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FIBERGLASS REINFORCED PLASTIC COMPOSITEMARKET KEUNGGULAN INDUSTRI REGULASI DAN PRODUKSI DALAM NEGERI
ir Seto Roseno B Eng M Sc
13 Agustus 2020PUSAT TEKNOLOGI MATERIAL
Composites An industry defining its own future by favouring
bull Innovation bull Unification bull Regulations
bull Visibility
The composite industry is relatively recent (1940s)
All segments along the value chain account for about 550000 jobs worldwide
Worldwide market in volume = 8 Millions of tons
Value of the worldwide composite market = 60 billion euros
North America
EuropeAsia
36
3331
IN VALUE
Europe has reached a high level of technicity
Stronger weight of high value-added applications
Aerospace
Wind energy
Asia Pacific amp Rest of the WorldNorth America
Value
euro22B
36
Volume
27 Mt
35
Average
Unit
Price
euro82kg
Value
euro18B
31
Volume
33 Mt
43
Average
Unit
Price
euro55kg
World
Total
Value
euro60B
Total
Volume
8 Mt
Average
Unit
Price
euro72kg
(1) USA Canada
(2) Europe Russia
Middle East and
Africa
(3) Asia Australia and
South America
Value per geography
GDP per capita
Composites volume per capita inkg per inhabitant
Development curvein Volume
Composites markets size by country depends on development level
Average prices by industry worldwide
Aeronautics
Wind Energy
Consumer Goods
Transportation
Marine
Construction
E amp E
Pipes amp Tanks
Unit Prices eurokg 0 5 10 15 20 25 30 35 40 45
Growth in volume mainly in Asia
Repartition of the composites market by region 1999 gt 2013 in Mt
RoW
Europe
Asia
North America
Repartition of the composites market by region 1999 gt 2013 in Mt
1999 2002 2007 2013
7
22
36
35
7
33
23
38
5
29
26
40
4
27
24
45
25(1) 51Weight of Asia in global growth in volume
2015
103
81
6259
COMPOSITES
COMPOSITES = DUA MATERIAL YANG BERBEDA SIFAT FISIK DAN
KIMIAWI NYA BERSATU SECARA MAKROSKOPIK MELALUI SUATU
PROSES KIMIA MENJADI SUATU MATERIAL BARU (KOMPOSIT)
DENGAN SIFAT FISIK DAN MEKANIKAL YANG BARU
COMPOSITES ALAMI (NATURAL MATERIAL)
COMPOSITES BUATAN (ENGINEERED MATERIAL)
COMPOSITES
9
Berdasarkan jenis penguat
bull Particle-reinforced composites
ndash Large-particle composites (Cermets tungsten carbida in cobalt semen beton bertulang)
ndash Dispersed-strenghtened composites (alumina in aluminium ThoriaThO2 in Nickel alloy)
bull Fiber-reinforced composites konstruksi kaku kuat dan ringan
ndash Discontinuous (Short) fiber composites
ndash Continuous (long) fiber composites
bull Structural-reinforced composites
ndash Laminar composites (kayu multipleks laminate carbon epoxy)
ndash Sandwich composites konstruksi ringan dengan kekakuan dan kekuatan bending yang tinggi (Honeycomb-carbon epoxy composites dinding kardus corrugated paper - paper)
KLASIFIKASI MATERIAL KOMPOSIT
10
Berdasarkan jenis matriks
bull Polymer matrix composites (PMC) Paling populer dengan beragam aplikasi
- Carbon fibre reinforced polymer
- Glass fibre reinforced polymer
- Metal fibre reinforced polymer
bull Metal matrix composites (MMC) Aerospace dan komponen mesin mobil
- Boron or carbon fibre reinforced Aluminium
- Alumina particle reinforced Aluminium
bull Ceramic matrix composites (CMC) Heat exhanger sistem pelindung panas komponen dengan lingkungan korosif dan erosif
- Zirconia in alumina
- Carbon fibre reinforced carbon
KLASIFIKASI MATERIAL KOMPOSIT
SERAT
(FIBER) +RESIN
(MATRIX) = COMPOSITES
bull GLASS (KACA)
bull CARBON
bull ARAMID
bull Fiberglass Reinforced Plastics
(FRP)
bull Carbon Fiber Reinforced Plastics
(CFRP)
bull Aramid Fiber Reinforced Plastics
POLYMER TECHNOLOGY COMPOSITES
bull POLYESTER
bull VINYLESTER
bull EPOXY
bull POLYPROPYLENE
bull POLYAMID
COMPOSITES BUATAN (ENGINEERED COMPOSITES) SEHARI-HARI
BETON = TULANGAN BESI + RESIN SEMEN
The Importance of Lightness for
Environmental Friendly Products
Mass Reduction for Less Energy Consumption
MATERIAL COMPOSITES
Thermoset
type
Density r
(kgm3)
Stiffnes
s E
(Gpa)
Tensile
strength
s (MPa)
Strain to
failure e
()
Tg 0C
Thermal
conductivity
k (Wm0C)
Specific
Heat Cp
(kJkg0C)
Thermal
expansion coeff
a (x106 0C-1)
Polyester 1100-1230 31-46 50-75 10-65 70- 017-022 13-23 55-100
Vinylester 1120-1130 31-33 70-81 30-80 70- - - -
Epoxy 1100-1200 26-38 60-85 15-80 65-175 017-020 105 45-65
Phenolic 1000-1250 30-40 60-80 18 300 012-024 14-18 25-60
PUR 1200 07 30-40 400-450 135 017-021 13-23 70-100
BMI 1200-1320 32-50 48-110 15-33 230-345 - - -
Polyimide 1430-1890 31-49 100-110 15-30 325-370 01-034 105-15 25-80
Al 2800 72 540 18 - 130 096 236
Steel 7790 205 640 25 - 54 046 11
MATRIKS POLIMER THERMOSET
Variasi sifat yang lebar disebabkan oleh adanya formulasi kimia yang berbeda dan penambahan aditif
Jenis Glass Fiber S Glass E Glass C Glass A Glass dll
Terms
Glass Type
S Glass E Glass C Glass A Glass
Silica (SiO2) Content 67 55 64 72
Al2O3 Content 23 14 6 1
Melting Point (Celcius) 915 836 745 745
Tensile Strength 665 500 440 440
Modulus Elastisitas 124 105 100 -
Application AEROSPACE BOAT CHEMICAL TANK CHEMICAL TANK
JENIS SERAT GLASS
CHINA
JENIS SERAT GLASS
C GLASS Calcium borosilicate glasses
used for CHEMICAL stability in corrosive
acid environments
E GLASS Alumina-calcium-borosilicate
glasses with a maximum alkali used as
general purpose fibers where STRENGTH
and high ELECTICAL RESISTIVITY are
required It manifests better electrical
insulation and strongly resists attack by
water More than 50 of the glass fibers
used for reinforcement is E-glass
C Glass
E Glass
C amp E GLASS
SUMBER AGY TECHNICAL PAPER HIGH STRENGTH GLASS FIBER
FAKTA
C GLASS 1 BOROS RESIN
2 KEKUATAN
KURANG
FAKTA
E GLASS 1 HEMAT RESIN
2 KEKUATAN BAIK
3 TAHAN LAMA
FAKTA
TEBAL BUKAN BERARTI KUAT
UNSUR MATRIX (RESIN)
TIDAK ADA KEKUATAN
ldquoMore than 50 of the glass fibers used for
reinforcement is E-glassrdquo
C glass E glass
E glass
C glass
KAIN WOVEN ROVING HASIL LAMINASI
JENIS SERAT GLASS
Kekuatan composites ditentukan oleh
1 Kekuatan amp Sifat Fiber
2 Kekuatan amp Sifat Resin
3 Fraksi Rasio Perbandingan Volume Fiber
dan Resin dalam Composites
rarr tergantung dari Proses Manufaktur
4 Geometri dan Orientasi Arah Fiber dalam
Composites
KEKUATAN COMPOSITES
PROSES MATERIAL
Proses Produksi Kain Fiberglass
Biji Kaca Benang Benang Kaca Kain Fiberglass
PROSES MATERIAL
Glass Beads
Glass Fiber Glass Roving YarnGlass Fabric
FIBERGLASS
PRODUK
MATERIAL DAN PRODUK FIBERGLASS
+
Resin + Additives
PERPADUAN COMPOSITES
BENANG KACA Potongan Serat Kaca CSM
CSM - CHOPPED STRAND MAT
chopped binder
Kain Fiberglass Generasi Pertama
BahanPengikat
SenyawaPada Resin
JENIS FIBERGLASS
Glass Roving Yarn Chopped Strand
ADVANTAGES DISADVANTAGES
Steel
1048707 Low cost 1048707 Corrodes easily
1048707 Ductile under ambient conditions
1048707 Has no lower fatigue limit for welded structures
1048707 Virtually isotropic 1048707 Heavy
1048707 Easily formed and fabricated 1048707 Brittle at low temperatures
1048707 Easily obtained (low relative cost) 1048707 Magnetic
1048707 Easily alloyed or heat treated for special operations
1048707 Easily repaired
1048707 Good fire resistance
1048707 Behaviour is well understood
Alumunium Alloy
1048707 Light weight 1048707 Poor fatigue properties
1048707 Corrosion resistant 1048707 Poor performance in fire
1048707 Easily formed1048707 Low melting point and softening temperature
1048707 Easily fabricated 1048707 High relative cost
1048707 Readily available 1048707 Strength and stiffness less than steel
1048707 Ductile
1048707 Non magnetic
FRP
1048707 Low magnetic properties
1048707 Low electrical conductivity (glass- reinforced plastics)
1048707 Resistance to corrosion
1048707 Resistance to rot and marine growth
1048707 Relatively high sonar transparency
1048707 Good strength to weight ratio
1048707 Good fatigue properties
1048707 Maintenance of properties at low temperatures
1048707 Availability
1048707 Can be manufactured to near net-shape
1048707 Stiffness and strength can be tailored to structural requirements
1048707 Excellent thermal insulation
1048707 Light weight
STEEL vs ALUMUNIUM vs COMPOSITES
Source
1Maritime Platforms Division Aeronautical and
Maritime Research Laboratory (Seref Aksu
Stuart Cannon Craig Gardiner and Matthew
Gudze
2 Metal Corrosion can be defined as the
destructive attack of a metal through interaction
with its environment
(httpwwwcorrosionistcomCorrosion_Fundament
alhtm)
28
Serat rarr penguat
Polimer matriks rarr pengikat
bull Sifat mekanik yang cukup baik
bull Viskositas dan temperatur pengerjaan rendah rarr mudah
dimanufaktur
bull Ketahanan korosi yang baik
bull Media perpindahan gaya rarr distribusi beban dari serat ke serat
bull Ulet rarr Melindungi serat yang getas
bull Size effect rarr Kekuatan dan kekakuan sangat tinggi
bull Aspect ratio (ld) tinggi rarr luas permukaan besar
bull Fleksibel rarr variasi teknik manufaktur
bull Serat dapat diatur sesuai dengan arah pembebanan
29
Advantages Polimer Composites
Kekuatan dan kekakuan spesifik yang tinggi FRCP vs material lain rarr kompetitif jika berat dipertimbangkan
Material Berat jenis
r (kgm3)
Kekakuan
E (GPa)
Kekuatan
tarik su
(MPa)
Kekakuan
spesifik
Er
Kekuatan
spesifik sur
Baja 7800 208 400 27 005
Aluminium 2700 70 200 259 007
Nylon 1100 25 80 23 007
Beton 2400 40 20 166 0008
Random
FRPC
1800 20 300 111 0006
Alligned FRPC
( serat)
1600 200 1500 125 094
Alligned FRCP
( serat)
1600 3 50 19 0001
Tensile Strength amp Modulus of Common Structural Materials
Densities of Common Structural Materials
Specific Tensile Strength amp Modulus of Common Structural Materials
Typical Properties of Common Structural Materials
Kesimpulan COMPOSITES = RINGAN amp KUAT
Jadi secara keseluruhan kekuatan composites
ditentukan oleh
1 Kekuatan amp Sifat Fiber
2 Kekuatan amp Sifat Resin
3 Fraksi Rasio Perbandingan Volume Fiber
dan Resin dalam Composites
4 Geometri dan Orientasi Arah Fiber dalam
Composites
PRODUKSI ANAK NEGERI
Proses Produksi Kain Fiberglass
Biji Kaca Benang Benang Kaca Kain Fiberglass
PROSES MATERIAL
Glass Beads
Glass Fiber Glass Roving YarnGlass Fabric
Proses Produksi Kain Fiberglass
Biji Kaca Benang Benang Kaca Kain Fiberglass
Glass Beads
Glass Fiber Glass Roving YarnGlass Fabric
PROSES MATERIAL
Benang Kaca Potongan Serat Kaca Chopped Strand Mat
CSM - Chopped Strand Mat
chopped binder
Produk Fiberglass Generasi Pertama
Bahan Pengikat
Senyawa Pada Resin
Glass Roving Yarn Chopped Strand
JENIS FIBERGLASS
Benang Kaca Woven Roving
WR - Woven Roving
Tenun Weaving
Produk Fiberglass Generasi Kedua
Glass Roving Yarn
JENIS FIBERGLASS
Multiaxial
MAX - Multiaxial
warp knitting
Produk Fiberglass Generasi Ketiga
Benang Kaca
Glass Roving Yarn
JENIS FIBERGLASS
MAX - Multiaxial Fabric
Fleece (optional)
Lapisan
MULTIAXIAL PROSES
Karakteristik CSM
bull Glass Content 30
bull Resin Content 70
bull Tensile Force
Chopped Strand Mat
JENIS FIBERGLASS
Karakteristik Woven Roving
bull Glass Content 45
bull Resin Content 55
Woven Roving
Resin
|
|
|
|
|
|
|
|
|
|
|
|
|
|
bull Kekuatan Tarik
JENIS FIBERGLASS
No Resin Rich Area
Karakteristik Multiaxial
bull Glass Content 60
bull Resin Content 40
Produk Fiberglass Ketiga MULTIAXIAL
JENIS FIBERGLASS
Perbedaan Woven Roving dan Multiaxial ndash Tampak Samping
JENIS FIBERGLASS
WR FRP
8 Ply WR 800
8 Ply CSM 450
Glass Weight 1 kg
Composite Weight 15kgm2
CSM FRP
22 Ply CSM 450
Glass Weight 1 kg
Composite Weight 18 kgm2
MULTIAXIAL FRP
13 Ply DB 800
Glass Weight 1 kg
Composite Weight
13 kgm2
JENIS FIBERGLASS
Multiaxial
FRP
Woven Roving
FRP
Chopped Strands Mat FRP
MULTIAXIAL
FAKTA
TEBAL BUKAN BERARTI KUAT
UNSUR MATRIX (RESIN)
TIDAK ADA KEKUATAN
ldquoMore than 50 of the glass fibers used for reinforcement is
E-glassrdquo
KarakteristikKekuatan
CSM WR MAX
Kekuatan Tarik 175 MPa 250 MPa 425 MPa
CSM 142
WR 70
KEKUATAN TARIK
Properties CSM Lamination WR Lamination MAX Lamination
Fabric Weight (kgm2) 1 1 1
Composite Weight (kgm2) 18 15 13
Resin usage (kgm2) 15 1 08
Amount of Fabric 22 Ply 16 Ply 13 Ply
Thickness 15 mm 12 mm 10 mm
Tensile Strength (Mpa) 125 1796 400
Tensile Strength (Nmmsup2) 28463 30958 4576
Processing Time High Med Low
Labour Cost High Med Low
MULTIAXIAL
Total Penggunaan Resin -51
Total Berat Kapal -40
Kekuatan Bangunan Kapal +59
Efisiensi Tenaga Kerja
Waktu Pengerjaan Lebih Cepat
KEUNGGULAN MATERIAL
Resapan Resin Lebih Baik amp Merata
Lapisan Lebih Sedikit
Meningkatkan Kekuatan Kapal
KEUNGGULAN MATERIAL
TRIAXIAL
DBL series DBT series
BIAXIAL
LT series DB series
UNIDIRECTIONAL
L series T series
QUADRIAXIAL
DBLT series
JENIS MULTIAXIAL
UNIDIRECTIONAL
DCMU 900 E ndash
KHUSUS UNTUK MEMPERKUAT BENDING KAPAL
PEMASANGAN KHUSUS PADA KEEL DAN TULANGAN
JENIS MULTIAXIAL UNTUK KAPAL
TRIAXIAL
DBL 600 ndash
APLIKASI PADA INDUSTRI PENERBANGAN
PEMASANGAN KHUSUS PADA
SAMBUNGAN BADAN DAN SAYAP
PESAWAT
JENIS MULTIAXIAL UNTUK PESAWAT
QUADRAXIAL
DBLT 800 ndash
APLIKASI PADA INDUSTRI ENERGI
DITERAPKAN UNTUK KEBUTUHAN PEMBANGKIT
LISTRIK ENERGI ANGIN
MULTIAXIAL UNTUK ENERGI
INDUSTRI KIMIA OLAHRAGA AUTOMOTIF
MULTIAXIAL UNTUK INDUSTRI LAINNYA
COMPOSITES
GUNAKAN MATERIAL FIBERGLASS
YANG SUDAH DISERTIFIKASI
BKI
FIBERGLASS UNTUK PEMBANGUNAN BAKAP
PERATURAN MENTERI PERHUBUNGAN
NOMOR PM 7 TAHUN 2013
TENTANG KEWAJIBAN KLASIFIKASI BAGI KAPAL BERBENDERA INDONESIA
PADA BADAN KLASIFIKASI
BADAN SERTIFIKASI MARITIM
Biro Klasifikasi IndonesiaDet Norske Veritas Germanischer Lloyds
PERATURAN BKI
Untuk Kapal Non-Metal
2006
PERSYARATAN MINIMUM
kekuatan material yang
harus digunakan
untuk membangun
Kapal Fiberglass
PEMBESARAN
Table 21
FIBERGLASS TRIAXIS COMPOSITES
TELAH BERSERTIFIKASI BKI
Biro Klasifikasi Indonesia
65
TEKNIK MANUFAKTUR
COMPOSITES
Wet hand lay-up
1) Peletakan
Dry Reinforcement
bull Dry reinforcement dan resin (+ katalis) ditaruh pada permukaan cetakan
2) Pemasukanpenekanan resin
bull Resin ditekan untuk meng-impregnasi serat dengan menggunakan rol
3) Pengulangan proses untuk lapisan lain
bull Beberapa lapisan dapat ditambahkan secara bertahap
4) Resin curing
bull Reaksi dimulai komponen dilepaskan setelah komponen mengeras
(fully cured)
Wet hand lay-up
Manufaktur komponen dapat dikerjakan dengan menggunakan beberapa lapis komposit
dengan memperhatikan kompatibilitas material dan tahapan curing Modifikasi proses dapat
dilakukan seperti
Vacuum bagging
setelah lay-up
Glass Roving
Bulk Resin
Catalyst
3) De-molding
2) Resin Cure
bull Curing dimulai dan komponen dilepaskan setelah pengerasan selesai
bull Serat gelas resin dan katalis dimasukkan kedalam spray gun
1) Spray-up
bull Campuran disemprotkan pada permukaan cetakan
Spray-up
69
Penyemprotan bakal komponen
Komponen
dilepaskan
dari cetakan
Full dispensing
system Chopper Roving
Atomised resin
and catalyst
Spray-up
Prepreg
1) LaminateAssembly 5) De-molding
3) Resin Melts Layup Consolidates
bull Prepreg serat yang sudah diimpregnasi oleh resin+katalis dalam kondisi padat
bull Lapisan prepreg digunting sesuai bentuk yang diinginkan kemudian diletakkan pada permukaan cetakan
sesuai bentuk komponen yang diinginkan Lay-up mudah dilakukan karena sifat ldquotackynessrdquo dari prepreg
2) Applied Vacuum Pressure and Heat
bull Tekanan dan panas diberikan resin mencair terjadi konsolidasi pada komponen
4) Resin Cures
bull Temperatur dinaikkan untuk memulai curing
Prepreg
Variasi proses Autoclave
Komponen dalam
vacuum-bag
bull Campuran resin (+katalis) dan chopped glass strands diperoleh dalam bentuk premixed compound Bulk molding
Compound (BMC) dalam bentuk adonan atau Sheet molding Compound (SMC) dalam bentuk lembaran
bull Ketika panas dan tekanan diberikan oleh cetakan compound mengalir sesuai bentuk komponen yang diinginkan
1) Placement of Charge
5) De-molding3) Squeeze to final dimensions
2) Mould Closure4) Resin Cure
bull Curing dimulai komponen dilepaskan setelah terjadi pengerasan yang cukup
Compression Molding
bull Preform atau dry reinforcement dimasukkan kedalam cetakan sesuai dengan bentuk komponen yang
diinginkan
bull Resin mengalir dengan penekanan atau pem-vakuman dan meng-impregnasi preform dan
mendorongmengeluarkan udara yang ada dalam preform
1) Preform Manufacture
2) Preform Compression
5) De-molding3) Resin Injection
4) Resin Cure
bull Curing terjadi cetakan dibuka setelah terjadi pengerasan yang mencukupi
Liquid Molding (RTM VARI VARTM)
Pultrusion
bull Dry roving or fabrics ditarik melalui bak berisi
campuran resin dan katalis
bull Campuran yang basah ditarik melalui cetakan
bull Sisa resin keluar cetakan
bull Pemanasan dilakukan untuk proses curing
bull Pendinginan dilakukan untuk mempercepat siklus
produksi
Cut-off
Cooling
Die sections
Resin bath
Fibre creel
Filament Winding
bull Dry roving ditarik melalui bak berisi campuran resin dan katalis
bull Wet roving digulungkan dalam keadaan tegang kepada mandrel
bull Kontrol mekanik dari pembawa serat mengatur orientasi peletakan serat pada
mandrel
INDUSTRI COMPOSITES
AEROSPACE
HISTORY
1950 ndash Boeing
1960 ndash F14 Tomcat
1981 ndash AV-8B Harrier
Source
Low-Cost Composite Materials and Structures for Aircraft Applications
httpwwwreinforcedplasticscom
httpwwwcentennialofflightgovessayEvolution_of_TechnologycompositesTech40htm
Automotive
Composite material is used in a number of applications in the automotive
industry due to its temperature resistance rigidity and fatigue strength
The benefits of using composites include greater fuel efficiency
corrosion resistance light weight and strength Composites also provide
a low-cost way to help keep designs looking fresh
Composites are used in
- interior parts (cockpit trimming seats instrument panels)
- exterior structure (body panels openings underbody frontrear
modules)
- engine compartment and fuelmechanical area parts (axles and
suspensions fuel and exhaust systems)
- electrical and electronic components
Lamborghinis Sesto Element carbon fiber
ldquoFat men cannot run as fast as thin men but we build most of our vehicles as though dead-weight fat increased speedhellip I cannot
imagine where the delusion that weight means strength
came fromhelliprdquo mdashHenry Ford
The mix of automotive materials is changing showing a boost for FRP in helping original
equipment manufacturers meet fuel economy and emissions challenges
(Source 2011 DuPont AutomotiveSAE survey of design engineers performed by Signet Research Inc)
Source
httpwwwtoraycomcsrhighlight2009hig_001_01html
The MonoCell tub for the McLaren MP4-12C supercar is moulded as a single
piece and weighs less than 80 kg (176 lbs)
COMPOSITES IN MARINE
TRIMARAN BOAT
AMERICA NAVYINDONESIAN NAVY
Visby Class corvette
Total length is 72 meters
The beam is 1040 meters
The displacement is 600 metric tones
fully equipped the worlds largest CRP
construction
The design of the Visby aims to minimize
the optical and infrared signature above
water acoustic and hydroa coustic
signature underwater electrical potential
and magnetic signature pressure signature
radar cross section and actively emitted
signals
A stealth corvette of the YS 2000 design
has a detection range of 13km in rough
seas and 22km in calm sea without
jamming In a jammed environment the
Visby would be detected at a range of 8km
in rough sea and 11km in calm sea
The material provides high strength and
rigidity low weight good shock resistance
low radar and magnetic signature
1996
Visby is a class of stealth corvettes for the Swedish Navy
ldquoReduced 50 of a Conventional Steelrdquo
Source
Hull Construction with composite materials for ships over 100m in length 2002
Massachusetts Institute of Technology
httpwwwnaval-technologycomprojectsvisby
YACHTS
KAL YUDISTIRAMARATHON 100 ADMIRAL YACHT
LOA 3050 MWidth 6 MFuel Tank 8000 LWater Tank 3000 LIce Box 500 LAccommodation Max 35 Personnel
2 x CATERPILLAR 3412E 1200 HPMARINE DIESEL ENGINE
PC 40 ndash KRI Krait 827Department of Indonesian Navy
LOA 40 MWidth 73 MPower 190Weapon Twin Cannon Barrels
127 mm Heavy Machine GunSpeed Knot 25 KnotDisplacement 105 tonAccommodation 23 personnel
PATROL BOAT
Rigid Inflatable BoatPATROL BOAT
Yachts
36m Luxury Yacht Moonraker
36m Luxury Yacht GoldenEye
50m Luxury Yacht Casino
Royale
45m Luxury Yacht Seashaw
Boat Parts
Barovans for Seismic Sweep
Centrifugal Liftfan House for Surface Effect
Ships
Composite Boat PropellersRTM
Deckhouses for Pilot Boats
Fairing Parts for Submarines
Flybridges for Motor yachts
Light Weight Gangway
MTB Launcher Mock-up
Pleasure Boats
12m Sailboat
12m Sail-Catamaranone-off
Canoes
Dragonfly 1000Catamaran Sailboat
Fantasy 37Sailboat
Farr 60Luxury Sailboat
EurodingyOlympic Dingy Class for
Woman
Hydrolift F23 Racing Boats
Kajacs
Najad 42Sailboat
Najad 520Sailboat
Najad 441Sailboat
Najad 391Sailboat
Nordwest 900Motorboat
Nordwest 1100Motorboat
Quatro 44Motorboat
Racemaster Competition Boats
Storebro 420
Storebro 345
Sweden Yacht 370Sailboat
Sweden Yacht 69Sailboat
Windy 41Motorboat
X-632Sailboat
X-362Sailboat
Commercial Boats
175m High Speed AmbulancePassenger Boat
19m High Speed Passenger Boat
20m High Speed Passenger Boat
364m Surface Effect Passenger Ship
45m Surface Effect Passenger Ship
120m Hull Structural Parts HSSS Catamaran Ferry
APPENDIX
Marine Vessel
1188m Fast Attack Vessel FMV 90 E
20m SAV-Surface Auxiliary Vessels
34m Personnel TransportCoast Guard Vessel
40ft Experimental SES
40m Landsort-Class Mine Hunters
54m Mine Counter Measure Vehicles SES
74m Coastal Patrol Boats
Fishing Boats
30 GT
12 GT
10 GT
5 GT
WISEWings In Surface Effect
HOVERCRAFT
Designed specifically for the tourist and transport industries the
Pioneer Mk3 hovercraft is amphibious and comfortably seats 25
passengers plus 1-crew The air-conditioned cabin allows for
maximum visibility for all aboard The Pioneer Mk3 is robust and
dynamic in its performance
Commercial hovercraft
Mk3 AirLift Hovercraft - 1215m
Power is economicaly provided by one Deutz diesel engine of
330kW (442hp) to cruise easily at 40 knots with much higher
speeds available according to the surface conditions The hull is
manufactured from fibreglassPVC foam composite sandwich
the windows are glass and the skirt is urethane coated nylon A
Military version is available with increased payload and systems
redundancy Power for the Military version comes from two Steyr
diesel engines with a total installed power of 320kW (429hp) All
transmission electrical hydraulic and air systems are duplicated
for maximum redundancy The increased performance of the
Military version comes from the reduced engine weight of the twin
Steyr installation cf the Deutz installation
Source
httpwwwnauticexpocomprodairlift-hovercraftcommercial-hovercrafts-25251-142868html
HOVERFLIGHT
BALLISTIC amp UNIT DEFENCED
Triaxis Composites Collaboration with Institute of Aeronautics and Space in the development of Missile Nose Cone
Polymer composites is the evolution of the military defence
Thin steel was the helmet material of
WWII and remained the principal material until around the 1980rsquos
The advantages of using steel
included a simple technology for manufacture of the helmets low cost and reasonably good
impact protection However these helmets were found to provide only marginal protection
against fragments
During the Vietnam War the US Army experimented with fiber-reinforced inserts in the
helmets These inserts improved ballistic protection but at the same time added weight and
reduced the air space between the head and the helmet
By the early part of the 1980rsquos the US military had developed the first all-composite
100 fiber-reinforced helmet This development resulted in even better ballistic protection
without altering the weight of the helmet Other improvements included better head coverage and
more space for ventilation
Source
Composites Armor - A difficult but huge market
by A Brent Strong Brigham Young University
MILITARY VEHICLES
HIGH SPEED TRAIN SHINKANSEN
Advanced Composites provide lightweight solutions for railway vehicles
saving as much as 50-80 of the weight compared with traditional
components
A lower overall weight translates into less stress faster acceleration and
higher speeds as well as reduced starting and stopping inertia Today
these are important criteria in global high-speed and metropolitan
railway projects
Fire smoke and toxic fumes are key safety criteria for interior
components of railway carriages Any material selected for an interior
component must meet international fire retardant standards
