low cost carbon fiber and novel resin systems for marine ... · presenter: dayakar penumadu....
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Low Cost Carbon Fiber and Novel Resin Systems for Marine and Hydrokinetic Composite Structures
Presenter: Dayakar PenumaduInstitute for Advanced Composites Manufacturing Innovation (IACMI) &
University of Tennessee, Knoxville (UTK)Tennessee, USA
International Symposium “Novel Composite Materials & Processes for Offshore Renewable Energy”
Friday 1st September 2017Cork, Ireland
“Novel Composite Materials and Processes for Offshore Renewable Energy” (MARINCOMP) (Grant no: 612531) is a European Commission, Marie Curie 7th Framework Programme funded Project, under the Industry Academia Partnerships and Pathways (IAPP) call: FP7-People-2013-IAPP.
The aims and objectives of the project are:
1. Aims to reduce the cost of offshore wind and tidal turbine blade structures2. To jointly develop and optimise carbon-fibre reinforced composite
materials which are tailored for long-term durability in the marine environment, and can be processed rapidly and cost-effectively3. New software tools such as a fatigue life design tool which
incorporates the effect of immersion in seawater, and a cost-performance model will be developed in the project4. Provide a step change in the use of carbon fibre in large high volume
composite structures
Source: http://www.marincomp.eu/
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January 9, 2015: President Obama Announces New Composite Institute
“…and today, we’re proud to announce our latest manufacturing hub, and it is right here in Tennessee. Led by the University of Tennessee–Knoxville, the hub will be home to 122 public and private partners who are teaming up to develop materials that are lighter and stronger than steel. ”
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Operated by an independent not-for-profit
Governed by a board of directors
A wholly owned subsidiary of the University of Tennessee Research Foundation
Incorporated in the State of Tennessee
Headquartered in Knoxville, Tennessee
$250M in funding with $70M from DOE and $180 from partners
What is IACMI?THE Composites Institute
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National institute addressing critical challenges
Five/Ten Year Technical Goals:• 25/50% lower carbon fiber–reinforced polymer (CFRP) cost
• 50/75% reduction in CFRP embodied energy
• 80/95% composite recyclability into useful products
Clean energy ProductivityDomestic production capacityJob growth and economic development
Life cycle energy consumption
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Technical Focus on Advanced Composites and Structures
Shared RD&D Facilities Support Industry
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Solutionspinning
line Carbon Fiber Technology
Facility Pre-pregproduction
pilot/full scale
Pilot-scalePCM
1,000 ton press
Full ScalePCM
4,000 ton press
Scale-up Across IACMI State Partners
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Recap on Carbon Fiber Composites(after Daniel & Ishai)
Materials and Length Scales
0
1000
2000
3000
4000
5000
6000
0 0.005 0.01 0.015 0.02
Tens
ile S
tres
s (M
Pa)
0
50
100
150
200
250
300
350
400
0 0.005 0.01 0.015 0.02
Mod
ulus
(GPa
)
Tensile Strain
Single Carbon Fiber
24k carbon fiber tow
t = 1/16” Pultruded plate
Single Fiber
TowPultrusion
Composite Additive Manufacturing for Tuned Microstructure: ORNL(MDF)-UTK Research
Big Area Additive Manufacturing of CarbonFiber Based ABS Composite System
U.S. Wave Resource Available Along our Coasts total ~2,640 TWh/yr.
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Sandia National Laboratories is a multi-mission laboratory managed and operated by National Technology and Engineering Solutions of Sandia, LLC., a wholly owned subsidiary of Honeywell International, Inc., for the U.S. Department of Energy’s National Nuclear Security Administration under contract DE-NA0003525.
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Material Design Tools for Marine and Hydrokinetic Composite StructuresBernadette Hernandez-Sanchez, SNLBudi Gunawan, SNLDavid Miller, MSUGeorge Bonheyo, PNNLScott Hughes, NRELFrancisco Presuel-Moreno, FAU
Project Overview
Marine and Hydrokinetics Advanced Materials Program: support the MHK industry through applied research and guidance on Materials & Coatings to enable viability, lower the cost of energy (COE), and accelerate commercialization.
