Upload
others
View
1
Download
0
Embed Size (px)
Citation preview
Bristol Composites Institute Launch and ACCIS 10th Anniversary Conference
The Composites Age is Arriving
Prof Mike Hinton HVMC Core TeamR&T Partnerships15th November 2017
UK Composites Manufacturing - Some History (1971)
UK Composites Manufacturing - Some History (1971)
▪ Strategy published Nov 2009
▪ To develop an integrated and cross-sector composites industry
▪ In a global market forecast to grow to £75bn by 2015
▪ Driving composites growth using advanced manufacturing
▪ Achieved by delivering improved— Strengthening capability
— Increasing sustainability
— Building capacity
▪ With industry and stakeholder leadership
4Composites Leadership Forum
UK Manufacturing of Composites – Political & Market View- UK Strategy
▪ Initiated by UK Composites Strategy (Nov 2009)
▪ Delivered on time and on budget
▪ Has more members and engagement than forecast
▪ Working on projects of utmost importance to UK
▪ Initiated the Composites Leadership Forum – advising BEIS etc. on needs of the sector
▪ Capability enhancements supported by HVM Catapult
▪ Major capex expansion underway to support ATI funded programs
The National Composites Centre:
Set Up & Funded by
Composites Leadership Forum
Established as a result the 2009 UK Composites
Strategy to strengthen leadership in the sector.
The CLF is working to influence the Government
and other bodies to bring together support for
composites and ensure growth and industrial
success for the UK.
Strategy refresh delivered 2016.
www.compositesleadershipforum.com
Stakeholders:
BEIS, Innovate UK, EPSRC, KTN Ltd, DIT
(formerly UKTI).
Delivery Partners:
National Composites Centre, Composites UK,
CIMComp.
Industry Groups:
Aerospace Growth Partnership, Automotive
Council, Motorsport Industries Association,
Construction, Defence, Renewables UK, Marine
Industries Alliance, Railway Industry Association,
Materials Suppliers
6Composites Leadership Forum
UK Trade Body for Composites :-
Ceramic MatrixComposites
Metal MatrixComposites
Carbon FibreReinforced Products
2017: $22.6 Bn2020: $30 BnCAGR 10.5%
Glass FibreReinforcedProducts
2017: $47.0 Bn2020: $57 BnCAGR 6.6%
Global Composite Products
2017:$79.6 Bn
2020: $97 Bn
CAGR 7%
Natural Fibre Reinforced Products
2017: $4.2 Bn2020: $5.8 BnCAGR 11.68%
2017: $3.3 Bn2020: $4.3 BnCAGR 9.7%
Carbon Fibre
2017: $3.2 Bn2020: $4.3BnCAGR 10.8%
Glass Fibre
2017: $11.8 Bn2020: $14.23BnCAGR 6.4%
Aramid Fibre
2017: $3.5 Bn2020: $4.6BnCAGR 6.4%
CompositeResins (TS)
2017: $1.1 Bn2020: $1.3BnCAGR 6.4%
2017: $518 M2020: $619 MCAGR 6.1%
Polymer Matrix Composites
- Significant global growth prospects for composite products
UK Manufacturing of Composites – Political & Market View
Source: Markets & Markets data compiled by NCC
The UK Market Opportunity
Composites Leadership Forum : Source Data @2016 9
Potential growth from composite part production from £2.3bn in 2015 to £12.5bn in 2030.Focus on High Growth Markets: Aerospace, Automotive and Defence
The UK Market Opportunity
Composites Leadership Forum : Source Data @2016 10
Potential growth from composite part production from £2.3bn in 2015 to £12.5bn in 2030.Focus on High Growth Markets: Aerospace, Automotive and Defence
UK Manufacturing of Composites – Political & Market View- Aerospace
UK Manufacturing of Composites – Political & Market View- Aerospace
UK Manufacturing of Composites – Political & Market View- Aerospace
Sector Body :- AGP Planning Body :- ATI
▪ A350 and A400 in production (composite wings)▪ Bombardier C-series EIS in service 2016 (composite wing)▪ Increasing use of composites in engines (blades, cases, nacelles)▪ (Production rates of A320 increasing)
▪ Next generation of single-aisle coulduse composite wing and engines withhigh composite content
Challenges:▪ Production rates▪ Globally mobile/ high value manufacturing
UK Manufacturing of Composites – Political & Market View- Aerospace
▪ Government commitment to UK Automotive Sector— Advanced Propulsion Centre:
£1bn over 10 years
— Automotive Inward investment organisation
— Investment in Skills
UK Manufacturing of Composites – Political & Market View- Automotive
High composites growth forecast: due to 2020 and 2025 emission targets
Applications include:▪ Structures (body in white)▪ Wheels and brakes▪ Suspension and clutches▪ Interiors (seat frames, consoles)
Challenges:▪ Cost, rate and quality (surface finish, painting, joining)▪ Capital cost of new production facilities▪ UK supply chain?