for Rail Interiors and Exteriors
Ceiling Panels Stairs
Seating Vestibules
Window Panels Door Pillars
Partition WallsDiffusers
Gangway and Cabinet Panels Cabin and
Desk panels
Door Pillars Lavatory Modules (standard and
Front and Rear EndsRoof Panels
Nose Cones Under Fairings
Source
httpwwwpctaerail_compositesphp
101
SKY BUS
2009
Europe is the world leader in offshore wind with
828 wind turbines and a cumulative capacity of 2056 MW spread across 38 offshore wind farms in 9
European countries
The UK and Denmark are the current leaders with a 44 and 30 share respectively In 2009
five countries built new offshore wind farms
UK (284 MW)
Demark (230 MW)
Sweden (30 MW)
Germany (30 MW)
Norway (23 MW)
2010
Asia leads the growth in global wind power which grew 358 GW in 2010 bringing
total global capacity to 1944 GW ndash up 225 from 2009
the Global Wind Energy Council (GWEC)
Asia accounted for 19 GW of new global wind power installations driven by China which installed 165
GW
ldquoChina now has 423 GW of wind powerrdquo
ldquoThis puts China firmly on a path to reach 200 GW of installed wind power by 2020 At the same
time China has become the worldrsquos largest producer of wind energy equipmentrdquo
Source
httpwwwreinforcedplasticscomview15655asia-leads-global-wind-power-growth
httpimgdeusmcomdesignnews288288605-Sandia_Sizes_up_Wind_Turbine_Blade_Design_C_largegif
WIND ENERGY
Marine Current Turbines
Source
httpwwwsiemenscompressenpressreleasepress=enpressrelease2011solar-hydroex201111005htm
httpwwwmarineturbinescom
A commercial marine current turbine consists of
two rotors which are fixed on a structure within the
sea current The twin rotors rotate with the
movement of the tidal flow and the blades pitch
through 180 degrees to optimally track tidal current
(Press picture Marine Current Turbines)
Wave Star Energys Multi-point Absorber
CFRP COLUMN REINFORCEMENT
INDUSTRIAL TANKS
107
INDUSTRIAL PIPES
PRESSURE TANKS
109
ldquoLetrsquos Make with Compositesrdquo
Composites An industry defining its own future by favouring
bull Innovation bull Unification bull Regulations
bull Visibility
The composite industry is relatively recent (1940s)
All segments along the value chain account for about 550000 jobs worldwide
Worldwide market in volume = 8 Millions of tons
Value of the worldwide composite market = 60 billion euros
North America
EuropeAsia
36
3331
IN VALUE
Europe has reached a high level of technicity
Stronger weight of high value-added applications
Aerospace
Wind energy
Asia Pacific amp Rest of the WorldNorth America
Value
euro22B
36
Volume
27 Mt
35
Average
Unit
Price
euro82kg
Value
euro18B
31
Volume
33 Mt
43
Average
Unit
Price
euro55kg
World
Total
Value
euro60B
Total
Volume
8 Mt
Average
Unit
Price
euro72kg
(1) USA Canada
(2) Europe Russia
Middle East and
Africa
(3) Asia Australia and
South America
Value per geography
GDP per capita
Composites volume per capita inkg per inhabitant
Development curvein Volume
Composites markets size by country depends on development level
Average prices by industry worldwide
Aeronautics
Wind Energy
Consumer Goods
Transportation
Marine
Construction
E amp E
Pipes amp Tanks
Unit Prices eurokg 0 5 10 15 20 25 30 35 40 45
Growth in volume mainly in Asia
Repartition of the composites market by region 1999 gt 2013 in Mt
RoW
Europe
Asia
North America
Repartition of the composites market by region 1999 gt 2013 in Mt
1999 2002 2007 2013
7
22
36
35
7
33
23
38
5
29
26
40
4
27
24
45
25(1) 51Weight of Asia in global growth in volume
2015
103
81
6259
COMPOSITES
COMPOSITES = DUA MATERIAL YANG BERBEDA SIFAT FISIK DAN
KIMIAWI NYA BERSATU SECARA MAKROSKOPIK MELALUI SUATU
PROSES KIMIA MENJADI SUATU MATERIAL BARU (KOMPOSIT)
DENGAN SIFAT FISIK DAN MEKANIKAL YANG BARU
COMPOSITES ALAMI (NATURAL MATERIAL)
COMPOSITES BUATAN (ENGINEERED MATERIAL)
COMPOSITES
9
Berdasarkan jenis penguat
bull Particle-reinforced composites
ndash Large-particle composites (Cermets tungsten carbida in cobalt semen beton bertulang)
ndash Dispersed-strenghtened composites (alumina in aluminium ThoriaThO2 in Nickel alloy)
bull Fiber-reinforced composites konstruksi kaku kuat dan ringan
ndash Discontinuous (Short) fiber composites
ndash Continuous (long) fiber composites
bull Structural-reinforced composites
ndash Laminar composites (kayu multipleks laminate carbon epoxy)
ndash Sandwich composites konstruksi ringan dengan kekakuan dan kekuatan bending yang tinggi (Honeycomb-carbon epoxy composites dinding kardus corrugated paper - paper)
KLASIFIKASI MATERIAL KOMPOSIT
10
Berdasarkan jenis matriks
bull Polymer matrix composites (PMC) Paling populer dengan beragam aplikasi
- Carbon fibre reinforced polymer
- Glass fibre reinforced polymer
- Metal fibre reinforced polymer
bull Metal matrix composites (MMC) Aerospace dan komponen mesin mobil
- Boron or carbon fibre reinforced Aluminium
- Alumina particle reinforced Aluminium
bull Ceramic matrix composites (CMC) Heat exhanger sistem pelindung panas komponen dengan lingkungan korosif dan erosif
- Zirconia in alumina
- Carbon fibre reinforced carbon
KLASIFIKASI MATERIAL KOMPOSIT
SERAT
(FIBER) +RESIN
(MATRIX) = COMPOSITES
bull GLASS (KACA)
bull CARBON
bull ARAMID
bull Fiberglass Reinforced Plastics
(FRP)
bull Carbon Fiber Reinforced Plastics
(CFRP)
bull Aramid Fiber Reinforced Plastics
POLYMER TECHNOLOGY COMPOSITES
bull POLYESTER
bull VINYLESTER
bull EPOXY
bull POLYPROPYLENE
bull POLYAMID
COMPOSITES BUATAN (ENGINEERED COMPOSITES) SEHARI-HARI
BETON = TULANGAN BESI + RESIN SEMEN
The Importance of Lightness for
Environmental Friendly Products
Mass Reduction for Less Energy Consumption
MATERIAL COMPOSITES
Thermoset
type
Density r
(kgm3)
Stiffnes
s E
(Gpa)
Tensile
strength
s (MPa)
Strain to
failure e
()
Tg 0C
Thermal
conductivity
k (Wm0C)
Specific
Heat Cp
(kJkg0C)
Thermal
expansion coeff
a (x106 0C-1)
Polyester 1100-1230 31-46 50-75 10-65 70- 017-022 13-23 55-100
Vinylester 1120-1130 31-33 70-81 30-80 70- - - -
Epoxy 1100-1200 26-38 60-85 15-80 65-175 017-020 105 45-65
Phenolic 1000-1250 30-40 60-80 18 300 012-024 14-18 25-60
PUR 1200 07 30-40 400-450 135 017-021 13-23 70-100
BMI 1200-1320 32-50 48-110 15-33 230-345 - - -
Polyimide 1430-1890 31-49 100-110 15-30 325-370 01-034 105-15 25-80
Al 2800 72 540 18 - 130 096 236
Steel 7790 205 640 25 - 54 046 11
MATRIKS POLIMER THERMOSET
Variasi sifat yang lebar disebabkan oleh adanya formulasi kimia yang berbeda dan penambahan aditif
Jenis Glass Fiber S Glass E Glass C Glass A Glass dll
Terms
Glass Type
S Glass E Glass C Glass A Glass
Silica (SiO2) Content 67 55 64 72
Al2O3 Content 23 14 6 1
Melting Point (Celcius) 915 836 745 745
Tensile Strength 665 500 440 440
Modulus Elastisitas 124 105 100 -
Application AEROSPACE BOAT CHEMICAL TANK CHEMICAL TANK
JENIS SERAT GLASS
CHINA
JENIS SERAT GLASS
C GLASS Calcium borosilicate glasses
used for CHEMICAL stability in corrosive
acid environments
E GLASS Alumina-calcium-borosilicate
glasses with a maximum alkali used as
general purpose fibers where STRENGTH
and high ELECTICAL RESISTIVITY are
required It manifests better electrical
insulation and strongly resists attack by
water More than 50 of the glass fibers
used for reinforcement is E-glass
C Glass
E Glass
C amp E GLASS
SUMBER AGY TECHNICAL PAPER HIGH STRENGTH GLASS FIBER
FAKTA
C GLASS 1 BOROS RESIN
2 KEKUATAN
KURANG
FAKTA
E GLASS 1 HEMAT RESIN
2 KEKUATAN BAIK
3 TAHAN LAMA
FAKTA
TEBAL BUKAN BERARTI KUAT
UNSUR MATRIX (RESIN)
TIDAK ADA KEKUATAN
ldquoMore than 50 of the glass fibers used for
reinforcement is E-glassrdquo
C glass E glass
E glass
C glass
KAIN WOVEN ROVING HASIL LAMINASI
JENIS SERAT GLASS
Kekuatan composites ditentukan oleh
1 Kekuatan amp Sifat Fiber
2 Kekuatan amp Sifat Resin
3 Fraksi Rasio Perbandingan Volume Fiber
dan Resin dalam Composites
rarr tergantung dari Proses Manufaktur
4 Geometri dan Orientasi Arah Fiber dalam
Composites
KEKUATAN COMPOSITES
PROSES MATERIAL
Proses Produksi Kain Fiberglass
Biji Kaca Benang Benang Kaca Kain Fiberglass
PROSES MATERIAL
Glass Beads
Glass Fiber Glass Roving YarnGlass Fabric
FIBERGLASS
PRODUK
MATERIAL DAN PRODUK FIBERGLASS
+
Resin + Additives
PERPADUAN COMPOSITES
BENANG KACA Potongan Serat Kaca CSM
CSM - CHOPPED STRAND MAT
chopped binder
Kain Fiberglass Generasi Pertama
BahanPengikat
SenyawaPada Resin
JENIS FIBERGLASS
Glass Roving Yarn Chopped Strand
ADVANTAGES DISADVANTAGES
Steel
1048707 Low cost 1048707 Corrodes easily
1048707 Ductile under ambient conditions
1048707 Has no lower fatigue limit for welded structures
1048707 Virtually isotropic 1048707 Heavy
1048707 Easily formed and fabricated 1048707 Brittle at low temperatures
1048707 Easily obtained (low relative cost) 1048707 Magnetic
1048707 Easily alloyed or heat treated for special operations
1048707 Easily repaired
1048707 Good fire resistance
1048707 Behaviour is well understood
Alumunium Alloy
1048707 Light weight 1048707 Poor fatigue properties
1048707 Corrosion resistant 1048707 Poor performance in fire
1048707 Easily formed1048707 Low melting point and softening temperature
1048707 Easily fabricated 1048707 High relative cost
1048707 Readily available 1048707 Strength and stiffness less than steel
1048707 Ductile
1048707 Non magnetic
FRP
1048707 Low magnetic properties
1048707 Low electrical conductivity (glass- reinforced plastics)
1048707 Resistance to corrosion
1048707 Resistance to rot and marine growth
1048707 Relatively high sonar transparency
1048707 Good strength to weight ratio
1048707 Good fatigue properties
1048707 Maintenance of properties at low temperatures
1048707 Availability
1048707 Can be manufactured to near net-shape
1048707 Stiffness and strength can be tailored to structural requirements
1048707 Excellent thermal insulation
1048707 Light weight
STEEL vs ALUMUNIUM vs COMPOSITES
Source
1Maritime Platforms Division Aeronautical and
Maritime Research Laboratory (Seref Aksu
Stuart Cannon Craig Gardiner and Matthew
Gudze
2 Metal Corrosion can be defined as the
destructive attack of a metal through interaction
with its environment
(httpwwwcorrosionistcomCorrosion_Fundament
alhtm)
28
Serat rarr penguat
Polimer matriks rarr pengikat
bull Sifat mekanik yang cukup baik
bull Viskositas dan temperatur pengerjaan rendah rarr mudah
dimanufaktur
bull Ketahanan korosi yang baik
bull Media perpindahan gaya rarr distribusi beban dari serat ke serat
bull Ulet rarr Melindungi serat yang getas
bull Size effect rarr Kekuatan dan kekakuan sangat tinggi
bull Aspect ratio (ld) tinggi rarr luas permukaan besar
bull Fleksibel rarr variasi teknik manufaktur
bull Serat dapat diatur sesuai dengan arah pembebanan
29
Advantages Polimer Composites
Kekuatan dan kekakuan spesifik yang tinggi FRCP vs material lain rarr kompetitif jika berat dipertimbangkan
Material Berat jenis
r (kgm3)
Kekakuan
E (GPa)
Kekuatan
tarik su
(MPa)
Kekakuan
spesifik
Er
Kekuatan
spesifik sur
Baja 7800 208 400 27 005
Aluminium 2700 70 200 259 007
Nylon 1100 25 80 23 007
Beton 2400 40 20 166 0008
Random
FRPC
1800 20 300 111 0006
Alligned FRPC
( serat)
1600 200 1500 125 094
Alligned FRCP
( serat)
1600 3 50 19 0001
Tensile Strength amp Modulus of Common Structural Materials
Densities of Common Structural Materials
Specific Tensile Strength amp Modulus of Common Structural Materials
Typical Properties of Common Structural Materials
Kesimpulan COMPOSITES = RINGAN amp KUAT
Jadi secara keseluruhan kekuatan composites
ditentukan oleh
1 Kekuatan amp Sifat Fiber
2 Kekuatan amp Sifat Resin
3 Fraksi Rasio Perbandingan Volume Fiber
dan Resin dalam Composites
4 Geometri dan Orientasi Arah Fiber dalam
Composites
PRODUKSI ANAK NEGERI
Proses Produksi Kain Fiberglass
Biji Kaca Benang Benang Kaca Kain Fiberglass
PROSES MATERIAL
Glass Beads
Glass Fiber Glass Roving YarnGlass Fabric
Proses Produksi Kain Fiberglass
Biji Kaca Benang Benang Kaca Kain Fiberglass
Glass Beads
Glass Fiber Glass Roving YarnGlass Fabric
PROSES MATERIAL
Benang Kaca Potongan Serat Kaca Chopped Strand Mat
CSM - Chopped Strand Mat
chopped binder
Produk Fiberglass Generasi Pertama
Bahan Pengikat
Senyawa Pada Resin
Glass Roving Yarn Chopped Strand
JENIS FIBERGLASS
Benang Kaca Woven Roving
WR - Woven Roving
Tenun Weaving
Produk Fiberglass Generasi Kedua
Glass Roving Yarn
JENIS FIBERGLASS
Multiaxial
MAX - Multiaxial
warp knitting
Produk Fiberglass Generasi Ketiga
Benang Kaca
Glass Roving Yarn
JENIS FIBERGLASS
MAX - Multiaxial Fabric
Fleece (optional)
Lapisan
MULTIAXIAL PROSES
Karakteristik CSM
bull Glass Content 30
bull Resin Content 70
bull Tensile Force
Chopped Strand Mat
JENIS FIBERGLASS
Karakteristik Woven Roving
bull Glass Content 45
bull Resin Content 55
Woven Roving
Resin
|
|
|
|
|
|
|
|
|
|
|
|
|
|
bull Kekuatan Tarik
JENIS FIBERGLASS
No Resin Rich Area
Karakteristik Multiaxial
bull Glass Content 60
bull Resin Content 40
Produk Fiberglass Ketiga MULTIAXIAL
JENIS FIBERGLASS
Perbedaan Woven Roving dan Multiaxial ndash Tampak Samping
JENIS FIBERGLASS
WR FRP
8 Ply WR 800
8 Ply CSM 450
Glass Weight 1 kg
Composite Weight 15kgm2
CSM FRP
22 Ply CSM 450
Glass Weight 1 kg
Composite Weight 18 kgm2
MULTIAXIAL FRP
13 Ply DB 800
Glass Weight 1 kg
Composite Weight
13 kgm2
JENIS FIBERGLASS
Multiaxial
FRP
Woven Roving
FRP
Chopped Strands Mat FRP
MULTIAXIAL
FAKTA
TEBAL BUKAN BERARTI KUAT
UNSUR MATRIX (RESIN)
TIDAK ADA KEKUATAN
ldquoMore than 50 of the glass fibers used for reinforcement is
E-glassrdquo
KarakteristikKekuatan
CSM WR MAX
Kekuatan Tarik 175 MPa 250 MPa 425 MPa
CSM 142
WR 70
KEKUATAN TARIK
Properties CSM Lamination WR Lamination MAX Lamination
Fabric Weight (kgm2) 1 1 1
Composite Weight (kgm2) 18 15 13
Resin usage (kgm2) 15 1 08
Amount of Fabric 22 Ply 16 Ply 13 Ply
Thickness 15 mm 12 mm 10 mm
Tensile Strength (Mpa) 125 1796 400
Tensile Strength (Nmmsup2) 28463 30958 4576
Processing Time High Med Low
Labour Cost High Med Low
MULTIAXIAL
Total Penggunaan Resin -51
Total Berat Kapal -40
Kekuatan Bangunan Kapal +59
Efisiensi Tenaga Kerja
Waktu Pengerjaan Lebih Cepat
KEUNGGULAN MATERIAL
Resapan Resin Lebih Baik amp Merata
Lapisan Lebih Sedikit
Meningkatkan Kekuatan Kapal
KEUNGGULAN MATERIAL
TRIAXIAL
DBL series DBT series
BIAXIAL
LT series DB series
UNIDIRECTIONAL
L series T series
QUADRIAXIAL
DBLT series
JENIS MULTIAXIAL
UNIDIRECTIONAL
DCMU 900 E ndash
KHUSUS UNTUK MEMPERKUAT BENDING KAPAL
PEMASANGAN KHUSUS PADA KEEL DAN TULANGAN
JENIS MULTIAXIAL UNTUK KAPAL
TRIAXIAL
DBL 600 ndash
APLIKASI PADA INDUSTRI PENERBANGAN
PEMASANGAN KHUSUS PADA
SAMBUNGAN BADAN DAN SAYAP
PESAWAT
JENIS MULTIAXIAL UNTUK PESAWAT
QUADRAXIAL
DBLT 800 ndash
APLIKASI PADA INDUSTRI ENERGI
DITERAPKAN UNTUK KEBUTUHAN PEMBANGKIT
LISTRIK ENERGI ANGIN
MULTIAXIAL UNTUK ENERGI
INDUSTRI KIMIA OLAHRAGA AUTOMOTIF
MULTIAXIAL UNTUK INDUSTRI LAINNYA
COMPOSITES
GUNAKAN MATERIAL FIBERGLASS
YANG SUDAH DISERTIFIKASI
BKI
FIBERGLASS UNTUK PEMBANGUNAN BAKAP
PERATURAN MENTERI PERHUBUNGAN
NOMOR PM 7 TAHUN 2013
TENTANG KEWAJIBAN KLASIFIKASI BAGI KAPAL BERBENDERA INDONESIA
PADA BADAN KLASIFIKASI
BADAN SERTIFIKASI MARITIM
Biro Klasifikasi IndonesiaDet Norske Veritas Germanischer Lloyds
PERATURAN BKI
Untuk Kapal Non-Metal
2006
PERSYARATAN MINIMUM
kekuatan material yang
harus digunakan
untuk membangun
Kapal Fiberglass
PEMBESARAN
Table 21
FIBERGLASS TRIAXIS COMPOSITES
TELAH BERSERTIFIKASI BKI
Biro Klasifikasi Indonesia
65
TEKNIK MANUFAKTUR
COMPOSITES
Wet hand lay-up
1) Peletakan
Dry Reinforcement
bull Dry reinforcement dan resin (+ katalis) ditaruh pada permukaan cetakan
2) Pemasukanpenekanan resin
bull Resin ditekan untuk meng-impregnasi serat dengan menggunakan rol
3) Pengulangan proses untuk lapisan lain
bull Beberapa lapisan dapat ditambahkan secara bertahap
4) Resin curing
bull Reaksi dimulai komponen dilepaskan setelah komponen mengeras
(fully cured)
Wet hand lay-up
Manufaktur komponen dapat dikerjakan dengan menggunakan beberapa lapis komposit
dengan memperhatikan kompatibilitas material dan tahapan curing Modifikasi proses dapat
dilakukan seperti
Vacuum bagging
setelah lay-up
Glass Roving
Bulk Resin
Catalyst
3) De-molding
2) Resin Cure
bull Curing dimulai dan komponen dilepaskan setelah pengerasan selesai
bull Serat gelas resin dan katalis dimasukkan kedalam spray gun
1) Spray-up
bull Campuran disemprotkan pada permukaan cetakan
Spray-up
69
Penyemprotan bakal komponen
Komponen
dilepaskan
dari cetakan
Full dispensing
system Chopper Roving
Atomised resin
and catalyst
Spray-up
Prepreg
1) LaminateAssembly 5) De-molding
3) Resin Melts Layup Consolidates
bull Prepreg serat yang sudah diimpregnasi oleh resin+katalis dalam kondisi padat
bull Lapisan prepreg digunting sesuai bentuk yang diinginkan kemudian diletakkan pada permukaan cetakan
sesuai bentuk komponen yang diinginkan Lay-up mudah dilakukan karena sifat ldquotackynessrdquo dari prepreg
2) Applied Vacuum Pressure and Heat
bull Tekanan dan panas diberikan resin mencair terjadi konsolidasi pada komponen
4) Resin Cures
bull Temperatur dinaikkan untuk memulai curing
Prepreg
Variasi proses Autoclave
Komponen dalam
vacuum-bag
bull Campuran resin (+katalis) dan chopped glass strands diperoleh dalam bentuk premixed compound Bulk molding
Compound (BMC) dalam bentuk adonan atau Sheet molding Compound (SMC) dalam bentuk lembaran
bull Ketika panas dan tekanan diberikan oleh cetakan compound mengalir sesuai bentuk komponen yang diinginkan
1) Placement of Charge
5) De-molding3) Squeeze to final dimensions
2) Mould Closure4) Resin Cure
bull Curing dimulai komponen dilepaskan setelah terjadi pengerasan yang cukup
Compression Molding
bull Preform atau dry reinforcement dimasukkan kedalam cetakan sesuai dengan bentuk komponen yang
diinginkan
bull Resin mengalir dengan penekanan atau pem-vakuman dan meng-impregnasi preform dan
mendorongmengeluarkan udara yang ada dalam preform
1) Preform Manufacture
2) Preform Compression
5) De-molding3) Resin Injection
4) Resin Cure
bull Curing terjadi cetakan dibuka setelah terjadi pengerasan yang mencukupi
Liquid Molding (RTM VARI VARTM)
Pultrusion
bull Dry roving or fabrics ditarik melalui bak berisi
campuran resin dan katalis
bull Campuran yang basah ditarik melalui cetakan
bull Sisa resin keluar cetakan
bull Pemanasan dilakukan untuk proses curing
bull Pendinginan dilakukan untuk mempercepat siklus
produksi
Cut-off
Cooling
Die sections
Resin bath
Fibre creel
Filament Winding
bull Dry roving ditarik melalui bak berisi campuran resin dan katalis
bull Wet roving digulungkan dalam keadaan tegang kepada mandrel
bull Kontrol mekanik dari pembawa serat mengatur orientasi peletakan serat pada
mandrel
INDUSTRI COMPOSITES
AEROSPACE
HISTORY
1950 ndash Boeing
1960 ndash F14 Tomcat
1981 ndash AV-8B Harrier
Source
Low-Cost Composite Materials and Structures for Aircraft Applications
httpwwwreinforcedplasticscom
httpwwwcentennialofflightgovessayEvolution_of_TechnologycompositesTech40htm
Automotive
Composite material is used in a number of applications in the automotive
industry due to its temperature resistance rigidity and fatigue strength
The benefits of using composites include greater fuel efficiency
corrosion resistance light weight and strength Composites also provide
a low-cost way to help keep designs looking fresh
Composites are used in
- interior parts (cockpit trimming seats instrument panels)
- exterior structure (body panels openings underbody frontrear
modules)
- engine compartment and fuelmechanical area parts (axles and
suspensions fuel and exhaust systems)
- electrical and electronic components
Lamborghinis Sesto Element carbon fiber
ldquoFat men cannot run as fast as thin men but we build most of our vehicles as though dead-weight fat increased speedhellip I cannot
imagine where the delusion that weight means strength
came fromhelliprdquo mdashHenry Ford
The mix of automotive materials is changing showing a boost for FRP in helping original
equipment manufacturers meet fuel economy and emissions challenges
(Source 2011 DuPont AutomotiveSAE survey of design engineers performed by Signet Research Inc)
Source
httpwwwtoraycomcsrhighlight2009hig_001_01html
The MonoCell tub for the McLaren MP4-12C supercar is moulded as a single
piece and weighs less than 80 kg (176 lbs)
COMPOSITES IN MARINE
TRIMARAN BOAT
AMERICA NAVYINDONESIAN NAVY
Visby Class corvette
Total length is 72 meters
The beam is 1040 meters
The displacement is 600 metric tones
fully equipped the worlds largest CRP
construction
The design of the Visby aims to minimize
the optical and infrared signature above
water acoustic and hydroa coustic
signature underwater electrical potential
and magnetic signature pressure signature
radar cross section and actively emitted
signals
A stealth corvette of the YS 2000 design
has a detection range of 13km in rough
seas and 22km in calm sea without
jamming In a jammed environment the
Visby would be detected at a range of 8km
in rough sea and 11km in calm sea
The material provides high strength and
rigidity low weight good shock resistance
low radar and magnetic signature
1996
Visby is a class of stealth corvettes for the Swedish Navy
ldquoReduced 50 of a Conventional Steelrdquo
Source
Hull Construction with composite materials for ships over 100m in length 2002
Massachusetts Institute of Technology
httpwwwnaval-technologycomprojectsvisby
YACHTS
KAL YUDISTIRAMARATHON 100 ADMIRAL YACHT
LOA 3050 MWidth 6 MFuel Tank 8000 LWater Tank 3000 LIce Box 500 LAccommodation Max 35 Personnel
2 x CATERPILLAR 3412E 1200 HPMARINE DIESEL ENGINE
PC 40 ndash KRI Krait 827Department of Indonesian Navy
LOA 40 MWidth 73 MPower 190Weapon Twin Cannon Barrels
127 mm Heavy Machine GunSpeed Knot 25 KnotDisplacement 105 tonAccommodation 23 personnel
PATROL BOAT
Rigid Inflatable BoatPATROL BOAT
Yachts
36m Luxury Yacht Moonraker
36m Luxury Yacht GoldenEye
50m Luxury Yacht Casino
Royale
45m Luxury Yacht Seashaw
Boat Parts
Barovans for Seismic Sweep
Centrifugal Liftfan House for Surface Effect
Ships
Composite Boat PropellersRTM
Deckhouses for Pilot Boats
Fairing Parts for Submarines
Flybridges for Motor yachts
Light Weight Gangway
MTB Launcher Mock-up
Pleasure Boats
12m Sailboat
12m Sail-Catamaranone-off
Canoes
Dragonfly 1000Catamaran Sailboat
Fantasy 37Sailboat
Farr 60Luxury Sailboat
EurodingyOlympic Dingy Class for
Woman
Hydrolift F23 Racing Boats
Kajacs
Najad 42Sailboat
Najad 520Sailboat
Najad 441Sailboat
Najad 391Sailboat
Nordwest 900Motorboat
Nordwest 1100Motorboat
Quatro 44Motorboat
Racemaster Competition Boats
Storebro 420
Storebro 345
Sweden Yacht 370Sailboat
Sweden Yacht 69Sailboat
Windy 41Motorboat
X-632Sailboat
X-362Sailboat
Commercial Boats
175m High Speed AmbulancePassenger Boat
19m High Speed Passenger Boat
20m High Speed Passenger Boat
364m Surface Effect Passenger Ship
45m Surface Effect Passenger Ship
120m Hull Structural Parts HSSS Catamaran Ferry
APPENDIX
Marine Vessel
1188m Fast Attack Vessel FMV 90 E
20m SAV-Surface Auxiliary Vessels
34m Personnel TransportCoast Guard Vessel
40ft Experimental SES
40m Landsort-Class Mine Hunters
54m Mine Counter Measure Vehicles SES
74m Coastal Patrol Boats
Fishing Boats
30 GT
12 GT
10 GT
5 GT
WISEWings In Surface Effect
HOVERCRAFT
Designed specifically for the tourist and transport industries the
Pioneer Mk3 hovercraft is amphibious and comfortably seats 25
passengers plus 1-crew The air-conditioned cabin allows for
maximum visibility for all aboard The Pioneer Mk3 is robust and
dynamic in its performance
Commercial hovercraft
Mk3 AirLift Hovercraft - 1215m
Power is economicaly provided by one Deutz diesel engine of
330kW (442hp) to cruise easily at 40 knots with much higher
speeds available according to the surface conditions The hull is
manufactured from fibreglassPVC foam composite sandwich
the windows are glass and the skirt is urethane coated nylon A
Military version is available with increased payload and systems
redundancy Power for the Military version comes from two Steyr
diesel engines with a total installed power of 320kW (429hp) All
transmission electrical hydraulic and air systems are duplicated
for maximum redundancy The increased performance of the
Military version comes from the reduced engine weight of the twin
Steyr installation cf the Deutz installation
Source
httpwwwnauticexpocomprodairlift-hovercraftcommercial-hovercrafts-25251-142868html
