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Presentation by David Hartman, Senior Technical Staff, Owens Corning at CAMX on October 15, 2014. Advances in reinforcement materials, specifically glass fiber materials, should not go unnoticed. In this presentation discover new advances in glass fiber technology areas, applications to various markets and the needs of those markets, as well as current advances in fiber reinforcement materials and forms.
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Advances in Reinforcement Materials
(Glass Fiber Materials)
October 13-16, 2014
Orange County Convention Center
Orlando, FL
Dave Hartman
Owens Corning Composite Solutions
October 15, 2014 Copyright © 2014 Owens Corning. All Rights Reserved.
ADVANCES IN GLASS FIBER REINFORCEMENTS
Sustainability Growth Opportunity
Global Megatrends
Material Drivers
High Performance Fibers
Attributes Form Function
Hybrids
Collaboration
3
Owens Corning and General Motors announced the first production automobile to be made entirely of Fiberglas™ -reinforced plastic, the Chevrolet Corvette, in 1953.
In the post-war years, Owens Corning expanded its product range to support the first Fiberglas™-reinforced plastic fishing rods, serving trays and pleasure boats.
The Hajj airport terminal in Saudi Arabia is constructed with a 105-acre Fiberglas™ roof
Source: Owens Corning road-show images 9/22/2014
Energy use, availability and efficiency
Climate change
Population / consumption
Personal desire to achieve sustainability
Green construction materials and renewables demand
WHY CHOOSE OWENS CORNING?
Operations sustainability
Product and supply chain sustainability
Innovation and collaboration to deliver energy efficiency and renewable energy solutions at scale
SUSTAINABILITY
4
DRIVING TO BE NET POSITIVE
STRONG GLOBAL MACRO TRENDS – BIG OPPORTUNITIES IN GLASS FIBER MARKETS
A GLOBAL AND GROWING GLASS FIBER MARKET
5
Construction 35%
Transportation 28%
Industrial 14%
Consumer 17%
Wind 6%
Glass reinforcements market defined as glass fiber reinforcements and direct conversion products as consumed, excluding yarns Source: Owens Corning management estimates as of Feb 2014
• Residential • Commercial • Water transportation
and storage
• Cars • Trucks, buses, trains • Marine
• Factories • Mining • Offshore platforms
• Appliances • Electronics • Recreation
A Key Material Enabling Solutions Essential to Everyday Life
A $7 Billion Global Market
-
1,000
2,000
3,000
4,000
5,000
1981 1989 1997 2005 2013
GLASS FIBER MARKET DEMAND
6
Gla
ss F
ibe
r K
To
ns
Glass fiber market demand excludes E-glass yarns Sources: Fiber Economics Bureau, Glass Fiber Europe, Global Trade Information Services, Inc. and Owens Corning management estimates
Glass Fiber Demand Has Grown at 1.6 Multiple of Industrial Production Growth
Historical Glass Fiber Market Growth Averaging 5%
0.5
1.1
0.9
1.7
0.4
0.5
2005-09 2010-12 2013-16
50%
60%
70%
80%
90%
100% 2004 2006 2008 2010 2012 2014 2016
GLASS FIBER INDUSTRY SUSTAINABLE GROWTH
7
Tighter Capacity Environment with High Facility Utilization Rates Expected in the Near Term
Glass fiber market demand excludes E-glass yarns Sources: Fiber Economics Bureau, Glass Fiber Europe, Global Trade Information Services, Inc. and Owens Corning management estimates as of September 2014
(high probability additions)
0.1/ yr 0.3/ yr 0.1/ yr 0.1/ yr 0.4/ yr 0.2/ yr
Change in global demand (MM T)
Change in global capacity (MM T)
Supply Tension
90% Threshold
Esti
mat
ed
Cap
acit
y U
tiliz
atio
n
WHY CHOOSE OWENS CORNING? GLASS REINFORCEMENT PRODUCTS AND THEIR APPLICATIONS
CHOPPED STRAND MAT AND CONTINUOUS FILAMENT MAT
Marine, transportation, recreation, corrosion resistance, construction
Construction, industrial, automotive, road paving
NON WOVEN VEIL
Wind, pipe, thermoplastic composites, industrial, recreational
KNITTED OR WOVEN FABRICS