UK Manufacturing of Composites – Political & Market View- Automotive
McLaren Composites Technology Centre
▪ 1st UK McLaren facility outside campus
▪ In-sourcing the development and manufacture of carbon fibre chassis
▪ Using advanced know-how and technology developed with HVM Catapult (AMRC)
▪ £50m combined investment
▪ 200 high level jobs
▪ Projected cost saving of £10m
▪ £100m GVA to UK economy by 2028
▪ Value of UK sourcing of a McLaren car to
grow by 8% (from current average of 50%)
▪ UK’s largest sector bycapital investment (£14b/pa)
▪ UK world leader in sub-seatechnologies
▪ Major opportunities in deepwater in Gulf of Mexico, WestAfrica (up to 30x deeper than North Sea)
Challenges:▪ Well depths up to 3000m▪ Well pressures increasing to >20k psi▪ Regulation/assurance (hence IUK mJumper project)
UK Manufacturing of Composites – Political & Market View- Oil & Gas
UK Manufacturing of Composites – Political & Market View- Oil & Gas
UK Manufacturing of Composites – Political & Market View- Renewables
Siemens Manufacturing Facility –Hull, UK
UK Manufacturing of Composites – Political & Market View- Renewables
▪ Current UK Gov’t Initiative :-
▪ Industrial Strategy Challenge Fund
- Faraday (Auto Batteries)- (Digital Manufacturing)- (Materials)
▪ Sector Deals- Construction- (Chemical Industry)- (Composites Manufacturing)
Composites Sector Deal - Initial Thought Process
Composites Leadership Forum 23
Delivering:• Aerospace and Automotive
Composites Roadmapping.• £XX APC, £XX IUK, £XX ATI
composite innovation projects.Ask:• Composite bridge demonstrator.
Link to Construction Sector Deal?
Industry Specific Work
Delivering:• HVM Catapult preforming Large
Scale Project • Scottish Lightweighting Centre.Ask:• National Composite Materials
Innovation Hub.• Materials extension to
CIMComp.• Composite related extension to
HVM Catapult Infrastructure.
Cross Sector Work
TechnologySustainability Skills/Workforce
Supply Chain Regulations & Standards
Delivering:• Composites Resource and
Efficiency Action Plan.• Climate Change Levy Scheme.
Ask:• Support for iComposites-style
collaborative research programme to address market failure.
Delivering:• Composite Trailblazer
Apprenticeship.• Composite Accredited Practitioner
Scheme.Ask:• HEFCE Catalyst fund proposal for
curriculum development.• Allow Apprenticeship levy to be
used on other forms of skills.
Delivering:• Industry database.
Ask:• Support for market & industry
data refresh, cross sector & supply chain analysis.
• Funding to support engagement and communication with industry.
