composite materials & activity in wales composites 140709.pdf · what are composites? 2-phase...

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Composite Materials & Activity in Wales


Composites Use

Current worldwide market estimated at 60bn EU’s, with expected growth of 5% pa.Major increases in aerospace, energy (automotive & sports/leisure).Increase markets and manufacturing base in Asia and developing world.Fibre costs expected to decrease.Resin costs expected to increase.

Wales has moderate activity, but needs to do some catching-up.

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Composite Materials

WHAT ARE COMPOSITE MATERIALS?

WHERE DO WE USE THEM?

WHY DO WE USE THEM?

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What are composites?

2-PHASE

MATERIAL

PARTICLE

REINFORCED

FIBRE

REINFORCED

COMPOSITE

STRUCTURE

METALS

CERAMICS

POLYMERS

SIZE

SHAPE

ARRANGEMENT

MATERIALS

SHORT

CONTINUOUS

ORIENTATION

ARRANGEMENT

MATERIALS

LAMINATEDMATERIALS

SANDWICHPANELS

Composites

2-PHASE

MATERIAL

PARTICLE

REINFORCED

FIBRE

REINFORCED

COMPOSITE

STRUCTURE

METALS

CERAMICS

POLYMERS

SIZE

SHAPE

ARRANGEMENT

MATERIALS

SHORT

CONTINUOUS

ORIENTATION

ARRANGEMENT

MATERIALS

LAMINATEDMATERIALS

SANDWICHPANELS


Matrix Materials

Metals: • Magnesium, Aluminium, Titanium alloys• For strength, high temperatures

Ceramics:• Alumina, Zirconia, Silicon Carbide, Silicon

Nitride, Ceramic glasses• For high temperatures

Polymers:• Thermosets (polyesters, epoxies, phenolics,

polyimides, etc)• Thermoplastics (polypropylene, nylon, PEEK

etc)• Low weight, can be low cost

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Reinforcements

Particles:• Ceramics, glass spheres, carbon, metals,

wood flour

Fibres:• Glass, carbon, polyaramid (Kevlar),

polypropylene, ceramic whiskers, carbon nanotubes, natural fibres

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Advantages of a Composite Structure

Increased stiffnessIncreased strengthReduced densityIncreased toughnessIncreased temperature resistanceImproved processibility (sometimes)Lower cost (sometimes)

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Advantages of a Composite Structure

Modified electrical conductivityModified thermal, optical, magnetic behaviourImproved corrosion resistanceLower gas permeabilityModified dynamic behaviour

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Stiff, Strong, Light

Bahrain Conference Centre Glass fibre reinforced polyester

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Stiff, Strong, Light

Bahrain Conference Centre Glass fibre reinforced polyesterEach vault is 50 m long, with 16 m overhangLow density and high stiffness are the main advantages

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Strong, Stiff, Light

Superyacht with 3 carbon-fibre composite mastsEach with 6 CF composite yardsHigh stiffness & strength, low weightNeed water and weathering resistance

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Composite is stiff enough to hold sails without lines, so masts can be rotatedEmbedded optical fibres allow continuous stress monitoring

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Qinetic ZephyrHigh Altitude, Long Endurance Unmanned Aerial VehicleSolar PoweredTest flights up to 3½ days



Boron / Aluminium struts on space shuttle


Corrosion Resistance

Glass fibre reinforced polyester widely used for boatsLuxury yachts to canoesLow weight, high stiffness, water resistant, easy to fabricate

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Corrosion Resistance

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Electrical Insulation

Footbridge over Madrid - Barcelona railwayGlass-fibre reinforced polyesterLow weight, high stiffness, good strengthNo EM interference with electric railway

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Electrical Insulation

Carbon Fibre needlesAllow MRI imaging during surgeryMetal needles would interfereNeed high stiffness, high hardness, biocompatibility

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Environmentally Friendly

Glass fibre polyester compositeHigh stiffness / low weightStrength can be maximised along lengthGood weathering resistance

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Aeroelastic (controlled twist) blades change aerodynamics as wind speed increases

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Biocomposites finding increased usageNatural fibres and natural resinsSome biodegradable, others not

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Small & Smart

Nano-composites based on carbon nanotubes and graphene

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Small & Smart

Ceramic / nanotube composite

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Small & Smart

Self-healing Composites

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Challenges with Composites Use

Increased complexity of materials

Increased variety of processing methods

Both are potentially advantageous, but can cause problems

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Composites Activity in Wales

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Training ProvidersBarry College; International Aerospace Training Centre (ICAT)

• Centre of Excellence; EASA Part 147; • HND/C – Academic partner - University of

GlamorganDeeside College

• Centre of Excellence; EASA Part 147• HND/C – Academic partner Glyndwr

Coleg Morgannwg • Edexcel NC

Ystrad Mynach College • Edexcel NC

Lufthansa Resource Technical Training (LRTT)

• EASA Part 14729


MITEC – Pembrokeshire CollegeManufacture

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Barry College

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Advanced Materials - Deeside College?

Training facility

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Bangor UniversityBio Composites

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Centre console trim

Various dampingand insulation parts C-pillar trim

Rear parcel shelf

Seat cushions

Door trim panels

Engine ShieldBumper

Wheel arch Head Rest

Roof liner

Rear Hatch

Boot Base

Sub-floor Covering

Bonnet Insulation


Cardiff UniversityManufacture/Testing/Analysis

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Cardiff UniversityMEC

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Rapid ManufacturingAdvanced Manufacturing

TechnologyMicro/Nano-Manufacture

Concurrent EngineeringICT in Manufacture

Operations Management

Intelligent ManufacturingInspection and Quality Assurance

Intelligent Control

Manufacturing Engineering Industrial Engineering

Systems Engineering


Cardiff UniversityMEC

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Swansea UniversityTesting/Analysis/Modelling

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Swansea UniversityTesting/Modelling/Analysis

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Swansea UniversityTesting/Modelling/Analysis

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Other Universities

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Swansea Metropolitan University• Automotive engineering• Non-destructive testing

Glyndwr University• Materials and Chemistry Research• Training (mainly with Deeside for Airbus)

University of GlamorganAberystwyth University


TWINDT & Joining

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Statistics

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Welsh Composites Manufacturers 2006Total 82

Sector %Aerospace 6Automotive 2Marine 33Sport / Leisure 9Construction 23Tanks, pipes, enclosures 10Raw materials 6Others 11

Estimates of Welsh Composites Workforce2008 1,500-2,0002010 2,000-2,5002012 4,000-5,000


ConnaughtAutomotive

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Morgan MarineConstruction

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Rhino Engineering LtdConstruction

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TycoConstruction

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Chocolate BikesSport

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JP SurfboardsLeisure

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Rockpool KayaksLeisure

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Cytec IndustriesMaterials

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composite materials & activity in wales composites 140709.pdf · what are composites? 2-phase...

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