HOVERFLIGHT
BALLISTIC amp UNIT DEFENCED
Triaxis Composites Collaboration with Institute of Aeronautics and Space in the development of Missile Nose Cone
Polymer composites is the evolution of the military defence
Thin steel was the helmet material of
WWII and remained the principal material until around the 1980rsquos
The advantages of using steel
included a simple technology for manufacture of the helmets low cost and reasonably good
impact protection However these helmets were found to provide only marginal protection
against fragments
During the Vietnam War the US Army experimented with fiber-reinforced inserts in the
helmets These inserts improved ballistic protection but at the same time added weight and
reduced the air space between the head and the helmet
By the early part of the 1980rsquos the US military had developed the first all-composite
100 fiber-reinforced helmet This development resulted in even better ballistic protection
without altering the weight of the helmet Other improvements included better head coverage and
more space for ventilation
Source
Composites Armor - A difficult but huge market
by A Brent Strong Brigham Young University
MILITARY VEHICLES
HIGH SPEED TRAIN SHINKANSEN
Advanced Composites provide lightweight solutions for railway vehicles
saving as much as 50-80 of the weight compared with traditional
components
A lower overall weight translates into less stress faster acceleration and
higher speeds as well as reduced starting and stopping inertia Today
these are important criteria in global high-speed and metropolitan
railway projects
Fire smoke and toxic fumes are key safety criteria for interior
components of railway carriages Any material selected for an interior
component must meet international fire retardant standards
for Rail Interiors and Exteriors
Ceiling Panels Stairs
Seating Vestibules
Window Panels Door Pillars
Partition WallsDiffusers
Gangway and Cabinet Panels Cabin and
Desk panels
Door Pillars Lavatory Modules (standard and
Front and Rear EndsRoof Panels
Nose Cones Under Fairings
Source
httpwwwpctaerail_compositesphp
101
SKY BUS
2009
Europe is the world leader in offshore wind with
828 wind turbines and a cumulative capacity of 2056 MW spread across 38 offshore wind farms in 9
European countries
The UK and Denmark are the current leaders with a 44 and 30 share respectively In 2009
five countries built new offshore wind farms
UK (284 MW)
Demark (230 MW)
Sweden (30 MW)
Germany (30 MW)
Norway (23 MW)
2010
Asia leads the growth in global wind power which grew 358 GW in 2010 bringing
total global capacity to 1944 GW ndash up 225 from 2009
the Global Wind Energy Council (GWEC)
Asia accounted for 19 GW of new global wind power installations driven by China which installed 165
GW
ldquoChina now has 423 GW of wind powerrdquo
ldquoThis puts China firmly on a path to reach 200 GW of installed wind power by 2020 At the same
time China has become the worldrsquos largest producer of wind energy equipmentrdquo
Source
httpwwwreinforcedplasticscomview15655asia-leads-global-wind-power-growth
httpimgdeusmcomdesignnews288288605-Sandia_Sizes_up_Wind_Turbine_Blade_Design_C_largegif
WIND ENERGY
Marine Current Turbines
Source
httpwwwsiemenscompressenpressreleasepress=enpressrelease2011solar-hydroex201111005htm
httpwwwmarineturbinescom
A commercial marine current turbine consists of
two rotors which are fixed on a structure within the
sea current The twin rotors rotate with the
movement of the tidal flow and the blades pitch
through 180 degrees to optimally track tidal current
(Press picture Marine Current Turbines)
Wave Star Energys Multi-point Absorber
CFRP COLUMN REINFORCEMENT
INDUSTRIAL TANKS
107
INDUSTRIAL PIPES
PRESSURE TANKS
109
ldquoLetrsquos Make with Compositesrdquo
The composite industry is relatively recent (1940s)
All segments along the value chain account for about 550000 jobs worldwide
Worldwide market in volume = 8 Millions of tons
Value of the worldwide composite market = 60 billion euros
North America
EuropeAsia
36
3331
IN VALUE
Europe has reached a high level of technicity
Stronger weight of high value-added applications
Aerospace
Wind energy
Asia Pacific amp Rest of the WorldNorth America
Value
euro22B
36
Volume
27 Mt
35
Average
Unit
Price
euro82kg
Value
euro18B
31
Volume
33 Mt
43
Average
Unit
Price
euro55kg
World
Total
Value
euro60B
Total
Volume
8 Mt
Average
Unit
Price
euro72kg
(1) USA Canada
(2) Europe Russia
Middle East and
Africa
(3) Asia Australia and
South America
Value per geography
GDP per capita
Composites volume per capita inkg per inhabitant
Development curvein Volume
Composites markets size by country depends on development level
Average prices by industry worldwide
Aeronautics
Wind Energy
Consumer Goods
Transportation
Marine
Construction
E amp E
Pipes amp Tanks
Unit Prices eurokg 0 5 10 15 20 25 30 35 40 45
Growth in volume mainly in Asia
Repartition of the composites market by region 1999 gt 2013 in Mt
RoW
Europe
Asia
North America
Repartition of the composites market by region 1999 gt 2013 in Mt
1999 2002 2007 2013
7
22
36
35
7
33
23
38
5
29
26
40
4
27
24
45
25(1) 51Weight of Asia in global growth in volume
2015
103
81
6259
COMPOSITES
COMPOSITES = DUA MATERIAL YANG BERBEDA SIFAT FISIK DAN
KIMIAWI NYA BERSATU SECARA MAKROSKOPIK MELALUI SUATU
PROSES KIMIA MENJADI SUATU MATERIAL BARU (KOMPOSIT)
DENGAN SIFAT FISIK DAN MEKANIKAL YANG BARU
COMPOSITES ALAMI (NATURAL MATERIAL)
COMPOSITES BUATAN (ENGINEERED MATERIAL)
COMPOSITES
9
Berdasarkan jenis penguat
bull Particle-reinforced composites
ndash Large-particle composites (Cermets tungsten carbida in cobalt semen beton bertulang)
ndash Dispersed-strenghtened composites (alumina in aluminium ThoriaThO2 in Nickel alloy)
bull Fiber-reinforced composites konstruksi kaku kuat dan ringan
ndash Discontinuous (Short) fiber composites
ndash Continuous (long) fiber composites
bull Structural-reinforced composites
ndash Laminar composites (kayu multipleks laminate carbon epoxy)
ndash Sandwich composites konstruksi ringan dengan kekakuan dan kekuatan bending yang tinggi (Honeycomb-carbon epoxy composites dinding kardus corrugated paper - paper)
KLASIFIKASI MATERIAL KOMPOSIT
10
Berdasarkan jenis matriks
bull Polymer matrix composites (PMC) Paling populer dengan beragam aplikasi
- Carbon fibre reinforced polymer
- Glass fibre reinforced polymer
- Metal fibre reinforced polymer
bull Metal matrix composites (MMC) Aerospace dan komponen mesin mobil
- Boron or carbon fibre reinforced Aluminium
- Alumina particle reinforced Aluminium
bull Ceramic matrix composites (CMC) Heat exhanger sistem pelindung panas komponen dengan lingkungan korosif dan erosif
- Zirconia in alumina
- Carbon fibre reinforced carbon
KLASIFIKASI MATERIAL KOMPOSIT
SERAT
(FIBER) +RESIN
(MATRIX) = COMPOSITES
bull GLASS (KACA)
bull CARBON
bull ARAMID
bull Fiberglass Reinforced Plastics
(FRP)
bull Carbon Fiber Reinforced Plastics
(CFRP)
bull Aramid Fiber Reinforced Plastics
POLYMER TECHNOLOGY COMPOSITES
bull POLYESTER
bull VINYLESTER
bull EPOXY
bull POLYPROPYLENE
bull POLYAMID
COMPOSITES BUATAN (ENGINEERED COMPOSITES) SEHARI-HARI
BETON = TULANGAN BESI + RESIN SEMEN
The Importance of Lightness for
Environmental Friendly Products
Mass Reduction for Less Energy Consumption
MATERIAL COMPOSITES
Thermoset
type
Density r
(kgm3)
Stiffnes
s E
(Gpa)
Tensile
strength
s (MPa)
Strain to
failure e
()
Tg 0C
Thermal
conductivity
k (Wm0C)
Specific
Heat Cp
(kJkg0C)
Thermal
expansion coeff
a (x106 0C-1)
Polyester 1100-1230 31-46 50-75 10-65 70- 017-022 13-23 55-100
Vinylester 1120-1130 31-33 70-81 30-80 70- - - -
Epoxy 1100-1200 26-38 60-85 15-80 65-175 017-020 105 45-65
Phenolic 1000-1250 30-40 60-80 18 300 012-024 14-18 25-60
PUR 1200 07 30-40 400-450 135 017-021 13-23 70-100
BMI 1200-1320 32-50 48-110 15-33 230-345 - - -
Polyimide 1430-1890 31-49 100-110 15-30 325-370 01-034 105-15 25-80
Al 2800 72 540 18 - 130 096 236
Steel 7790 205 640 25 - 54 046 11
MATRIKS POLIMER THERMOSET
Variasi sifat yang lebar disebabkan oleh adanya formulasi kimia yang berbeda dan penambahan aditif
Jenis Glass Fiber S Glass E Glass C Glass A Glass dll
Terms
Glass Type
S Glass E Glass C Glass A Glass
Silica (SiO2) Content 67 55 64 72
Al2O3 Content 23 14 6 1
Melting Point (Celcius) 915 836 745 745
Tensile Strength 665 500 440 440
Modulus Elastisitas 124 105 100 -
Application AEROSPACE BOAT CHEMICAL TANK CHEMICAL TANK
JENIS SERAT GLASS
CHINA
JENIS SERAT GLASS
C GLASS Calcium borosilicate glasses
used for CHEMICAL stability in corrosive
acid environments
E GLASS Alumina-calcium-borosilicate
glasses with a maximum alkali used as
general purpose fibers where STRENGTH
and high ELECTICAL RESISTIVITY are
required It manifests better electrical
insulation and strongly resists attack by
water More than 50 of the glass fibers
used for reinforcement is E-glass
C Glass
E Glass
C amp E GLASS
SUMBER AGY TECHNICAL PAPER HIGH STRENGTH GLASS FIBER
FAKTA
C GLASS 1 BOROS RESIN
2 KEKUATAN
KURANG
FAKTA
E GLASS 1 HEMAT RESIN
2 KEKUATAN BAIK
3 TAHAN LAMA
FAKTA
TEBAL BUKAN BERARTI KUAT
UNSUR MATRIX (RESIN)
TIDAK ADA KEKUATAN
ldquoMore than 50 of the glass fibers used for
reinforcement is E-glassrdquo
C glass E glass
E glass
C glass
KAIN WOVEN ROVING HASIL LAMINASI
JENIS SERAT GLASS
Kekuatan composites ditentukan oleh
1 Kekuatan amp Sifat Fiber
2 Kekuatan amp Sifat Resin
3 Fraksi Rasio Perbandingan Volume Fiber
dan Resin dalam Composites
rarr tergantung dari Proses Manufaktur
4 Geometri dan Orientasi Arah Fiber dalam
Composites
KEKUATAN COMPOSITES
PROSES MATERIAL
Proses Produksi Kain Fiberglass
Biji Kaca Benang Benang Kaca Kain Fiberglass
PROSES MATERIAL
Glass Beads
Glass Fiber Glass Roving YarnGlass Fabric
FIBERGLASS
PRODUK
MATERIAL DAN PRODUK FIBERGLASS
+
Resin + Additives
PERPADUAN COMPOSITES
BENANG KACA Potongan Serat Kaca CSM
CSM - CHOPPED STRAND MAT
chopped binder
Kain Fiberglass Generasi Pertama
BahanPengikat
SenyawaPada Resin
JENIS FIBERGLASS
Glass Roving Yarn Chopped Strand
ADVANTAGES DISADVANTAGES
Steel
1048707 Low cost 1048707 Corrodes easily
1048707 Ductile under ambient conditions
1048707 Has no lower fatigue limit for welded structures
1048707 Virtually isotropic 1048707 Heavy
1048707 Easily formed and fabricated 1048707 Brittle at low temperatures
1048707 Easily obtained (low relative cost) 1048707 Magnetic
1048707 Easily alloyed or heat treated for special operations
1048707 Easily repaired
1048707 Good fire resistance
1048707 Behaviour is well understood
Alumunium Alloy
1048707 Light weight 1048707 Poor fatigue properties
1048707 Corrosion resistant 1048707 Poor performance in fire
1048707 Easily formed1048707 Low melting point and softening temperature
1048707 Easily fabricated 1048707 High relative cost
1048707 Readily available 1048707 Strength and stiffness less than steel
1048707 Ductile
1048707 Non magnetic
FRP
1048707 Low magnetic properties
1048707 Low electrical conductivity (glass- reinforced plastics)
1048707 Resistance to corrosion
1048707 Resistance to rot and marine growth
1048707 Relatively high sonar transparency
1048707 Good strength to weight ratio
1048707 Good fatigue properties
1048707 Maintenance of properties at low temperatures
1048707 Availability
1048707 Can be manufactured to near net-shape
1048707 Stiffness and strength can be tailored to structural requirements
1048707 Excellent thermal insulation
1048707 Light weight
STEEL vs ALUMUNIUM vs COMPOSITES
Source
1Maritime Platforms Division Aeronautical and
Maritime Research Laboratory (Seref Aksu
Stuart Cannon Craig Gardiner and Matthew
Gudze
2 Metal Corrosion can be defined as the
destructive attack of a metal through interaction
with its environment
(httpwwwcorrosionistcomCorrosion_Fundament
alhtm)
28
Serat rarr penguat
Polimer matriks rarr pengikat
bull Sifat mekanik yang cukup baik
bull Viskositas dan temperatur pengerjaan rendah rarr mudah
dimanufaktur
bull Ketahanan korosi yang baik
bull Media perpindahan gaya rarr distribusi beban dari serat ke serat
bull Ulet rarr Melindungi serat yang getas
bull Size effect rarr Kekuatan dan kekakuan sangat tinggi
bull Aspect ratio (ld) tinggi rarr luas permukaan besar
bull Fleksibel rarr variasi teknik manufaktur
bull Serat dapat diatur sesuai dengan arah pembebanan
29
Advantages Polimer Composites
Kekuatan dan kekakuan spesifik yang tinggi FRCP vs material lain rarr kompetitif jika berat dipertimbangkan
Material Berat jenis
r (kgm3)
Kekakuan
E (GPa)
Kekuatan
tarik su
(MPa)
Kekakuan
spesifik
Er
Kekuatan
spesifik sur
Baja 7800 208 400 27 005
Aluminium 2700 70 200 259 007
Nylon 1100 25 80 23 007
Beton 2400 40 20 166 0008
Random
FRPC
1800 20 300 111 0006
Alligned FRPC
( serat)
1600 200 1500 125 094
Alligned FRCP
( serat)
1600 3 50 19 0001
Tensile Strength amp Modulus of Common Structural Materials
Densities of Common Structural Materials
Specific Tensile Strength amp Modulus of Common Structural Materials
Typical Properties of Common Structural Materials
Kesimpulan COMPOSITES = RINGAN amp KUAT
Jadi secara keseluruhan kekuatan composites
ditentukan oleh
1 Kekuatan amp Sifat Fiber
2 Kekuatan amp Sifat Resin
3 Fraksi Rasio Perbandingan Volume Fiber
dan Resin dalam Composites
4 Geometri dan Orientasi Arah Fiber dalam
Composites
PRODUKSI ANAK NEGERI
Proses Produksi Kain Fiberglass
Biji Kaca Benang Benang Kaca Kain Fiberglass
PROSES MATERIAL
Glass Beads
Glass Fiber Glass Roving YarnGlass Fabric
Proses Produksi Kain Fiberglass
Biji Kaca Benang Benang Kaca Kain Fiberglass
Glass Beads
Glass Fiber Glass Roving YarnGlass Fabric
PROSES MATERIAL
Benang Kaca Potongan Serat Kaca Chopped Strand Mat
CSM - Chopped Strand Mat
chopped binder
Produk Fiberglass Generasi Pertama
Bahan Pengikat
Senyawa Pada Resin
Glass Roving Yarn Chopped Strand
JENIS FIBERGLASS
Benang Kaca Woven Roving
WR - Woven Roving
Tenun Weaving
Produk Fiberglass Generasi Kedua
Glass Roving Yarn
JENIS FIBERGLASS
Multiaxial
MAX - Multiaxial
warp knitting
Produk Fiberglass Generasi Ketiga
Benang Kaca
Glass Roving Yarn
JENIS FIBERGLASS
MAX - Multiaxial Fabric
Fleece (optional)
Lapisan
MULTIAXIAL PROSES
Karakteristik CSM
bull Glass Content 30
bull Resin Content 70
bull Tensile Force
Chopped Strand Mat
JENIS FIBERGLASS
Karakteristik Woven Roving
bull Glass Content 45
bull Resin Content 55
Woven Roving
Resin
|
|
|
|
|
|
|
|
|
|
|
|
|
|
bull Kekuatan Tarik
JENIS FIBERGLASS
No Resin Rich Area
Karakteristik Multiaxial
bull Glass Content 60
bull Resin Content 40
Produk Fiberglass Ketiga MULTIAXIAL
JENIS FIBERGLASS
Perbedaan Woven Roving dan Multiaxial ndash Tampak Samping
JENIS FIBERGLASS
WR FRP
8 Ply WR 800
8 Ply CSM 450
Glass Weight 1 kg
Composite Weight 15kgm2
CSM FRP
22 Ply CSM 450
Glass Weight 1 kg
Composite Weight 18 kgm2
MULTIAXIAL FRP
13 Ply DB 800
Glass Weight 1 kg
Composite Weight
13 kgm2
JENIS FIBERGLASS
Multiaxial
FRP
Woven Roving
FRP
Chopped Strands Mat FRP
MULTIAXIAL
FAKTA
TEBAL BUKAN BERARTI KUAT
UNSUR MATRIX (RESIN)
TIDAK ADA KEKUATAN
ldquoMore than 50 of the glass fibers used for reinforcement is
E-glassrdquo
KarakteristikKekuatan
CSM WR MAX
Kekuatan Tarik 175 MPa 250 MPa 425 MPa
CSM 142
WR 70
KEKUATAN TARIK
Properties CSM Lamination WR Lamination MAX Lamination
Fabric Weight (kgm2) 1 1 1
Composite Weight (kgm2) 18 15 13
Resin usage (kgm2) 15 1 08
Amount of Fabric 22 Ply 16 Ply 13 Ply
Thickness 15 mm 12 mm 10 mm
Tensile Strength (Mpa) 125 1796 400
Tensile Strength (Nmmsup2) 28463 30958 4576
Processing Time High Med Low
Labour Cost High Med Low
MULTIAXIAL
Total Penggunaan Resin -51
Total Berat Kapal -40
Kekuatan Bangunan Kapal +59
Efisiensi Tenaga Kerja
Waktu Pengerjaan Lebih Cepat
KEUNGGULAN MATERIAL
Resapan Resin Lebih Baik amp Merata
Lapisan Lebih Sedikit
Meningkatkan Kekuatan Kapal
KEUNGGULAN MATERIAL
TRIAXIAL
DBL series DBT series
BIAXIAL
LT series DB series
UNIDIRECTIONAL
L series T series
QUADRIAXIAL
DBLT series
JENIS MULTIAXIAL
UNIDIRECTIONAL
DCMU 900 E ndash
KHUSUS UNTUK MEMPERKUAT BENDING KAPAL
PEMASANGAN KHUSUS PADA KEEL DAN TULANGAN
JENIS MULTIAXIAL UNTUK KAPAL
TRIAXIAL
DBL 600 ndash
APLIKASI PADA INDUSTRI PENERBANGAN
PEMASANGAN KHUSUS PADA
SAMBUNGAN BADAN DAN SAYAP
PESAWAT
JENIS MULTIAXIAL UNTUK PESAWAT
QUADRAXIAL
DBLT 800 ndash
APLIKASI PADA INDUSTRI ENERGI
DITERAPKAN UNTUK KEBUTUHAN PEMBANGKIT
LISTRIK ENERGI ANGIN
MULTIAXIAL UNTUK ENERGI
INDUSTRI KIMIA OLAHRAGA AUTOMOTIF
MULTIAXIAL UNTUK INDUSTRI LAINNYA
COMPOSITES
GUNAKAN MATERIAL FIBERGLASS
YANG SUDAH DISERTIFIKASI
BKI
FIBERGLASS UNTUK PEMBANGUNAN BAKAP
PERATURAN MENTERI PERHUBUNGAN
NOMOR PM 7 TAHUN 2013
TENTANG KEWAJIBAN KLASIFIKASI BAGI KAPAL BERBENDERA INDONESIA
PADA BADAN KLASIFIKASI
BADAN SERTIFIKASI MARITIM
Biro Klasifikasi IndonesiaDet Norske Veritas Germanischer Lloyds
PERATURAN BKI
Untuk Kapal Non-Metal
2006
PERSYARATAN MINIMUM
kekuatan material yang
harus digunakan
untuk membangun
Kapal Fiberglass
PEMBESARAN
Table 21
FIBERGLASS TRIAXIS COMPOSITES
TELAH BERSERTIFIKASI BKI
Biro Klasifikasi Indonesia
65
TEKNIK MANUFAKTUR
COMPOSITES
Wet hand lay-up
1) Peletakan
Dry Reinforcement
bull Dry reinforcement dan resin (+ katalis) ditaruh pada permukaan cetakan
2) Pemasukanpenekanan resin
bull Resin ditekan untuk meng-impregnasi serat dengan menggunakan rol
3) Pengulangan proses untuk lapisan lain
bull Beberapa lapisan dapat ditambahkan secara bertahap
4) Resin curing
bull Reaksi dimulai komponen dilepaskan setelah komponen mengeras
(fully cured)
Wet hand lay-up
Manufaktur komponen dapat dikerjakan dengan menggunakan beberapa lapis komposit
dengan memperhatikan kompatibilitas material dan tahapan curing Modifikasi proses dapat
dilakukan seperti
Vacuum bagging
setelah lay-up
Glass Roving
Bulk Resin
Catalyst
3) De-molding
2) Resin Cure
bull Curing dimulai dan komponen dilepaskan setelah pengerasan selesai
bull Serat gelas resin dan katalis dimasukkan kedalam spray gun
1) Spray-up
bull Campuran disemprotkan pada permukaan cetakan
Spray-up
69
Penyemprotan bakal komponen
Komponen
dilepaskan
dari cetakan
Full dispensing
system Chopper Roving
Atomised resin
and catalyst
Spray-up
Prepreg
1) LaminateAssembly 5) De-molding
3) Resin Melts Layup Consolidates
bull Prepreg serat yang sudah diimpregnasi oleh resin+katalis dalam kondisi padat
bull Lapisan prepreg digunting sesuai bentuk yang diinginkan kemudian diletakkan pada permukaan cetakan
sesuai bentuk komponen yang diinginkan Lay-up mudah dilakukan karena sifat ldquotackynessrdquo dari prepreg
2) Applied Vacuum Pressure and Heat
bull Tekanan dan panas diberikan resin mencair terjadi konsolidasi pada komponen
4) Resin Cures
bull Temperatur dinaikkan untuk memulai curing
Prepreg
Variasi proses Autoclave
Komponen dalam
vacuum-bag
bull Campuran resin (+katalis) dan chopped glass strands diperoleh dalam bentuk premixed compound Bulk molding
Compound (BMC) dalam bentuk adonan atau Sheet molding Compound (SMC) dalam bentuk lembaran
bull Ketika panas dan tekanan diberikan oleh cetakan compound mengalir sesuai bentuk komponen yang diinginkan
1) Placement of Charge
5) De-molding3) Squeeze to final dimensions
2) Mould Closure4) Resin Cure
bull Curing dimulai komponen dilepaskan setelah terjadi pengerasan yang cukup
Compression Molding
bull Preform atau dry reinforcement dimasukkan kedalam cetakan sesuai dengan bentuk komponen yang
diinginkan
bull Resin mengalir dengan penekanan atau pem-vakuman dan meng-impregnasi preform dan
mendorongmengeluarkan udara yang ada dalam preform
1) Preform Manufacture
2) Preform Compression
5) De-molding3) Resin Injection
4) Resin Cure
bull Curing terjadi cetakan dibuka setelah terjadi pengerasan yang mencukupi
Liquid Molding (RTM VARI VARTM)
Pultrusion
bull Dry roving or fabrics ditarik melalui bak berisi
campuran resin dan katalis
bull Campuran yang basah ditarik melalui cetakan
bull Sisa resin keluar cetakan
bull Pemanasan dilakukan untuk proses curing
bull Pendinginan dilakukan untuk mempercepat siklus
produksi
Cut-off
Cooling
Die sections
Resin bath
Fibre creel
Filament Winding
bull Dry roving ditarik melalui bak berisi campuran resin dan katalis
bull Wet roving digulungkan dalam keadaan tegang kepada mandrel
bull Kontrol mekanik dari pembawa serat mengatur orientasi peletakan serat pada
mandrel
INDUSTRI COMPOSITES
AEROSPACE
HISTORY
1950 ndash Boeing
1960 ndash F14 Tomcat
1981 ndash AV-8B Harrier
Source
Low-Cost Composite Materials and Structures for Aircraft Applications
httpwwwreinforcedplasticscom
httpwwwcentennialofflightgovessayEvolution_of_TechnologycompositesTech40htm
Automotive
Composite material is used in a number of applications in the automotive
industry due to its temperature resistance rigidity and fatigue strength
The benefits of using composites include greater fuel efficiency
corrosion resistance light weight and strength Composites also provide
a low-cost way to help keep designs looking fresh
Composites are used in
- interior parts (cockpit trimming seats instrument panels)
- exterior structure (body panels openings underbody frontrear
modules)
- engine compartment and fuelmechanical area parts (axles and
suspensions fuel and exhaust systems)
- electrical and electronic components
Lamborghinis Sesto Element carbon fiber
ldquoFat men cannot run as fast as thin men but we build most of our vehicles as though dead-weight fat increased speedhellip I cannot
imagine where the delusion that weight means strength
came fromhelliprdquo mdashHenry Ford
The mix of automotive materials is changing showing a boost for FRP in helping original
equipment manufacturers meet fuel economy and emissions challenges
(Source 2011 DuPont AutomotiveSAE survey of design engineers performed by Signet Research Inc)
Source
httpwwwtoraycomcsrhighlight2009hig_001_01html
The MonoCell tub for the McLaren MP4-12C supercar is moulded as a single
piece and weighs less than 80 kg (176 lbs)
COMPOSITES IN MARINE
TRIMARAN BOAT
AMERICA NAVYINDONESIAN NAVY
Visby Class corvette
Total length is 72 meters
The beam is 1040 meters
The displacement is 600 metric tones
fully equipped the worlds largest CRP
construction
The design of the Visby aims to minimize
the optical and infrared signature above
water acoustic and hydroa coustic
signature underwater electrical potential
and magnetic signature pressure signature
radar cross section and actively emitted
signals
A stealth corvette of the YS 2000 design
has a detection range of 13km in rough
seas and 22km in calm sea without
jamming In a jammed environment the
Visby would be detected at a range of 8km
in rough sea and 11km in calm sea
The material provides high strength and
rigidity low weight good shock resistance
low radar and magnetic signature
1996
Visby is a class of stealth corvettes for the Swedish Navy
ldquoReduced 50 of a Conventional Steelrdquo
Source
Hull Construction with composite materials for ships over 100m in length 2002
Massachusetts Institute of Technology
httpwwwnaval-technologycomprojectsvisby
YACHTS
KAL YUDISTIRAMARATHON 100 ADMIRAL YACHT
LOA 3050 MWidth 6 MFuel Tank 8000 LWater Tank 3000 LIce Box 500 LAccommodation Max 35 Personnel
2 x CATERPILLAR 3412E 1200 HPMARINE DIESEL ENGINE
PC 40 ndash KRI Krait 827Department of Indonesian Navy
LOA 40 MWidth 73 MPower 190Weapon Twin Cannon Barrels
127 mm Heavy Machine GunSpeed Knot 25 KnotDisplacement 105 tonAccommodation 23 personnel
PATROL BOAT
Rigid Inflatable BoatPATROL BOAT
Yachts
36m Luxury Yacht Moonraker
36m Luxury Yacht GoldenEye
50m Luxury Yacht Casino
Royale
45m Luxury Yacht Seashaw
Boat Parts
Barovans for Seismic Sweep
Centrifugal Liftfan House for Surface Effect
Ships
Composite Boat PropellersRTM
Deckhouses for Pilot Boats
Fairing Parts for Submarines
Flybridges for Motor yachts
Light Weight Gangway
MTB Launcher Mock-up
Pleasure Boats
12m Sailboat
12m Sail-Catamaranone-off
Canoes
Dragonfly 1000Catamaran Sailboat
Fantasy 37Sailboat
Farr 60Luxury Sailboat
EurodingyOlympic Dingy Class for
Woman
Hydrolift F23 Racing Boats
Kajacs
Najad 42Sailboat
Najad 520Sailboat
Najad 441Sailboat
Najad 391Sailboat
Nordwest 900Motorboat
Nordwest 1100Motorboat
Quatro 44Motorboat
Racemaster Competition Boats
Storebro 420
Storebro 345
Sweden Yacht 370Sailboat
Sweden Yacht 69Sailboat
Windy 41Motorboat
X-632Sailboat
X-362Sailboat
Commercial Boats
