Composites Future: ‘minimum mass, minimum energy, maximum performance’

EFRO, Uitgeest, 14-12 -2016,

‘Valorisatie Hightech Sector Composieten Noord-Holland’,

Adriaan Beukers

Composites Future: ‘minimum mass, minimum energy, maximum performance’

SUSTAINABLE

Circular

ECONOMICS

Anglo-saxon

Rhine-land

share vs

stakeholders value

LIFE TIME

TRAVEL HISTORY:

(spec. drag, time,

speed, capacity)

for moving

or being moved

objects

SUSTAINABLE

POLITICS:

Paris Climate

treaty

Shell & Exxon

CEO’s plead

for CO2 tax

PROACTIVE vs REACTIVE

GB’s decline in

manufacturing jobs

(>96: >750.000 fte)

in change for

services & trading,

a rise in rest of EU

Transport and velocity domains

Total (system + payload) weight, so reduce system weight!

15kgf PREQto move

100kg WTOTAL

Transport Systems (price of speed, G. Gabrielli – Th. von Kármán, 1950)

force to overcome drag, per unit moving system weight

liquid fuel history: ‘a one century history of slash and burn’

SABIC/GEP-DSM

BASF/DSM

Emirates

Delta Airlines

10-20 -->100 30$/barrel

Cheap Materials become Scarce, even dumpedeg cheap oil, easy exploitable wells, new circular economies, EC2020

Exploration

(<5$/barrel

is based on

shared profit1/31/7

classical markets

aerospace & wind

energy show

highest global

growth now,

be in front

of the big

volume

composite

markets!

ref. Lucintel

CAGR: compound anual growth rate

size of bubbles: indicating for market size

Global Composites Market Opportunity 2012-2017

NL

Specialties:

Marine

Aerospace

Pipe & Tank

Construction

Composieten Nederland 2020

GrootComposiet1 2009-2014, EFRO

2 2016-2020, PNH

CompoWorld1 2011-2015, ZZL, PF&NF

2 2016-2018

BioComposieten 2014-2018, EDR

World Class Composite Solution, Het Noorden > 2015

Maritiem - Luchtvaart 2014-2018, Rijn Delta, Drechtsteden

& een aantal Field Labs

‘the knowledge chain’

