Advanced Composites: Enhanced Performance and Sustainabilityproceedings.ndia.org/jsem2007/3847_Winandy.pdf · added bio-composites to promote long-term resource sustainability and

Forest Products LaboratoryForest Products LaboratoryUSDA Forest Service, Madison, WI USAUSDA Forest Service, Madison, WI USA

Jerrold E. Winandy, Jerrold E. Winandy, USDA FS USDA FS Forest Products LabForest Products Labhttp://http://www.fpl.fs.fed.uswww.fpl.fs.fed.us

Advanced Composites: Advanced Composites: Enhanced Enhanced Performance and Performance and SustainabilitySustainability


Driving Forces & Challenges to Driving Forces & Challenges to Achieving Sustainable EconomiesAchieving Sustainable Economies•• UrbanizationUrbanization•• Rapid Technological and Information ChangeRapid Technological and Information Change•• Climate Change and VariabilityClimate Change and Variability•• GlobalizationGlobalization•• Accountability Accountability •• EnergyEnergy•• Invasive and Exotic SpeciesInvasive and Exotic Species•• Changing Wood ResourceChanging Wood Resource

–– Small DiameterSmall Diameter–– Wood Waste Utilization & RecyclingWood Waste Utilization & Recycling–– Plantation/Short Rotation Woody CropsPlantation/Short Rotation Woody Crops–– Genetic selection/Genetically Modified SpeciesGenetic selection/Genetically Modified Species


11stst Tenet of Resource Sustainability:Tenet of Resource Sustainability:To achieve true resource To achieve true resource sustainability, always choose the sustainability, always choose the material that has the maximum material that has the maximum utility and minimum longutility and minimum long--term term impact on the environment. impact on the environment.

USDA Forest ServiceForest ProductsLaboratory


22ndnd Tenet of Resource Sustainability:Tenet of Resource Sustainability:When using biobased materials is When using biobased materials is appropriate, a fundamental underappropriate, a fundamental under--standing of those biomaterials, their standing of those biomaterials, their conversion processes, and their conversion processes, and their engineering potentials is a basic engineering potentials is a basic requirement for sustainable forestry. requirement for sustainable forestry.

USDA Forest ServiceForest ProductsLaboratory


FPL Advanced Composites FPL Advanced Composites Research ProgramResearch Program

•• NanocrystallineNanocrystalline--Cellulose CompositesCellulose Composites•• Enhanced HyperEnhanced Hyper--performance Compositesperformance Composites•• Advanced Structures/HousingAdvanced Structures/Housing•• Resource Sustainability & Resource Sustainability &

BioBio--based Economybased Economy•• Small Diameter & Underutilized SpeciesSmall Diameter & Underutilized Species•• HazardousHazardous--fuels Timber Fuels Reductionfuels Timber Fuels Reduction•• ValueValue--added Use of Exotic/Invasive Speciesadded Use of Exotic/Invasive Species•• Integrated Biomass TechnologiesIntegrated Biomass Technologies


FPL’s Strategic Plan for Composites Research

Wood composites, alone or in combinations with Wood composites, alone or in combinations with other natural fibers or alternative materials, are the other natural fibers or alternative materials, are the means to sustainable forestry. No other technology is means to sustainable forestry. No other technology is as adaptable, or as compatible with how we currently as adaptable, or as compatible with how we currently use building materials or can it add more value or use building materials or can it add more value or functionality/serviceability. Biocomposites are a critical functionality/serviceability. Biocomposites are a critical technology as we evolve to a biobased economy.technology as we evolve to a biobased economy.


USDA, Forest ServiceForest Products Laboratory

Mission: Engineered Composites ScienceMission: Engineered Composites ScienceDevelop a fundamental understanding of wood and biocomposite materials and then use that knowledge to enhance existing and develop new technologies and products that meet user needs, promote forest resource sustainability, and empower the conversion to a bio-based economy.