Construction (panels and translucent panels), corrosion resistant pipe and tanks, consumer (sanitary, recreational vehicles), transportation (headliner, body parts, semi-structural parts)
CONTINUOUS FIBER MULTI-END ROVING
Transportation, consumer electrical/ electronics and appliances
CHOPPED STRAND, DRY-USE
Building products (roofing and gypsum), industrial specialties
CHOPPED STRAND, WET-USE
Chemical and sewage, oil, water processing (pipe and tanks), industrial (high-pressure vessels, pultruded items), wind energy, aerospace, ballistics, transportation (muffler filling), electrical (optical cable)
CONTINUOUS FIBER TYPE 30® SINGLE END ROVING
8
Applications
Processes
1932-1946 Start of the Industry
OC introduces FiberglasTM
Commercial Boat Hulls
FRP Car Body (Stout Scarab)
CSM / CFM Process
Resin Systems Developed
Hand Lay-up Process
1947-1960 Niche Applications
Chopped Strands Process
Carbon Fibers Developed
Direct Roving Process
Spray-up Process
Pultrusion Process
Commercial FRP Car Body
Composite Panels (Trucks)
Helicopter Blades (Alouette II)
1961-1978 Industrial Applications
Filament Winding Process
SMC Process
High-Strength Glass Process (S)
Kevlar® Fibers Developed
Glass Reinforced Thermoplastics
SMC Air Deflector
Glass Mat Reinforced Shingles
Commercial Wind Turbine Blades
1979-1996 Corrosion Resistance
Continuous Fiber Thermoplastic Laminates
Long-fiber Thermoplastics
Resin Infusion Process
Composite Storage Tanks
Fiberglass Windows
Hybrid Front-End Modules
1997-Present Hybrid Technology Integration
Hybrid Molding Technologies
Commercial Wind Turbine
Commercial Aircraft
Structural Automotive Parts
Consumer Electronics
COMPOSITE APPLICATIONS AND PROCESSES
9
0
1MM
2MM
3MM
4MM
5MM
Graph depicts glass fiber market demand, in kilotons Kevlar is a registered trademark of E. I. du Pont de Nemours and Company
Production of energy with no emission of CO2 (wind, tidal, solar, geothermal)
Providing the basic infrastructure to deliver clean water to excess of 5-billion people
Providing housing and infrastructure to a growing population in developing and third-world countries
Reducing the weight of modes of transportation to responding to increasing cost of energy
CLEAN ENERGY
WATER INFRASTRUCTURE
URBAN INFRASTRUCTURE
INDUSTRIAL LIGHT WEIGHTING
COMPOSITES OPPORTUNITY - GLOBAL MEGATRENDS
10 © iStock pictures
DRIVERS FOR COMPOSITES IN THE WIND MARKET
Long and light blades
Increased blade performance
Development of low-wind and off-shore sites
Cost-of-energy reduction
11
MATERIALS TO ENABLE LONGER BLADES
6,05,55,04,54,0
700
650
600
550
500
450
400
350
LOG (N)
Pe
ak S
tre
ss [
MP
a]
ADV
H
Fiber
Source: Risoe / DTU tests 2013 on UD laminates, Momentive Epoxy resin L135/H137
800750700650600
1200
1100
1000
900
800
700
Compression Strength, MPa, 95/5% CI
Te
nsile
Str
en
gth
, M
Pa
, 9
5/
5%
CI
Advantex® E
Windstrand® H
Fiberglass type
Higher Composite Stiffness and Fatigue Performance
Fatigue Performance at R=0.1, E-glass vs H-glass UD Fabric/epoxy
12
13
Acoustic and fracture surface analysis of 45o tension in Advantex®glass/epoxy lamina The improved fiber-matrix adhesion leads to a higher transverse strength
Source: Owens Corning WindStrand® fibers and data. Panels dry-wound roving and infused using Momentive epoxy RIMR 135/H137
E-glass UD/epoxy WindStrand® UD/epoxy
Higher Composite fiber-matrix adhesion for Durability
MATERIALS TO IMPROVE BLADE DURABILITY
DRIVERS FOR COMPOSITES IN AUTOMOTIVE
© iStock picture
Fuel Consumption Reduction
CO2 Emission Reduction
Vehicle Light Weighting
Enhanced parts performance and durability
Efficiency gains
14
BODY PANEL LIGHT-WEIGHTING MATERIAL ANALYSIS
MS Cost Availability
Manufacturing compatibility
Weight Welding Corrosion 0 0
AHSS Cost Availability Manufacturing compatibility
Welding Ductility Providing Class A finish
13-15 (2.3 kg)
2.08
Al Cost Availability Light weight Forming Corrosion Low melting temperature