kennis

ontwikkeling

kennis

verspreiding

kennis

valorisatie

TU’s

HBO’sMBO’s

Composieten NHInternationale ontwikkelingen en trends

Begroot Gerealiseerd Restbudget % besteed

5.264.825€ 2.279.184€ 2.985.641€

ATO 1.049.000€ 661.574€ 387.426€ 63%

Syntens 849.600€ 529.887€ 319.713€ 62%

WMC 297.025€ -€ 297.025€ 0%

TUD 240.000€ 88.224€ 151.776€ 37%

Inholland 400.000€ 125.249€ 274.751€ 31%

TNO 370.000€ 96.491€ 273.509€ 26%

NHN 63.750€ 32.172€ 31.578€ 50%

Solico 107.000€ 14.990€ 92.010€ 14%

Polux 152.000€ 161.035€ -9.035€ 106%

2MV 135.200€ 31.170€ 104.030€ 23%

Schaap Composites 127.000€ 21.861€ 105.139€ 17%

NPSP 127.000€ 127.000€ -€ 100%

Smit/Utec 127.000€ 105.038€ 21.962€ 83%

Manshanden 149.500€ 32.654€ 116.846€ 22%

Rhebergen 107.000€ -€ 107.000€ 0%

Everstrip 127.000€ 73.982€ 53.018€ 58%

CPT 517.000€ 124.507€ 392.493€ 24%

Duneworks 107.000€ 53.351€ 53.649€ 50%

GBT 212.750€ -€ 212.750€ 0%

Innovatiebudget

GrootComposiet1 2009-2013, EFRO

valorisatie 2 2016-2019, EFRO

HTSM

Technologie programma >2011, NL

Construction

Pipe & tank

Marine

NH composites

on the move

Composites penetrating tradional material sectors

Begroot Gerealiseerd Restbudget % besteed

5.264.825€ 2.279.184€ 2.985.641€

ATO 1.049.000€ 661.574€ 387.426€ 63%

Syntens 849.600€ 529.887€ 319.713€ 62%

WMC 297.025€ -€ 297.025€ 0%

TUD 240.000€ 88.224€ 151.776€ 37%

Inholland 400.000€ 125.249€ 274.751€ 31%

TNO 370.000€ 96.491€ 273.509€ 26%

NHN 63.750€ 32.172€ 31.578€ 50%

Solico 107.000€ 14.990€ 92.010€ 14%

Polux 152.000€ 161.035€ -9.035€ 106%

2MV 135.200€ 31.170€ 104.030€ 23%

Schaap Composites 127.000€ 21.861€ 105.139€ 17%

NPSP 127.000€ 127.000€ -€ 100%

Smit/Utec 127.000€ 105.038€ 21.962€ 83%

Manshanden 149.500€ 32.654€ 116.846€ 22%

Rhebergen 107.000€ -€ 107.000€ 0%

Everstrip 127.000€ 73.982€ 53.018€ 58%

CPT 517.000€ 124.507€ 392.493€ 24%

Duneworks 107.000€ 53.351€ 53.649€ 50%

GBT 212.750€ -€ 212.750€ 0%

Innovatiebudget

Begroot Gerealiseerd Restbudget % besteed

5.264.825€ 2.279.184€ 2.985.641€

ATO 1.049.000€ 661.574€ 387.426€ 63%

Syntens 849.600€ 529.887€ 319.713€ 62%

WMC 297.025€ -€ 297.025€ 0%

TUD 240.000€ 88.224€ 151.776€ 37%

Inholland 400.000€ 125.249€ 274.751€ 31%

TNO 370.000€ 96.491€ 273.509€ 26%

NHN 63.750€ 32.172€ 31.578€ 50%

Solico 107.000€ 14.990€ 92.010€ 14%

Polux 152.000€ 161.035€ -9.035€ 106%

2MV 135.200€ 31.170€ 104.030€ 23%

Schaap Composites 127.000€ 21.861€ 105.139€ 17%

NPSP 127.000€ 127.000€ -€ 100%

Smit/Utec 127.000€ 105.038€ 21.962€ 83%

Manshanden 149.500€ 32.654€ 116.846€ 22%

Rhebergen 107.000€ -€ 107.000€ 0%

Everstrip 127.000€ 73.982€ 53.018€ 58%

CPT 517.000€ 124.507€ 392.493€ 24%

Duneworks 107.000€ 53.351€ 53.649€ 50%

GBT 212.750€ -€ 212.750€ 0%

Innovatiebudget

Kennis is zilver,

bedrijvigheid is goud

≈ 20 years Crossover Luchtvaart-Maritiem, 2014

Infra StructuresFibreCore, LSPolyproducts

Pressure vesselshoses, et ceteraALE, Taniq, CPT

Lighter transport countspackaging on the move 2010

domestic gasses and fluids

lightness, dematerialization

Dutch Recent Infra Composites

Architecture & Civil engineering meets Aerospace

ruled by:

New regulations (health & safety)

Maintenance cost reduction

Lightness and architectural freedom

(refurbishing old structures, without weight penalty)

supported by

LCA premium

Composites on the Move1: ‘minimum mass, minimum energy, maximum performance’

LIFE TIME

TRAVEL HISTORY:

(time, speed,

capacity)

VABO,Volvo, CompoW, NLR

CTC, Luinstra, CompoW, UT

Tankwell, CPT, GrootComp, TUD

TenCate, DTC, K&vE, Airborne, TUD

EML, Jan Veenendaal, TUD

Low8, Koppert, TUD

Composites on the Move2: ‘minimum mass, minimum energy, maximum performance’

LIFE TIME

TRAVEL HISTORY:

(time, speed,

capacity)