Wood & Biocomposites: the science of taking biomaterials apart & reconstructing

them for specific engineering uses.• Chips/Flakes/Strands/Fibers• Nanoscience

– Fiber surface activation– NCC-reinforced Composites

• Resins – Hot:UF/PF/pMDI– Cold:PR, Urethane– Thermo-plastic– Ceramic/Inorganic

• Processing– Dry- or Wet-formed and

Hot/Cold Pressed – Melt-blended and

Extruded/Molded

Performance of BioPerformance of Bio--Composites = f (Composites = f (materials & processmaterials & process))


WoodWood--based Composite based Composite Technologies: AdvantagesTechnologies: Advantages

•• Generally accepted worldwideGenerally accepted worldwide•• Add value to diverse species and Add value to diverse species and

materials:materials:•• SmallSmall--diameter timberdiameter timber•• FastFast--grown plantation timbergrown plantation timber•• AgAg-- & Lignocellulosic& Lignocellulosic--residuesresidues•• Exotic/Invasive speciesExotic/Invasive species•• Recycled lumber and EWCRecycled lumber and EWC--panelspanels•• Timber removed as HazardousTimber removed as Hazardous--fuelfuel


WoodWood--based Composite based Composite Technologies: AdvantagesTechnologies: Advantages

•• LightLight•• StrongStrong•• Easily workedEasily worked•• Cost effectiveCost effective


Wood & Competitive Materials in Residential Buildings

5%

5%

11%

39%

40%

Solid WoodOthersEngineered WoodMetalsPlastics

[estimate by Freedonia Group, 2002]

~9.3 billion M~9.3 billion M33, 2002, 2002


WoodWood--based Composite based Composite Technologies: LimitationsTechnologies: Limitations

•• Current performance limits broader Current performance limits broader applications in Commercial/Nonapplications in Commercial/Non--Residential Residential construction and Advanced Materials marketsconstruction and Advanced Materials markets

•• Public and Engineering communities perceive Public and Engineering communities perceive problems with:problems with:

•• FireFire•• Structural performance/creepStructural performance/creep•• Durability & waterDurability & water--related issuesrelated issues•• ServiceService--lifelife

•• Timber harvesting is not seen as “Green”Timber harvesting is not seen as “Green”


Four Problems in Developing the Next-generation of Engineered

BioComposites (EBC)•• Identify and exceed user needsIdentify and exceed user needs•• Develop more robust Develop more robust EBC’sEBC’s•• Develop advanced Develop advanced EBC’sEBC’s with high with high

performance and reliability for performance and reliability for commercial /noncommercial /non--residential constructionresidential construction

•• Develop new ecoDevelop new eco--friendly, costfriendly, cost--competitive technologies for harvesting, competitive technologies for harvesting, processing, and endprocessing, and end--ofof--life reuse.life reuse.


The Future of Advanced Wood-and Lignocellulosic-Composites

I.I. Nanotechnology Nanotechnology II.II. Biorefinery: Biorefinery: BiofuelsBiofuels & & BioenergyBioenergyIII.III. Advanced BioAdvanced Bio--based Compositesbased CompositesIV.IV. Advanced StructuresAdvanced StructuresV.V. Sustainability and Enhancing Sustainability and Enhancing

Transition to a Biobased EconomyTransition to a Biobased Economy


I.I.Nanotechnology and Nanotechnology and WoodWood-- & Bio& Bio--compositescomposites

With engineered biocomposites, With engineered biocomposites, nanotechnology will not be a science in itself. nanotechnology will not be a science in itself. It will become the fundamental scale for It will become the fundamental scale for approaching a problem, similar to how we now approaching a problem, similar to how we now think of using a “material sciencethink of using a “material science--type” approach. type” approach.

Nanotechnology will become a standard for Nanotechnology will become a standard for a basic type of approach to science. It will provide a basic type of approach to science. It will provide a tool by which we quantify or model the relationa tool by which we quantify or model the relation--ship between “Materialsship between “Materials--ProcessProcess--Performance”.Performance”.