high CTE
35-40 (6.5 kg)
2.76 – 3.27
Mg Light weight Damping High temperature performance
Availability Ductility Corrosion, welding, fire
safety
40-45 (7.5 kg)
4.45 – 4.52
LFTP Functional integration
Part consolidation
Cost, corrosion resistance
Semi structural
Low melt temp, High
CTE
Crash worthiness
20-35 ~2 – 7
SMC Class A finish Cost, corrosion resistance
Part consolidation
Inner to outer
adhesion
High CTE Crash worthiness
15-20 (2.7 kg)
~2 – 4
GFRP prepreg
Light weight Part consolidation
Corrosion resistance
Cost Throughput Crash worthiness
35-45 ~4 – 8
CFRP prepreg
Light weight Part consolidation
Corrosion resistance
Cost Throughput Crash worthiness
50-70 (12 kg)
~10 – 30
Material Largest Benefits Largest Drawbacks
Source: US DOT NHTSA- August 2012 “Mass Reduction for Light-Duty Vehicles for Model Years 2017-2025”
% Weight Savings*
$/kg Cost Premium
* Example calculation: baseline mild steel design mid-size hood is 17.9 kg -15.6= 2.3kg AHSS weight saved at $4.80 cost increase or $4.80/2.3kg= 2.08 $/kg cost increase premium
15
Baseline of % weight savings and cost premium to mild steel design for mid-size hood
Durability
Pollution Control
Rising costs for traditional materials
Corrosion resistance
DRIVERS FOR COMPOSITES IN INDUSTRIAL APPLICATIONS
© Paulo Manuel Furtado Pires / shutterstock.com Courtsery Plasticos Industriales de Tampico (PITSA), of Tampico, Mexico Courtersy of Potok-M LLC, RU
16
~40 hrs
SS-304*
STRESS CORROSION CRACKING OF STAINLESS STEEL VS. COMPOSITE
Boron-Free-E-CR-Glass-FRP composite provides superior corrosion performance • Stress rupture of composite rods in 1 Normal acids (HCl - H2SO4) • Superior corrosion resistant resin used in both samples • Based on analytical calculations considering iso-corrosion charts without corrosion resistant coatings for SS-304*
17
LOWERING COST OF CORROSION WITH BORON-FREE-E-CR-FRP
Scrubber system built with SS-2205 → Inspected after 12 months → Severe corrosion inspected → resulted in $5 million losses within a short period of time
E-CR-FRP material offered exceptional corrosion resistance for such units. FRP units are in operation with minimal maintenance → Lowering cost of corrosion
Chemical and power plant stack liners
Coal power plant scrubber units Each scrubber unit holds ~ 1 million gallons of lime slurry → highly corrosive environment Each unit costs ~ $200- $500 Million → Huge investment
Source: Lieser, M., “How to Use FRP Material to Lower Corrosion Costs”, Polymer Society vol. 5, No.5, (2013): p.22-27 © shutterstock.com
18
© shutterstock.com
DRIVERS FOR COMPOSITES IN THE CONSTRUCTION MARKET
Durability
Performance & Design Flexibility
Materials Conservation & Energy efficiency
Product Availability in All Business Cycles
Productivity Improvement
19
OPPORTUNITY FOR COMPOSITES GROWTH
Global Structural Materials Market 800MM tons, $xxxB Industry
Global Composites Materials Market 9.2MM tons, $21B Industry
Glass
Reinforcement
4.5MM tons (94%) $7B (58%)
Advanced
Reinforcement
0.3MM tons (6%) $5B (42%)
E-glass
ECR-glass
R-glass
Cost
Pe
rfo
rma
nc
e
H-glass
Aramid
Carbon
UHMWPE
Global Reinforcement Fibers 4.8MM tons, $12B Industry
S-glass
Glass reinforcements market defined as glass fiber reinforcements and direct conversion products as consumed, excluding E-glass yarns Source: JEC, Lucintel and Owens Corning management estimates as of September 2014
Global megatrends, continued growth in industrial production, and traditional material substitution support market growth at 5-7% CAGR
20
Aluminum
Composites 1-2%
Plastics
Wood Steel
COMPARISON OF HIGH PERFORMANCE FIBER AND UNI-DIRECTIONAL COMPOSITE PROPERTIES
Property Test
Method Unit E-Glass
ECR-Glass
Boron free H-Glass R-Glass S-Glass Carbon
Fiber and Bulk Glass Properties
Density ASTM C693 g/cm3 2.55-2.58 2,62 2,61 2.55 2,45 1.79
Refractive Index (bulk annealed) ASTM C1648 - 1.547-1.562 1.56-1.57 1,566 1.54 1,522
