Hello all,
Here we go again…….
BATTLING FISCAL PRESSURE
The World Trade Organization (WTO) came out with a statement in April that global trade was expected to slow to just 3.7 % in 2012 in the aftermath of Europe’s sovereign debt crisis and events such as Japan’s earthquake and the Arab Spring, with U.S.debt concerns & flooding in Thailand contributing to a certain extent. Sobering news indeed, when one compares it with the 5 % slowdown in 2011 and 13.7 % in 2010. The figures are based on the total volume of merchandise exported across borders, accounting for changes in prices and exchange rates [Yahoo Finance]. Developing countries are expected to lead the growth in goods traded this year with a forecast 5.6 % increase in exports compared to 2 % for industrialized nations.
The biggest news to cheer about was perhaps the free fall of crude oil price last Friday due to adequate supplies and waning geo-political tensions in the Middle East [CNBC]. Consumers can expect to witness oil at below $100 through the summer, barring unforeseen circumstances. Less pain at the pump in the weeks ahead ?
RIDING IN COMFORT…WITH COMPOSITES
Designing with composites is a fascinating experience as engineers will testify. More often than not, it involves using principles of statics and dynamics especially for load-bearing applications. Carmaker Audi is about to roll out glass fiber reinforced epoxy coil springs in one of its models by the year-end and this will be followed by extending to more mid-sized and luxury models in 2013 [Plastics & Rubber Weekly]. Any reduction in unsprung mass in a car’s chassis and suspension improves ride comfort and handling which has been exemplarily demonstrated in the composite spring that is 40% lighter than its steel counterpart in spite of an overall increase in diameter. Though the composite “wire” (in reference to the shape) is thicker, the number of turns is fewer. GFRP helices are known to absorb torsional loads. Alternating layers of glass fibers at +/- 45 degrees (acting either in compression or tension) are wound on a central core of glass fiber impreganted epoxy resin. Torsional loads in the glass fibers are thus converted into tensile and compressive loads. Weight reduction is to the tune of 4 kgs. While the composite spring is unusually bright green in color, a dose of graphite in the mix renders it black. Audi states that it is already working on red and blue springs for enthusiastic drivers !
The joy of a comfort ride on colorful composite springs would be unmistakable…that’s the icing on the cake.
ALLIANCES – MEETING OF THE MINDS
The key to maximizing composite performance is fiber orientation…a maxim that is always in the minds of product designers. This has added significance in automotive applications where stiffness, strength, impact resistance and toughness of parts can positively influence weight reduction. The plastics industry, in conjunction with several universities and testing labs has now developed process modeling for LFRT injection molded parts. The modeling reportedly facilitates prediction of mechanical properties well in advance and would enable companies to bypass the trial-and-error phase. The simulation software enables engineers to use data to judge how glass fibers are affected by the molding process and how the molding will affect the finished part. Toolmakers can effectively determine the positioning of the gate [Plastics News].
There are several links in the concept-to-commercialization chain…it is heartening to note that the confluence of software developers, designers, fiber/resin producers and automakers contributes to a high level of synergy that makes technology appear so simplistic in the final analysis !
STRATEGIC CHOICE OF PLIES
Techno-commercial economics has been one of the reasons for evolution and success of hybrid composites. Judicious choice is however a prime requisite. Recent tests on mechanical properties of contact molded specimens with an interply configuration of high modulus glass and carbon fibers in an epoxy resin matrix provided interesting results.It was observed that the flexural modulus decreased with increasing % of high modulus glass fibers. Further, positive hybrid effects were found by substituting carbon fibers for glass fibers. The presence of a thin layer of high modulus glass impregnated epoxy on the compressive surface of the hybrid laminate yielded the highest flexural strength [Sciencia].
The best of both worlds in laminate configuration ? Not a new concept, but it does provide a greater insight to tailoring design, nevertheless !
OFFHORE WIND – GIANT STRIDES
When we speak of wind energy installation in Europe, giga is the current buzzword..mega is considered the dinosaur age (in a lighter vein !). This is more so with offshore wind energy. The U.K. has more than 2GW of wind turbines installed at sea, representing more than half of the European total and is targeting 18GW by 2020 [Yahoo Finance]. Germany plans to build 10GW which is the equivalent of nine atomic plants. According to Bloomberg New Energy Finance, offshore wind costs about $232/MWh of power generated, compared to $80 for onshore wind, $62 for gas-fired plants and $77 for coal.With a view to reduce costs, offshore windpower producers are building custom ships at record rates that allow one to install turbines in deeper waters, lift heavier weights, cope with bigger swells and carry more machines to wind-farm sites, thereby speeding up project completion. The bottomline…reduce cost of technology to bridge the price differential.
I have always been awed by the European wind energy business model, in general and the U.K. in particular. They think years ahead and plan resourcefully to circumvent potential roadblocks. That admiration has been upped a notch yet again and not without good reason.