NanocrystallineNanocrystalline Cellulose, Cellulose, NanoNano--activated Fiber Surfaces, & activated Fiber Surfaces, &

NanoNano--reinforced Compositesreinforced Composites

TEM image of cellulose nanocrystals

• Using commercial wood pulp

• H2S04 hydrolysis

• Dispersed In PP-polymer matrix


Major Technology shifts require Strategic ReinventionMajor Technology shifts require Strategic Reinvention


Trus-joist/Weyerhaeuser, Inc

Major Product advances require Major Product advances require continual refocusing of Strategic Visioncontinual refocusing of Strategic Vision


II.II.Likely Scenarios for the Likely Scenarios for the Forest Biomass BiorefineryForest Biomass Biorefinery

•• Stand Alone BiorefineryStand Alone Biorefinery(without fiber production)

•• Integrated Biomass TechnologiesIntegrated Biomass Technologies

(EtOH Composites Paper Energy)


Integrated Biomass Utilization1a. Biofuels: EtOH from Hemicellulose

EtOH


Integrated Biomass UtilizationIntegrated Biomass Utilization1b. Value1b. Value--added Biobased Adhesivesadded Biobased AdhesivesPharmaceuticals, and Biochemicals.Pharmaceuticals, and Biochemicals.


Integrated Biomass UtilizationIntegrated Biomass Utilization2. Value2. Value--added Composites & Paperadded Composites & Paper


Integrated Biomass UtilizationIntegrated Biomass Utilization3. Energy from Biomass3. Energy from Biomass


III.III.Problem Areas for Advanced Problem Areas for Advanced CompositesComposites ResearchResearch

••Understand base materials and theUnderstand base materials and therelationship between materials, relationship between materials, their processing and propertiestheir processing and properties

••Define performance requirements forDefine performance requirements forexisting and develop the next existing and develop the next generation of compositesgeneration of composites

••Address resource sustainability and Address resource sustainability and educate users that wood and educate users that wood and woodwood--based composites are the based composites are the means to sustainable forestrymeans to sustainable forestry


•• EW C & M DF: Enhance structural EW C & M DF: Enhance structural strength & enhance durabilitystrength & enhance durability

••M DF: Define the effects of therm al M DF: Define the effects of therm al treatm ents strength and utilitytreatm ents strength and utility

••EW C: Developing FireEW C: Developing Fire--and Decayand Decay--Resistant Engineered W ood Resistant Engineered W ood Com posites Com posites

••EW C: Define cardinal thresholds of EW C: Define cardinal thresholds of tem p. and M C for decay tem p. and M C for decay

Enhance Perform ance and Durability Enhance Perform ance and Durability for the existing “for the existing “statestate--ofof--art”art”in EW C:in EW C:


Advanced Bio-Composites:

•• Corrugated Fiberboard Corrugated Fiberboard (1940’s)(1940’s)

•• FPL Spaceboard FPL Spaceboard (1970’s(1970’s--80’s)80’s)

•• 3D Engineered Fiberboard3D Engineered Fiberboard•• Lightweight Systems Lightweight Systems

–– FurnitureFurniture–– PackagingPackaging–– Engineered PalletsEngineered Pallets–– Emergency StructuresEmergency Structures

•• Biomemetic/Smart SystemsBiomemetic/Smart Systems•• Bamboo CompositesBamboo Composites

Corrugated Paperboard vs. Corrugated Paperboard vs. 3D3D--Engineered FiberboardEngineered Fiberboard

Bamboo HiBamboo Hi--Shock BoardShock Board


Three-dimensional Engineered Fiberboard (3DEF)


Use of 3DEF for Emergency Structures

(Post hurricane/tornado/tsunami)3DEF panels as floor panels 3DEF panels as roof panels

3DEF panels as wall panels WallsFloors

Roofs


InorganicInorganic--bound bound WoodWood--fiber Compositesfiber Composites

•• CementCement

•• NonNon--sinteredsinteredCeramicsCeramics

•• SilicatesSilicates


Wood Thermoplastic CompositesBasic research on WTPC Basic research on WTPC

over the last 15over the last 15--20 years has 20 years has formed the basis for formed the basis for phenomenal recent and phenomenal recent and future growth for WTPC in future growth for WTPC in Building & ConstructionBuilding & Construction

0

5

10

15

20

1990 1995 2000 2005 2010

Year

Mar

ket S

hare

(%)

WTPC Decking


Advanced BiocompositesAdvanced BiocompositesLowLow--cost, Rapidlycost, Rapidly--built, ADAbuilt, ADA--accessible, accessible,