175m High Speed AmbulancePassenger Boat
19m High Speed Passenger Boat
20m High Speed Passenger Boat
364m Surface Effect Passenger Ship
45m Surface Effect Passenger Ship
120m Hull Structural Parts HSSS Catamaran Ferry
APPENDIX
Marine Vessel
1188m Fast Attack Vessel FMV 90 E
20m SAV-Surface Auxiliary Vessels
34m Personnel TransportCoast Guard Vessel
40ft Experimental SES
40m Landsort-Class Mine Hunters
54m Mine Counter Measure Vehicles SES
74m Coastal Patrol Boats
Fishing Boats
30 GT
12 GT
10 GT
5 GT
WISEWings In Surface Effect
HOVERCRAFT
Designed specifically for the tourist and transport industries the
Pioneer Mk3 hovercraft is amphibious and comfortably seats 25
passengers plus 1-crew The air-conditioned cabin allows for
maximum visibility for all aboard The Pioneer Mk3 is robust and
dynamic in its performance
Commercial hovercraft
Mk3 AirLift Hovercraft - 1215m
Power is economicaly provided by one Deutz diesel engine of
330kW (442hp) to cruise easily at 40 knots with much higher
speeds available according to the surface conditions The hull is
manufactured from fibreglassPVC foam composite sandwich
the windows are glass and the skirt is urethane coated nylon A
Military version is available with increased payload and systems
redundancy Power for the Military version comes from two Steyr
diesel engines with a total installed power of 320kW (429hp) All
transmission electrical hydraulic and air systems are duplicated
for maximum redundancy The increased performance of the
Military version comes from the reduced engine weight of the twin
Steyr installation cf the Deutz installation
Source
httpwwwnauticexpocomprodairlift-hovercraftcommercial-hovercrafts-25251-142868html
HOVERFLIGHT
BALLISTIC amp UNIT DEFENCED
Triaxis Composites Collaboration with Institute of Aeronautics and Space in the development of Missile Nose Cone
Polymer composites is the evolution of the military defence
Thin steel was the helmet material of
WWII and remained the principal material until around the 1980rsquos
The advantages of using steel
included a simple technology for manufacture of the helmets low cost and reasonably good
impact protection However these helmets were found to provide only marginal protection
against fragments
During the Vietnam War the US Army experimented with fiber-reinforced inserts in the
helmets These inserts improved ballistic protection but at the same time added weight and
reduced the air space between the head and the helmet
By the early part of the 1980rsquos the US military had developed the first all-composite
100 fiber-reinforced helmet This development resulted in even better ballistic protection
without altering the weight of the helmet Other improvements included better head coverage and
more space for ventilation
Source
Composites Armor - A difficult but huge market
by A Brent Strong Brigham Young University
MILITARY VEHICLES
HIGH SPEED TRAIN SHINKANSEN
Advanced Composites provide lightweight solutions for railway vehicles
saving as much as 50-80 of the weight compared with traditional
components
A lower overall weight translates into less stress faster acceleration and
higher speeds as well as reduced starting and stopping inertia Today
these are important criteria in global high-speed and metropolitan
railway projects
Fire smoke and toxic fumes are key safety criteria for interior
components of railway carriages Any material selected for an interior
component must meet international fire retardant standards
for Rail Interiors and Exteriors
Ceiling Panels Stairs
Seating Vestibules
Window Panels Door Pillars
Partition WallsDiffusers
Gangway and Cabinet Panels Cabin and
Desk panels
Door Pillars Lavatory Modules (standard and
Front and Rear EndsRoof Panels
Nose Cones Under Fairings
Source
httpwwwpctaerail_compositesphp
101
SKY BUS
2009
Europe is the world leader in offshore wind with
828 wind turbines and a cumulative capacity of 2056 MW spread across 38 offshore wind farms in 9
European countries
The UK and Denmark are the current leaders with a 44 and 30 share respectively In 2009
five countries built new offshore wind farms
UK (284 MW)
Demark (230 MW)
Sweden (30 MW)
Germany (30 MW)
Norway (23 MW)
2010
Asia leads the growth in global wind power which grew 358 GW in 2010 bringing
total global capacity to 1944 GW ndash up 225 from 2009
the Global Wind Energy Council (GWEC)
Asia accounted for 19 GW of new global wind power installations driven by China which installed 165
GW
ldquoChina now has 423 GW of wind powerrdquo
ldquoThis puts China firmly on a path to reach 200 GW of installed wind power by 2020 At the same
time China has become the worldrsquos largest producer of wind energy equipmentrdquo
Source
httpwwwreinforcedplasticscomview15655asia-leads-global-wind-power-growth
httpimgdeusmcomdesignnews288288605-Sandia_Sizes_up_Wind_Turbine_Blade_Design_C_largegif
WIND ENERGY
Marine Current Turbines
Source
httpwwwsiemenscompressenpressreleasepress=enpressrelease2011solar-hydroex201111005htm
httpwwwmarineturbinescom
A commercial marine current turbine consists of
two rotors which are fixed on a structure within the
sea current The twin rotors rotate with the
movement of the tidal flow and the blades pitch
through 180 degrees to optimally track tidal current
(Press picture Marine Current Turbines)
Wave Star Energys Multi-point Absorber
CFRP COLUMN REINFORCEMENT
INDUSTRIAL TANKS
107
INDUSTRIAL PIPES
PRESSURE TANKS
109
ldquoLetrsquos Make with Compositesrdquo
Europe has reached a high level of technicity
Stronger weight of high value-added applications
Aerospace
Wind energy
Asia Pacific amp Rest of the WorldNorth America
Value
euro22B
36
Volume
27 Mt
35
Average
Unit
Price
euro82kg
Value
euro18B
31
Volume
33 Mt
43
Average
Unit
Price
euro55kg
World
Total
Value
euro60B
Total
Volume
8 Mt
Average
Unit
Price
euro72kg
(1) USA Canada
(2) Europe Russia
Middle East and
Africa
(3) Asia Australia and
South America
Value per geography
GDP per capita
Composites volume per capita inkg per inhabitant
Development curvein Volume
Composites markets size by country depends on development level
Average prices by industry worldwide
Aeronautics
Wind Energy
Consumer Goods
Transportation
Marine
Construction
E amp E
Pipes amp Tanks
Unit Prices eurokg 0 5 10 15 20 25 30 35 40 45
Growth in volume mainly in Asia
Repartition of the composites market by region 1999 gt 2013 in Mt
RoW
Europe
Asia
North America
Repartition of the composites market by region 1999 gt 2013 in Mt
1999 2002 2007 2013
7
22
36
35
7
33
23
38
5
29
26
40
4
27
24
45
25(1) 51Weight of Asia in global growth in volume
2015
103
81
6259
COMPOSITES
COMPOSITES = DUA MATERIAL YANG BERBEDA SIFAT FISIK DAN
KIMIAWI NYA BERSATU SECARA MAKROSKOPIK MELALUI SUATU
PROSES KIMIA MENJADI SUATU MATERIAL BARU (KOMPOSIT)
DENGAN SIFAT FISIK DAN MEKANIKAL YANG BARU
COMPOSITES ALAMI (NATURAL MATERIAL)
COMPOSITES BUATAN (ENGINEERED MATERIAL)
COMPOSITES
9
Berdasarkan jenis penguat
bull Particle-reinforced composites
ndash Large-particle composites (Cermets tungsten carbida in cobalt semen beton bertulang)
ndash Dispersed-strenghtened composites (alumina in aluminium ThoriaThO2 in Nickel alloy)
bull Fiber-reinforced composites konstruksi kaku kuat dan ringan
ndash Discontinuous (Short) fiber composites
ndash Continuous (long) fiber composites
bull Structural-reinforced composites
ndash Laminar composites (kayu multipleks laminate carbon epoxy)
ndash Sandwich composites konstruksi ringan dengan kekakuan dan kekuatan bending yang tinggi (Honeycomb-carbon epoxy composites dinding kardus corrugated paper - paper)
KLASIFIKASI MATERIAL KOMPOSIT
10
Berdasarkan jenis matriks
bull Polymer matrix composites (PMC) Paling populer dengan beragam aplikasi
- Carbon fibre reinforced polymer
- Glass fibre reinforced polymer
- Metal fibre reinforced polymer
bull Metal matrix composites (MMC) Aerospace dan komponen mesin mobil
- Boron or carbon fibre reinforced Aluminium
- Alumina particle reinforced Aluminium
bull Ceramic matrix composites (CMC) Heat exhanger sistem pelindung panas komponen dengan lingkungan korosif dan erosif
- Zirconia in alumina
- Carbon fibre reinforced carbon
KLASIFIKASI MATERIAL KOMPOSIT
SERAT
(FIBER) +RESIN
(MATRIX) = COMPOSITES
bull GLASS (KACA)
bull CARBON
bull ARAMID
bull Fiberglass Reinforced Plastics
(FRP)
bull Carbon Fiber Reinforced Plastics
(CFRP)
bull Aramid Fiber Reinforced Plastics
POLYMER TECHNOLOGY COMPOSITES
bull POLYESTER
bull VINYLESTER
bull EPOXY
bull POLYPROPYLENE
bull POLYAMID
COMPOSITES BUATAN (ENGINEERED COMPOSITES) SEHARI-HARI
BETON = TULANGAN BESI + RESIN SEMEN
The Importance of Lightness for
Environmental Friendly Products
Mass Reduction for Less Energy Consumption
MATERIAL COMPOSITES
Thermoset
type
Density r
(kgm3)
Stiffnes
s E
(Gpa)
Tensile
strength
s (MPa)
Strain to
failure e
()
Tg 0C
Thermal
conductivity
k (Wm0C)
Specific
Heat Cp
(kJkg0C)
Thermal
expansion coeff
a (x106 0C-1)
Polyester 1100-1230 31-46 50-75 10-65 70- 017-022 13-23 55-100
Vinylester 1120-1130 31-33 70-81 30-80 70- - - -
Epoxy 1100-1200 26-38 60-85 15-80 65-175 017-020 105 45-65
Phenolic 1000-1250 30-40 60-80 18 300 012-024 14-18 25-60
PUR 1200 07 30-40 400-450 135 017-021 13-23 70-100
BMI 1200-1320 32-50 48-110 15-33 230-345 - - -
Polyimide 1430-1890 31-49 100-110 15-30 325-370 01-034 105-15 25-80
Al 2800 72 540 18 - 130 096 236
Steel 7790 205 640 25 - 54 046 11
MATRIKS POLIMER THERMOSET
Variasi sifat yang lebar disebabkan oleh adanya formulasi kimia yang berbeda dan penambahan aditif
Jenis Glass Fiber S Glass E Glass C Glass A Glass dll
Terms
Glass Type
S Glass E Glass C Glass A Glass
Silica (SiO2) Content 67 55 64 72
Al2O3 Content 23 14 6 1
Melting Point (Celcius) 915 836 745 745
Tensile Strength 665 500 440 440
Modulus Elastisitas 124 105 100 -
Application AEROSPACE BOAT CHEMICAL TANK CHEMICAL TANK
JENIS SERAT GLASS
CHINA
JENIS SERAT GLASS
C GLASS Calcium borosilicate glasses
used for CHEMICAL stability in corrosive
acid environments
E GLASS Alumina-calcium-borosilicate
glasses with a maximum alkali used as
general purpose fibers where STRENGTH
and high ELECTICAL RESISTIVITY are
required It manifests better electrical
insulation and strongly resists attack by
water More than 50 of the glass fibers
used for reinforcement is E-glass
C Glass
E Glass
C amp E GLASS
SUMBER AGY TECHNICAL PAPER HIGH STRENGTH GLASS FIBER
FAKTA
C GLASS 1 BOROS RESIN
2 KEKUATAN
KURANG
FAKTA
E GLASS 1 HEMAT RESIN
2 KEKUATAN BAIK
3 TAHAN LAMA
FAKTA
TEBAL BUKAN BERARTI KUAT
UNSUR MATRIX (RESIN)
TIDAK ADA KEKUATAN
ldquoMore than 50 of the glass fibers used for
reinforcement is E-glassrdquo
C glass E glass
E glass
C glass
KAIN WOVEN ROVING HASIL LAMINASI
JENIS SERAT GLASS
Kekuatan composites ditentukan oleh
1 Kekuatan amp Sifat Fiber
2 Kekuatan amp Sifat Resin
3 Fraksi Rasio Perbandingan Volume Fiber
dan Resin dalam Composites
rarr tergantung dari Proses Manufaktur
4 Geometri dan Orientasi Arah Fiber dalam
Composites
KEKUATAN COMPOSITES
PROSES MATERIAL
Proses Produksi Kain Fiberglass
Biji Kaca Benang Benang Kaca Kain Fiberglass
PROSES MATERIAL
Glass Beads
Glass Fiber Glass Roving YarnGlass Fabric
FIBERGLASS
PRODUK
MATERIAL DAN PRODUK FIBERGLASS
+
Resin + Additives
PERPADUAN COMPOSITES
BENANG KACA Potongan Serat Kaca CSM
CSM - CHOPPED STRAND MAT
chopped binder
Kain Fiberglass Generasi Pertama
BahanPengikat
SenyawaPada Resin
JENIS FIBERGLASS
Glass Roving Yarn Chopped Strand
ADVANTAGES DISADVANTAGES
Steel
1048707 Low cost 1048707 Corrodes easily
1048707 Ductile under ambient conditions
1048707 Has no lower fatigue limit for welded structures
1048707 Virtually isotropic 1048707 Heavy
1048707 Easily formed and fabricated 1048707 Brittle at low temperatures
1048707 Easily obtained (low relative cost) 1048707 Magnetic
1048707 Easily alloyed or heat treated for special operations
1048707 Easily repaired
1048707 Good fire resistance
1048707 Behaviour is well understood
Alumunium Alloy
1048707 Light weight 1048707 Poor fatigue properties
1048707 Corrosion resistant 1048707 Poor performance in fire
1048707 Easily formed1048707 Low melting point and softening temperature
1048707 Easily fabricated 1048707 High relative cost
1048707 Readily available 1048707 Strength and stiffness less than steel
1048707 Ductile
1048707 Non magnetic
FRP
1048707 Low magnetic properties
1048707 Low electrical conductivity (glass- reinforced plastics)
1048707 Resistance to corrosion
1048707 Resistance to rot and marine growth
1048707 Relatively high sonar transparency
1048707 Good strength to weight ratio
1048707 Good fatigue properties
1048707 Maintenance of properties at low temperatures
1048707 Availability
1048707 Can be manufactured to near net-shape
1048707 Stiffness and strength can be tailored to structural requirements
1048707 Excellent thermal insulation
1048707 Light weight
STEEL vs ALUMUNIUM vs COMPOSITES
Source
1Maritime Platforms Division Aeronautical and
Maritime Research Laboratory (Seref Aksu
Stuart Cannon Craig Gardiner and Matthew
Gudze
2 Metal Corrosion can be defined as the
destructive attack of a metal through interaction
with its environment
(httpwwwcorrosionistcomCorrosion_Fundament
alhtm)
28
Serat rarr penguat
Polimer matriks rarr pengikat
bull Sifat mekanik yang cukup baik
bull Viskositas dan temperatur pengerjaan rendah rarr mudah
dimanufaktur
bull Ketahanan korosi yang baik
bull Media perpindahan gaya rarr distribusi beban dari serat ke serat
bull Ulet rarr Melindungi serat yang getas
bull Size effect rarr Kekuatan dan kekakuan sangat tinggi
bull Aspect ratio (ld) tinggi rarr luas permukaan besar
bull Fleksibel rarr variasi teknik manufaktur
bull Serat dapat diatur sesuai dengan arah pembebanan
29
Advantages Polimer Composites
Kekuatan dan kekakuan spesifik yang tinggi FRCP vs material lain rarr kompetitif jika berat dipertimbangkan
Material Berat jenis
r (kgm3)
Kekakuan
E (GPa)
Kekuatan
tarik su
(MPa)
Kekakuan
spesifik
Er
Kekuatan
spesifik sur
Baja 7800 208 400 27 005
Aluminium 2700 70 200 259 007
Nylon 1100 25 80 23 007
Beton 2400 40 20 166 0008
Random
FRPC
1800 20 300 111 0006
Alligned FRPC
( serat)
1600 200 1500 125 094
Alligned FRCP
( serat)
1600 3 50 19 0001
Tensile Strength amp Modulus of Common Structural Materials
Densities of Common Structural Materials
Specific Tensile Strength amp Modulus of Common Structural Materials
Typical Properties of Common Structural Materials
Kesimpulan COMPOSITES = RINGAN amp KUAT
Jadi secara keseluruhan kekuatan composites
ditentukan oleh
1 Kekuatan amp Sifat Fiber
2 Kekuatan amp Sifat Resin
3 Fraksi Rasio Perbandingan Volume Fiber
dan Resin dalam Composites
4 Geometri dan Orientasi Arah Fiber dalam
Composites
PRODUKSI ANAK NEGERI
Proses Produksi Kain Fiberglass
Biji Kaca Benang Benang Kaca Kain Fiberglass
PROSES MATERIAL
Glass Beads
Glass Fiber Glass Roving YarnGlass Fabric
Proses Produksi Kain Fiberglass
Biji Kaca Benang Benang Kaca Kain Fiberglass
Glass Beads
Glass Fiber Glass Roving YarnGlass Fabric
PROSES MATERIAL
Benang Kaca Potongan Serat Kaca Chopped Strand Mat
CSM - Chopped Strand Mat
chopped binder
Produk Fiberglass Generasi Pertama
Bahan Pengikat
Senyawa Pada Resin
Glass Roving Yarn Chopped Strand
JENIS FIBERGLASS
Benang Kaca Woven Roving
WR - Woven Roving
Tenun Weaving
Produk Fiberglass Generasi Kedua
Glass Roving Yarn
JENIS FIBERGLASS
Multiaxial
MAX - Multiaxial
warp knitting
Produk Fiberglass Generasi Ketiga
Benang Kaca
Glass Roving Yarn
JENIS FIBERGLASS
MAX - Multiaxial Fabric
Fleece (optional)
Lapisan
MULTIAXIAL PROSES
Karakteristik CSM
bull Glass Content 30
bull Resin Content 70
bull Tensile Force
Chopped Strand Mat
JENIS FIBERGLASS
Karakteristik Woven Roving
bull Glass Content 45
bull Resin Content 55
Woven Roving
Resin
|
|
|
|
|
|
|
|
|
|
|
|
|
|
bull Kekuatan Tarik
JENIS FIBERGLASS
No Resin Rich Area
Karakteristik Multiaxial
bull Glass Content 60
bull Resin Content 40
Produk Fiberglass Ketiga MULTIAXIAL
JENIS FIBERGLASS
Perbedaan Woven Roving dan Multiaxial ndash Tampak Samping
JENIS FIBERGLASS
WR FRP
8 Ply WR 800
8 Ply CSM 450
Glass Weight 1 kg
Composite Weight 15kgm2
CSM FRP
22 Ply CSM 450
Glass Weight 1 kg
Composite Weight 18 kgm2
MULTIAXIAL FRP
13 Ply DB 800
Glass Weight 1 kg
Composite Weight
13 kgm2
JENIS FIBERGLASS
Multiaxial
FRP
Woven Roving
FRP
Chopped Strands Mat FRP
MULTIAXIAL
FAKTA
TEBAL BUKAN BERARTI KUAT
UNSUR MATRIX (RESIN)
TIDAK ADA KEKUATAN
ldquoMore than 50 of the glass fibers used for reinforcement is
E-glassrdquo
KarakteristikKekuatan
CSM WR MAX
Kekuatan Tarik 175 MPa 250 MPa 425 MPa
CSM 142
WR 70
KEKUATAN TARIK
Properties CSM Lamination WR Lamination MAX Lamination
Fabric Weight (kgm2) 1 1 1
Composite Weight (kgm2) 18 15 13
Resin usage (kgm2) 15 1 08
Amount of Fabric 22 Ply 16 Ply 13 Ply
Thickness 15 mm 12 mm 10 mm
Tensile Strength (Mpa) 125 1796 400
Tensile Strength (Nmmsup2) 28463 30958 4576
Processing Time High Med Low
Labour Cost High Med Low
MULTIAXIAL
Total Penggunaan Resin -51
Total Berat Kapal -40
Kekuatan Bangunan Kapal +59
Efisiensi Tenaga Kerja
Waktu Pengerjaan Lebih Cepat
KEUNGGULAN MATERIAL
Resapan Resin Lebih Baik amp Merata
Lapisan Lebih Sedikit
Meningkatkan Kekuatan Kapal
KEUNGGULAN MATERIAL
TRIAXIAL
DBL series DBT series
BIAXIAL
LT series DB series
UNIDIRECTIONAL
L series T series
QUADRIAXIAL
DBLT series
JENIS MULTIAXIAL
UNIDIRECTIONAL
DCMU 900 E ndash
KHUSUS UNTUK MEMPERKUAT BENDING KAPAL
PEMASANGAN KHUSUS PADA KEEL DAN TULANGAN
JENIS MULTIAXIAL UNTUK KAPAL
TRIAXIAL
DBL 600 ndash
APLIKASI PADA INDUSTRI PENERBANGAN
PEMASANGAN KHUSUS PADA
SAMBUNGAN BADAN DAN SAYAP
PESAWAT
JENIS MULTIAXIAL UNTUK PESAWAT
QUADRAXIAL
DBLT 800 ndash
APLIKASI PADA INDUSTRI ENERGI
DITERAPKAN UNTUK KEBUTUHAN PEMBANGKIT
LISTRIK ENERGI ANGIN
MULTIAXIAL UNTUK ENERGI
INDUSTRI KIMIA OLAHRAGA AUTOMOTIF
MULTIAXIAL UNTUK INDUSTRI LAINNYA
COMPOSITES
GUNAKAN MATERIAL FIBERGLASS
YANG SUDAH DISERTIFIKASI
BKI
FIBERGLASS UNTUK PEMBANGUNAN BAKAP
PERATURAN MENTERI PERHUBUNGAN
NOMOR PM 7 TAHUN 2013
TENTANG KEWAJIBAN KLASIFIKASI BAGI KAPAL BERBENDERA INDONESIA
PADA BADAN KLASIFIKASI
BADAN SERTIFIKASI MARITIM
Biro Klasifikasi IndonesiaDet Norske Veritas Germanischer Lloyds
PERATURAN BKI
Untuk Kapal Non-Metal
2006
PERSYARATAN MINIMUM
kekuatan material yang
harus digunakan
untuk membangun
Kapal Fiberglass
PEMBESARAN
Table 21
FIBERGLASS TRIAXIS COMPOSITES
TELAH BERSERTIFIKASI BKI
Biro Klasifikasi Indonesia
65
TEKNIK MANUFAKTUR
COMPOSITES
Wet hand lay-up
1) Peletakan
Dry Reinforcement
bull Dry reinforcement dan resin (+ katalis) ditaruh pada permukaan cetakan
2) Pemasukanpenekanan resin
bull Resin ditekan untuk meng-impregnasi serat dengan menggunakan rol
3) Pengulangan proses untuk lapisan lain
bull Beberapa lapisan dapat ditambahkan secara bertahap
4) Resin curing
bull Reaksi dimulai komponen dilepaskan setelah komponen mengeras
(fully cured)
Wet hand lay-up
Manufaktur komponen dapat dikerjakan dengan menggunakan beberapa lapis komposit
dengan memperhatikan kompatibilitas material dan tahapan curing Modifikasi proses dapat
dilakukan seperti
Vacuum bagging
setelah lay-up
Glass Roving
Bulk Resin
Catalyst
3) De-molding
2) Resin Cure
bull Curing dimulai dan komponen dilepaskan setelah pengerasan selesai
bull Serat gelas resin dan katalis dimasukkan kedalam spray gun
1) Spray-up
bull Campuran disemprotkan pada permukaan cetakan
Spray-up
69
Penyemprotan bakal komponen
Komponen
dilepaskan
dari cetakan
Full dispensing
system Chopper Roving
Atomised resin
and catalyst
Spray-up
Prepreg
1) LaminateAssembly 5) De-molding
3) Resin Melts Layup Consolidates
bull Prepreg serat yang sudah diimpregnasi oleh resin+katalis dalam kondisi padat
bull Lapisan prepreg digunting sesuai bentuk yang diinginkan kemudian diletakkan pada permukaan cetakan
sesuai bentuk komponen yang diinginkan Lay-up mudah dilakukan karena sifat ldquotackynessrdquo dari prepreg
2) Applied Vacuum Pressure and Heat
bull Tekanan dan panas diberikan resin mencair terjadi konsolidasi pada komponen
4) Resin Cures
bull Temperatur dinaikkan untuk memulai curing
Prepreg
Variasi proses Autoclave
Komponen dalam
vacuum-bag
bull Campuran resin (+katalis) dan chopped glass strands diperoleh dalam bentuk premixed compound Bulk molding
Compound (BMC) dalam bentuk adonan atau Sheet molding Compound (SMC) dalam bentuk lembaran
bull Ketika panas dan tekanan diberikan oleh cetakan compound mengalir sesuai bentuk komponen yang diinginkan
1) Placement of Charge
5) De-molding3) Squeeze to final dimensions
2) Mould Closure4) Resin Cure
bull Curing dimulai komponen dilepaskan setelah terjadi pengerasan yang cukup
Compression Molding
bull Preform atau dry reinforcement dimasukkan kedalam cetakan sesuai dengan bentuk komponen yang
diinginkan
bull Resin mengalir dengan penekanan atau pem-vakuman dan meng-impregnasi preform dan
mendorongmengeluarkan udara yang ada dalam preform
1) Preform Manufacture
2) Preform Compression
5) De-molding3) Resin Injection
4) Resin Cure
bull Curing terjadi cetakan dibuka setelah terjadi pengerasan yang mencukupi
Liquid Molding (RTM VARI VARTM)
Pultrusion
bull Dry roving or fabrics ditarik melalui bak berisi
campuran resin dan katalis
bull Campuran yang basah ditarik melalui cetakan
bull Sisa resin keluar cetakan
bull Pemanasan dilakukan untuk proses curing
bull Pendinginan dilakukan untuk mempercepat siklus
produksi
Cut-off
Cooling
Die sections
Resin bath
Fibre creel
Filament Winding
bull Dry roving ditarik melalui bak berisi campuran resin dan katalis
bull Wet roving digulungkan dalam keadaan tegang kepada mandrel
bull Kontrol mekanik dari pembawa serat mengatur orientasi peletakan serat pada
mandrel
INDUSTRI COMPOSITES
AEROSPACE
HISTORY
1950 ndash Boeing
1960 ndash F14 Tomcat
1981 ndash AV-8B Harrier
Source
Low-Cost Composite Materials and Structures for Aircraft Applications
httpwwwreinforcedplasticscom
httpwwwcentennialofflightgovessayEvolution_of_TechnologycompositesTech40htm
Automotive
Composite material is used in a number of applications in the automotive
industry due to its temperature resistance rigidity and fatigue strength
The benefits of using composites include greater fuel efficiency
corrosion resistance light weight and strength Composites also provide
a low-cost way to help keep designs looking fresh
Composites are used in
- interior parts (cockpit trimming seats instrument panels)
- exterior structure (body panels openings underbody frontrear
modules)
- engine compartment and fuelmechanical area parts (axles and
suspensions fuel and exhaust systems)
- electrical and electronic components
Lamborghinis Sesto Element carbon fiber
ldquoFat men cannot run as fast as thin men but we build most of our vehicles as though dead-weight fat increased speedhellip I cannot
imagine where the delusion that weight means strength
came fromhelliprdquo mdashHenry Ford
The mix of automotive materials is changing showing a boost for FRP in helping original
equipment manufacturers meet fuel economy and emissions challenges
(Source 2011 DuPont AutomotiveSAE survey of design engineers performed by Signet Research Inc)
Source
httpwwwtoraycomcsrhighlight2009hig_001_01html
The MonoCell tub for the McLaren MP4-12C supercar is moulded as a single
piece and weighs less than 80 kg (176 lbs)
COMPOSITES IN MARINE
TRIMARAN BOAT
AMERICA NAVYINDONESIAN NAVY
Visby Class corvette
Total length is 72 meters
The beam is 1040 meters
The displacement is 600 metric tones
fully equipped the worlds largest CRP
construction
The design of the Visby aims to minimize
the optical and infrared signature above
water acoustic and hydroa coustic
signature underwater electrical potential
and magnetic signature pressure signature
radar cross section and actively emitted
signals
A stealth corvette of the YS 2000 design
has a detection range of 13km in rough
seas and 22km in calm sea without
jamming In a jammed environment the
Visby would be detected at a range of 8km
in rough sea and 11km in calm sea
The material provides high strength and
rigidity low weight good shock resistance
low radar and magnetic signature
1996
Visby is a class of stealth corvettes for the Swedish Navy
ldquoReduced 50 of a Conventional Steelrdquo
Source
Hull Construction with composite materials for ships over 100m in length 2002
Massachusetts Institute of Technology
