Hello everyone,
Here we go again……
EUROPE – SLEEPING GIANT ?
The World Economic Forum has just released its latest Global Competitiveness Report 2012-’13 which assesses the competitiveness landscape of 144 economies, providing insight to the drivers of their economy and prosperity. No surprises in Switzerland and Singapore retaining the top two spots yet again. What is interesting is that six European nations figure in the top ten countries that include Finland, Sweden, Netherlands, Germany and the U.K. The Report emphasizes persisting competitiveness divides across and within regions as short-term approaches and political gridlock continue to hold back the economic performance of many countries and regions. Productivity improvements and private sector investment would be the key to improving global economies at a time of heightened uncertainty of the global economic outlook.
Europe may be down but not out !
WAIT AND WATCH
Last week’s analysis by the International Monetary Fund [IMF] states that the emerging, developing economies are now more resilient due to improved policy making and increased room to respond to shocks without undermining sustainability. There is a possibility of the IMF cutting down the global forecast in October from the 3.5% and 3.9% July projections for 2012 and 2013 respectively [BBC News].
Cautious optimism continues to be the watchword, aided in part by Q3 stock market trends and September crude oil price dip.
THE ODD COUPLE
Teijin‘s aramid fiber and Toho‘s carbon fiber used in conjunction for a building application ? Sounds like an odd couple? The world’s largest composite building (new wing of the Stedelijk Museum in Amsterdam) was opened in the last week of September. With a 98,400 sq.ft. footprint, the new wing features a large windowless expanse of composite facade that rises diagonally from a glass lobby and forms a slim peak to shelter the plaza below. The architects chose the aramid-carbon fiber combo because its negative thermal expansion co-efficient makes it suitable for a structural application besides creating a smooth, seamless surface [European Plastics News].
This application is unique in several ways-largest composites area for a building, twain of exotic high performance fibers perhaps used in conjunction for the first time for an architectural showpiece.
More on aramid fiber…… Late September, Teijin introduced its unidirectional laminate fabric specifically developed for bulletproof vests not only to withstand bullets and bullet fragments, but also other forms of assault such as stabbing. The UD fabric made up of four layers of aramid fiber yarns has a special 0/90/0/90 degree configuration to ensure that strength of the fibers is used to optimal effect and prevent the material from shrinking . The UD technology ensures that that fibers are parallel in every layer. Each layer is individually constructed in the resin matrix and a thermoplastic film is completely laminated over the four layers, thereby providing maximum protection and providing requisite wear and tear. The bulletproof vests made with this configuration are lighter and offer greater flexibility and comfort than standard bulletproof vests [Innovation in Textiles].
Such continuing developments are attempts to make the world a safer place by affording greater, comfortable protection to human beings.
DESIGNERS’ IMAGINATION
Designers draw inspiration from different fields to fire their imagination. A composite car seat backrest that integrates the seat frame and back panel into a single structure, reduces the need for foam, eliminates metal almost entirely and shortens the trimming process has been successfully designed with aesthetics in mind and drew inspiration from sportswear and fashion design ! Aptly christened the Performance Seat, it is 30% thinner and weighs 20% less than conventional seats with steel frames [Design News]. The outer frame’s composite material consists of nylon, continuous glass fiber reinforcement & a metal recliner adapter combined through an injection molding process. It provides the necessary support to pass crash tests and contains a thin, flexible seat area consisting of the back panel. The back panel conforms to differing body sizes, shapes & postures of the driver and passengers by changing as people move in the seat. The panel was inspired by office furniture with flexible thermoplastic support and eliminates 75% of the foam used in today’s cushioning in car seats. Mainstream production of the all-composite back panel is expected to commence in 2014 [Faurecia].
Classic example of a successful product derived from multi-disciplinary design.
A recent study analyzed the reliability estimation of the pultrusion process of a flat plate using the first order reliability method. The implementation of the numerical process model is validated by comparing the deterministic temperature and cure degree of profiles with corresponding analyses in literature. Results showed that an increase in the pulling speed yields an increase in the probability of the maximum composite temperature being greater than the resin degradation temperature. A similar trend was also observed for the probability of the centerline degree of cure at the exit being less than 0.8 [Sciencia].