Biocomposite SurfacesBiocomposite Surfaces

Four Field Trials: CA, WI, MD, NYCommercialized in 2005


IV.IV.Advanced Structures will require Advanced Structures will require Advanced Engineered Materials:Advanced Engineered Materials:

FPL is developing the bioFPL is developing the bio--based based technologies to pioneer these technologies to pioneer these

future materialsfuture materials


Engineering and MaterialsEngineering and MaterialsEnhanced Wood MaterialsEnhanced Wood Materials


Engineering and MaterialsEngineering and MaterialsDeconstruction & ReuseDeconstruction & Reuse

3 Trillion (1012) Bd.Ft. = 23.5 Billion (109) m3


V.V. To develop a sustainable bioTo develop a sustainable bio--based, rather than a based, rather than a petropetro--centric centric economy, we must develop valueeconomy, we must develop value--added bioadded bio--composites to promote composites to promote longlong--term resource sustainabilityterm resource sustainability and and economic developmenteconomic development

•• HazardousHazardous--fuels reductionfuels reduction•• Forest & Range residuesForest & Range residues•• PostPost--industrial wood waste industrial wood waste •• PostPost--consumer wood wasteconsumer wood waste•• Exotic/Invasive remediationExotic/Invasive remediation•• Recycling WPC lumberRecycling WPC lumber•• Biocomposites: Biocomposites:

Juniper/SaltJuniper/Salt--cedar, Fibers from Chickencedar, Fibers from Chicken--feathers, feathers, Corn Stalks, Guayule, Corn Stalks, Guayule, AgaveAgave, & Sterile Digested , & Sterile Digested Bovine BiomassBovine Biomass

MDF-CFF


To develop a sustainable bioTo develop a sustainable bio--based based economy, rather than a economy, rather than a petropetro--centric society, centric society,

we need to develop valuewe need to develop value--added bioadded bio--composites to promote longcomposites to promote long--term resource term resource sustainabilitysustainability and economic developmentand economic development

OSB from Burnt Pine WPC from Invasive Juniper and Salt-cedar

Chicken-feather MDFAg-residue Biocomposites


Value-added Uses for Exotic-Invasive Species

Sustainable Forestry and Resource Management

FPL’s Advance Composites Science Research Program

fpl.fs.fed.us/rwu4706

Hazardous Forest Fuels Utilization

Playground Safety and ADA-accessibility

Leadership in Development of New WTPC Building Products

Define Field (Solar, biological, Thermal) Performance of WTPC Building Products

Jerrold E. Winandy, USDA FS Forest Products Lab�http://www.fpl.fs.fed.usDriving Forces & Challenges to Achieving Sustainable EconomiesFPL Advanced Composites Research ProgramFPL’s Strategic Plan for Composites Research�USDA, �Forest Service�Forest Products �Laboratory�Wood & Biocomposites: the science of taking biomaterials apart & reconstructing them for specific engineering uses.Wood-based Composite Technologies: AdvantagesWood-based Composite Technologies: AdvantagesWood & Competitive Materials in Residential BuildingsWood-based Composite Technologies: LimitationsFour Problems in Developing the Next-generation of Engineered BioComposites (EBC)The Future of Advanced Wood-and Lignocellulosic-CompositesI. Nanotechnology and Wood- & Bio-compositesNanocrystalline Cellulose, �Nano-activated Fiber Surfaces, & �Nano-reinforced CompositesII. Likely Scenarios for the �Forest Biomass BiorefineryAdvanced Bio-Composites: �Three-dimensional Engineered Fiberboard (3DEF)Use of 3DEF for Emergency Structures�(Post hurricane/tornado/tsunami)Inorganic-bound �Wood-fiber CompositesWood Thermoplastic CompositesAdvanced BiocompositesV. To develop a sustainable bio-based, rather than a petro-centric economy, we must develop value-added bio-composites to prom

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Advanced Composites: Enhanced Performance and Sustainabilityproceedings.ndia.org/jsem2007/3847_Winandy.pdf · added bio-composites to promote long-term resource sustainability and