COMPOSITES EUROPE 2012 Blog

ERBO GmbH, which is exhibiting at COMPOSITES EUROPE 2009 in Stuttgart, is presenting a world first in the field of suction technology for milling machines. Previously, suction extraction had been impossible for five-axis milling machines. ERBO has developed a procedure that provides an optimal solution for such machines. A combination of high pressure suction and custom-made evacuation nozzles for each individual tool allows suction directly at the tool-tip itself.

Dust and chips are captured directly via a movable joint device that can move along every axis, and are then fed to the high-performance extraction system. Particularly when constructing large moulds (for instance, for wind turbine rotors), dust and chips require much cleaning of components.

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Polymer composites have been in use at Automobili Lamborghini since 1983, and since 2001 carbon fiber composites have been used for the production of all body panels and several portions of the spaceframe structure of the Murciélago. At the International AVK Conference (26.-27 October 2009, Stuttgart) Maurizio Reggiani (Vice-president of R&D and CTO, Automobili Lamborghini S.p.A.) and Paolo Feraboli (Professor and Director of the Automobili Lamborghini Composites Laboratory) will present the composites research and development at Automobili Lamborghini. The presentation will be divided in two sections.

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Technical principles, trends and innovations – in an international lecture forum, the COMPOSITES EUROPE trade fair will again present specialist lectures on current topics relevant to the industry in 2009. The COMPOSITES Forum will focus on all areas of composite applications. Topics range from crash-safe materials in the automotive field to sandwich panels in aircraft construction, from growth potential in the construction of wind energy parks to production and machining processes for composites. The programme features a total of 26 lectures and presentations in English and German.

From damage simulation to serial production
New technologies for the serial production of carbon-reinforced plastics (CRP) will be demonstrated by the IKV - Institut für Kunststoffverarbeitung of RWTH Aachen. The IKV scientists developed three new process chains enabling the production of materials with a fibre content exceeding 50 percent in less than ten minutes.

The mechanical behaviour of CRP sandwich panels in practical tests is explained by the speakers from Fraunhofer IWM for CRP foam core sandwich panels. In its lecture, the Fraunhofer Entwicklungszentrum für Röntgentechnik (EZRT) presents non-invasive test procedures, from 3D computer tomography to radioscopy to thermography and ultrasonic techniques.

Dassault Systemes Simulia provides information on possibilities for FEM analysis of lightweight fibre composite structures. The use of the finite element method allows predictions on processes of damage and failure in supercritical load conditions.

The combination of highly elastic composites and aesthetically pleasing design is demonstrated by Huntsman and D3 who cooperated closely in designing a sophisticated carbon fibre chair moulded in four parts. Products from Huntsman’s Araldite series were used in the project. The two companies show how complex parts can be produced simply and cost-effectively using simple tooling technology.

The COMPOSITES Forum is located in Hall 4 and designed as an open lecture area. Admission is free for all trade fair visitors.

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With new themes, new special forums and a 15-percent increase in exhibitor numbers, the COMPOSITES EUROPE 2009 specialist fair is gaining momentum. At its fourth edition to be held from 27 to 29 October in Stuttgart, more than 300 exhibitors will present technologies and products covering the entire value creation chain of fibre-reinforced plastics. The spotlight will be on innovative solutions for important application industries such as vehicle construction, aircraft construction and aerospace as well as the building and construction sector.

Key players of the industry such as AOC Resins, Exel Composites and Huntsman will once again be present in Stuttgart. In Krauss-Maffei, RAMPF Tooling, Henkel, DSM Composites Resins, Carbon Composites e.V., Zoltek and Cam Elyaf, however, COMPOSITES EUROPE could also win major new exhibitors this year. The organisers succeeded in bringing almost the entire sector of automated cutting to Stuttgart with Gerber Technology, Lectra, Expert Systemtechnik, Topcut-Bullmer and Zünd Systemtechnik AG.

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To ensure their suitability when used in wind energy systems, the epoxy resin adhesives used must be suitably certified by Germanischer Lloyd (GL). This is because rotor blades must withstand extreme stresses. The larger the unit, the higher the demands on the fatigue strength of the rotor blades manufactured from composites. In the near future, experts predict 10 megawatt systems with 80 metre long wind vanes.