httpwwwnaval-technologycomprojectsvisby
YACHTS
KAL YUDISTIRAMARATHON 100 ADMIRAL YACHT
LOA 3050 MWidth 6 MFuel Tank 8000 LWater Tank 3000 LIce Box 500 LAccommodation Max 35 Personnel
2 x CATERPILLAR 3412E 1200 HPMARINE DIESEL ENGINE
PC 40 ndash KRI Krait 827Department of Indonesian Navy
LOA 40 MWidth 73 MPower 190Weapon Twin Cannon Barrels
127 mm Heavy Machine GunSpeed Knot 25 KnotDisplacement 105 tonAccommodation 23 personnel
PATROL BOAT
Rigid Inflatable BoatPATROL BOAT
Yachts
36m Luxury Yacht Moonraker
36m Luxury Yacht GoldenEye
50m Luxury Yacht Casino
Royale
45m Luxury Yacht Seashaw
Boat Parts
Barovans for Seismic Sweep
Centrifugal Liftfan House for Surface Effect
Ships
Composite Boat PropellersRTM
Deckhouses for Pilot Boats
Fairing Parts for Submarines
Flybridges for Motor yachts
Light Weight Gangway
MTB Launcher Mock-up
Pleasure Boats
12m Sailboat
12m Sail-Catamaranone-off
Canoes
Dragonfly 1000Catamaran Sailboat
Fantasy 37Sailboat
Farr 60Luxury Sailboat
EurodingyOlympic Dingy Class for
Woman
Hydrolift F23 Racing Boats
Kajacs
Najad 42Sailboat
Najad 520Sailboat
Najad 441Sailboat
Najad 391Sailboat
Nordwest 900Motorboat
Nordwest 1100Motorboat
Quatro 44Motorboat
Racemaster Competition Boats
Storebro 420
Storebro 345
Sweden Yacht 370Sailboat
Sweden Yacht 69Sailboat
Windy 41Motorboat
X-632Sailboat
X-362Sailboat
Commercial Boats
175m High Speed AmbulancePassenger Boat
19m High Speed Passenger Boat
20m High Speed Passenger Boat
364m Surface Effect Passenger Ship
45m Surface Effect Passenger Ship
120m Hull Structural Parts HSSS Catamaran Ferry
APPENDIX
Marine Vessel
1188m Fast Attack Vessel FMV 90 E
20m SAV-Surface Auxiliary Vessels
34m Personnel TransportCoast Guard Vessel
40ft Experimental SES
40m Landsort-Class Mine Hunters
54m Mine Counter Measure Vehicles SES
74m Coastal Patrol Boats
Fishing Boats
30 GT
12 GT
10 GT
5 GT
WISEWings In Surface Effect
HOVERCRAFT
Designed specifically for the tourist and transport industries the
Pioneer Mk3 hovercraft is amphibious and comfortably seats 25
passengers plus 1-crew The air-conditioned cabin allows for
maximum visibility for all aboard The Pioneer Mk3 is robust and
dynamic in its performance
Commercial hovercraft
Mk3 AirLift Hovercraft - 1215m
Power is economicaly provided by one Deutz diesel engine of
330kW (442hp) to cruise easily at 40 knots with much higher
speeds available according to the surface conditions The hull is
manufactured from fibreglassPVC foam composite sandwich
the windows are glass and the skirt is urethane coated nylon A
Military version is available with increased payload and systems
redundancy Power for the Military version comes from two Steyr
diesel engines with a total installed power of 320kW (429hp) All
transmission electrical hydraulic and air systems are duplicated
for maximum redundancy The increased performance of the
Military version comes from the reduced engine weight of the twin
Steyr installation cf the Deutz installation
Source
httpwwwnauticexpocomprodairlift-hovercraftcommercial-hovercrafts-25251-142868html
HOVERFLIGHT
BALLISTIC amp UNIT DEFENCED
Triaxis Composites Collaboration with Institute of Aeronautics and Space in the development of Missile Nose Cone
Polymer composites is the evolution of the military defence
Thin steel was the helmet material of
WWII and remained the principal material until around the 1980rsquos
The advantages of using steel
included a simple technology for manufacture of the helmets low cost and reasonably good
impact protection However these helmets were found to provide only marginal protection
against fragments
During the Vietnam War the US Army experimented with fiber-reinforced inserts in the
helmets These inserts improved ballistic protection but at the same time added weight and
reduced the air space between the head and the helmet
By the early part of the 1980rsquos the US military had developed the first all-composite
100 fiber-reinforced helmet This development resulted in even better ballistic protection
without altering the weight of the helmet Other improvements included better head coverage and
more space for ventilation
Source
Composites Armor - A difficult but huge market
by A Brent Strong Brigham Young University
MILITARY VEHICLES
HIGH SPEED TRAIN SHINKANSEN
Advanced Composites provide lightweight solutions for railway vehicles
saving as much as 50-80 of the weight compared with traditional
components
A lower overall weight translates into less stress faster acceleration and
higher speeds as well as reduced starting and stopping inertia Today
these are important criteria in global high-speed and metropolitan
railway projects
Fire smoke and toxic fumes are key safety criteria for interior
components of railway carriages Any material selected for an interior
component must meet international fire retardant standards
for Rail Interiors and Exteriors
Ceiling Panels Stairs
Seating Vestibules
Window Panels Door Pillars
Partition WallsDiffusers
Gangway and Cabinet Panels Cabin and
Desk panels
Door Pillars Lavatory Modules (standard and
Front and Rear EndsRoof Panels
Nose Cones Under Fairings
Source
httpwwwpctaerail_compositesphp
101
SKY BUS
2009
Europe is the world leader in offshore wind with
828 wind turbines and a cumulative capacity of 2056 MW spread across 38 offshore wind farms in 9
European countries
The UK and Denmark are the current leaders with a 44 and 30 share respectively In 2009
five countries built new offshore wind farms
UK (284 MW)
Demark (230 MW)
Sweden (30 MW)
Germany (30 MW)
Norway (23 MW)
2010
Asia leads the growth in global wind power which grew 358 GW in 2010 bringing
total global capacity to 1944 GW ndash up 225 from 2009
the Global Wind Energy Council (GWEC)
Asia accounted for 19 GW of new global wind power installations driven by China which installed 165
GW
ldquoChina now has 423 GW of wind powerrdquo
ldquoThis puts China firmly on a path to reach 200 GW of installed wind power by 2020 At the same
time China has become the worldrsquos largest producer of wind energy equipmentrdquo
Source
httpwwwreinforcedplasticscomview15655asia-leads-global-wind-power-growth
httpimgdeusmcomdesignnews288288605-Sandia_Sizes_up_Wind_Turbine_Blade_Design_C_largegif
WIND ENERGY
Marine Current Turbines
Source
httpwwwsiemenscompressenpressreleasepress=enpressrelease2011solar-hydroex201111005htm
httpwwwmarineturbinescom
A commercial marine current turbine consists of
two rotors which are fixed on a structure within the
sea current The twin rotors rotate with the
movement of the tidal flow and the blades pitch
through 180 degrees to optimally track tidal current
(Press picture Marine Current Turbines)
Wave Star Energys Multi-point Absorber
CFRP COLUMN REINFORCEMENT
INDUSTRIAL TANKS
107
INDUSTRIAL PIPES
PRESSURE TANKS
109
ldquoLetrsquos Make with Compositesrdquo
GDP per capita
Composites volume per capita inkg per inhabitant
Development curvein Volume
Composites markets size by country depends on development level
Average prices by industry worldwide
Aeronautics
Wind Energy
Consumer Goods
Transportation
Marine
Construction
E amp E
Pipes amp Tanks
Unit Prices eurokg 0 5 10 15 20 25 30 35 40 45
Growth in volume mainly in Asia
Repartition of the composites market by region 1999 gt 2013 in Mt
RoW
Europe
Asia
North America
Repartition of the composites market by region 1999 gt 2013 in Mt
1999 2002 2007 2013
7
22
36
35
7
33
23
38
5
29
26
40
4
27
24
45
25(1) 51Weight of Asia in global growth in volume
2015
103
81
6259
COMPOSITES
COMPOSITES = DUA MATERIAL YANG BERBEDA SIFAT FISIK DAN
KIMIAWI NYA BERSATU SECARA MAKROSKOPIK MELALUI SUATU
PROSES KIMIA MENJADI SUATU MATERIAL BARU (KOMPOSIT)
DENGAN SIFAT FISIK DAN MEKANIKAL YANG BARU
COMPOSITES ALAMI (NATURAL MATERIAL)
COMPOSITES BUATAN (ENGINEERED MATERIAL)
COMPOSITES
9
Berdasarkan jenis penguat
bull Particle-reinforced composites
ndash Large-particle composites (Cermets tungsten carbida in cobalt semen beton bertulang)
ndash Dispersed-strenghtened composites (alumina in aluminium ThoriaThO2 in Nickel alloy)
bull Fiber-reinforced composites konstruksi kaku kuat dan ringan
ndash Discontinuous (Short) fiber composites
ndash Continuous (long) fiber composites
bull Structural-reinforced composites
ndash Laminar composites (kayu multipleks laminate carbon epoxy)
ndash Sandwich composites konstruksi ringan dengan kekakuan dan kekuatan bending yang tinggi (Honeycomb-carbon epoxy composites dinding kardus corrugated paper - paper)
KLASIFIKASI MATERIAL KOMPOSIT
10
Berdasarkan jenis matriks
bull Polymer matrix composites (PMC) Paling populer dengan beragam aplikasi
- Carbon fibre reinforced polymer
- Glass fibre reinforced polymer
- Metal fibre reinforced polymer
bull Metal matrix composites (MMC) Aerospace dan komponen mesin mobil
- Boron or carbon fibre reinforced Aluminium
- Alumina particle reinforced Aluminium
bull Ceramic matrix composites (CMC) Heat exhanger sistem pelindung panas komponen dengan lingkungan korosif dan erosif
- Zirconia in alumina
- Carbon fibre reinforced carbon
KLASIFIKASI MATERIAL KOMPOSIT
SERAT
(FIBER) +RESIN
(MATRIX) = COMPOSITES
bull GLASS (KACA)
bull CARBON
bull ARAMID
bull Fiberglass Reinforced Plastics
(FRP)
bull Carbon Fiber Reinforced Plastics
(CFRP)
bull Aramid Fiber Reinforced Plastics
POLYMER TECHNOLOGY COMPOSITES
bull POLYESTER
bull VINYLESTER
bull EPOXY
bull POLYPROPYLENE
bull POLYAMID
COMPOSITES BUATAN (ENGINEERED COMPOSITES) SEHARI-HARI
BETON = TULANGAN BESI + RESIN SEMEN
The Importance of Lightness for
Environmental Friendly Products
Mass Reduction for Less Energy Consumption
MATERIAL COMPOSITES
Thermoset
type
Density r
(kgm3)
Stiffnes
s E
(Gpa)
Tensile
strength
s (MPa)
Strain to
failure e
()
Tg 0C
Thermal
conductivity
k (Wm0C)
Specific
Heat Cp
(kJkg0C)
Thermal
expansion coeff
a (x106 0C-1)
Polyester 1100-1230 31-46 50-75 10-65 70- 017-022 13-23 55-100
Vinylester 1120-1130 31-33 70-81 30-80 70- - - -
Epoxy 1100-1200 26-38 60-85 15-80 65-175 017-020 105 45-65
Phenolic 1000-1250 30-40 60-80 18 300 012-024 14-18 25-60
PUR 1200 07 30-40 400-450 135 017-021 13-23 70-100
BMI 1200-1320 32-50 48-110 15-33 230-345 - - -
Polyimide 1430-1890 31-49 100-110 15-30 325-370 01-034 105-15 25-80
Al 2800 72 540 18 - 130 096 236
Steel 7790 205 640 25 - 54 046 11
MATRIKS POLIMER THERMOSET
Variasi sifat yang lebar disebabkan oleh adanya formulasi kimia yang berbeda dan penambahan aditif
Jenis Glass Fiber S Glass E Glass C Glass A Glass dll
Terms
Glass Type
S Glass E Glass C Glass A Glass
Silica (SiO2) Content 67 55 64 72
Al2O3 Content 23 14 6 1
Melting Point (Celcius) 915 836 745 745
Tensile Strength 665 500 440 440
Modulus Elastisitas 124 105 100 -
Application AEROSPACE BOAT CHEMICAL TANK CHEMICAL TANK
JENIS SERAT GLASS
CHINA
JENIS SERAT GLASS
C GLASS Calcium borosilicate glasses
used for CHEMICAL stability in corrosive
acid environments
E GLASS Alumina-calcium-borosilicate
glasses with a maximum alkali used as
general purpose fibers where STRENGTH
and high ELECTICAL RESISTIVITY are
required It manifests better electrical
insulation and strongly resists attack by
water More than 50 of the glass fibers
used for reinforcement is E-glass
C Glass
E Glass
C amp E GLASS
SUMBER AGY TECHNICAL PAPER HIGH STRENGTH GLASS FIBER
FAKTA
C GLASS 1 BOROS RESIN
2 KEKUATAN
KURANG
FAKTA
E GLASS 1 HEMAT RESIN
2 KEKUATAN BAIK
3 TAHAN LAMA
FAKTA
TEBAL BUKAN BERARTI KUAT
UNSUR MATRIX (RESIN)
TIDAK ADA KEKUATAN
ldquoMore than 50 of the glass fibers used for
reinforcement is E-glassrdquo
C glass E glass
E glass
C glass
KAIN WOVEN ROVING HASIL LAMINASI
JENIS SERAT GLASS
Kekuatan composites ditentukan oleh
1 Kekuatan amp Sifat Fiber
2 Kekuatan amp Sifat Resin
3 Fraksi Rasio Perbandingan Volume Fiber
dan Resin dalam Composites
rarr tergantung dari Proses Manufaktur
4 Geometri dan Orientasi Arah Fiber dalam
Composites
KEKUATAN COMPOSITES
PROSES MATERIAL
Proses Produksi Kain Fiberglass
Biji Kaca Benang Benang Kaca Kain Fiberglass
PROSES MATERIAL
Glass Beads
Glass Fiber Glass Roving YarnGlass Fabric
FIBERGLASS
PRODUK
MATERIAL DAN PRODUK FIBERGLASS
+
Resin + Additives
PERPADUAN COMPOSITES
BENANG KACA Potongan Serat Kaca CSM
CSM - CHOPPED STRAND MAT
chopped binder
Kain Fiberglass Generasi Pertama
BahanPengikat
SenyawaPada Resin
JENIS FIBERGLASS
Glass Roving Yarn Chopped Strand
ADVANTAGES DISADVANTAGES
Steel
1048707 Low cost 1048707 Corrodes easily
1048707 Ductile under ambient conditions
1048707 Has no lower fatigue limit for welded structures
1048707 Virtually isotropic 1048707 Heavy
1048707 Easily formed and fabricated 1048707 Brittle at low temperatures
1048707 Easily obtained (low relative cost) 1048707 Magnetic
1048707 Easily alloyed or heat treated for special operations
1048707 Easily repaired
1048707 Good fire resistance
1048707 Behaviour is well understood
Alumunium Alloy
1048707 Light weight 1048707 Poor fatigue properties
1048707 Corrosion resistant 1048707 Poor performance in fire
1048707 Easily formed1048707 Low melting point and softening temperature
1048707 Easily fabricated 1048707 High relative cost
1048707 Readily available 1048707 Strength and stiffness less than steel
1048707 Ductile
1048707 Non magnetic
FRP
1048707 Low magnetic properties
1048707 Low electrical conductivity (glass- reinforced plastics)
1048707 Resistance to corrosion
1048707 Resistance to rot and marine growth
1048707 Relatively high sonar transparency
1048707 Good strength to weight ratio
1048707 Good fatigue properties
1048707 Maintenance of properties at low temperatures
1048707 Availability
1048707 Can be manufactured to near net-shape
1048707 Stiffness and strength can be tailored to structural requirements
1048707 Excellent thermal insulation
1048707 Light weight
STEEL vs ALUMUNIUM vs COMPOSITES
Source
1Maritime Platforms Division Aeronautical and
Maritime Research Laboratory (Seref Aksu
Stuart Cannon Craig Gardiner and Matthew
Gudze
2 Metal Corrosion can be defined as the
destructive attack of a metal through interaction
with its environment
(httpwwwcorrosionistcomCorrosion_Fundament
alhtm)
28
Serat rarr penguat
Polimer matriks rarr pengikat
bull Sifat mekanik yang cukup baik
bull Viskositas dan temperatur pengerjaan rendah rarr mudah
dimanufaktur
bull Ketahanan korosi yang baik
bull Media perpindahan gaya rarr distribusi beban dari serat ke serat
bull Ulet rarr Melindungi serat yang getas
bull Size effect rarr Kekuatan dan kekakuan sangat tinggi
bull Aspect ratio (ld) tinggi rarr luas permukaan besar
bull Fleksibel rarr variasi teknik manufaktur
bull Serat dapat diatur sesuai dengan arah pembebanan
29
Advantages Polimer Composites
Kekuatan dan kekakuan spesifik yang tinggi FRCP vs material lain rarr kompetitif jika berat dipertimbangkan
Material Berat jenis
r (kgm3)
Kekakuan
E (GPa)
Kekuatan
tarik su
(MPa)
Kekakuan
spesifik
Er
Kekuatan
spesifik sur
Baja 7800 208 400 27 005
Aluminium 2700 70 200 259 007
Nylon 1100 25 80 23 007
Beton 2400 40 20 166 0008
Random
FRPC
1800 20 300 111 0006
Alligned FRPC
( serat)
1600 200 1500 125 094
Alligned FRCP
( serat)
1600 3 50 19 0001
Tensile Strength amp Modulus of Common Structural Materials
Densities of Common Structural Materials
Specific Tensile Strength amp Modulus of Common Structural Materials
Typical Properties of Common Structural Materials
Kesimpulan COMPOSITES = RINGAN amp KUAT
Jadi secara keseluruhan kekuatan composites
ditentukan oleh
1 Kekuatan amp Sifat Fiber
2 Kekuatan amp Sifat Resin
3 Fraksi Rasio Perbandingan Volume Fiber
dan Resin dalam Composites
4 Geometri dan Orientasi Arah Fiber dalam
Composites
PRODUKSI ANAK NEGERI
Proses Produksi Kain Fiberglass
Biji Kaca Benang Benang Kaca Kain Fiberglass
PROSES MATERIAL
Glass Beads
Glass Fiber Glass Roving YarnGlass Fabric
Proses Produksi Kain Fiberglass
Biji Kaca Benang Benang Kaca Kain Fiberglass
Glass Beads
Glass Fiber Glass Roving YarnGlass Fabric
PROSES MATERIAL
Benang Kaca Potongan Serat Kaca Chopped Strand Mat
CSM - Chopped Strand Mat
chopped binder
Produk Fiberglass Generasi Pertama
Bahan Pengikat
Senyawa Pada Resin
Glass Roving Yarn Chopped Strand
JENIS FIBERGLASS
Benang Kaca Woven Roving
WR - Woven Roving
Tenun Weaving
Produk Fiberglass Generasi Kedua
Glass Roving Yarn
JENIS FIBERGLASS
Multiaxial
MAX - Multiaxial
warp knitting
Produk Fiberglass Generasi Ketiga
Benang Kaca
Glass Roving Yarn
JENIS FIBERGLASS
MAX - Multiaxial Fabric
Fleece (optional)
Lapisan
MULTIAXIAL PROSES
Karakteristik CSM
bull Glass Content 30
bull Resin Content 70
bull Tensile Force
Chopped Strand Mat
JENIS FIBERGLASS
Karakteristik Woven Roving
bull Glass Content 45
bull Resin Content 55
Woven Roving
Resin
|
|
|
|
|
|
|
|
|
|
|
|
|
|
bull Kekuatan Tarik
JENIS FIBERGLASS
No Resin Rich Area
Karakteristik Multiaxial
bull Glass Content 60
bull Resin Content 40
Produk Fiberglass Ketiga MULTIAXIAL
JENIS FIBERGLASS
Perbedaan Woven Roving dan Multiaxial ndash Tampak Samping
JENIS FIBERGLASS
WR FRP
8 Ply WR 800
8 Ply CSM 450
Glass Weight 1 kg
Composite Weight 15kgm2
CSM FRP
22 Ply CSM 450
Glass Weight 1 kg
Composite Weight 18 kgm2
MULTIAXIAL FRP
13 Ply DB 800
Glass Weight 1 kg
Composite Weight
13 kgm2
JENIS FIBERGLASS
Multiaxial
FRP
Woven Roving
FRP
Chopped Strands Mat FRP
MULTIAXIAL
FAKTA
TEBAL BUKAN BERARTI KUAT
UNSUR MATRIX (RESIN)
TIDAK ADA KEKUATAN
ldquoMore than 50 of the glass fibers used for reinforcement is
E-glassrdquo
KarakteristikKekuatan
CSM WR MAX
Kekuatan Tarik 175 MPa 250 MPa 425 MPa
CSM 142
WR 70
KEKUATAN TARIK
Properties CSM Lamination WR Lamination MAX Lamination
Fabric Weight (kgm2) 1 1 1
Composite Weight (kgm2) 18 15 13
Resin usage (kgm2) 15 1 08
Amount of Fabric 22 Ply 16 Ply 13 Ply
Thickness 15 mm 12 mm 10 mm
Tensile Strength (Mpa) 125 1796 400
Tensile Strength (Nmmsup2) 28463 30958 4576
Processing Time High Med Low
Labour Cost High Med Low
MULTIAXIAL
Total Penggunaan Resin -51
Total Berat Kapal -40
Kekuatan Bangunan Kapal +59
Efisiensi Tenaga Kerja
Waktu Pengerjaan Lebih Cepat
KEUNGGULAN MATERIAL
Resapan Resin Lebih Baik amp Merata
Lapisan Lebih Sedikit
Meningkatkan Kekuatan Kapal
KEUNGGULAN MATERIAL
TRIAXIAL
DBL series DBT series
BIAXIAL
LT series DB series
UNIDIRECTIONAL
L series T series
QUADRIAXIAL
DBLT series
JENIS MULTIAXIAL
UNIDIRECTIONAL
DCMU 900 E ndash
KHUSUS UNTUK MEMPERKUAT BENDING KAPAL
PEMASANGAN KHUSUS PADA KEEL DAN TULANGAN
JENIS MULTIAXIAL UNTUK KAPAL
TRIAXIAL
DBL 600 ndash
APLIKASI PADA INDUSTRI PENERBANGAN
PEMASANGAN KHUSUS PADA
SAMBUNGAN BADAN DAN SAYAP
PESAWAT
JENIS MULTIAXIAL UNTUK PESAWAT
QUADRAXIAL
DBLT 800 ndash
APLIKASI PADA INDUSTRI ENERGI
DITERAPKAN UNTUK KEBUTUHAN PEMBANGKIT
LISTRIK ENERGI ANGIN
MULTIAXIAL UNTUK ENERGI
INDUSTRI KIMIA OLAHRAGA AUTOMOTIF
MULTIAXIAL UNTUK INDUSTRI LAINNYA
COMPOSITES
GUNAKAN MATERIAL FIBERGLASS
YANG SUDAH DISERTIFIKASI
BKI
FIBERGLASS UNTUK PEMBANGUNAN BAKAP
PERATURAN MENTERI PERHUBUNGAN
NOMOR PM 7 TAHUN 2013
TENTANG KEWAJIBAN KLASIFIKASI BAGI KAPAL BERBENDERA INDONESIA
PADA BADAN KLASIFIKASI
BADAN SERTIFIKASI MARITIM
Biro Klasifikasi IndonesiaDet Norske Veritas Germanischer Lloyds
PERATURAN BKI
Untuk Kapal Non-Metal
2006
PERSYARATAN MINIMUM
kekuatan material yang
harus digunakan
untuk membangun
Kapal Fiberglass
PEMBESARAN
Table 21
FIBERGLASS TRIAXIS COMPOSITES
TELAH BERSERTIFIKASI BKI
Biro Klasifikasi Indonesia
65
TEKNIK MANUFAKTUR
COMPOSITES
Wet hand lay-up
1) Peletakan
Dry Reinforcement
bull Dry reinforcement dan resin (+ katalis) ditaruh pada permukaan cetakan
2) Pemasukanpenekanan resin
bull Resin ditekan untuk meng-impregnasi serat dengan menggunakan rol
3) Pengulangan proses untuk lapisan lain
bull Beberapa lapisan dapat ditambahkan secara bertahap
4) Resin curing
bull Reaksi dimulai komponen dilepaskan setelah komponen mengeras
(fully cured)
Wet hand lay-up
Manufaktur komponen dapat dikerjakan dengan menggunakan beberapa lapis komposit
dengan memperhatikan kompatibilitas material dan tahapan curing Modifikasi proses dapat
dilakukan seperti
Vacuum bagging
setelah lay-up
Glass Roving
Bulk Resin
Catalyst
3) De-molding
2) Resin Cure
bull Curing dimulai dan komponen dilepaskan setelah pengerasan selesai
bull Serat gelas resin dan katalis dimasukkan kedalam spray gun
1) Spray-up
bull Campuran disemprotkan pada permukaan cetakan
Spray-up
69
Penyemprotan bakal komponen
Komponen
dilepaskan
dari cetakan
Full dispensing
system Chopper Roving
Atomised resin
and catalyst
Spray-up
Prepreg
1) LaminateAssembly 5) De-molding
3) Resin Melts Layup Consolidates
bull Prepreg serat yang sudah diimpregnasi oleh resin+katalis dalam kondisi padat
bull Lapisan prepreg digunting sesuai bentuk yang diinginkan kemudian diletakkan pada permukaan cetakan
sesuai bentuk komponen yang diinginkan Lay-up mudah dilakukan karena sifat ldquotackynessrdquo dari prepreg
2) Applied Vacuum Pressure and Heat
bull Tekanan dan panas diberikan resin mencair terjadi konsolidasi pada komponen
4) Resin Cures
bull Temperatur dinaikkan untuk memulai curing
Prepreg
Variasi proses Autoclave
Komponen dalam
vacuum-bag
bull Campuran resin (+katalis) dan chopped glass strands diperoleh dalam bentuk premixed compound Bulk molding
Compound (BMC) dalam bentuk adonan atau Sheet molding Compound (SMC) dalam bentuk lembaran
bull Ketika panas dan tekanan diberikan oleh cetakan compound mengalir sesuai bentuk komponen yang diinginkan
1) Placement of Charge
5) De-molding3) Squeeze to final dimensions
2) Mould Closure4) Resin Cure
bull Curing dimulai komponen dilepaskan setelah terjadi pengerasan yang cukup
Compression Molding
bull Preform atau dry reinforcement dimasukkan kedalam cetakan sesuai dengan bentuk komponen yang
diinginkan
bull Resin mengalir dengan penekanan atau pem-vakuman dan meng-impregnasi preform dan
mendorongmengeluarkan udara yang ada dalam preform
1) Preform Manufacture
2) Preform Compression
5) De-molding3) Resin Injection
4) Resin Cure
bull Curing terjadi cetakan dibuka setelah terjadi pengerasan yang mencukupi
Liquid Molding (RTM VARI VARTM)
Pultrusion
bull Dry roving or fabrics ditarik melalui bak berisi
campuran resin dan katalis
bull Campuran yang basah ditarik melalui cetakan
bull Sisa resin keluar cetakan
bull Pemanasan dilakukan untuk proses curing
bull Pendinginan dilakukan untuk mempercepat siklus
produksi
Cut-off
Cooling
Die sections
Resin bath
Fibre creel
Filament Winding
bull Dry roving ditarik melalui bak berisi campuran resin dan katalis
bull Wet roving digulungkan dalam keadaan tegang kepada mandrel
bull Kontrol mekanik dari pembawa serat mengatur orientasi peletakan serat pada
mandrel
INDUSTRI COMPOSITES
AEROSPACE
HISTORY
1950 ndash Boeing
1960 ndash F14 Tomcat
1981 ndash AV-8B Harrier
Source
Low-Cost Composite Materials and Structures for Aircraft Applications
httpwwwreinforcedplasticscom
httpwwwcentennialofflightgovessayEvolution_of_TechnologycompositesTech40htm
Automotive
Composite material is used in a number of applications in the automotive
industry due to its temperature resistance rigidity and fatigue strength
The benefits of using composites include greater fuel efficiency
corrosion resistance light weight and strength Composites also provide
a low-cost way to help keep designs looking fresh
Composites are used in
- interior parts (cockpit trimming seats instrument panels)
- exterior structure (body panels openings underbody frontrear
modules)
- engine compartment and fuelmechanical area parts (axles and
suspensions fuel and exhaust systems)
- electrical and electronic components
Lamborghinis Sesto Element carbon fiber
ldquoFat men cannot run as fast as thin men but we build most of our vehicles as though dead-weight fat increased speedhellip I cannot
imagine where the delusion that weight means strength
came fromhelliprdquo mdashHenry Ford
The mix of automotive materials is changing showing a boost for FRP in helping original
equipment manufacturers meet fuel economy and emissions challenges
(Source 2011 DuPont AutomotiveSAE survey of design engineers performed by Signet Research Inc)
Source
httpwwwtoraycomcsrhighlight2009hig_001_01html
The MonoCell tub for the McLaren MP4-12C supercar is moulded as a single
piece and weighs less than 80 kg (176 lbs)
COMPOSITES IN MARINE
TRIMARAN BOAT
AMERICA NAVYINDONESIAN NAVY
Visby Class corvette
Total length is 72 meters