Delivering:• Modernising Composite
Materials Regulations Paper.• Ongoing work challenging
materials based standards.Ask:• TBC
Part and Materials Value For UK
0
2
4
6
8
10
12
14
2015 2016 2017 2018 2019 2020 2021 2022 2023 2024 2025 2026 2027 2028 2029 2030
Val
ue
/£b
n
UK CompositeProducts
Material Value
Material Valuefrom UK withNCMCMaterial Valuefrom UKwithout NCMCNCMC work increases
UK produced materials, increasing UK GVA and
Automation and process optimisation will lead to material cost dominating composite product cost.Need to capture the material supply chain in the UK, increasing UK GVA and reducing imported goods.(example: without action, up to £3.4bn of carbon fibre may need to be imported by 2030)
NCMC - Indicative Academic Projects
Matrix Reinforcement Intermediates Sustainability
M1
Large sca le production of monomers from bio-
mass (as drop in replacements for selected
polymers)
R1
High performance discontinuous
compos ites I1
High-speed weaving of broadcloth
through machine development and
tow s izing
S1
More susta inable matrices and s izes
(thermosets and thermoplastics )
M2
Appl ication of multi -sca le model l ing techniques
to optimise performance through rational des ign
and formulation
R2
Structured s ize
I2
Variable width broadcloth weaving
S2
More susta inable reinforcements (fibres ,
fi lms , precursers )
M3
Development of lower temperature cure
process ing for thermoset compos ites R3
Next generation carbon fibres
I3
Nearnet 2D preforming
S3
New solvolys is processes for improved
fibre recovery - Current thermoset matrices
and carbon & glass fibre
M4
Developing new reactors to enable the rapid
sca le up of new monomers R4
Higher performance low-cost (glass )
fibres I4
Direct preforming with long
discontinuous tows into formable
preforms
S4
M5Tai loring exis ting matrix/reinforcement interface
regions to improve mechanica l performance R5High performance polymer tape
compos ites I53D weaving of broadcloth (2.5D
weaving) S5Improved pyrolys is processes for carbon
fibre recovery from legacy matrices
M6Development of rel iable sel f heal ing polymer
matricesR6
Next generation fibres to displace
conventional carbonI6
3D weaving of thick and complex
near-net preforms S6
Improved s izes for fibres
M7
Developing tough, high operating temperature
(350-400 C) matrices R7
In s i tu formation of reinforcing s tructures
I7
Novel cutting technologies , for
example laser based (with
AMRC/MTC)
S7
Compos ites with variable discontinuous
fibre properties
M8
Developing the next generation of
multi functional compos ites us ing new
nanomateria ls
R8
New des ign tools
I8
Yarns or tows from discontinuous
(recycled) fibres and hybrid fibres S8
QC methods and s tandards for recovered
fibres (NPL-led?)
M9Developing s tandards for routine use of
nanocompos ites across supply chainR9
Fibres as del ivery routes for addition
components (LINK TO MATRICES)I9
Novel cyl indrica l 3D preforms S9
Development of short fibre a l ignment
processes
M10
Reducing rel iance on VOCs by developing water-
borne technologies and moving towards ci rcular
process ing
R10
Hierarchica l s tructured fibre tows
I10
Just-in time prepregging of 3D
preforms S10
LCA methodologies
S11Process ing mixtures of recovered glass
and carbon fibre
Composites Leadership Forum 25
• Increasing demand for large components (aerospace, wind, construction…)
• Processes and costs that suit increased manufacturing rates (105/y not 102/y)
• Automated manufacture
• Reducing cost and time to market (design >certification>in-service)
• Growing the UK skills/expertise to compete with the world (supply chains)
UK Manufacturing of Composites – Political & Market View
- Big Challenges
• Increasing demand for large components (aerospace, wind, construction…)
• Processes and costs that suit increased manufacturing rates (105/y not 102/y)
• Automated manufacture
• Reducing cost and time to market (design >certification>in-service)
• Growing the UK skills/expertise to compete with the world (supply chains)
UK Manufacturing of Composites – Political & Market View
- Big Challenges
• Increasing demand for large components (aerospace, wind, construction…)
• Processes and costs that suit increased manufacturing rates (105/y not 102/y)
• Automated manufacture
• Reducing cost and time to market (design >certification>in-service)
• Growing the UK skills/expertise to compete with the world (supply chains)
UK Manufacturing of Composites – Political & Market View
- Big Challenges
There has never been a better time for Composites
Discussion and questions