fiber Sizes : Long continuous fibers (> 1-10 cm ) Short fibers (< 1 cm) Nano reinforcements Matrix materials Photo: Carbon fiber; Polymers: Thermo set polymers: e.g. polyester, epoxy, vinyl ester etc. Thermo plastic: e.g. polypropylene, polyamide Elastomerers: e.g. rubber Metals Matrix made of Ceramic or glass materials SiC Silisium Carbide Nasjonalt senter for komposittkompetanse 8
9 Mechanical properties Metals vs uniaxial composites Material Vf (Volume fraction) Density Kg/m3 E-modulus GPa σ1 GPa Al = 1 Specific stiffness Al = 1 Specific Strength Al= 1 E-glass/Epoxy 0, ,5 0,85 4,7 Carbon/Epoxy 0, ,8 3,42 4,55 HS Al Alloy ,0 1,00 1,00 HS Steel ,2 0,85 0,42 Ref: Prof. MG Bader; Univ. of Surrey; England Photo: Strain Instrument; Nasjonalt senter for komposittkompetanse 9
10 Case 1: Boing 787-Dreamliner More than 50% composites by weight (80% by volume) Composites used in airframe, leading edge, tail, wings etc. Some benefits: Lower weight Lover emissions of CO2 and NOX Non corrosive material gives the opportunity to have higher humidity in the cabin Better environment for the passengers Larger windows. Photo: Boeing 787; Nasjonalt senter for komposittkompetanse 10
11 Case 1: Development in use of composites in civil aerospace industry Source: Dipl. Ing Uli Burge; Technische Universität Berlin Nasjonalt senter for komposittkompetanse 11
12 Case 2: Composites used in the car industry Composites in Cars since 1950`s Light weight solutions' - green footprints Higher energy adsorptions High corrosion resistance High production cost used in expensive cars, trucks etc. Photo: Trabant Plastic Bomber DDR 1957; Nasjonalt senter for komposittkompetanse 12
13 Composites in Mercedes McLaren Source: Dr. Ing. M Wacker; Jacob Composites Gmbh, Wilhelmsdorf; Tyskland Nasjonalt senter for komposittkompetanse 13
14 Composites in Porse Carrera GT Source: Dr. Ing. M Wacker; Jacob Composites Gmbh, Wilhelmsdorf; Tyskland Nasjonalt senter for komposittkompetanse 14
15 The world composite industry today Source: Frédérique Mutel; President & CEO; JEC-composites Nasjonalt senter for komposittkompetanse 15
16 Main Trends in Composite Industry High growth rate in Asia Wind energy applications Increasing penetration in Aerospace Developing of new production processes High growth rate of thermoplastics New advanced materials are developed Photo: Wind turbine blade; Nasjonalt senter for komposittkompetanse 16
17 Development of Composite Applications World Wide Source: Frédérique Mutel; President & CEO; JEC-composites Nasjonalt senter for komposittkompetanse 17
18 The Norwegian composite industry About 100 to 150 enterprises 80 % SME with 1-10 employees 20% larger enterprises Growing number witch change into composites Applications: Parts and components to larger applications Leisure equipment (Skis, poles, helmets etc.) Pipes and tanks Marine sector (Leisure vessels) Building and construction Offshore Defense Agents for suppliers and equipment Photo: Pole; Photo: Tidebaronessen; Photo: LPG-gas containers; Nasjonalt senter for komposittkompetanse 18
19 Composites and light weight metals - the best of two worlds Use of composites will grow! Light weight metals and composites will complement each others in advanced applications! The best of two worlds! Photo: Composite bridge in Fredrikstad; Tommy Cielicki; Nasjonalt senter for komposittkompetanse 19
20 Thank you for your attention! Photo: F35 JSF; Nasjonalt senter for komposittkompetanse 20
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