The beam is 1040 meters
The displacement is 600 metric tones
fully equipped the worlds largest CRP
construction
The design of the Visby aims to minimize
the optical and infrared signature above
water acoustic and hydroa coustic
signature underwater electrical potential
and magnetic signature pressure signature
radar cross section and actively emitted
signals
A stealth corvette of the YS 2000 design
has a detection range of 13km in rough
seas and 22km in calm sea without
jamming In a jammed environment the
Visby would be detected at a range of 8km
in rough sea and 11km in calm sea
The material provides high strength and
rigidity low weight good shock resistance
low radar and magnetic signature
1996
Visby is a class of stealth corvettes for the Swedish Navy
ldquoReduced 50 of a Conventional Steelrdquo
Source
Hull Construction with composite materials for ships over 100m in length 2002
Massachusetts Institute of Technology
httpwwwnaval-technologycomprojectsvisby
YACHTS
KAL YUDISTIRAMARATHON 100 ADMIRAL YACHT
LOA 3050 MWidth 6 MFuel Tank 8000 LWater Tank 3000 LIce Box 500 LAccommodation Max 35 Personnel
2 x CATERPILLAR 3412E 1200 HPMARINE DIESEL ENGINE
PC 40 ndash KRI Krait 827Department of Indonesian Navy
LOA 40 MWidth 73 MPower 190Weapon Twin Cannon Barrels
127 mm Heavy Machine GunSpeed Knot 25 KnotDisplacement 105 tonAccommodation 23 personnel
PATROL BOAT
Rigid Inflatable BoatPATROL BOAT
Yachts
36m Luxury Yacht Moonraker
36m Luxury Yacht GoldenEye
50m Luxury Yacht Casino
Royale
45m Luxury Yacht Seashaw
Boat Parts
Barovans for Seismic Sweep
Centrifugal Liftfan House for Surface Effect
Ships
Composite Boat PropellersRTM
Deckhouses for Pilot Boats
Fairing Parts for Submarines
Flybridges for Motor yachts
Light Weight Gangway
MTB Launcher Mock-up
Pleasure Boats
12m Sailboat
12m Sail-Catamaranone-off
Canoes
Dragonfly 1000Catamaran Sailboat
Fantasy 37Sailboat
Farr 60Luxury Sailboat
EurodingyOlympic Dingy Class for
Woman
Hydrolift F23 Racing Boats
Kajacs
Najad 42Sailboat
Najad 520Sailboat
Najad 441Sailboat
Najad 391Sailboat
Nordwest 900Motorboat
Nordwest 1100Motorboat
Quatro 44Motorboat
Racemaster Competition Boats
Storebro 420
Storebro 345
Sweden Yacht 370Sailboat
Sweden Yacht 69Sailboat
Windy 41Motorboat
X-632Sailboat
X-362Sailboat
Commercial Boats
175m High Speed AmbulancePassenger Boat
19m High Speed Passenger Boat
20m High Speed Passenger Boat
364m Surface Effect Passenger Ship
45m Surface Effect Passenger Ship
120m Hull Structural Parts HSSS Catamaran Ferry
APPENDIX
Marine Vessel
1188m Fast Attack Vessel FMV 90 E
20m SAV-Surface Auxiliary Vessels
34m Personnel TransportCoast Guard Vessel
40ft Experimental SES
40m Landsort-Class Mine Hunters
54m Mine Counter Measure Vehicles SES
74m Coastal Patrol Boats
Fishing Boats
30 GT
12 GT
10 GT
5 GT
WISEWings In Surface Effect
HOVERCRAFT
Designed specifically for the tourist and transport industries the
Pioneer Mk3 hovercraft is amphibious and comfortably seats 25
passengers plus 1-crew The air-conditioned cabin allows for
maximum visibility for all aboard The Pioneer Mk3 is robust and
dynamic in its performance
Commercial hovercraft
Mk3 AirLift Hovercraft - 1215m
Power is economicaly provided by one Deutz diesel engine of
330kW (442hp) to cruise easily at 40 knots with much higher
speeds available according to the surface conditions The hull is
manufactured from fibreglassPVC foam composite sandwich
the windows are glass and the skirt is urethane coated nylon A
Military version is available with increased payload and systems
redundancy Power for the Military version comes from two Steyr
diesel engines with a total installed power of 320kW (429hp) All
transmission electrical hydraulic and air systems are duplicated
for maximum redundancy The increased performance of the
Military version comes from the reduced engine weight of the twin
Steyr installation cf the Deutz installation
Source
httpwwwnauticexpocomprodairlift-hovercraftcommercial-hovercrafts-25251-142868html
HOVERFLIGHT
BALLISTIC amp UNIT DEFENCED
Triaxis Composites Collaboration with Institute of Aeronautics and Space in the development of Missile Nose Cone
Polymer composites is the evolution of the military defence
Thin steel was the helmet material of
WWII and remained the principal material until around the 1980rsquos
The advantages of using steel
included a simple technology for manufacture of the helmets low cost and reasonably good
impact protection However these helmets were found to provide only marginal protection
against fragments
During the Vietnam War the US Army experimented with fiber-reinforced inserts in the
helmets These inserts improved ballistic protection but at the same time added weight and
reduced the air space between the head and the helmet
By the early part of the 1980rsquos the US military had developed the first all-composite
100 fiber-reinforced helmet This development resulted in even better ballistic protection
without altering the weight of the helmet Other improvements included better head coverage and
more space for ventilation
Source
Composites Armor - A difficult but huge market
by A Brent Strong Brigham Young University
MILITARY VEHICLES
HIGH SPEED TRAIN SHINKANSEN
Advanced Composites provide lightweight solutions for railway vehicles
saving as much as 50-80 of the weight compared with traditional
components
A lower overall weight translates into less stress faster acceleration and
higher speeds as well as reduced starting and stopping inertia Today
these are important criteria in global high-speed and metropolitan
railway projects
Fire smoke and toxic fumes are key safety criteria for interior
components of railway carriages Any material selected for an interior
component must meet international fire retardant standards
for Rail Interiors and Exteriors
Ceiling Panels Stairs
Seating Vestibules
Window Panels Door Pillars
Partition WallsDiffusers
Gangway and Cabinet Panels Cabin and
Desk panels
Door Pillars Lavatory Modules (standard and
Front and Rear EndsRoof Panels
Nose Cones Under Fairings
Source
httpwwwpctaerail_compositesphp
101
SKY BUS
2009
Europe is the world leader in offshore wind with
828 wind turbines and a cumulative capacity of 2056 MW spread across 38 offshore wind farms in 9
European countries
The UK and Denmark are the current leaders with a 44 and 30 share respectively In 2009
five countries built new offshore wind farms
UK (284 MW)
Demark (230 MW)
Sweden (30 MW)
Germany (30 MW)
Norway (23 MW)
2010
Asia leads the growth in global wind power which grew 358 GW in 2010 bringing
total global capacity to 1944 GW ndash up 225 from 2009
the Global Wind Energy Council (GWEC)
Asia accounted for 19 GW of new global wind power installations driven by China which installed 165
GW
ldquoChina now has 423 GW of wind powerrdquo
ldquoThis puts China firmly on a path to reach 200 GW of installed wind power by 2020 At the same
time China has become the worldrsquos largest producer of wind energy equipmentrdquo
Source
httpwwwreinforcedplasticscomview15655asia-leads-global-wind-power-growth
httpimgdeusmcomdesignnews288288605-Sandia_Sizes_up_Wind_Turbine_Blade_Design_C_largegif
WIND ENERGY
Marine Current Turbines
Source
httpwwwsiemenscompressenpressreleasepress=enpressrelease2011solar-hydroex201111005htm
httpwwwmarineturbinescom
A commercial marine current turbine consists of
two rotors which are fixed on a structure within the
sea current The twin rotors rotate with the
movement of the tidal flow and the blades pitch
through 180 degrees to optimally track tidal current
(Press picture Marine Current Turbines)
Wave Star Energys Multi-point Absorber
CFRP COLUMN REINFORCEMENT
INDUSTRIAL TANKS
107
INDUSTRIAL PIPES
PRESSURE TANKS
109
ldquoLetrsquos Make with Compositesrdquo
Average prices by industry worldwide
Aeronautics
Wind Energy
Consumer Goods
Transportation
Marine
Construction
E amp E
Pipes amp Tanks
Unit Prices eurokg 0 5 10 15 20 25 30 35 40 45
Growth in volume mainly in Asia
Repartition of the composites market by region 1999 gt 2013 in Mt
RoW
Europe
Asia
North America
Repartition of the composites market by region 1999 gt 2013 in Mt
1999 2002 2007 2013
7
22
36
35
7
33
23
38
5
29
26
40
4
27
24
45
25(1) 51Weight of Asia in global growth in volume
2015
103
81
6259
COMPOSITES
COMPOSITES = DUA MATERIAL YANG BERBEDA SIFAT FISIK DAN
KIMIAWI NYA BERSATU SECARA MAKROSKOPIK MELALUI SUATU
PROSES KIMIA MENJADI SUATU MATERIAL BARU (KOMPOSIT)
DENGAN SIFAT FISIK DAN MEKANIKAL YANG BARU
COMPOSITES ALAMI (NATURAL MATERIAL)
COMPOSITES BUATAN (ENGINEERED MATERIAL)
COMPOSITES
9
Berdasarkan jenis penguat
bull Particle-reinforced composites
ndash Large-particle composites (Cermets tungsten carbida in cobalt semen beton bertulang)
ndash Dispersed-strenghtened composites (alumina in aluminium ThoriaThO2 in Nickel alloy)
bull Fiber-reinforced composites konstruksi kaku kuat dan ringan
ndash Discontinuous (Short) fiber composites
ndash Continuous (long) fiber composites
bull Structural-reinforced composites
ndash Laminar composites (kayu multipleks laminate carbon epoxy)
ndash Sandwich composites konstruksi ringan dengan kekakuan dan kekuatan bending yang tinggi (Honeycomb-carbon epoxy composites dinding kardus corrugated paper - paper)
KLASIFIKASI MATERIAL KOMPOSIT
10
Berdasarkan jenis matriks
bull Polymer matrix composites (PMC) Paling populer dengan beragam aplikasi
- Carbon fibre reinforced polymer
- Glass fibre reinforced polymer
- Metal fibre reinforced polymer
bull Metal matrix composites (MMC) Aerospace dan komponen mesin mobil
- Boron or carbon fibre reinforced Aluminium
- Alumina particle reinforced Aluminium
bull Ceramic matrix composites (CMC) Heat exhanger sistem pelindung panas komponen dengan lingkungan korosif dan erosif
- Zirconia in alumina
- Carbon fibre reinforced carbon
KLASIFIKASI MATERIAL KOMPOSIT
SERAT
(FIBER) +RESIN
(MATRIX) = COMPOSITES
bull GLASS (KACA)
bull CARBON
bull ARAMID
bull Fiberglass Reinforced Plastics
(FRP)
bull Carbon Fiber Reinforced Plastics
(CFRP)
bull Aramid Fiber Reinforced Plastics
POLYMER TECHNOLOGY COMPOSITES
bull POLYESTER
bull VINYLESTER
bull EPOXY
bull POLYPROPYLENE
bull POLYAMID
COMPOSITES BUATAN (ENGINEERED COMPOSITES) SEHARI-HARI
BETON = TULANGAN BESI + RESIN SEMEN
The Importance of Lightness for
Environmental Friendly Products
Mass Reduction for Less Energy Consumption
MATERIAL COMPOSITES
Thermoset
type
Density r
(kgm3)
Stiffnes
s E
(Gpa)
Tensile
strength
s (MPa)
Strain to
failure e
()
Tg 0C
Thermal
conductivity
k (Wm0C)
Specific
Heat Cp
(kJkg0C)
Thermal
expansion coeff
a (x106 0C-1)
Polyester 1100-1230 31-46 50-75 10-65 70- 017-022 13-23 55-100
Vinylester 1120-1130 31-33 70-81 30-80 70- - - -
Epoxy 1100-1200 26-38 60-85 15-80 65-175 017-020 105 45-65
Phenolic 1000-1250 30-40 60-80 18 300 012-024 14-18 25-60
PUR 1200 07 30-40 400-450 135 017-021 13-23 70-100
BMI 1200-1320 32-50 48-110 15-33 230-345 - - -
Polyimide 1430-1890 31-49 100-110 15-30 325-370 01-034 105-15 25-80
Al 2800 72 540 18 - 130 096 236
Steel 7790 205 640 25 - 54 046 11
MATRIKS POLIMER THERMOSET
Variasi sifat yang lebar disebabkan oleh adanya formulasi kimia yang berbeda dan penambahan aditif
Jenis Glass Fiber S Glass E Glass C Glass A Glass dll
Terms
Glass Type
S Glass E Glass C Glass A Glass
Silica (SiO2) Content 67 55 64 72
Al2O3 Content 23 14 6 1
Melting Point (Celcius) 915 836 745 745
Tensile Strength 665 500 440 440
Modulus Elastisitas 124 105 100 -
Application AEROSPACE BOAT CHEMICAL TANK CHEMICAL TANK
JENIS SERAT GLASS
CHINA
JENIS SERAT GLASS
C GLASS Calcium borosilicate glasses
used for CHEMICAL stability in corrosive
acid environments
E GLASS Alumina-calcium-borosilicate
glasses with a maximum alkali used as
general purpose fibers where STRENGTH
and high ELECTICAL RESISTIVITY are
required It manifests better electrical
insulation and strongly resists attack by
water More than 50 of the glass fibers
used for reinforcement is E-glass
C Glass
E Glass
C amp E GLASS
SUMBER AGY TECHNICAL PAPER HIGH STRENGTH GLASS FIBER
FAKTA
C GLASS 1 BOROS RESIN
2 KEKUATAN
KURANG
FAKTA
E GLASS 1 HEMAT RESIN
2 KEKUATAN BAIK
3 TAHAN LAMA
FAKTA
TEBAL BUKAN BERARTI KUAT
UNSUR MATRIX (RESIN)
TIDAK ADA KEKUATAN
ldquoMore than 50 of the glass fibers used for
reinforcement is E-glassrdquo
C glass E glass
E glass
C glass
KAIN WOVEN ROVING HASIL LAMINASI
JENIS SERAT GLASS
Kekuatan composites ditentukan oleh
1 Kekuatan amp Sifat Fiber
2 Kekuatan amp Sifat Resin
3 Fraksi Rasio Perbandingan Volume Fiber
dan Resin dalam Composites
rarr tergantung dari Proses Manufaktur
4 Geometri dan Orientasi Arah Fiber dalam
Composites
KEKUATAN COMPOSITES
PROSES MATERIAL
Proses Produksi Kain Fiberglass
Biji Kaca Benang Benang Kaca Kain Fiberglass
PROSES MATERIAL
Glass Beads
Glass Fiber Glass Roving YarnGlass Fabric
FIBERGLASS
PRODUK
MATERIAL DAN PRODUK FIBERGLASS
+
Resin + Additives
PERPADUAN COMPOSITES
BENANG KACA Potongan Serat Kaca CSM
CSM - CHOPPED STRAND MAT
chopped binder
Kain Fiberglass Generasi Pertama
BahanPengikat
SenyawaPada Resin
JENIS FIBERGLASS
Glass Roving Yarn Chopped Strand
ADVANTAGES DISADVANTAGES
Steel
1048707 Low cost 1048707 Corrodes easily
1048707 Ductile under ambient conditions
1048707 Has no lower fatigue limit for welded structures
1048707 Virtually isotropic 1048707 Heavy
1048707 Easily formed and fabricated 1048707 Brittle at low temperatures
1048707 Easily obtained (low relative cost) 1048707 Magnetic
1048707 Easily alloyed or heat treated for special operations
1048707 Easily repaired
1048707 Good fire resistance
1048707 Behaviour is well understood
Alumunium Alloy
1048707 Light weight 1048707 Poor fatigue properties
1048707 Corrosion resistant 1048707 Poor performance in fire
1048707 Easily formed1048707 Low melting point and softening temperature
1048707 Easily fabricated 1048707 High relative cost
1048707 Readily available 1048707 Strength and stiffness less than steel
1048707 Ductile
1048707 Non magnetic
FRP
1048707 Low magnetic properties
1048707 Low electrical conductivity (glass- reinforced plastics)
1048707 Resistance to corrosion
1048707 Resistance to rot and marine growth
1048707 Relatively high sonar transparency
1048707 Good strength to weight ratio
1048707 Good fatigue properties
1048707 Maintenance of properties at low temperatures
1048707 Availability
1048707 Can be manufactured to near net-shape
1048707 Stiffness and strength can be tailored to structural requirements
1048707 Excellent thermal insulation
1048707 Light weight
STEEL vs ALUMUNIUM vs COMPOSITES
Source
1Maritime Platforms Division Aeronautical and
Maritime Research Laboratory (Seref Aksu
Stuart Cannon Craig Gardiner and Matthew
Gudze
2 Metal Corrosion can be defined as the
destructive attack of a metal through interaction
with its environment
(httpwwwcorrosionistcomCorrosion_Fundament
alhtm)
28
Serat rarr penguat
Polimer matriks rarr pengikat
bull Sifat mekanik yang cukup baik
bull Viskositas dan temperatur pengerjaan rendah rarr mudah
dimanufaktur
bull Ketahanan korosi yang baik
bull Media perpindahan gaya rarr distribusi beban dari serat ke serat
bull Ulet rarr Melindungi serat yang getas
bull Size effect rarr Kekuatan dan kekakuan sangat tinggi
bull Aspect ratio (ld) tinggi rarr luas permukaan besar
bull Fleksibel rarr variasi teknik manufaktur
bull Serat dapat diatur sesuai dengan arah pembebanan
29
Advantages Polimer Composites
Kekuatan dan kekakuan spesifik yang tinggi FRCP vs material lain rarr kompetitif jika berat dipertimbangkan
Material Berat jenis
r (kgm3)
Kekakuan
E (GPa)
Kekuatan
tarik su
(MPa)
Kekakuan
spesifik
Er
Kekuatan
spesifik sur
Baja 7800 208 400 27 005
Aluminium 2700 70 200 259 007
Nylon 1100 25 80 23 007
Beton 2400 40 20 166 0008
Random
FRPC
1800 20 300 111 0006
Alligned FRPC
( serat)
1600 200 1500 125 094
Alligned FRCP
( serat)
1600 3 50 19 0001
Tensile Strength amp Modulus of Common Structural Materials
Densities of Common Structural Materials
Specific Tensile Strength amp Modulus of Common Structural Materials
Typical Properties of Common Structural Materials
Kesimpulan COMPOSITES = RINGAN amp KUAT
Jadi secara keseluruhan kekuatan composites
ditentukan oleh
1 Kekuatan amp Sifat Fiber
2 Kekuatan amp Sifat Resin
3 Fraksi Rasio Perbandingan Volume Fiber
dan Resin dalam Composites
4 Geometri dan Orientasi Arah Fiber dalam
Composites
PRODUKSI ANAK NEGERI
Proses Produksi Kain Fiberglass
Biji Kaca Benang Benang Kaca Kain Fiberglass
PROSES MATERIAL
Glass Beads
Glass Fiber Glass Roving YarnGlass Fabric
Proses Produksi Kain Fiberglass
Biji Kaca Benang Benang Kaca Kain Fiberglass
Glass Beads
Glass Fiber Glass Roving YarnGlass Fabric
PROSES MATERIAL
Benang Kaca Potongan Serat Kaca Chopped Strand Mat
CSM - Chopped Strand Mat
chopped binder
Produk Fiberglass Generasi Pertama
Bahan Pengikat
Senyawa Pada Resin
Glass Roving Yarn Chopped Strand
JENIS FIBERGLASS
Benang Kaca Woven Roving
WR - Woven Roving
Tenun Weaving
Produk Fiberglass Generasi Kedua
Glass Roving Yarn
JENIS FIBERGLASS
Multiaxial
MAX - Multiaxial
warp knitting
Produk Fiberglass Generasi Ketiga
Benang Kaca
Glass Roving Yarn
JENIS FIBERGLASS
MAX - Multiaxial Fabric
Fleece (optional)
Lapisan
MULTIAXIAL PROSES
Karakteristik CSM
bull Glass Content 30
bull Resin Content 70
bull Tensile Force
Chopped Strand Mat
JENIS FIBERGLASS
Karakteristik Woven Roving
bull Glass Content 45
bull Resin Content 55
Woven Roving
Resin
|
|
|
|
|
|
|
|
|
|
|
|
|
|
bull Kekuatan Tarik
JENIS FIBERGLASS
No Resin Rich Area
Karakteristik Multiaxial
bull Glass Content 60
bull Resin Content 40
Produk Fiberglass Ketiga MULTIAXIAL
JENIS FIBERGLASS
Perbedaan Woven Roving dan Multiaxial ndash Tampak Samping
JENIS FIBERGLASS
WR FRP
8 Ply WR 800
8 Ply CSM 450
Glass Weight 1 kg
Composite Weight 15kgm2
CSM FRP
22 Ply CSM 450
Glass Weight 1 kg
Composite Weight 18 kgm2
MULTIAXIAL FRP
13 Ply DB 800
Glass Weight 1 kg
Composite Weight
13 kgm2
JENIS FIBERGLASS
Multiaxial
FRP
Woven Roving
FRP
Chopped Strands Mat FRP
MULTIAXIAL
FAKTA
TEBAL BUKAN BERARTI KUAT
UNSUR MATRIX (RESIN)
TIDAK ADA KEKUATAN
ldquoMore than 50 of the glass fibers used for reinforcement is
E-glassrdquo
KarakteristikKekuatan
CSM WR MAX
Kekuatan Tarik 175 MPa 250 MPa 425 MPa
CSM 142
WR 70
KEKUATAN TARIK
Properties CSM Lamination WR Lamination MAX Lamination
Fabric Weight (kgm2) 1 1 1
Composite Weight (kgm2) 18 15 13
Resin usage (kgm2) 15 1 08
Amount of Fabric 22 Ply 16 Ply 13 Ply
Thickness 15 mm 12 mm 10 mm
Tensile Strength (Mpa) 125 1796 400
Tensile Strength (Nmmsup2) 28463 30958 4576
Processing Time High Med Low
Labour Cost High Med Low
MULTIAXIAL
Total Penggunaan Resin -51
Total Berat Kapal -40
Kekuatan Bangunan Kapal +59
Efisiensi Tenaga Kerja
Waktu Pengerjaan Lebih Cepat
KEUNGGULAN MATERIAL
Resapan Resin Lebih Baik amp Merata
Lapisan Lebih Sedikit
Meningkatkan Kekuatan Kapal
KEUNGGULAN MATERIAL
TRIAXIAL
DBL series DBT series
BIAXIAL
LT series DB series
UNIDIRECTIONAL
L series T series
QUADRIAXIAL
DBLT series
JENIS MULTIAXIAL
UNIDIRECTIONAL
DCMU 900 E ndash
KHUSUS UNTUK MEMPERKUAT BENDING KAPAL
PEMASANGAN KHUSUS PADA KEEL DAN TULANGAN
JENIS MULTIAXIAL UNTUK KAPAL
TRIAXIAL
DBL 600 ndash
APLIKASI PADA INDUSTRI PENERBANGAN
PEMASANGAN KHUSUS PADA
SAMBUNGAN BADAN DAN SAYAP
PESAWAT
JENIS MULTIAXIAL UNTUK PESAWAT
QUADRAXIAL
DBLT 800 ndash
APLIKASI PADA INDUSTRI ENERGI
DITERAPKAN UNTUK KEBUTUHAN PEMBANGKIT
LISTRIK ENERGI ANGIN
MULTIAXIAL UNTUK ENERGI
INDUSTRI KIMIA OLAHRAGA AUTOMOTIF
MULTIAXIAL UNTUK INDUSTRI LAINNYA
COMPOSITES
GUNAKAN MATERIAL FIBERGLASS
YANG SUDAH DISERTIFIKASI
BKI
FIBERGLASS UNTUK PEMBANGUNAN BAKAP
PERATURAN MENTERI PERHUBUNGAN
NOMOR PM 7 TAHUN 2013
TENTANG KEWAJIBAN KLASIFIKASI BAGI KAPAL BERBENDERA INDONESIA
PADA BADAN KLASIFIKASI
BADAN SERTIFIKASI MARITIM
Biro Klasifikasi IndonesiaDet Norske Veritas Germanischer Lloyds
PERATURAN BKI
Untuk Kapal Non-Metal
2006
PERSYARATAN MINIMUM
kekuatan material yang
harus digunakan
untuk membangun
Kapal Fiberglass
PEMBESARAN
Table 21
FIBERGLASS TRIAXIS COMPOSITES
TELAH BERSERTIFIKASI BKI
Biro Klasifikasi Indonesia
65
TEKNIK MANUFAKTUR
COMPOSITES
Wet hand lay-up
1) Peletakan
Dry Reinforcement
bull Dry reinforcement dan resin (+ katalis) ditaruh pada permukaan cetakan
2) Pemasukanpenekanan resin
bull Resin ditekan untuk meng-impregnasi serat dengan menggunakan rol
3) Pengulangan proses untuk lapisan lain
bull Beberapa lapisan dapat ditambahkan secara bertahap
4) Resin curing
bull Reaksi dimulai komponen dilepaskan setelah komponen mengeras
(fully cured)
Wet hand lay-up
Manufaktur komponen dapat dikerjakan dengan menggunakan beberapa lapis komposit
dengan memperhatikan kompatibilitas material dan tahapan curing Modifikasi proses dapat
dilakukan seperti
Vacuum bagging
setelah lay-up
Glass Roving
Bulk Resin
Catalyst
3) De-molding
2) Resin Cure
bull Curing dimulai dan komponen dilepaskan setelah pengerasan selesai
bull Serat gelas resin dan katalis dimasukkan kedalam spray gun
1) Spray-up
bull Campuran disemprotkan pada permukaan cetakan
Spray-up
69
Penyemprotan bakal komponen
Komponen
dilepaskan
dari cetakan
Full dispensing
system Chopper Roving
Atomised resin
and catalyst
Spray-up
Prepreg
1) LaminateAssembly 5) De-molding
3) Resin Melts Layup Consolidates
bull Prepreg serat yang sudah diimpregnasi oleh resin+katalis dalam kondisi padat
bull Lapisan prepreg digunting sesuai bentuk yang diinginkan kemudian diletakkan pada permukaan cetakan
sesuai bentuk komponen yang diinginkan Lay-up mudah dilakukan karena sifat ldquotackynessrdquo dari prepreg
2) Applied Vacuum Pressure and Heat
bull Tekanan dan panas diberikan resin mencair terjadi konsolidasi pada komponen
4) Resin Cures
bull Temperatur dinaikkan untuk memulai curing
Prepreg
Variasi proses Autoclave
Komponen dalam
vacuum-bag
bull Campuran resin (+katalis) dan chopped glass strands diperoleh dalam bentuk premixed compound Bulk molding
Compound (BMC) dalam bentuk adonan atau Sheet molding Compound (SMC) dalam bentuk lembaran
bull Ketika panas dan tekanan diberikan oleh cetakan compound mengalir sesuai bentuk komponen yang diinginkan
1) Placement of Charge
5) De-molding3) Squeeze to final dimensions
2) Mould Closure4) Resin Cure
bull Curing dimulai komponen dilepaskan setelah terjadi pengerasan yang cukup
Compression Molding
bull Preform atau dry reinforcement dimasukkan kedalam cetakan sesuai dengan bentuk komponen yang
diinginkan
bull Resin mengalir dengan penekanan atau pem-vakuman dan meng-impregnasi preform dan
mendorongmengeluarkan udara yang ada dalam preform
1) Preform Manufacture
2) Preform Compression
5) De-molding3) Resin Injection
4) Resin Cure
bull Curing terjadi cetakan dibuka setelah terjadi pengerasan yang mencukupi
Liquid Molding (RTM VARI VARTM)
Pultrusion
bull Dry roving or fabrics ditarik melalui bak berisi
campuran resin dan katalis
bull Campuran yang basah ditarik melalui cetakan
bull Sisa resin keluar cetakan
bull Pemanasan dilakukan untuk proses curing
bull Pendinginan dilakukan untuk mempercepat siklus
produksi
Cut-off
Cooling
Die sections
Resin bath
Fibre creel
Filament Winding
bull Dry roving ditarik melalui bak berisi campuran resin dan katalis
bull Wet roving digulungkan dalam keadaan tegang kepada mandrel
bull Kontrol mekanik dari pembawa serat mengatur orientasi peletakan serat pada
mandrel
INDUSTRI COMPOSITES
AEROSPACE
HISTORY
1950 ndash Boeing
1960 ndash F14 Tomcat
1981 ndash AV-8B Harrier
Source
Low-Cost Composite Materials and Structures for Aircraft Applications
httpwwwreinforcedplasticscom
httpwwwcentennialofflightgovessayEvolution_of_TechnologycompositesTech40htm
Automotive
Composite material is used in a number of applications in the automotive
industry due to its temperature resistance rigidity and fatigue strength
The benefits of using composites include greater fuel efficiency
corrosion resistance light weight and strength Composites also provide
a low-cost way to help keep designs looking fresh
Composites are used in
- interior parts (cockpit trimming seats instrument panels)
- exterior structure (body panels openings underbody frontrear
modules)
- engine compartment and fuelmechanical area parts (axles and
suspensions fuel and exhaust systems)
- electrical and electronic components
Lamborghinis Sesto Element carbon fiber
