natural fiber composites: design, testing and engineering · spe thermoset topcon. february 20,...
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SPE THERMOSET TOPCONFebruary 20, 2018
Natural Fiber Composites: Design, Testing and Engineering
Trey Riddle, PhDsunstrands.com
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Introduction
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Where are we now?How far do we
want to go?vs.
* M. Abbey
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BIGthink BIG
impact
profit people planet
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Industrial BioMaterials:
Compatibility is Key
BioBased:Rapidly Renewable
Traditional:Energy/Oil Intensive
Bio-Composite
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Manufacturers Interests
Low cost
Weight reductions
End of Life (Landfill)
Increased surface area
Reduced environmental hazards
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Additional Value of Biomaterials
Attractive
Meet performance metrics
(Eco) Marketing appealNew revenue streamsMarketing leverage
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The Sustainable Materials Company
Sunstrand is not just building a company, We’re building an industry
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Attractive Intersection of
Science & Ag
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Value InTransparency
• I am 5th generation American Farmer • I grew up farming cattle, wheat, corn and
alfalfa hay• I am a US Navy Veteran. I served on warships
in the South Pacific & Middle East• I grow hemp and kenaf in rural Kentucky
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Environmental Credentials
• Net negative carbon emissions compared to glass fiber which produces ~1,900lb of CO2 per ton
• Rapidly renewable and sustainable• Weight reductions increase fuel economy
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Biomaterial Supply Chain
Customer
End UsePlastics
InputsProducts
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Main Fiber Line Area Dry (Mil) Processing
PackagingDrying LineWet (Reactor) Processing
Processing capacity of bamboo, hemp, kenaf, flax and others
Industrial Plant in
Louisville, KY
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The USA is ahead…
• USA uses more composite materials than any other country
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…and behind
• The USA uses a negligible amount of natural fibers in the US
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Europe: Market Leaders
Bioplastics/Biocomposites market • 2014: $543M• CAGR of 20% since 2008• $5.8B by 2030
Auto industry in 2014• Before peak auto• Natural fiber usage = ~100MM lb• NA manufactures 4X more vehicles
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Fiber Properties
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Where Do Natural Fibers Come
From?
• Primary fibers: Flax, Hemp, Kenaf, Jute• Members of the Bast family
“Bast” Fiber~25%
Core, Hurd, Shive ~75%
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Filament Testing:Fiber Bundles
• Testing is generally of fiber bundles• Cellulose fibers held together by lignin• Can still follow typical ASTM filament specs• Inherent variability in fiber response
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Fiber Engineering (Mechanical)
Properties
Fiber Density(g/m3)
Length(mm)
Diameter(µm)
Elongationat break
(%)
Tensilestrength*
(MPa)
Cotton 1.21 15–56 12–35 2–10 287–597Coir 0.3–3.0 7–30 15–25Flax 1.38 10–65 5–38 1.2–3 343–1035Jute 1.23 0.8–6 5–35 1.5–3.1 187–773Sisal 1.20 0.8–8 7–47 1.9–3 507–855Hemp 1.35 5–55 10–51 1.6–4.5 580–1110Henequen 1.4 8–33 3–4.7 430–580Ramie 1.44 40–250 18–80 2–4 400–938Kenaf (bast) 1.2 1.4–11 12–36 2.7–6.9 295–930Kenaf (core) 0.31 0.4–1.1 18–37Pineapple 1.5 3–8 8–41 1–3 170–1627Bagasse 1.2 0.8–2.8 10–34 0.9 20–290Southern yellow pine 0.51 2.7–4.6 32–43Douglas fir 0.48 2.7–4.6 32–43Aspen 0.39 0.7–1.6 20–30
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Mechanical Properties
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Comparison to Glass Fiber
• Natural fibers are not as stiff or strong as glass fibers• Natural fibers are very light: 1.0-1.4 SG• Good specific properties
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Design Approach
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Composite Testing
• Testing of bio-fiber composites is the same as traditional composites
• Failure mechanism also similar• Matrix cracking, debonding, fiber
breakage, etc
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Composite Design
Opportunities to match glass fiber composite response• Requires increasing Vf
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Composite Response
Rule of mixtures• Match stiffness with reduced weight by
adding Vf
• Stiffness in particular, sometimes strength
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Example of Modulus Matching
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Design Considerations
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Short Fiber
• Natural fibers are inherently short• Well suited for discontinuous systems• Compounding, non-wovens
• Continuous strand systems are available, but at higher costs
• Similar to carbon fiber prices
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Matrix Bonding & Critical Length
• Polar fibers do not bond with non-polar resins• Increase mechanical locking through refining
(fibrillation) but reduce strength• Sizings (coupling) or resin additives can be used• “Knockdown factors” can be empirically derived
and used in modeling• Interfacial Shear Strength requires critical length
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Manufacturing Considerations
• Lignocellulosic materials are hydrophilic• Can be mitigated
• Temperature effects• Possible degradation at temps above 390F (200C)
• Weight (handling) issues• Fibers are very light, nearly ½ glass
• Clumping• Fuzzy fibers can cling each other
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Application Examples
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Products/Compatible Manufacturing
Processes
Short (< 4in) Discontinuous fibers• Nonwovens – Veils/Chopped Strand Mat
• Open mold infusion• Sheet molding• Pultrusion
• Bulk molding compound• Thermoplastic compounding
Yarn Systems• Typical fabrics for laminates• Pultrusion• Filament Winding
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Industry First Biomaterial
Spray-up
• Core material for complex sandwich panels geometries• Compatible with chopper gun systems• Large complex molds
• Opportunities to decrease weight & density
• Opportunities to increase flexural stiffness and strength
• Reduce costs
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Large Scale 3-D Printing
• 3D printed pavilion that used Sunstrand’s bamboo fiber• 1/3 of the embodied energy and an order of magnitude
less carbon footprint of carbon fiber –resin systems normally used in large scale additive manufacturing
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Final Thoughts
• Leverage marketing • There are some issues• Match stiffness and in some cases strength • Possibilities for cost and weight reduction• Goal is “near” drop-in compatibility• Consistent materials systems are available
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www.sunstrands.com1401 Locust StreetLouisville, KY 40206
Sunstrand: The Sustainable Materials Company
WE are changing the way YOUR stuff is made