Taniq, Zumro,

Futura, Airborne

K&vE/Fokker,TUD

Boeing, TenCate, DTC, K&vE, TUD

Walter Extra

400&500, TUD

Euro Enaer,

K3C, TUD

CATO, Sumitomo,

Bond Laminates,

TUD

DTC/Dornier, TUD

Life-time energy savings per 100kgaverage values for energy

savings by

weight reduction

IFEU 2004, 1GJ is about 30lt kerosine

42,000lt

450,000lt

600,000lt

EFFICIENCY improvements

since the 50’s,

aerodynamics: L/D ≈ 15%

propulsion: SFC ≈ 40 % (Genx/CSMleap)

structure : 0.50 > OEW/MTOW > 0.60

Major R&D Challenges:

Structures, Materials &

Manufacturing Techniques

Boeing 787: composites content Wf > 50%, Vf > 70%, 1/R ≈ 2

KLM rounding Spijkerboor

A320/B737 - alikes

structure efficiency

used for aircraft

OEW / MTOW =

42 ton / 74 ton = 0.56

Johnston distribution OEW:

50%: 21ton for systems, crew and power-plant(s)

50%: 21ton for structure in total

• 10.5ton for wing , undercarriage (6% ) and movables (6%), (12%=5 ton)

• 10.5ton for fuselage and empennage (13%)

candidate aluminium structure for change into CFRP

• 16.0ton for wing, fuselage and empennage shell structures (38%)

ColdFeather ’95 & Tankwell ’15: 3&4ton weight reduction per unit!

max weight saving by change

is about 25%, equal to 4ton (≈ 10% OEW), for A320/B737 alikes! (0.51)

B787.8

OEW/MTOW

≈117t/228t≈

0.51

Energy saving: 667 GJ/year.100kg Specific energy content: 35 MJ/litre

So fuel saving per year per 100kg: 19000 litre

Sell tickets priced per kilogram not per seat!

A320/B737 AIRCRAFT, -100kgmass reduction pays for itself

‘TankWell’ Composite Containers

Inter-modal transport containers:

road transport limits capacity, grossweight <44, <40 & <32ton

STAINLESS STEEL

replaced

by E-GLASS FRP:

-40% empty weight

reduced

per road transport

+3000kg more payload

7-9% cost reduction

• Vessel capacity (31000lt)

• tare weight/pay load

up to 36ton

• Temperature controlled

• max pressure 4 bar

Design and Development StrategyDesign and Production of Composite Structurescooled trailer system weight

reduced from ca. 9300

to 6500 kgf

‘integration’

1995, Focwa/Cintec 30% weight reduction challenge, > A320 & B737

Cheap Buoyancysupply inter and intra modality transport chains

(road, rail and water)

human supply chain or the transport of

food, water, minerals, energy & building materials

River and sea

harbours

permanent

dwellings

3%

transport cost

expenditure rule

Bouyancy is more efficient than Wheels and Aerodynamic lift

higher aquisition cost, less maintenance cost, more added value

WATER CARRIESbarges for European

canal transport

Kempenaar & Spits

(cooled food) barges

new materials & processes

Wempty / Wpayload =

800 / 2300 ≈ 1/3,

potential glass FRP

from 800 to 550 ton,

+ 250 ton > - 10 trailers

Life time ENERGY SAVINGS HIGH SPEED FERRIES

33% reduction by weight

-7% kerosine,1650GJ//35MJ/lt

47 ton/100kg.lifetime

E-GlassFRP, corrosion resistance, thermal & acoustic insolation

steel

aluminium

GlassFRP

+

addedo

values(integration)

Lightweight composite Structures

Aerospace meets Maritime,from technology push to market pull

Royal Huisman, Damen, v.Lent, De Vries, VABO, Holland Jachtbouw?