ldquoFat men cannot run as fast as thin men but we build most of our vehicles as though dead-weight fat increased speedhellip I cannot
imagine where the delusion that weight means strength
came fromhelliprdquo mdashHenry Ford
The mix of automotive materials is changing showing a boost for FRP in helping original
equipment manufacturers meet fuel economy and emissions challenges
(Source 2011 DuPont AutomotiveSAE survey of design engineers performed by Signet Research Inc)
Source
httpwwwtoraycomcsrhighlight2009hig_001_01html
The MonoCell tub for the McLaren MP4-12C supercar is moulded as a single
piece and weighs less than 80 kg (176 lbs)
COMPOSITES IN MARINE
TRIMARAN BOAT
AMERICA NAVYINDONESIAN NAVY
Visby Class corvette
Total length is 72 meters
The beam is 1040 meters
The displacement is 600 metric tones
fully equipped the worlds largest CRP
construction
The design of the Visby aims to minimize
the optical and infrared signature above
water acoustic and hydroa coustic
signature underwater electrical potential
and magnetic signature pressure signature
radar cross section and actively emitted
signals
A stealth corvette of the YS 2000 design
has a detection range of 13km in rough
seas and 22km in calm sea without
jamming In a jammed environment the
Visby would be detected at a range of 8km
in rough sea and 11km in calm sea
The material provides high strength and
rigidity low weight good shock resistance
low radar and magnetic signature
1996
Visby is a class of stealth corvettes for the Swedish Navy
ldquoReduced 50 of a Conventional Steelrdquo
Source
Hull Construction with composite materials for ships over 100m in length 2002
Massachusetts Institute of Technology
httpwwwnaval-technologycomprojectsvisby
YACHTS
KAL YUDISTIRAMARATHON 100 ADMIRAL YACHT
LOA 3050 MWidth 6 MFuel Tank 8000 LWater Tank 3000 LIce Box 500 LAccommodation Max 35 Personnel
2 x CATERPILLAR 3412E 1200 HPMARINE DIESEL ENGINE
PC 40 ndash KRI Krait 827Department of Indonesian Navy
LOA 40 MWidth 73 MPower 190Weapon Twin Cannon Barrels
127 mm Heavy Machine GunSpeed Knot 25 KnotDisplacement 105 tonAccommodation 23 personnel
PATROL BOAT
Rigid Inflatable BoatPATROL BOAT
Yachts
36m Luxury Yacht Moonraker
36m Luxury Yacht GoldenEye
50m Luxury Yacht Casino
Royale
45m Luxury Yacht Seashaw
Boat Parts
Barovans for Seismic Sweep
Centrifugal Liftfan House for Surface Effect
Ships
Composite Boat PropellersRTM
Deckhouses for Pilot Boats
Fairing Parts for Submarines
Flybridges for Motor yachts
Light Weight Gangway
MTB Launcher Mock-up
Pleasure Boats
12m Sailboat
12m Sail-Catamaranone-off
Canoes
Dragonfly 1000Catamaran Sailboat
Fantasy 37Sailboat
Farr 60Luxury Sailboat
EurodingyOlympic Dingy Class for
Woman
Hydrolift F23 Racing Boats
Kajacs
Najad 42Sailboat
Najad 520Sailboat
Najad 441Sailboat
Najad 391Sailboat
Nordwest 900Motorboat
Nordwest 1100Motorboat
Quatro 44Motorboat
Racemaster Competition Boats
Storebro 420
Storebro 345
Sweden Yacht 370Sailboat
Sweden Yacht 69Sailboat
Windy 41Motorboat
X-632Sailboat
X-362Sailboat
Commercial Boats
175m High Speed AmbulancePassenger Boat
19m High Speed Passenger Boat
20m High Speed Passenger Boat
364m Surface Effect Passenger Ship
45m Surface Effect Passenger Ship
120m Hull Structural Parts HSSS Catamaran Ferry
APPENDIX
Marine Vessel
1188m Fast Attack Vessel FMV 90 E
20m SAV-Surface Auxiliary Vessels
34m Personnel TransportCoast Guard Vessel
40ft Experimental SES
40m Landsort-Class Mine Hunters
54m Mine Counter Measure Vehicles SES
74m Coastal Patrol Boats
Fishing Boats
30 GT
12 GT
10 GT
5 GT
WISEWings In Surface Effect
HOVERCRAFT
Designed specifically for the tourist and transport industries the
Pioneer Mk3 hovercraft is amphibious and comfortably seats 25
passengers plus 1-crew The air-conditioned cabin allows for
maximum visibility for all aboard The Pioneer Mk3 is robust and
dynamic in its performance
Commercial hovercraft
Mk3 AirLift Hovercraft - 1215m
Power is economicaly provided by one Deutz diesel engine of
330kW (442hp) to cruise easily at 40 knots with much higher
speeds available according to the surface conditions The hull is
manufactured from fibreglassPVC foam composite sandwich
the windows are glass and the skirt is urethane coated nylon A
Military version is available with increased payload and systems
redundancy Power for the Military version comes from two Steyr
diesel engines with a total installed power of 320kW (429hp) All
transmission electrical hydraulic and air systems are duplicated
for maximum redundancy The increased performance of the
Military version comes from the reduced engine weight of the twin
Steyr installation cf the Deutz installation
Source
httpwwwnauticexpocomprodairlift-hovercraftcommercial-hovercrafts-25251-142868html
HOVERFLIGHT
BALLISTIC amp UNIT DEFENCED
Triaxis Composites Collaboration with Institute of Aeronautics and Space in the development of Missile Nose Cone
Polymer composites is the evolution of the military defence
Thin steel was the helmet material of
WWII and remained the principal material until around the 1980rsquos
The advantages of using steel
included a simple technology for manufacture of the helmets low cost and reasonably good
impact protection However these helmets were found to provide only marginal protection
against fragments
During the Vietnam War the US Army experimented with fiber-reinforced inserts in the
helmets These inserts improved ballistic protection but at the same time added weight and
reduced the air space between the head and the helmet
By the early part of the 1980rsquos the US military had developed the first all-composite
100 fiber-reinforced helmet This development resulted in even better ballistic protection
without altering the weight of the helmet Other improvements included better head coverage and
more space for ventilation
Source
Composites Armor - A difficult but huge market
by A Brent Strong Brigham Young University
MILITARY VEHICLES
HIGH SPEED TRAIN SHINKANSEN
Advanced Composites provide lightweight solutions for railway vehicles
saving as much as 50-80 of the weight compared with traditional
components
A lower overall weight translates into less stress faster acceleration and
higher speeds as well as reduced starting and stopping inertia Today
these are important criteria in global high-speed and metropolitan
railway projects
Fire smoke and toxic fumes are key safety criteria for interior
components of railway carriages Any material selected for an interior
component must meet international fire retardant standards
for Rail Interiors and Exteriors
Ceiling Panels Stairs
Seating Vestibules
Window Panels Door Pillars
Partition WallsDiffusers
Gangway and Cabinet Panels Cabin and
Desk panels
Door Pillars Lavatory Modules (standard and
Front and Rear EndsRoof Panels
Nose Cones Under Fairings
Source
httpwwwpctaerail_compositesphp
101
SKY BUS
2009
Europe is the world leader in offshore wind with
828 wind turbines and a cumulative capacity of 2056 MW spread across 38 offshore wind farms in 9
European countries
The UK and Denmark are the current leaders with a 44 and 30 share respectively In 2009
five countries built new offshore wind farms
UK (284 MW)
Demark (230 MW)
Sweden (30 MW)
Germany (30 MW)
Norway (23 MW)
2010
Asia leads the growth in global wind power which grew 358 GW in 2010 bringing
total global capacity to 1944 GW ndash up 225 from 2009
the Global Wind Energy Council (GWEC)
Asia accounted for 19 GW of new global wind power installations driven by China which installed 165
GW
ldquoChina now has 423 GW of wind powerrdquo
ldquoThis puts China firmly on a path to reach 200 GW of installed wind power by 2020 At the same
time China has become the worldrsquos largest producer of wind energy equipmentrdquo
Source
httpwwwreinforcedplasticscomview15655asia-leads-global-wind-power-growth
httpimgdeusmcomdesignnews288288605-Sandia_Sizes_up_Wind_Turbine_Blade_Design_C_largegif
WIND ENERGY
Marine Current Turbines
Source
httpwwwsiemenscompressenpressreleasepress=enpressrelease2011solar-hydroex201111005htm
httpwwwmarineturbinescom
A commercial marine current turbine consists of
two rotors which are fixed on a structure within the
sea current The twin rotors rotate with the
movement of the tidal flow and the blades pitch
through 180 degrees to optimally track tidal current
(Press picture Marine Current Turbines)
Wave Star Energys Multi-point Absorber
CFRP COLUMN REINFORCEMENT
INDUSTRIAL TANKS
107
INDUSTRIAL PIPES
PRESSURE TANKS
109
ldquoLetrsquos Make with Compositesrdquo
Growth in volume mainly in Asia
Repartition of the composites market by region 1999 gt 2013 in Mt
RoW
Europe
Asia
North America
Repartition of the composites market by region 1999 gt 2013 in Mt
1999 2002 2007 2013
7
22
36
35
7
33
23
38
5
29
26
40
4
27
24
45
25(1) 51Weight of Asia in global growth in volume
2015
103
81
6259
COMPOSITES
COMPOSITES = DUA MATERIAL YANG BERBEDA SIFAT FISIK DAN
KIMIAWI NYA BERSATU SECARA MAKROSKOPIK MELALUI SUATU
PROSES KIMIA MENJADI SUATU MATERIAL BARU (KOMPOSIT)
DENGAN SIFAT FISIK DAN MEKANIKAL YANG BARU
COMPOSITES ALAMI (NATURAL MATERIAL)
COMPOSITES BUATAN (ENGINEERED MATERIAL)
COMPOSITES
9
Berdasarkan jenis penguat
bull Particle-reinforced composites
ndash Large-particle composites (Cermets tungsten carbida in cobalt semen beton bertulang)
ndash Dispersed-strenghtened composites (alumina in aluminium ThoriaThO2 in Nickel alloy)
bull Fiber-reinforced composites konstruksi kaku kuat dan ringan
ndash Discontinuous (Short) fiber composites
ndash Continuous (long) fiber composites
bull Structural-reinforced composites
ndash Laminar composites (kayu multipleks laminate carbon epoxy)
ndash Sandwich composites konstruksi ringan dengan kekakuan dan kekuatan bending yang tinggi (Honeycomb-carbon epoxy composites dinding kardus corrugated paper - paper)
KLASIFIKASI MATERIAL KOMPOSIT
10
Berdasarkan jenis matriks
bull Polymer matrix composites (PMC) Paling populer dengan beragam aplikasi
- Carbon fibre reinforced polymer
- Glass fibre reinforced polymer
- Metal fibre reinforced polymer
bull Metal matrix composites (MMC) Aerospace dan komponen mesin mobil
- Boron or carbon fibre reinforced Aluminium
- Alumina particle reinforced Aluminium
bull Ceramic matrix composites (CMC) Heat exhanger sistem pelindung panas komponen dengan lingkungan korosif dan erosif
- Zirconia in alumina
- Carbon fibre reinforced carbon
KLASIFIKASI MATERIAL KOMPOSIT
SERAT
(FIBER) +RESIN
(MATRIX) = COMPOSITES
bull GLASS (KACA)
bull CARBON
bull ARAMID
bull Fiberglass Reinforced Plastics
(FRP)
bull Carbon Fiber Reinforced Plastics
(CFRP)
bull Aramid Fiber Reinforced Plastics
POLYMER TECHNOLOGY COMPOSITES
bull POLYESTER
bull VINYLESTER
bull EPOXY
bull POLYPROPYLENE
bull POLYAMID
COMPOSITES BUATAN (ENGINEERED COMPOSITES) SEHARI-HARI
BETON = TULANGAN BESI + RESIN SEMEN
The Importance of Lightness for
Environmental Friendly Products
Mass Reduction for Less Energy Consumption
MATERIAL COMPOSITES
Thermoset
type
Density r
(kgm3)
Stiffnes
s E
(Gpa)
Tensile
strength
s (MPa)
Strain to
failure e
()
Tg 0C
Thermal
conductivity
k (Wm0C)
Specific
Heat Cp
(kJkg0C)
Thermal
expansion coeff
a (x106 0C-1)
Polyester 1100-1230 31-46 50-75 10-65 70- 017-022 13-23 55-100
Vinylester 1120-1130 31-33 70-81 30-80 70- - - -
Epoxy 1100-1200 26-38 60-85 15-80 65-175 017-020 105 45-65
Phenolic 1000-1250 30-40 60-80 18 300 012-024 14-18 25-60
PUR 1200 07 30-40 400-450 135 017-021 13-23 70-100
BMI 1200-1320 32-50 48-110 15-33 230-345 - - -
Polyimide 1430-1890 31-49 100-110 15-30 325-370 01-034 105-15 25-80
Al 2800 72 540 18 - 130 096 236
Steel 7790 205 640 25 - 54 046 11
MATRIKS POLIMER THERMOSET
Variasi sifat yang lebar disebabkan oleh adanya formulasi kimia yang berbeda dan penambahan aditif
Jenis Glass Fiber S Glass E Glass C Glass A Glass dll
Terms
Glass Type
S Glass E Glass C Glass A Glass
Silica (SiO2) Content 67 55 64 72
Al2O3 Content 23 14 6 1
Melting Point (Celcius) 915 836 745 745
Tensile Strength 665 500 440 440
Modulus Elastisitas 124 105 100 -
Application AEROSPACE BOAT CHEMICAL TANK CHEMICAL TANK
JENIS SERAT GLASS
CHINA
JENIS SERAT GLASS
C GLASS Calcium borosilicate glasses
used for CHEMICAL stability in corrosive
acid environments
E GLASS Alumina-calcium-borosilicate
glasses with a maximum alkali used as
general purpose fibers where STRENGTH
and high ELECTICAL RESISTIVITY are
required It manifests better electrical
insulation and strongly resists attack by
water More than 50 of the glass fibers
used for reinforcement is E-glass
C Glass
E Glass
C amp E GLASS
SUMBER AGY TECHNICAL PAPER HIGH STRENGTH GLASS FIBER
FAKTA
C GLASS 1 BOROS RESIN
2 KEKUATAN
KURANG
FAKTA
E GLASS 1 HEMAT RESIN
2 KEKUATAN BAIK
3 TAHAN LAMA
FAKTA
TEBAL BUKAN BERARTI KUAT
UNSUR MATRIX (RESIN)
TIDAK ADA KEKUATAN
ldquoMore than 50 of the glass fibers used for
reinforcement is E-glassrdquo
C glass E glass
E glass
C glass
KAIN WOVEN ROVING HASIL LAMINASI
JENIS SERAT GLASS
Kekuatan composites ditentukan oleh
1 Kekuatan amp Sifat Fiber
2 Kekuatan amp Sifat Resin
3 Fraksi Rasio Perbandingan Volume Fiber
dan Resin dalam Composites
rarr tergantung dari Proses Manufaktur
4 Geometri dan Orientasi Arah Fiber dalam
Composites
KEKUATAN COMPOSITES
PROSES MATERIAL
Proses Produksi Kain Fiberglass
Biji Kaca Benang Benang Kaca Kain Fiberglass
PROSES MATERIAL
Glass Beads
Glass Fiber Glass Roving YarnGlass Fabric
FIBERGLASS
PRODUK
MATERIAL DAN PRODUK FIBERGLASS
+
Resin + Additives
PERPADUAN COMPOSITES
BENANG KACA Potongan Serat Kaca CSM
CSM - CHOPPED STRAND MAT
chopped binder
Kain Fiberglass Generasi Pertama
BahanPengikat
SenyawaPada Resin
JENIS FIBERGLASS
Glass Roving Yarn Chopped Strand
ADVANTAGES DISADVANTAGES
Steel
1048707 Low cost 1048707 Corrodes easily
1048707 Ductile under ambient conditions
1048707 Has no lower fatigue limit for welded structures
1048707 Virtually isotropic 1048707 Heavy
1048707 Easily formed and fabricated 1048707 Brittle at low temperatures
1048707 Easily obtained (low relative cost) 1048707 Magnetic
1048707 Easily alloyed or heat treated for special operations
1048707 Easily repaired
1048707 Good fire resistance
1048707 Behaviour is well understood
Alumunium Alloy
1048707 Light weight 1048707 Poor fatigue properties
1048707 Corrosion resistant 1048707 Poor performance in fire
1048707 Easily formed1048707 Low melting point and softening temperature
1048707 Easily fabricated 1048707 High relative cost
1048707 Readily available 1048707 Strength and stiffness less than steel
1048707 Ductile
1048707 Non magnetic
FRP
1048707 Low magnetic properties
1048707 Low electrical conductivity (glass- reinforced plastics)
1048707 Resistance to corrosion
1048707 Resistance to rot and marine growth
1048707 Relatively high sonar transparency
1048707 Good strength to weight ratio
1048707 Good fatigue properties
1048707 Maintenance of properties at low temperatures
1048707 Availability
1048707 Can be manufactured to near net-shape
1048707 Stiffness and strength can be tailored to structural requirements
1048707 Excellent thermal insulation
1048707 Light weight
STEEL vs ALUMUNIUM vs COMPOSITES
Source
1Maritime Platforms Division Aeronautical and
Maritime Research Laboratory (Seref Aksu
Stuart Cannon Craig Gardiner and Matthew
Gudze
2 Metal Corrosion can be defined as the
destructive attack of a metal through interaction
with its environment
(httpwwwcorrosionistcomCorrosion_Fundament
alhtm)
28
Serat rarr penguat
Polimer matriks rarr pengikat
bull Sifat mekanik yang cukup baik
bull Viskositas dan temperatur pengerjaan rendah rarr mudah
dimanufaktur
bull Ketahanan korosi yang baik
bull Media perpindahan gaya rarr distribusi beban dari serat ke serat
bull Ulet rarr Melindungi serat yang getas
bull Size effect rarr Kekuatan dan kekakuan sangat tinggi
bull Aspect ratio (ld) tinggi rarr luas permukaan besar
bull Fleksibel rarr variasi teknik manufaktur
bull Serat dapat diatur sesuai dengan arah pembebanan
29
Advantages Polimer Composites
Kekuatan dan kekakuan spesifik yang tinggi FRCP vs material lain rarr kompetitif jika berat dipertimbangkan
Material Berat jenis
r (kgm3)
Kekakuan
E (GPa)
Kekuatan
tarik su
(MPa)
Kekakuan
spesifik
Er
Kekuatan
spesifik sur
Baja 7800 208 400 27 005
Aluminium 2700 70 200 259 007
Nylon 1100 25 80 23 007
Beton 2400 40 20 166 0008
Random
FRPC
1800 20 300 111 0006
Alligned FRPC
( serat)
1600 200 1500 125 094
Alligned FRCP
( serat)
1600 3 50 19 0001
Tensile Strength amp Modulus of Common Structural Materials
Densities of Common Structural Materials
Specific Tensile Strength amp Modulus of Common Structural Materials
Typical Properties of Common Structural Materials
Kesimpulan COMPOSITES = RINGAN amp KUAT
Jadi secara keseluruhan kekuatan composites
ditentukan oleh
1 Kekuatan amp Sifat Fiber
2 Kekuatan amp Sifat Resin
3 Fraksi Rasio Perbandingan Volume Fiber
dan Resin dalam Composites
4 Geometri dan Orientasi Arah Fiber dalam
Composites
PRODUKSI ANAK NEGERI
Proses Produksi Kain Fiberglass
Biji Kaca Benang Benang Kaca Kain Fiberglass
PROSES MATERIAL
Glass Beads
Glass Fiber Glass Roving YarnGlass Fabric
Proses Produksi Kain Fiberglass
Biji Kaca Benang Benang Kaca Kain Fiberglass
Glass Beads
Glass Fiber Glass Roving YarnGlass Fabric
PROSES MATERIAL
Benang Kaca Potongan Serat Kaca Chopped Strand Mat
CSM - Chopped Strand Mat
chopped binder
Produk Fiberglass Generasi Pertama
Bahan Pengikat
Senyawa Pada Resin
Glass Roving Yarn Chopped Strand
JENIS FIBERGLASS
Benang Kaca Woven Roving
WR - Woven Roving
Tenun Weaving
Produk Fiberglass Generasi Kedua
Glass Roving Yarn
JENIS FIBERGLASS
Multiaxial
MAX - Multiaxial
warp knitting
Produk Fiberglass Generasi Ketiga
Benang Kaca
Glass Roving Yarn
JENIS FIBERGLASS
MAX - Multiaxial Fabric
Fleece (optional)
Lapisan
MULTIAXIAL PROSES
Karakteristik CSM
bull Glass Content 30
bull Resin Content 70
bull Tensile Force
Chopped Strand Mat
JENIS FIBERGLASS
Karakteristik Woven Roving
bull Glass Content 45
bull Resin Content 55
Woven Roving
Resin
|
|
|
|
|
|
|
|
|
|
|
|
|
|
bull Kekuatan Tarik
JENIS FIBERGLASS
No Resin Rich Area
Karakteristik Multiaxial
bull Glass Content 60
bull Resin Content 40
Produk Fiberglass Ketiga MULTIAXIAL
JENIS FIBERGLASS
Perbedaan Woven Roving dan Multiaxial ndash Tampak Samping
JENIS FIBERGLASS
WR FRP
8 Ply WR 800
8 Ply CSM 450
Glass Weight 1 kg
Composite Weight 15kgm2
CSM FRP
22 Ply CSM 450
Glass Weight 1 kg
Composite Weight 18 kgm2
MULTIAXIAL FRP
13 Ply DB 800
Glass Weight 1 kg
Composite Weight
13 kgm2
JENIS FIBERGLASS
Multiaxial
FRP
Woven Roving
FRP
Chopped Strands Mat FRP
MULTIAXIAL
FAKTA
TEBAL BUKAN BERARTI KUAT
UNSUR MATRIX (RESIN)
TIDAK ADA KEKUATAN
ldquoMore than 50 of the glass fibers used for reinforcement is
E-glassrdquo
KarakteristikKekuatan
CSM WR MAX
Kekuatan Tarik 175 MPa 250 MPa 425 MPa
CSM 142
WR 70
KEKUATAN TARIK
Properties CSM Lamination WR Lamination MAX Lamination
Fabric Weight (kgm2) 1 1 1
Composite Weight (kgm2) 18 15 13
Resin usage (kgm2) 15 1 08
Amount of Fabric 22 Ply 16 Ply 13 Ply
Thickness 15 mm 12 mm 10 mm
Tensile Strength (Mpa) 125 1796 400
Tensile Strength (Nmmsup2) 28463 30958 4576
Processing Time High Med Low
Labour Cost High Med Low
MULTIAXIAL
Total Penggunaan Resin -51
Total Berat Kapal -40
Kekuatan Bangunan Kapal +59
Efisiensi Tenaga Kerja
Waktu Pengerjaan Lebih Cepat
KEUNGGULAN MATERIAL
Resapan Resin Lebih Baik amp Merata
Lapisan Lebih Sedikit
Meningkatkan Kekuatan Kapal
KEUNGGULAN MATERIAL
TRIAXIAL
DBL series DBT series
BIAXIAL
LT series DB series
UNIDIRECTIONAL
L series T series
QUADRIAXIAL
DBLT series
JENIS MULTIAXIAL
UNIDIRECTIONAL
DCMU 900 E ndash
KHUSUS UNTUK MEMPERKUAT BENDING KAPAL
PEMASANGAN KHUSUS PADA KEEL DAN TULANGAN
JENIS MULTIAXIAL UNTUK KAPAL
TRIAXIAL
DBL 600 ndash
APLIKASI PADA INDUSTRI PENERBANGAN
PEMASANGAN KHUSUS PADA
SAMBUNGAN BADAN DAN SAYAP
PESAWAT
JENIS MULTIAXIAL UNTUK PESAWAT
QUADRAXIAL
DBLT 800 ndash
APLIKASI PADA INDUSTRI ENERGI
DITERAPKAN UNTUK KEBUTUHAN PEMBANGKIT
LISTRIK ENERGI ANGIN
MULTIAXIAL UNTUK ENERGI
INDUSTRI KIMIA OLAHRAGA AUTOMOTIF
MULTIAXIAL UNTUK INDUSTRI LAINNYA
COMPOSITES
GUNAKAN MATERIAL FIBERGLASS
YANG SUDAH DISERTIFIKASI
BKI
FIBERGLASS UNTUK PEMBANGUNAN BAKAP
PERATURAN MENTERI PERHUBUNGAN
NOMOR PM 7 TAHUN 2013
TENTANG KEWAJIBAN KLASIFIKASI BAGI KAPAL BERBENDERA INDONESIA
PADA BADAN KLASIFIKASI
BADAN SERTIFIKASI MARITIM
Biro Klasifikasi IndonesiaDet Norske Veritas Germanischer Lloyds
PERATURAN BKI
Untuk Kapal Non-Metal
2006
PERSYARATAN MINIMUM
kekuatan material yang
harus digunakan
untuk membangun
Kapal Fiberglass
PEMBESARAN
Table 21
FIBERGLASS TRIAXIS COMPOSITES
TELAH BERSERTIFIKASI BKI
Biro Klasifikasi Indonesia
65
TEKNIK MANUFAKTUR
COMPOSITES
Wet hand lay-up
1) Peletakan
Dry Reinforcement
bull Dry reinforcement dan resin (+ katalis) ditaruh pada permukaan cetakan
2) Pemasukanpenekanan resin
bull Resin ditekan untuk meng-impregnasi serat dengan menggunakan rol
3) Pengulangan proses untuk lapisan lain
bull Beberapa lapisan dapat ditambahkan secara bertahap
4) Resin curing
bull Reaksi dimulai komponen dilepaskan setelah komponen mengeras
(fully cured)
Wet hand lay-up
Manufaktur komponen dapat dikerjakan dengan menggunakan beberapa lapis komposit
dengan memperhatikan kompatibilitas material dan tahapan curing Modifikasi proses dapat
dilakukan seperti
Vacuum bagging
setelah lay-up
Glass Roving
Bulk Resin
Catalyst
3) De-molding
2) Resin Cure
bull Curing dimulai dan komponen dilepaskan setelah pengerasan selesai
bull Serat gelas resin dan katalis dimasukkan kedalam spray gun
1) Spray-up
bull Campuran disemprotkan pada permukaan cetakan
Spray-up
69
Penyemprotan bakal komponen
Komponen
dilepaskan
dari cetakan
Full dispensing
system Chopper Roving
Atomised resin
and catalyst
Spray-up
Prepreg
1) LaminateAssembly 5) De-molding
3) Resin Melts Layup Consolidates
bull Prepreg serat yang sudah diimpregnasi oleh resin+katalis dalam kondisi padat
bull Lapisan prepreg digunting sesuai bentuk yang diinginkan kemudian diletakkan pada permukaan cetakan
sesuai bentuk komponen yang diinginkan Lay-up mudah dilakukan karena sifat ldquotackynessrdquo dari prepreg
2) Applied Vacuum Pressure and Heat
bull Tekanan dan panas diberikan resin mencair terjadi konsolidasi pada komponen
4) Resin Cures
bull Temperatur dinaikkan untuk memulai curing
Prepreg
Variasi proses Autoclave
Komponen dalam
vacuum-bag
bull Campuran resin (+katalis) dan chopped glass strands diperoleh dalam bentuk premixed compound Bulk molding
Compound (BMC) dalam bentuk adonan atau Sheet molding Compound (SMC) dalam bentuk lembaran
bull Ketika panas dan tekanan diberikan oleh cetakan compound mengalir sesuai bentuk komponen yang diinginkan
1) Placement of Charge
5) De-molding3) Squeeze to final dimensions
2) Mould Closure4) Resin Cure
bull Curing dimulai komponen dilepaskan setelah terjadi pengerasan yang cukup
Compression Molding
bull Preform atau dry reinforcement dimasukkan kedalam cetakan sesuai dengan bentuk komponen yang
diinginkan
bull Resin mengalir dengan penekanan atau pem-vakuman dan meng-impregnasi preform dan
mendorongmengeluarkan udara yang ada dalam preform
1) Preform Manufacture
2) Preform Compression
5) De-molding3) Resin Injection
4) Resin Cure
bull Curing terjadi cetakan dibuka setelah terjadi pengerasan yang mencukupi
Liquid Molding (RTM VARI VARTM)
Pultrusion
bull Dry roving or fabrics ditarik melalui bak berisi
campuran resin dan katalis
bull Campuran yang basah ditarik melalui cetakan
bull Sisa resin keluar cetakan
bull Pemanasan dilakukan untuk proses curing
bull Pendinginan dilakukan untuk mempercepat siklus
produksi
Cut-off
Cooling
Die sections
Resin bath
Fibre creel
Filament Winding
bull Dry roving ditarik melalui bak berisi campuran resin dan katalis
bull Wet roving digulungkan dalam keadaan tegang kepada mandrel
bull Kontrol mekanik dari pembawa serat mengatur orientasi peletakan serat pada
mandrel
INDUSTRI COMPOSITES
AEROSPACE
HISTORY
1950 ndash Boeing
1960 ndash F14 Tomcat
1981 ndash AV-8B Harrier
Source
Low-Cost Composite Materials and Structures for Aircraft Applications
httpwwwreinforcedplasticscom
httpwwwcentennialofflightgovessayEvolution_of_TechnologycompositesTech40htm
Automotive
Composite material is used in a number of applications in the automotive