Conductivity ASTM C177 watts/m•K 1.0-1.3 1,22 1,34 6.83
Pristine Fiber Tensile Strength ASTM D2101 MPa 3450-3790 3750 4130 4450-4580 4830-5080 4400
Specific Pristine Strength Calculation × 105 m 1.36-1.50 1,43 1.58 1.74 2.01-2.12 2.46
Young's Modulus GPa 69-72 81 87,5 87 88 230
Specific Modulus Calculation × 106 m 2.73-2.85 3,15 3,33 3.48 3,67 12.8
Elongation at Break % 4,8 4,9 4.9 5.35 5,5 1.8
Thermal Properties
Coefficient of Thermal Expansion, 23-300 °C ASTM D696 × 10-6 cm/cm•°C 5,4 6 5,3 4.1 3,4 - 0.6
Specific Heat @ 23 °C ASTM C832 kJ/kg•K 0,807 0,79 0.75 0,810 1.130
Fiber Tensile Strength v. Temperature
Pristine Fiber Tensile Strength, -196 °C ASTM D2101 MPa 5310 5935 7220 7826
Pristine Fiber Tensile Strength, 22 °C ASTM D2101 MPa 3450-3790 3587 4130 4450 5047 4400
Fiber Weight Loss @ 96 °C, 24 hours, 17µm
10% HCl % 31,68 7,88 7,59 1,53 0.05
10% H2SO4 % 32,00 6,91 6,48 1,17
1 N Nitric % 23,47 7,21 6,67 1,42
NaOH pH=12.88 % 5,40 3,24 12,65 19,34 1.10
Impregnated Strand Properties
Tensile Strength ASTM D2343 MPa 2000-2500 2200-2600 2400 -2800 3050-3400 3410-3830 4000
Tensile Modulus ASTM D2343 GPa 78-80 81-83 90 - 91 89-91 86.9-95.8 230
Toughness ASTM D2343 MPa 37 56 69 82-90
Unidirectional Composite Properties1
Tensile Strength ISO 527-5 MPa 1120 1200 1260 1560 1550 1780
Tensile Modulus ISO 527-5 GPa 46 48 52,5 51.6 53 153
Poisson's Ratio ASTM D638 - 0,29 0,33 0,33 0.32 0,27 0.28
Fiber Volume Fraction ASTM D2734 % 60 60 60 60 60 57 2
1 MGS RIM 135 epoxy + RIMH 137 hardener 2 EPON 826 DM HS-Carbon Fiber OC data pub..2011
Glass and Carbon Fiber linear-elastic behavior enables structural composites
21
COMPARISON OF GLASS AND CARBON FIBER ATTRIBUTES
Carbon Fiber
High elastic modulus
Low shear modulus
Low strain to failure
Catastrophic failure
Prone to damage
Light-weight
Alkaline resistance
Electrical conductor
Thermal conductor
Shrinks with heat
Glass Fiber
Linear-elastic
High shear modulus
High strain to failure
Ductile failure mode
Impact toughness
Denser fiber
Acid resistance
Electrical insulator
Thermal insulator
Expands with heat
Glass and Carbon Fiber attributes compliment each other for selective placement of hybrid forms and multifunctional integration
Source: Owens Corning Type30® fiber and data © shutterstock.com 22
Steel
Aluminum SMC 50 GF-chop
SMC 55 CF-chop
SMC 55 CF-uni
CM EP 55 CF-uni
CM PA6 55 CF-uni
CM PA6 55 CF-quasi
IM PA6 50 CF-chop
IM PA6 60 GF-chop
0.0
0.2
0.4
0.6
0.8
1.0
1.2
1.4
1.6
1.8
0.00 1.00 2.00 3.00 4.00 5.00 6.00 7.00 8.00 9.00
Spe
cifi
c St
ren
gth
[m
x10
^5]
Specific Modulus [mx10^6]
Composite Specific Strength vs Specific Modulus
COMPOSITE DESIGN AND MATERIAL PROCESS INTERACTIONS INFLUENCE HYBRID FORM AND FUNCTION
Hybrid attributes for composite design:
Selective placement of CF where needed for
design function in a GF composite is efficient
where it compliments the load environment
GF/CF mixed in the process by hybrid form
depends on the material flow, alignment and
orientation for the design load environment
GF enables CF dispersion, flow, wetting and
consolidation to improve IM, LFT, EC, RTM…
productivity and consistency
GF can help reduce materials and process
cost of CF lighter weight structures
GF increases strain to failure for impact and
flexural fatigue resistance in CF structures
GF enables isolation of CF galvanic corrosion
GF improves shear-compression failure of CF
GF improves bearing strength of mechanical
fasteners and adhesive joints
Source: Owens Corning and “Mass Reduction for Light-Duty Vehicles for Model Years 2017-2025” US DOT NHTSA- August 2012 23
Compounding
Polymer Tool in Press
Glass Roving
Compounding
Polymer Polymer Tool in Press
Injection Molding
COLLABORATION IN KEY MARKET SEGMENTS
© shutterstock.com; © iStock picture
INDUSTRIAL
TRANSPORTATION
WIND ENERGY
BUILDING AND CONSTRUCTION
24
THANK YOU
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