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Composite Materials & Activity in Wales
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Composites Use
Current worldwide market estimated at 60bn EU’s, with expected growth of 5% pa.Major increases in aerospace, energy (automotive & sports/leisure).Increase markets and manufacturing base in Asia and developing world.Fibre costs expected to decrease.Resin costs expected to increase.
Wales has moderate activity, but needs to do some catching-up.
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Composite Materials
WHAT ARE COMPOSITE MATERIALS?
WHERE DO WE USE THEM?
WHY DO WE USE THEM?
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What are composites?
2-PHASE
MATERIAL
PARTICLE
REINFORCED
FIBRE
REINFORCED
COMPOSITE
STRUCTURE
METALS
CERAMICS
POLYMERS
SIZE
SHAPE
ARRANGEMENT
MATERIALS
SHORT
CONTINUOUS
ORIENTATION
ARRANGEMENT
MATERIALS
LAMINATEDMATERIALS
SANDWICHPANELS
Composites
2-PHASE
MATERIAL
PARTICLE
REINFORCED
FIBRE
REINFORCED
COMPOSITE
STRUCTURE
METALS
CERAMICS
POLYMERS
SIZE
SHAPE
ARRANGEMENT
MATERIALS
SHORT
CONTINUOUS
ORIENTATION
ARRANGEMENT
MATERIALS
LAMINATEDMATERIALS
SANDWICHPANELS
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Matrix Materials
Metals: • Magnesium, Aluminium, Titanium alloys• For strength, high temperatures
Ceramics:• Alumina, Zirconia, Silicon Carbide, Silicon
Nitride, Ceramic glasses• For high temperatures
Polymers:• Thermosets (polyesters, epoxies, phenolics,
polyimides, etc)• Thermoplastics (polypropylene, nylon, PEEK
etc)• Low weight, can be low cost
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Reinforcements
Particles:• Ceramics, glass spheres, carbon, metals,
wood flour
Fibres:• Glass, carbon, polyaramid (Kevlar),
polypropylene, ceramic whiskers, carbon nanotubes, natural fibres
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Advantages of a Composite Structure
Increased stiffnessIncreased strengthReduced densityIncreased toughnessIncreased temperature resistanceImproved processibility (sometimes)Lower cost (sometimes)
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Advantages of a Composite Structure
Modified electrical conductivityModified thermal, optical, magnetic behaviourImproved corrosion resistanceLower gas permeabilityModified dynamic behaviour
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Stiff, Strong, Light
Bahrain Conference Centre Glass fibre reinforced polyester
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Stiff, Strong, Light
Bahrain Conference Centre Glass fibre reinforced polyesterEach vault is 50 m long, with 16 m overhangLow density and high stiffness are the main advantages
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Strong, Stiff, Light
Superyacht with 3 carbon-fibre composite mastsEach with 6 CF composite yardsHigh stiffness & strength, low weightNeed water and weathering resistance
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Strong, Stiff, Light
Composite is stiff enough to hold sails without lines, so masts can be rotatedEmbedded optical fibres allow continuous stress monitoring
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Strong, Stiff, Light
Qinetic ZephyrHigh Altitude, Long Endurance Unmanned Aerial VehicleSolar PoweredTest flights up to 3½ days
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Strong, Stiff, Light
Boron / Aluminium struts on space shuttle
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Corrosion Resistance
Glass fibre reinforced polyester widely used for boatsLuxury yachts to canoesLow weight, high stiffness, water resistant, easy to fabricate
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Corrosion Resistance
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Electrical Insulation
Footbridge over Madrid - Barcelona railwayGlass-fibre reinforced polyesterLow weight, high stiffness, good strengthNo EM interference with electric railway
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Electrical Insulation
Carbon Fibre needlesAllow MRI imaging during surgeryMetal needles would interfereNeed high stiffness, high hardness, biocompatibility
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Environmentally Friendly
Glass fibre polyester compositeHigh stiffness / low weightStrength can be maximised along lengthGood weathering resistance
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Environmentally Friendly
Aeroelastic (controlled twist) blades change aerodynamics as wind speed increases
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Environmentally Friendly
Biocomposites finding increased usageNatural fibres and natural resinsSome biodegradable, others not
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Small & Smart
Nano-composites based on carbon nanotubes and graphene
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Small & Smart
Ceramic / nanotube composite
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Small & Smart
Self-healing Composites
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Challenges with Composites Use
Increased complexity of materials
Increased variety of processing methods
Both are potentially advantageous, but can cause problems
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Composites Activity in Wales
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Training ProvidersBarry College; International Aerospace Training Centre (ICAT)
• Centre of Excellence; EASA Part 147; • HND/C – Academic partner - University of
GlamorganDeeside College
• Centre of Excellence; EASA Part 147• HND/C – Academic partner Glyndwr
Coleg Morgannwg • Edexcel NC
Ystrad Mynach College • Edexcel NC
Lufthansa Resource Technical Training (LRTT)
• EASA Part 14729
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MITEC – Pembrokeshire CollegeManufacture
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Barry College
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Advanced Materials - Deeside College?
Training facility
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Bangor UniversityBio Composites
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Centre console trim
Various dampingand insulation parts C-pillar trim
Rear parcel shelf
Seat cushions
Door trim panels
Engine ShieldBumper
Wheel arch Head Rest
Roof liner
Rear Hatch
Boot Base
Sub-floor Covering
Bonnet Insulation
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Cardiff UniversityManufacture/Testing/Analysis
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Cardiff UniversityMEC
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Rapid ManufacturingAdvanced Manufacturing
TechnologyMicro/Nano-Manufacture
Concurrent EngineeringICT in Manufacture
Operations Management
Intelligent ManufacturingInspection and Quality Assurance
Intelligent Control
Manufacturing Engineering Industrial Engineering
Systems Engineering
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Cardiff UniversityMEC
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Swansea UniversityTesting/Analysis/Modelling
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Swansea UniversityTesting/Modelling/Analysis
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Swansea UniversityTesting/Modelling/Analysis
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Other Universities
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Swansea Metropolitan University• Automotive engineering• Non-destructive testing
Glyndwr University• Materials and Chemistry Research• Training (mainly with Deeside for Airbus)
University of GlamorganAberystwyth University
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TWINDT & Joining
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Statistics
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Welsh Composites Manufacturers 2006Total 82
Sector %Aerospace 6Automotive 2Marine 33Sport / Leisure 9Construction 23Tanks, pipes, enclosures 10Raw materials 6Others 11
Estimates of Welsh Composites Workforce2008 1,500-2,0002010 2,000-2,5002012 4,000-5,000
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United Aerospace LtdAerospace/High Tech
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Copyright © 2008 United Aerospace Ltd http://www.united-aerospace.com
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Contour Premium SeatingAerospace
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Copyright © 2008 Contour Premium Aircraft Seating http://www.contour.aero/
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NordamAerospace/MRO
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Copyright © 2008 NORDAM http://www.nordam.com/
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AirbusAerospace
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Copyright © 2008 AIRBUS http://www.airbus.com/
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Griffin InteriorsAerospace/Construction
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Copyright © 2008 GRIFFING INTERIORS LTD http://www.griffininteriors.co.uk
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ConnaughtAutomotive
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Morgan MarineConstruction
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Rhino Engineering LtdConstruction
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TycoConstruction
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Chocolate BikesSport
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JP SurfboardsLeisure
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Rockpool KayaksLeisure
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Cytec IndustriesMaterials
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