PLASTICS : ONE-UPMANSHIP
The battle between thermosets and thermoplastics is perennial. Volvo heavy duty trucks from 2013 could well feature an injection molded PC/ABS roof fairing. Replacing traditional thermosetting resin for this application, SABIC claims that the thermoplastic replacement replete with proprietary in-mold coating (IMC) technology reduces energy requirements, enables recycling, achieves 30 % weight reduction, produces a part with a Class A surface finish ready for in-line painting; whilst simultaneously delivering an ideal balance of impact resistance, co-efficient of linear thermal expansion, density and heat deflection temperature (HDT) to withstand bake ovens [Plastics Today].
At the end of the day, it is performance that matters. The automotive sector which is in top gear continues to be the beneficiary of path-breaking technological breakthroughs and consumers take pride in driving state-of-the art vehicles.
Entrapped air in cast parts could severely impact the performance in continuous service. Freudenberg uses Computed Tomography (CT) scanning technique to check even distribution of fibers in non-woven fabrics and enables objects to be viewed from all conceivable angles. The images generated can be used to identify component damage and analyze its causes. The entire component can be viewed as a transparent image or can make its plastic covering disappear at the click of a mouse. Developed on the basis of X-ray technology, the CT technique allows for creation of computer-assisted 3-D images that provide an exact look at the interior of components [Plastics Today].
STRETCHED TO THE LIMIT
How many of us have gone through the frustrating experience of limited elasticity of spectacle earpieces. A solution could well be in sight. An eyewear retailer in Japan has chosen SABIC’s Polyetherimide (PEI) resin to meet Japanese consumer demand for new eyewear styles. The exceptional elasticity, long-term performance and lightweight allowed the company to eliminate aluminum and titanium from the material selection process for the earpieces. The excellent elasticity (can be bent freely) coupled with resistance to deformation allows the spectacle frame to be bent easily, yet returned to its original shape. It meets JIS B7285 standard, the testing for which includes 20,000 bending repetitions (opening & closing the frame). The resin’s dimensional stability ensures that the lenses are retained in the frame, while heat deflection resistance at high temperatures protects the frame when exposed to hot sun. The clincher is the resin being amenable to precision thin-wall molding and it’s availability in custom colors to provide a wide range of aesthetic effects [Plastics & Rubber Weekly].
Can you think of other applications that require such exceptional elasticity, resistance to deformation and temperature resistance ? PEI may well be the answer.
STRONGER INTERFACE
Advances in thin film applications to improve adhesive strength have been the backbone of technological breakthroughs, especially in glass fiber sizing. In recent studies, hyperbranched epoxy was modified with by vegetable oil based highly branched polyester resin at different weight percentages and the properties of the cured systems were evaluated for their adhesive strength. FTIR, XRD, TGA & SEM analyses showed that the modified systems displayed improved properties over pristine epoxy. The hyperbranched epoxy with 30 % (by weight) polyester resin was found to be the optimum with respect to performance [Sciencia].
Could the findings provide further continuous improvements in glass fiber sizing ? Possibilities are endless, for sure.
As the curtain-raiser to the 2012 Arabian World Construction Summit in Abu Dhabi later this month, it’s boom time for the construction & infrastructure sector in the GCC. The region is all set to award projects worth $286 billion over the next four years for infrastructure (including roads, bridges, rail, sewerage, wastewater and marine) and construction [Trade Arabia]. The enormous potential for composites [RP-feature] in the aforesaid sectors cannot be overstated. It would be an excellent opportunity for composites processors[GCM-feature] to partake in the Summit.
AMERICAN PRIDE
A few years back, offshoring was a dreaded word in the U.S. with several companies opening up manufacturing outlets in China to take advantage of lower production cost. This trend is now on the wane (with rising labor costs in China), and the word “reshoring” has now become music to the ears of Americans. Manufacturing is witnessing a resurgence and processors are slowly bringing back production to the U.S. The low cost of natural gas (read energy) is also aiding this transformation to a significant extent- thanks to fracking technology being so successful and NG being in oversupply, as we speak.
Patience and self-belief are virtues …… add a dash of game-changing technological advancements and it is easy to comprehend why past glory can be restored over time.
TOWERING HEIGHTS
Crude oil being dubbed as “black gold ” is not without reason. In an attempt to raise its profile further, the Caspian sea country Azerbaijan is looking to build the tallest building in the world. At 1,050 meters, it will dwarf Dubai’s showpiece Burj Khalifa and likely be taller than the planned 1,000 meter Kingdom Tower in Saudi Arabia. Azerbaijan obviously wants to use its newly found oil wealth to project an image of modernity [Arabian Business].
Aah, the towering beauty and power of black gold !!
Till the next post,
Cheers,
Email: SS@essjaycomposites.com
Twitter: @essjaycomposite
Website: www.essjaycomposites.com
Sundaram
ESSJAY Composites 
You must be logged in to post a comment.