WIND – ARE WE THERE YET ?
Extending the findings of model simulation to real life situations is becoming the norm in recent times. Claimed to be the most sophisticated climate model ever created, researchers at Stanford University’s School of Engineering and the University of Delaware claim there is enough wind over land and at sea to produce at least 50% the world’s power demand by 2030 (equivalent to 5.75 terrawatts). A 3-dimensional atmosphere-ocean-land computer model to calculate the planet’s theoretical maximum wind power potential was adapted that also factored reduction in wind speeds. The model separates the wind in the atmosphere into hypothetical boxes stacked on top of and next to each other. This greater detail enabled calculation of each wind turbine’s exposure to winds that change in space and over time. It also accounts for the wind claimed by each turbine and calculates the effect of these changes in wind speed on global temperatures, moisture, clouds and climate. It was found that the potential available energy in wind runs to hundreds of terrawatts. The saturation wind power potential would coincide with the point at which return on building new turbines would eventually plateau – but the saturation point is itself more than 230 terrawatts. Without significant effect on the world’s climate, it would require 4 million 100-ft high turbines, each producing 5 MW to supply 7.5 terrawatts of power [Design News].
Fascinating stats on a global basis from a single model. Nations (and politicians) should take cognizance of the fact when formulating “green” policies. Would there be adequate glass and carbon fibers/fabrics to meet this demand ? That should be the prime concern !
TRAIN RIDE – LIGHT & SAFE
When it comes to lightweighting coupled with fire retardance, rail interiors benefit a great deal. In anticipation of the upcoming pan-European norm (CEN/TS45545) for fire safety in rail interiors, a new PC/ABS sheet grade combines enhanced sustainability and advanced thermoplastic technologies with non-chlorinated and non-brominated flame retardance, thereby enhancing prospects of replacement of traditional metal and lower performing thermosets [Plastics Today]. SABIC‘s new PC/ABS opaque, solid, low-gloss fire retardant alloy meets the requirements of Restriction of Hazardous Substances (RoHS) directive and delivers high stiffness for railway sidewalls, tables and seating. In addition to CEN/TS 45545 R6 (seating), the PC/ABS sheet complies with European standards including the French NF F16-101 M1 F1 norm (at 2-4 mm). Added advantages claimed are the ability to be thermoformed at a lower temperature than traditional PC, molded-in color capability that avoids cost and environmental hazards of secondary painting + excellent aesthetics.
Karl Mayer Malimo claims to have developed a new range of geogrids with very high load-bearing capacities, having a tensile strength of 1,000kN in both the weft and zero inlay directions (as per DIN EN ISO 10319 test standard). Geogrids versatility in the construction sector is well known – in soil stabilization in road building, laying railway tracks, bridge building, construction of dams/dykes etc. Raschel knitting machines with parallel weft insertion and the facility to feed-in webs is now an established feature for producing strong reinforcing textiles. The extremely strong geogrids have raw fabric weight of 3,300 gsm, a construction consisting of high-strength polyester in the weft and zero-inlay directions and a flame retardant coating. The machines are capable of processing glass fiber rovings and basalt in gauge E3 and working widths of 213 inches. A major advantage in terms of flexibility is that webs can also be fed in and the innovative raschel machine can incorporate layers of webs to produce composites in a single step without additional time and effort [Innovation in Textiles].
STUCK FOR KEEPS
3M has introduced a fast-tacking seaming cylinder spray adhesive with a unique wide-web spray pattern for bonding geotextile fabrics. Time savings close to 56% over traditional sewing have been claimed. The adhesive reportedly lets contractors create quick, permanent bonds, provides a seam strength that outperforms fabric strength. It is simple to use with workers just having to spray the adhesive on the two fabrics being bonded and applying pressure to the seam. The bond strength meets American Association of State Highway & Transportation Officials (AASHTO) M288-06 requirements for seam efficiency. By eliminating the need for expensive sewing machines and generators on site; downtime for equipment maintenance/repair is avoided, resulting in overall materials and labor saving [Nonwovens Industry].