The enormous rotor blades consist of two half shells, that are produced in suitable moulds from cross-linked hard foams and inserted balsa woods, which are subsequently stuck together. The balsa wood is cultivated in plantations in Ecuador and is harvested after six years. From a one metre long tree trunk, rectangular timber sections are cut and stuck together to make 1.22 metre long and five centimetre wide ashlars. These blocks are then cut into boards against the grain and finely sprayed with a resin solution to protect them against moisture.

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Whether recreational craft, aircraft components such as the fuselage and wing shells, railway trucks, surfboards, rotor blades for wind power plants or superstructures of commercial vehicles or caravans, without sandwich structures the most important applications of composites would be inconceivable. A sandwich structure is a type of lightweight construction, in which the components consist of force absorbing covering layers that are kept at a distance by a relatively soft, normally light, core material.

The sandwich structure is a production process for semi-finished goods, in which several layers with diverse characteristics are embedded in a material. Almost always, this involves the use of diverse composites, since despite being of a low weight these components are very rigid. They are computed according to the linear sandwich theory. The core material preferably consists of paper honeycombs, foam materials or balsa wood. It transmits arising shear loads and supports the covering layers. The thermally insulating and acoustic insulating properties of the very light core materials are also frequently utilized.

Optiplan GmbH from Oelsnitz is one of the leading manufacturers of glass fibre reinforced plastics as panels and reels under the Polydet brand. Apart from the main application as high-grade wall coverings on vehicle superstuctures, GRP products are also used in the technical, industrial and construction sectors. The company will present its latest products at the Composites Europe trade fair, which takes place in Stuttgart from 27 to 29 October 2009.

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The wind energy industry is one of the most important customers for composites; at the same time the greatest challenges are made here on the load-bearing capability of the fibre reinforced plastics. Consequently, not only the right raw materials but also their specific blend is a major precondition for use in wind energy.

The industrial production of the enormous blades would be impossible to achieve without the use of technical plastics. Production of the models or the moulds for constructing the rotor shells or the rotor blades as such would be impossible. Even the adhesion of the upper and lower shell would be virtually impossible to achieve.

Two-component metering and mixing systems are required so that the right mixture of epoxy and polyurethane resins as well as modelling and adhesive pastes can be used. A reputable manufacturer of this processing technique is Tartler GmbH from Lützelbach, which will demonstrate its competencies at the COMPOSITES EUROPE trade fair, which will take place from 27 to 29 October 2009 in Stuttgart.

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Despite the increase in production capacities, the demand for carbon fibres continues to be far greater than the supply. This is evident from the annual market survey by the AVK – Industrievereinigung Verstärkte Kunststoffe e.V. The worldwide capacity in 2007 is estimated to have been 55,000 tons. The applications are multifarious and consist primarily of the sports sector, wind energy, the oil industry, the automobile and transport sector as well as civil engineering. By 2010, an annual increase in the demand for CRP is predicted to be between 14 and 16 per cent. This is due to the development of new applications over and above the previous use. Current new developments can be found, e.g. with hydrogen tanks, although the main application continues to be aviation. Experts think that even though fibre production will experience a double-digit increase as expected, there will continue to be bottlenecks at least in the medium-term. Read Full Post

Epoxy resins are the elixir for numerous composite applications. They consist of polymers, which together with suitable hardeners produce a duroplastic plastic of high strength and chemical stability. When epoxy resin and hardener are mixed, after a specific time, curing of the originally viscose mixture takes place. Depending on the formulation and temperature, this time span can take a few minutes or may last several hours. In some cases, the curing time may also take several months.

The Krempel-Group, from Vaihingen, offers with the BD system, prepregs that are based on modified epoxy resins with high impact resistance and excellent dynamic properties. These can be processed into high strength structural components with all standard processes. The curing range is between 85 and 140 degrees Celsius, the maximum dimensional stability under heat is 125 degrees Celsius.

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The experts of the AVK – Industrievereinigung Verstärkte Kunststoffe e.V. forecast an annual double-digit percentage growth rate for natural fibre reinforced plastics as well as for wood-plastic composites (WPC).  The reasons for this are the aspects of energy saving during production and the associated reduction in carbon dioxide.

The most important applications are the automobile, construction, furniture as well as industrial and consumer goods. Even so, the use of natural fibre reinforced plastics is stagnating in the automobile sector in the German market which currently accounts for 30,000 tons annually.

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