The Challenge: Proper structural/component materials and coatings are critical to reducing engineering barriers, COE, and commercialization time
Structure Design & Component: (LOADS! uncertainty in composite/design) Environmental Exposure Issues Cost (Manufacture, O&M, Reliability) Safety & Certification
Partners: Sandia National Laboratories (Lead): Materials Evaluation & Coatings Pacific Northwest National Laboratory: Biofouling & Environmental Exposure Montana State University: Composite Materials Evaluation & Development North Dakota State University: Antifouling Coatings & Biofouling Evaluation Brigham Young University: Antifouling Coatings
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Examples of Some MHK Designs Exploring Composite Materials (listed in alphabetical order)
17Ocean Renewable Power Company Resolute Marine Energy
Lockheed Martin-OTEC Cold Water Pipe
All Photos Obtained From Company Websites and Literature References
Verdant Power
Columbia Power TechnologiesAquaHarmonics
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MHK Composite Workshop
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• Worked with MHK community, supply chain, composite/coatings manufactures, U.S. Navy, Oil & Gas, and Marine Industries to understand needs and available resources to support MHK stakeholders. Results Presented at the 2016 Marine Energy Technology Symposium.
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MHK Composites Barriers & NeedsTop Barriers Identified to Using Composites for MHK include: Uncertainty in materials properties and selection for component (Short-Mid Term).
Industry wants to know if composites are the right materials to invest in? Why? Uncertainty in design with limited design tools & methodologies available (Mid-Long Term). Composites reliability and maintenance (inspection, repair) is not well understood (Mid-Long Term). Limited guidance on composites manufacture and assembly available to MHK developers (Long
Term). Weight and transportation issues affect current designs and manufacture (Long Term). Materials cost will affect final design ($/lb) (Long Term).
Top Composite Research Needs include: Reduce uncertainty of materials selection by evaluating performance properties of coupons and
substructure in artificial and actual saltwater environments (Short-Long Term). Evaluate MHK environmental effects on joints, seals, and fasteners of dissimilar materials in order to
facilitate complex geometries and modularity (Mid to long term). Test component at full-scale structures to facilitate design optimization (Mid-Long Term). Identify failure mechanisms and damage tolerances (Short-Long Term). Determine the influence of the manufacturing process on the structural performance (Mid-Long
Term). Determine what standards and certification process are needed for new materials to be employed
in the MHK energy industry (Long Term). 19
Short 1-5 (yrs).Mid 5-10 Long 10-20
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Database can be found in 2 locations online and is free for users to download.
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http://energy.sandia.gov/energy/renewable-energy/water-power/technology-development/advanced-materials/mhk-materials-database/
• Both the wind and water icons take you to webpages that house the link.
• Under Water Power Database and Tools
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Environmental Composite Performance Testing at MSU
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Couponsto
Structural elements
Elements to
Substructure
Testing to
Dissemination
Three different conditions are of interest:1. Dry State2. Artificial Sea Water (partial to full saturation)3. Actual Sea Water (partial to full saturation)
*soaked in tanks at PNNL (FY17-18)
Past efforts have indicated decrease in performance due to water uptake
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Evaluating Biofouling on Composite & CoatingPerformance at PNNL
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Evaluate under static & flow conditions with unfiltered natural seawater.
Two Tanks will be used:1. Flow2. StaticShort Term Testing at 3 months
PNNL Marine Sciences Laboratory in Sequim , WA Flow Static
Examples of Tailor Made Coatings Testing at PNNL.
Currently Testing Composites and Coatings for Industry
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Developing Substructure Testing at NREL & MSU for FY18-19
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Developing test plan to examine joints, plys, …..and other elements of design Three different conditions are also of interest:1. Dry State2. Artificial Sea Water (partial to full
saturation)3. Actual Sea Water (partial to full
saturation)
Test Frame at MSU
• Full-scale and component testing• Characterization, strength, and fatigue test
capabilities• 500 kN actuators, reaction stands to 17 MNm• Extensive structural measurement equipment
and condition monitoring systems
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Science Framework Utilized for Durability• Response of fibers, tows, resin, core material interfaces
to harsh naval environment• Response of fiber reinforced composite facings to multi-
axial static loading (tensile, compressive, torsional, combination involving principal stress rotation)
• Behavior under fatigue loading (tension-tension in this study) while the samples (composite facings and sandwich materials) allowed to have access to sea water
• Delamination behavior between facings and core materials
• Coupled effects of sea water and temperature• Utilization of high resolution computed tomography and
surface 3D DIC to relate process-property-environment effects.