Game-changing technology breakthroughs are all about speed of assembly and reduction in cycle time, whilst simultaneously ensuring adherence to international standards on performance requirements.
Welcome to the new class of satellite launch vehicles with carbon fiber composite shells. CFRP is ideal for launch vehicles as it meets the requirements of keeping the vehicle small and making it stronger as satellites get bigger. The Vega satellite launcher completed its maiden flight in Q1 for the European Space Agency (ESA) and was designed to be a compact tool for economic launches into polar and low-Earth orbits for the multiple European satellites for scientific and earth observation missions [Design News].
Lap this up with NASA’s Curiosity rover mission to Mars that is currently bringing us exciting news whether the planet was habitable.
CHEMISTRY- THE CUTTING EDGE
The bane of polyolefins has been poor adhesion characteristics. Over the years, the problem has been circumvented to a great extent through technological advances (recall screen printing success!). High performance polyolefin fibers are gaining market share in a multitude of high end industrial, medical, consumer product applications such as sporting goods, ballistic protection and climbing ropes. Poor adhesion between the fiber and resin in composite structures has been a common failure mode and cause for premature failure [Innovation in Textiles]. Not any more, if one were to go by the recent successful demonstration of Reactive Surface Technology (RST) treatments for functionalizing temperature-sensitive fibers in general and polyolefins in particular. Fibers are coated using cold microwave technology via a shrink-wrap effect of the coating around the fiber. The chemistry results in direct curing on the fiber surface while the fiber effectively remains cold. The RST process is claimed to be ideally suited for treating high-performance polyolefins as the fibers are transparent to microwave processing and are not directly heated.
Science provides improbable answers to almost anything. Impossible is nothing…remember the Adidas slogan ? Did they have science “also” in mind when coining that famous slogan?
PASTRIES……TO BIO-PLASTICS
Coffee and Starbucks have become almost synonymous. Starbucks revolutionized our approach to drinking coffee. Their latest experimental innovation in Hong Kong in sustainability, in converting used coffee grounds and unconsumed pastries into chemicals that could be used to make bio-plastics, has shown encouraging results. Acid hydrolysis is the technique used to break down the pastries to succinic acid [Greenbiz]. Pastries and other baked goods destined for the trash are blended with fungi that generate enzymes which break down the carbohydrates in the pastries to simple sugar that are then fermented and exposed to bacteria [Oilprice]. The end result is succinic acid that can be used in production of medicines and laundry detergents as also bio-plastics. The goal is to find use for the 1.3 billion tons of food waste that is dumped every year.
Let’s all toast to Starbucks’ efforts in finding a sweet spot for food waste !
HEADING TO MEXICO
We heard of offshoring and then, more recently, reshoring with the manufacturing renaissance in the U.S. thanks to success in fracking technology that has resulted in an abundance of natural gas and reduced energy costs. The latest concept is “nearshoring” with Mexico being dubbed as the new China. With lower shipping costs and increasingly competitive wages, Mexico is enjoying a manufacturing boom, attracting billions of dollars in foreign investment from firms that are building factories to supply the North American market [CNBC]. Owens Corning and Zoltek already have manufacturing plants in operation for glass and carbon fiber respectively. Most auto majors such as GM, Nissan, Honda, Mazda, Audi have all announced plans to open up plants in Mexico over the next few years. Italian tiremaker Pirelli, Swedish appliances giant Electrolux, aluminum producer Alcoa and GE, amongst others have also announced similar plans.Much of the appeal is lower labor costs. It makes commercial sense from a logistics perspective also. Today it costs $5,000 to ship a container from China to the U.S.(still increasing by recent count) compared with $3,000 to truck the same freight in from Mexico.
Is “China-low cost” a thing of the past ? Obviously so, if one makes a logical assessment embodying all factors. Little wonder that the Chinese are establishing plants overseas after being constantly plagued by allegations of unfair trade practices.
All is fair in global trade AND landed cost (manufacturing location + logistics) ? Its the bottom line that matters.
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Till the next post,
Cheers,
Email: SS@essjaycomposites.com
Twitter: @essjaycomposite
Website: www.essjaycomposites.com
Sundaram
ESSJAY Composites 
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