Composites Future: TTintoB‘minimum mass, minimum energy, maximum performance’

Almost THE END

‘the knowledge chain’

Knowledge

dissemination

Knowledge

development

Knowledge

valorisation

EFRO ‘Valorisatie Hightech Sector Composieten Noord-Holland’

Uitgeest, 14-12 -2016

Concept, materials and manufacturing techniques selection

Fast structures, maximum performance driven

Composiet in Opmars 1America’s Cup 2013

Concept, materials and manufacturing technique selection

Life cycle cost driven

Composiet in Opmars 2civil constructions 2013

Concept, materials and manufacturing techniques

Performance/price driven

Composiet in Opmars 3

2013 BMWi3

CompositesGlobal Automotive Materials Market (2011-2017) in $B

2013 BMW i3

Concept, materials

and manufacturing technique selection

Price/performance driven

Airbus 350, 2013

Taniq

Actiflow

Infinious

ALE

Airborne

K&vE

WMC/CompEx

Bond Laminates

Conform/Hylid

DTC / Mupio

Feltrin Composites

CLC / LS

Euro Enaer (‡)

Senz/Protension

MOCS/CTC

a challenge

for entrepreneurs

Composiet in Opmars 4

glass, aramide and carbon fiber

reinforced thermoplastics:

PA, PES, PEI and PPS

Sumitomo, Fonteijne

TenCateAC, Bond laminates

DTC, K&vE, Airborn,ALE, Fokker

Thermoplastic

Composites

low pressure

short cycle time

proces development

material development

Design and Production of Composite Structuresit takes 20 years for take off

Since 1995 > 25 innovations, spin off’s & techno starters

?

?

NWO!?

IP or Exclusive Know How (EKH) is essential for technostart up’s

Sharing Knowledge and Opportunities is seed for growth

Pro-active attitude of key players is a prerequisite

‘Design and Production of Composite Structures’ 2012

Knowledge

dissemination

Knowledge

development

Knowledge

utilization

an example

fundamentalresearch

appliedresearch

utilization

GTI ’S

TNO (SBIR))NLR (CompoWorld)et cetera

GB’S &MULTINATIONALS(20%)

‘off shoring’

innovations by ‘in shoring’ academic techno starters

TU’s

Uni’s NEW SME’S

‘YesDelft’GrootComposiet

et cetera

STW

demonstrator

valorisatie

grants

TTI’s HBO’s

Ir. Lianne Waghto

The endFuture exhaust system paradigm: ‘from assembly to integral system’Manage heat, pressure, sound & CO2 + Nox emmision in a 3D shell structure

Design and Production of Composite Structures ‘COMPOSITES’

DISSEMINATION

UTILIZATION

DEVELOPMENT

KNOWLEDGE

• Ferrari Maranello

Structures

Processes

Materialscomposites

Actual position:

DSM

‘flying doctors’

Lightweightinsulating

hot gas exhaustsystems

PyrogelSuperwool

Carbon/Peti330phenylethynyl-terminated imide oligomer

(LaRC PETI-5)

Patent Pending

Temperature decline:

from 700o to 100oC

Transmission loss:

ca 50 dB, ΔW≈60%

Protension:

blue helmets,

radomes, wheels

FOCWA:

cooled trailers

Bosal/Agusta:

exhaust systems

Turn Implicit Knowledge into Explicit IP TTintoB

Zumro Resque Bags

Taniq Turbo hoses

ALE pressure vessels

Turn Implicit Knowledge into Explicit IP TTintoB

KeyKeg packaging

Airborne

oil & gas tubing

CPT containers

Kennis is zilver,

bedrijvigheid is goud

Crossover Luchtvaart-Maritiem

Gemeente Papendrecht, 10 maart 2014, Apollo Hotel

AXBow, Lex Keuning TUD & Marin

K&vE: inductie lassen

Downhole tubes , AirborneFlexible hoses, Taniq

Composites Future: TTintoB‘minimum mass, minimum energy, maximum performance’

THE END

‘the knowledge chain’

Knowledge

dissemination

Knowledge

development

Knowledge

valorisation

EFRO ‘Valorisatie Hightech Sector Composieten Noord-Holland’

Uitgeest, 14-12 -2016