Equi-bi-directional carbon fiber fabric/vinyl ester LT650 supplied by DevoldToray T700 12k towVE sizing Dow Derakane 510A-40, VE
VARTM process
Composite Material System Considered
CF/VE Facing
CF/VE with H100 Core
VARTM Set-up
Intact PVC H-100 foam and sea-water induced damage, sea water penetrates only to outer few cells where damage/degradation is highly localized
US Navy RelevanceMarine composites are exposed to sea water environment and temperature fluctuations over extended periods. The integrity of sandwich structures and configurational distortions subjected to the aforementioned exposures plays a significant role in their incorporation within naval designs and needs to be evaluated. Extreme loading condition of interests to Navy:• Sea water• Temperature range -50 ºC to 75 ºC• Water confinement• Coupling effects of l temp and sea
water, hydrostatic pressure / stress σo σo
L LCL
Hh
h
E
E
G
1
3
2 x
Sea Water induced expansionon Facing (layer 3) causes configurational distortions
Broad Classification from Sea Water UptakeSchematic curves representing a solid line, designated by LF, corresponds to linear Fickian diffusion and four possible categories of non-fickian weight-gain sorption data.• LF- Linear Fickian• “A” and “B” are typical variations corresponding to both neat polymers and fiber reinforced
composites• B represents the circumstance of two-stage diffusion• “C” accounts for the case of rapidly increasing fluid content. “D” accords with weight loss that is
attributable to chemical or physical break-down, both types not good for marine applications
VARTM-CFVE weight gain data for sea, distilled, and tap water.
• Pre-condition• Prepare specimens• Density of sea water 1.022 g/mL• Immersing in sea water at 40 ºC at least 3
months
Anisotropy of Moisture Induced Expansion Coefficient
Sample Conditions Average coefficient of moisture expansion
(µε/1% weight gain)
[0/90]2S 340
[15/75]2S 730
[30/60]2S 760
[±45]2S 1020
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Degradation Effect on Fatigue Behavior
100 mm gage length
extensometer was used
to record strain data.
• Frequency of 1 HZ
• σ max/σ min = 0.2
• 0.60, 0.67, 0.80 of failue
stress/strength considered in
this study.
Comparison of type of confinement
• When fatigued with condition of water confinement, fatigue life was reduced by up to 50% of loading cycles compared to sample in air.
At least 3 of [±45]2S CF/VE samples in each case were utilized for a
fatigue life diagram for: (a) dry coupons fatigued in air, (b) dry coupons
fatigue while confined, and (c) dry coupon fatigue while only one-sided
confined.
• Confined effect: Internal water pressure rapidly increasing due to incompressibility during the downloading stage of the fatigue cycle
Fatigue in air
Fatigue with water confinement
Mechanical testing coupled with 3D DIC
Black on white speckle on surface sample. Subset between 33-35 pixel was used to track the strain from image to image.
Damage evolution in fiber dominated CFVE at 200, 500, 800, 1000 MPa
Why does damage localization occur in these bands and how doesLong-term and coupled sea water exposure exacerbate this observation?
Sea water exposure effects on damage evolution matrix dominated CF/VE subjected to 10 tensile load-
unload cycles
Compression Behavior
100 kN Actuator Displacement Rate of 1.3 mm/min
VIC-3D Cameras
VIC-3D Lights
Combined Loading and Compression Test Fixture
Speckle Pattern Compression Sample
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Degree Orientation
Compression Modulus (GPa)
Failure Stress (MPa)
Compression Strength
(% Reduction)Dry Wet Dry Wet
0 41.0 64.1 461189
-49.2 to -59.057.1 234
4513.4 10.6 125 105
-12.4 to -18.410.3 102
10.3 11.2 129 10411.1 113
90
44.0 40.8 429 229
-26.4 to -50.146.1 63.1 431 33148.6 49.1 450 214N/A 48.3 N/A 262
Effect of Compression Behavior
Compression - orthogonal view xz
xz plane
x
Dry 45 degree fiber orientation CFVE approximately 0.63 cm beneath surface
Wet 45 degree fiber orientation CFVE approximately 0.67 cm beneath surface
2.33 cm
2.33 cm
Neutron tomographic reconstructions of dry and wet specimen
a) dry S1 b) dry S4 d) wet S4 c) wet S1
Concluding Remarks• Effects of degradation associated with long-term exposure to sea water and harsh
marine conditions on carbon fiber vinyl ester based composites and H100 PVC polymeric foam based sandwich structures was evaluated, compression behavior is strongly affected.
• For sandwich structures, important considerations in implementing composites for design should consider degradation associated with critical energy release rate corresponding to the delamination of facing with foam core material, a reduction of 30% was observed for CF/VE system manufactured using VARTM.
• Fatigue life for biaxial carbon fiber fabric based composites show substantial effect of sea water confinement on reduction in number of cycles to failure for tension-tension fatigue. A stress ratio of 0.55 can be considered for safe design, considering the anisotropy.
• Shape distortions due to moisture induced expansion from one-sided exposure can be estimated using a shear lag model, based on laboratory data corresponding to moisture uptake and related strain measurements.
• 3D DIC technique revealed occurrence of strain localizations and damage concentration zones and high resolution radiation based tomography using both x-rays and neutrons showed important differences resulting in the microstructure from marine environmental exposure conditions. Laboratory tests are representative of larger size panels for the considered material and manufacturing system.