industry due to its temperature resistance rigidity and fatigue strength
The benefits of using composites include greater fuel efficiency
corrosion resistance light weight and strength Composites also provide
a low-cost way to help keep designs looking fresh
Composites are used in
- interior parts (cockpit trimming seats instrument panels)
- exterior structure (body panels openings underbody frontrear
modules)
- engine compartment and fuelmechanical area parts (axles and
suspensions fuel and exhaust systems)
- electrical and electronic components
Lamborghinis Sesto Element carbon fiber
ldquoFat men cannot run as fast as thin men but we build most of our vehicles as though dead-weight fat increased speedhellip I cannot
imagine where the delusion that weight means strength
came fromhelliprdquo mdashHenry Ford
The mix of automotive materials is changing showing a boost for FRP in helping original
equipment manufacturers meet fuel economy and emissions challenges
(Source 2011 DuPont AutomotiveSAE survey of design engineers performed by Signet Research Inc)
Source
httpwwwtoraycomcsrhighlight2009hig_001_01html
The MonoCell tub for the McLaren MP4-12C supercar is moulded as a single
piece and weighs less than 80 kg (176 lbs)
COMPOSITES IN MARINE
TRIMARAN BOAT
AMERICA NAVYINDONESIAN NAVY
Visby Class corvette
Total length is 72 meters
The beam is 1040 meters
The displacement is 600 metric tones
fully equipped the worlds largest CRP
construction
The design of the Visby aims to minimize
the optical and infrared signature above
water acoustic and hydroa coustic
signature underwater electrical potential
and magnetic signature pressure signature
radar cross section and actively emitted
signals
A stealth corvette of the YS 2000 design
has a detection range of 13km in rough
seas and 22km in calm sea without
jamming In a jammed environment the
Visby would be detected at a range of 8km
in rough sea and 11km in calm sea
The material provides high strength and
rigidity low weight good shock resistance
low radar and magnetic signature
1996
Visby is a class of stealth corvettes for the Swedish Navy
ldquoReduced 50 of a Conventional Steelrdquo
Source
Hull Construction with composite materials for ships over 100m in length 2002
Massachusetts Institute of Technology
httpwwwnaval-technologycomprojectsvisby
YACHTS
KAL YUDISTIRAMARATHON 100 ADMIRAL YACHT
LOA 3050 MWidth 6 MFuel Tank 8000 LWater Tank 3000 LIce Box 500 LAccommodation Max 35 Personnel
2 x CATERPILLAR 3412E 1200 HPMARINE DIESEL ENGINE
PC 40 ndash KRI Krait 827Department of Indonesian Navy
LOA 40 MWidth 73 MPower 190Weapon Twin Cannon Barrels
127 mm Heavy Machine GunSpeed Knot 25 KnotDisplacement 105 tonAccommodation 23 personnel
PATROL BOAT
Rigid Inflatable BoatPATROL BOAT
Yachts
36m Luxury Yacht Moonraker
36m Luxury Yacht GoldenEye
50m Luxury Yacht Casino
Royale
45m Luxury Yacht Seashaw
Boat Parts
Barovans for Seismic Sweep
Centrifugal Liftfan House for Surface Effect
Ships
Composite Boat PropellersRTM
Deckhouses for Pilot Boats
Fairing Parts for Submarines
Flybridges for Motor yachts
Light Weight Gangway
MTB Launcher Mock-up
Pleasure Boats
12m Sailboat
12m Sail-Catamaranone-off
Canoes
Dragonfly 1000Catamaran Sailboat
Fantasy 37Sailboat
Farr 60Luxury Sailboat
EurodingyOlympic Dingy Class for
Woman
Hydrolift F23 Racing Boats
Kajacs
Najad 42Sailboat
Najad 520Sailboat
Najad 441Sailboat
Najad 391Sailboat
Nordwest 900Motorboat
Nordwest 1100Motorboat
Quatro 44Motorboat
Racemaster Competition Boats
Storebro 420
Storebro 345
Sweden Yacht 370Sailboat
Sweden Yacht 69Sailboat
Windy 41Motorboat
X-632Sailboat
X-362Sailboat
Commercial Boats
175m High Speed AmbulancePassenger Boat
19m High Speed Passenger Boat
20m High Speed Passenger Boat
364m Surface Effect Passenger Ship
45m Surface Effect Passenger Ship
120m Hull Structural Parts HSSS Catamaran Ferry
APPENDIX
Marine Vessel
1188m Fast Attack Vessel FMV 90 E
20m SAV-Surface Auxiliary Vessels
34m Personnel TransportCoast Guard Vessel
40ft Experimental SES
40m Landsort-Class Mine Hunters
54m Mine Counter Measure Vehicles SES
74m Coastal Patrol Boats
Fishing Boats
30 GT
12 GT
10 GT
5 GT
WISEWings In Surface Effect
HOVERCRAFT
Designed specifically for the tourist and transport industries the
Pioneer Mk3 hovercraft is amphibious and comfortably seats 25
passengers plus 1-crew The air-conditioned cabin allows for
maximum visibility for all aboard The Pioneer Mk3 is robust and
dynamic in its performance
Commercial hovercraft
Mk3 AirLift Hovercraft - 1215m
Power is economicaly provided by one Deutz diesel engine of
330kW (442hp) to cruise easily at 40 knots with much higher
speeds available according to the surface conditions The hull is
manufactured from fibreglassPVC foam composite sandwich
the windows are glass and the skirt is urethane coated nylon A
Military version is available with increased payload and systems
redundancy Power for the Military version comes from two Steyr
diesel engines with a total installed power of 320kW (429hp) All
transmission electrical hydraulic and air systems are duplicated
for maximum redundancy The increased performance of the
Military version comes from the reduced engine weight of the twin
Steyr installation cf the Deutz installation
Source
httpwwwnauticexpocomprodairlift-hovercraftcommercial-hovercrafts-25251-142868html
HOVERFLIGHT
BALLISTIC amp UNIT DEFENCED
Triaxis Composites Collaboration with Institute of Aeronautics and Space in the development of Missile Nose Cone
Polymer composites is the evolution of the military defence
Thin steel was the helmet material of
WWII and remained the principal material until around the 1980rsquos
The advantages of using steel
included a simple technology for manufacture of the helmets low cost and reasonably good
impact protection However these helmets were found to provide only marginal protection
against fragments
During the Vietnam War the US Army experimented with fiber-reinforced inserts in the
helmets These inserts improved ballistic protection but at the same time added weight and
reduced the air space between the head and the helmet
By the early part of the 1980rsquos the US military had developed the first all-composite
100 fiber-reinforced helmet This development resulted in even better ballistic protection
without altering the weight of the helmet Other improvements included better head coverage and
more space for ventilation
Source
Composites Armor - A difficult but huge market
by A Brent Strong Brigham Young University
MILITARY VEHICLES
HIGH SPEED TRAIN SHINKANSEN
Advanced Composites provide lightweight solutions for railway vehicles
saving as much as 50-80 of the weight compared with traditional
components
A lower overall weight translates into less stress faster acceleration and
higher speeds as well as reduced starting and stopping inertia Today
these are important criteria in global high-speed and metropolitan
railway projects
Fire smoke and toxic fumes are key safety criteria for interior
components of railway carriages Any material selected for an interior
component must meet international fire retardant standards
for Rail Interiors and Exteriors
Ceiling Panels Stairs
Seating Vestibules
Window Panels Door Pillars
Partition WallsDiffusers
Gangway and Cabinet Panels Cabin and
Desk panels
Door Pillars Lavatory Modules (standard and
Front and Rear EndsRoof Panels
Nose Cones Under Fairings
Source
httpwwwpctaerail_compositesphp
101
SKY BUS
2009
Europe is the world leader in offshore wind with
828 wind turbines and a cumulative capacity of 2056 MW spread across 38 offshore wind farms in 9
European countries
The UK and Denmark are the current leaders with a 44 and 30 share respectively In 2009
five countries built new offshore wind farms
UK (284 MW)
Demark (230 MW)
Sweden (30 MW)
Germany (30 MW)
Norway (23 MW)
2010
Asia leads the growth in global wind power which grew 358 GW in 2010 bringing
total global capacity to 1944 GW ndash up 225 from 2009
the Global Wind Energy Council (GWEC)
Asia accounted for 19 GW of new global wind power installations driven by China which installed 165
GW
ldquoChina now has 423 GW of wind powerrdquo
ldquoThis puts China firmly on a path to reach 200 GW of installed wind power by 2020 At the same
time China has become the worldrsquos largest producer of wind energy equipmentrdquo
Source
httpwwwreinforcedplasticscomview15655asia-leads-global-wind-power-growth
httpimgdeusmcomdesignnews288288605-Sandia_Sizes_up_Wind_Turbine_Blade_Design_C_largegif
WIND ENERGY
Marine Current Turbines
Source
httpwwwsiemenscompressenpressreleasepress=enpressrelease2011solar-hydroex201111005htm
httpwwwmarineturbinescom
A commercial marine current turbine consists of
two rotors which are fixed on a structure within the
sea current The twin rotors rotate with the
movement of the tidal flow and the blades pitch
through 180 degrees to optimally track tidal current
(Press picture Marine Current Turbines)
Wave Star Energys Multi-point Absorber
CFRP COLUMN REINFORCEMENT
INDUSTRIAL TANKS
107
INDUSTRIAL PIPES
PRESSURE TANKS
109
ldquoLetrsquos Make with Compositesrdquo
COMPOSITES
COMPOSITES = DUA MATERIAL YANG BERBEDA SIFAT FISIK DAN
KIMIAWI NYA BERSATU SECARA MAKROSKOPIK MELALUI SUATU
PROSES KIMIA MENJADI SUATU MATERIAL BARU (KOMPOSIT)
DENGAN SIFAT FISIK DAN MEKANIKAL YANG BARU
COMPOSITES ALAMI (NATURAL MATERIAL)
COMPOSITES BUATAN (ENGINEERED MATERIAL)
COMPOSITES
9
Berdasarkan jenis penguat
bull Particle-reinforced composites
ndash Large-particle composites (Cermets tungsten carbida in cobalt semen beton bertulang)
ndash Dispersed-strenghtened composites (alumina in aluminium ThoriaThO2 in Nickel alloy)
bull Fiber-reinforced composites konstruksi kaku kuat dan ringan
ndash Discontinuous (Short) fiber composites
ndash Continuous (long) fiber composites
bull Structural-reinforced composites
ndash Laminar composites (kayu multipleks laminate carbon epoxy)
ndash Sandwich composites konstruksi ringan dengan kekakuan dan kekuatan bending yang tinggi (Honeycomb-carbon epoxy composites dinding kardus corrugated paper - paper)
KLASIFIKASI MATERIAL KOMPOSIT
10
Berdasarkan jenis matriks
bull Polymer matrix composites (PMC) Paling populer dengan beragam aplikasi
- Carbon fibre reinforced polymer
- Glass fibre reinforced polymer
- Metal fibre reinforced polymer
bull Metal matrix composites (MMC) Aerospace dan komponen mesin mobil
- Boron or carbon fibre reinforced Aluminium
- Alumina particle reinforced Aluminium
bull Ceramic matrix composites (CMC) Heat exhanger sistem pelindung panas komponen dengan lingkungan korosif dan erosif
- Zirconia in alumina
- Carbon fibre reinforced carbon
KLASIFIKASI MATERIAL KOMPOSIT
SERAT
(FIBER) +RESIN
(MATRIX) = COMPOSITES
bull GLASS (KACA)
bull CARBON
bull ARAMID
bull Fiberglass Reinforced Plastics
(FRP)
bull Carbon Fiber Reinforced Plastics
(CFRP)
bull Aramid Fiber Reinforced Plastics
POLYMER TECHNOLOGY COMPOSITES
bull POLYESTER
bull VINYLESTER
bull EPOXY
bull POLYPROPYLENE
bull POLYAMID
COMPOSITES BUATAN (ENGINEERED COMPOSITES) SEHARI-HARI
BETON = TULANGAN BESI + RESIN SEMEN
The Importance of Lightness for
Environmental Friendly Products
Mass Reduction for Less Energy Consumption
MATERIAL COMPOSITES
Thermoset
type
Density r
(kgm3)
Stiffnes
s E
(Gpa)
Tensile
strength
s (MPa)
Strain to
failure e
()
Tg 0C
Thermal
conductivity
k (Wm0C)
Specific
Heat Cp
(kJkg0C)
Thermal
expansion coeff
a (x106 0C-1)
Polyester 1100-1230 31-46 50-75 10-65 70- 017-022 13-23 55-100
Vinylester 1120-1130 31-33 70-81 30-80 70- - - -
Epoxy 1100-1200 26-38 60-85 15-80 65-175 017-020 105 45-65
Phenolic 1000-1250 30-40 60-80 18 300 012-024 14-18 25-60
PUR 1200 07 30-40 400-450 135 017-021 13-23 70-100
BMI 1200-1320 32-50 48-110 15-33 230-345 - - -
Polyimide 1430-1890 31-49 100-110 15-30 325-370 01-034 105-15 25-80
Al 2800 72 540 18 - 130 096 236
Steel 7790 205 640 25 - 54 046 11
MATRIKS POLIMER THERMOSET
Variasi sifat yang lebar disebabkan oleh adanya formulasi kimia yang berbeda dan penambahan aditif
Jenis Glass Fiber S Glass E Glass C Glass A Glass dll
Terms
Glass Type
S Glass E Glass C Glass A Glass
Silica (SiO2) Content 67 55 64 72
Al2O3 Content 23 14 6 1
Melting Point (Celcius) 915 836 745 745
Tensile Strength 665 500 440 440
Modulus Elastisitas 124 105 100 -
Application AEROSPACE BOAT CHEMICAL TANK CHEMICAL TANK
JENIS SERAT GLASS
CHINA
JENIS SERAT GLASS
C GLASS Calcium borosilicate glasses
used for CHEMICAL stability in corrosive
acid environments
E GLASS Alumina-calcium-borosilicate
glasses with a maximum alkali used as
general purpose fibers where STRENGTH
and high ELECTICAL RESISTIVITY are
required It manifests better electrical
insulation and strongly resists attack by
water More than 50 of the glass fibers
used for reinforcement is E-glass
C Glass
E Glass
C amp E GLASS
SUMBER AGY TECHNICAL PAPER HIGH STRENGTH GLASS FIBER
FAKTA
C GLASS 1 BOROS RESIN
2 KEKUATAN
KURANG
FAKTA
E GLASS 1 HEMAT RESIN
2 KEKUATAN BAIK
3 TAHAN LAMA
FAKTA
TEBAL BUKAN BERARTI KUAT
UNSUR MATRIX (RESIN)
TIDAK ADA KEKUATAN
ldquoMore than 50 of the glass fibers used for
reinforcement is E-glassrdquo
C glass E glass
E glass
C glass
KAIN WOVEN ROVING HASIL LAMINASI
JENIS SERAT GLASS
Kekuatan composites ditentukan oleh
1 Kekuatan amp Sifat Fiber
2 Kekuatan amp Sifat Resin
3 Fraksi Rasio Perbandingan Volume Fiber
dan Resin dalam Composites
rarr tergantung dari Proses Manufaktur
4 Geometri dan Orientasi Arah Fiber dalam
Composites
KEKUATAN COMPOSITES
PROSES MATERIAL
Proses Produksi Kain Fiberglass
Biji Kaca Benang Benang Kaca Kain Fiberglass
PROSES MATERIAL
Glass Beads
Glass Fiber Glass Roving YarnGlass Fabric
FIBERGLASS
PRODUK
MATERIAL DAN PRODUK FIBERGLASS
+
Resin + Additives
PERPADUAN COMPOSITES
BENANG KACA Potongan Serat Kaca CSM
CSM - CHOPPED STRAND MAT
chopped binder
Kain Fiberglass Generasi Pertama
BahanPengikat
SenyawaPada Resin
JENIS FIBERGLASS
Glass Roving Yarn Chopped Strand
ADVANTAGES DISADVANTAGES
Steel
1048707 Low cost 1048707 Corrodes easily
1048707 Ductile under ambient conditions
1048707 Has no lower fatigue limit for welded structures
1048707 Virtually isotropic 1048707 Heavy
1048707 Easily formed and fabricated 1048707 Brittle at low temperatures
1048707 Easily obtained (low relative cost) 1048707 Magnetic
1048707 Easily alloyed or heat treated for special operations
1048707 Easily repaired
1048707 Good fire resistance
1048707 Behaviour is well understood
Alumunium Alloy
1048707 Light weight 1048707 Poor fatigue properties
1048707 Corrosion resistant 1048707 Poor performance in fire
1048707 Easily formed1048707 Low melting point and softening temperature
1048707 Easily fabricated 1048707 High relative cost
1048707 Readily available 1048707 Strength and stiffness less than steel
1048707 Ductile
1048707 Non magnetic
FRP
1048707 Low magnetic properties
1048707 Low electrical conductivity (glass- reinforced plastics)
1048707 Resistance to corrosion
1048707 Resistance to rot and marine growth
1048707 Relatively high sonar transparency
1048707 Good strength to weight ratio
1048707 Good fatigue properties
1048707 Maintenance of properties at low temperatures
1048707 Availability
1048707 Can be manufactured to near net-shape
1048707 Stiffness and strength can be tailored to structural requirements
1048707 Excellent thermal insulation
1048707 Light weight
STEEL vs ALUMUNIUM vs COMPOSITES
Source
1Maritime Platforms Division Aeronautical and
Maritime Research Laboratory (Seref Aksu
Stuart Cannon Craig Gardiner and Matthew
Gudze
2 Metal Corrosion can be defined as the
destructive attack of a metal through interaction
with its environment
(httpwwwcorrosionistcomCorrosion_Fundament
alhtm)
28
Serat rarr penguat
Polimer matriks rarr pengikat
bull Sifat mekanik yang cukup baik
bull Viskositas dan temperatur pengerjaan rendah rarr mudah
dimanufaktur
bull Ketahanan korosi yang baik
bull Media perpindahan gaya rarr distribusi beban dari serat ke serat
bull Ulet rarr Melindungi serat yang getas
bull Size effect rarr Kekuatan dan kekakuan sangat tinggi
bull Aspect ratio (ld) tinggi rarr luas permukaan besar
bull Fleksibel rarr variasi teknik manufaktur
bull Serat dapat diatur sesuai dengan arah pembebanan
29
Advantages Polimer Composites
Kekuatan dan kekakuan spesifik yang tinggi FRCP vs material lain rarr kompetitif jika berat dipertimbangkan
Material Berat jenis
r (kgm3)
Kekakuan
E (GPa)
Kekuatan
tarik su
(MPa)
Kekakuan
spesifik
Er
Kekuatan
spesifik sur
Baja 7800 208 400 27 005
Aluminium 2700 70 200 259 007
Nylon 1100 25 80 23 007
Beton 2400 40 20 166 0008
Random
FRPC
1800 20 300 111 0006
Alligned FRPC
( serat)
1600 200 1500 125 094
Alligned FRCP
( serat)
1600 3 50 19 0001
Tensile Strength amp Modulus of Common Structural Materials
Densities of Common Structural Materials
Specific Tensile Strength amp Modulus of Common Structural Materials
Typical Properties of Common Structural Materials
Kesimpulan COMPOSITES = RINGAN amp KUAT
Jadi secara keseluruhan kekuatan composites
ditentukan oleh
1 Kekuatan amp Sifat Fiber
2 Kekuatan amp Sifat Resin
3 Fraksi Rasio Perbandingan Volume Fiber
dan Resin dalam Composites
4 Geometri dan Orientasi Arah Fiber dalam
Composites
PRODUKSI ANAK NEGERI
Proses Produksi Kain Fiberglass
Biji Kaca Benang Benang Kaca Kain Fiberglass
PROSES MATERIAL
Glass Beads
Glass Fiber Glass Roving YarnGlass Fabric
Proses Produksi Kain Fiberglass
Biji Kaca Benang Benang Kaca Kain Fiberglass
Glass Beads
Glass Fiber Glass Roving YarnGlass Fabric
PROSES MATERIAL
Benang Kaca Potongan Serat Kaca Chopped Strand Mat
CSM - Chopped Strand Mat
chopped binder
Produk Fiberglass Generasi Pertama
Bahan Pengikat
Senyawa Pada Resin
Glass Roving Yarn Chopped Strand
JENIS FIBERGLASS
Benang Kaca Woven Roving
WR - Woven Roving
Tenun Weaving
Produk Fiberglass Generasi Kedua
Glass Roving Yarn
JENIS FIBERGLASS
Multiaxial
MAX - Multiaxial
warp knitting
Produk Fiberglass Generasi Ketiga
Benang Kaca
Glass Roving Yarn
JENIS FIBERGLASS
MAX - Multiaxial Fabric
Fleece (optional)
Lapisan
MULTIAXIAL PROSES
Karakteristik CSM
bull Glass Content 30
bull Resin Content 70
bull Tensile Force
Chopped Strand Mat
JENIS FIBERGLASS
Karakteristik Woven Roving
bull Glass Content 45
bull Resin Content 55
Woven Roving
Resin
|
|
|
|
|
|
|
|
|
|
|
|
|
|
bull Kekuatan Tarik
JENIS FIBERGLASS
No Resin Rich Area
Karakteristik Multiaxial
bull Glass Content 60
bull Resin Content 40
Produk Fiberglass Ketiga MULTIAXIAL
JENIS FIBERGLASS
Perbedaan Woven Roving dan Multiaxial ndash Tampak Samping
JENIS FIBERGLASS
WR FRP
8 Ply WR 800
8 Ply CSM 450
Glass Weight 1 kg
Composite Weight 15kgm2
CSM FRP
22 Ply CSM 450
Glass Weight 1 kg
Composite Weight 18 kgm2
MULTIAXIAL FRP
13 Ply DB 800
Glass Weight 1 kg
Composite Weight
13 kgm2
JENIS FIBERGLASS
Multiaxial
FRP
Woven Roving
FRP
Chopped Strands Mat FRP
MULTIAXIAL
FAKTA
TEBAL BUKAN BERARTI KUAT
UNSUR MATRIX (RESIN)
TIDAK ADA KEKUATAN
ldquoMore than 50 of the glass fibers used for reinforcement is
E-glassrdquo
KarakteristikKekuatan
CSM WR MAX
Kekuatan Tarik 175 MPa 250 MPa 425 MPa
CSM 142
WR 70
KEKUATAN TARIK
Properties CSM Lamination WR Lamination MAX Lamination
Fabric Weight (kgm2) 1 1 1
Composite Weight (kgm2) 18 15 13
Resin usage (kgm2) 15 1 08
Amount of Fabric 22 Ply 16 Ply 13 Ply
Thickness 15 mm 12 mm 10 mm
Tensile Strength (Mpa) 125 1796 400
Tensile Strength (Nmmsup2) 28463 30958 4576
Processing Time High Med Low
Labour Cost High Med Low
MULTIAXIAL
Total Penggunaan Resin -51
Total Berat Kapal -40
Kekuatan Bangunan Kapal +59
Efisiensi Tenaga Kerja
Waktu Pengerjaan Lebih Cepat
KEUNGGULAN MATERIAL
Resapan Resin Lebih Baik amp Merata
Lapisan Lebih Sedikit
Meningkatkan Kekuatan Kapal
KEUNGGULAN MATERIAL
TRIAXIAL
DBL series DBT series
BIAXIAL
LT series DB series
UNIDIRECTIONAL
L series T series
QUADRIAXIAL
DBLT series
JENIS MULTIAXIAL
UNIDIRECTIONAL
DCMU 900 E ndash
KHUSUS UNTUK MEMPERKUAT BENDING KAPAL
PEMASANGAN KHUSUS PADA KEEL DAN TULANGAN
JENIS MULTIAXIAL UNTUK KAPAL
TRIAXIAL
DBL 600 ndash
APLIKASI PADA INDUSTRI PENERBANGAN
PEMASANGAN KHUSUS PADA
SAMBUNGAN BADAN DAN SAYAP
PESAWAT
JENIS MULTIAXIAL UNTUK PESAWAT
QUADRAXIAL
DBLT 800 ndash
APLIKASI PADA INDUSTRI ENERGI
DITERAPKAN UNTUK KEBUTUHAN PEMBANGKIT
LISTRIK ENERGI ANGIN
MULTIAXIAL UNTUK ENERGI
INDUSTRI KIMIA OLAHRAGA AUTOMOTIF
MULTIAXIAL UNTUK INDUSTRI LAINNYA
COMPOSITES
GUNAKAN MATERIAL FIBERGLASS
YANG SUDAH DISERTIFIKASI
BKI
FIBERGLASS UNTUK PEMBANGUNAN BAKAP
PERATURAN MENTERI PERHUBUNGAN
NOMOR PM 7 TAHUN 2013
TENTANG KEWAJIBAN KLASIFIKASI BAGI KAPAL BERBENDERA INDONESIA
PADA BADAN KLASIFIKASI
BADAN SERTIFIKASI MARITIM
Biro Klasifikasi IndonesiaDet Norske Veritas Germanischer Lloyds
PERATURAN BKI
Untuk Kapal Non-Metal
2006
PERSYARATAN MINIMUM
kekuatan material yang
harus digunakan
untuk membangun
Kapal Fiberglass
PEMBESARAN
Table 21
FIBERGLASS TRIAXIS COMPOSITES
TELAH BERSERTIFIKASI BKI
Biro Klasifikasi Indonesia
65
TEKNIK MANUFAKTUR
COMPOSITES
Wet hand lay-up
1) Peletakan
Dry Reinforcement
bull Dry reinforcement dan resin (+ katalis) ditaruh pada permukaan cetakan
2) Pemasukanpenekanan resin
bull Resin ditekan untuk meng-impregnasi serat dengan menggunakan rol
3) Pengulangan proses untuk lapisan lain
bull Beberapa lapisan dapat ditambahkan secara bertahap
4) Resin curing
bull Reaksi dimulai komponen dilepaskan setelah komponen mengeras
(fully cured)
Wet hand lay-up
Manufaktur komponen dapat dikerjakan dengan menggunakan beberapa lapis komposit
dengan memperhatikan kompatibilitas material dan tahapan curing Modifikasi proses dapat
dilakukan seperti
Vacuum bagging
setelah lay-up
Glass Roving
Bulk Resin
Catalyst
3) De-molding
2) Resin Cure
bull Curing dimulai dan komponen dilepaskan setelah pengerasan selesai
bull Serat gelas resin dan katalis dimasukkan kedalam spray gun
1) Spray-up
bull Campuran disemprotkan pada permukaan cetakan
Spray-up
69
Penyemprotan bakal komponen
Komponen
dilepaskan
dari cetakan
Full dispensing
system Chopper Roving
Atomised resin
and catalyst
Spray-up
Prepreg
1) LaminateAssembly 5) De-molding
3) Resin Melts Layup Consolidates
bull Prepreg serat yang sudah diimpregnasi oleh resin+katalis dalam kondisi padat
bull Lapisan prepreg digunting sesuai bentuk yang diinginkan kemudian diletakkan pada permukaan cetakan
sesuai bentuk komponen yang diinginkan Lay-up mudah dilakukan karena sifat ldquotackynessrdquo dari prepreg
2) Applied Vacuum Pressure and Heat
bull Tekanan dan panas diberikan resin mencair terjadi konsolidasi pada komponen
4) Resin Cures
bull Temperatur dinaikkan untuk memulai curing
Prepreg
Variasi proses Autoclave
Komponen dalam
vacuum-bag
bull Campuran resin (+katalis) dan chopped glass strands diperoleh dalam bentuk premixed compound Bulk molding
Compound (BMC) dalam bentuk adonan atau Sheet molding Compound (SMC) dalam bentuk lembaran
bull Ketika panas dan tekanan diberikan oleh cetakan compound mengalir sesuai bentuk komponen yang diinginkan
1) Placement of Charge
5) De-molding3) Squeeze to final dimensions
2) Mould Closure4) Resin Cure
bull Curing dimulai komponen dilepaskan setelah terjadi pengerasan yang cukup
Compression Molding
bull Preform atau dry reinforcement dimasukkan kedalam cetakan sesuai dengan bentuk komponen yang
diinginkan
bull Resin mengalir dengan penekanan atau pem-vakuman dan meng-impregnasi preform dan
mendorongmengeluarkan udara yang ada dalam preform
1) Preform Manufacture
2) Preform Compression
5) De-molding3) Resin Injection
4) Resin Cure
bull Curing terjadi cetakan dibuka setelah terjadi pengerasan yang mencukupi
Liquid Molding (RTM VARI VARTM)
Pultrusion
bull Dry roving or fabrics ditarik melalui bak berisi
campuran resin dan katalis
bull Campuran yang basah ditarik melalui cetakan
bull Sisa resin keluar cetakan
bull Pemanasan dilakukan untuk proses curing
bull Pendinginan dilakukan untuk mempercepat siklus
produksi
Cut-off
Cooling
Die sections
Resin bath
Fibre creel
Filament Winding
bull Dry roving ditarik melalui bak berisi campuran resin dan katalis
bull Wet roving digulungkan dalam keadaan tegang kepada mandrel
bull Kontrol mekanik dari pembawa serat mengatur orientasi peletakan serat pada
mandrel
INDUSTRI COMPOSITES
AEROSPACE
HISTORY
1950 ndash Boeing
1960 ndash F14 Tomcat
1981 ndash AV-8B Harrier
Source
Low-Cost Composite Materials and Structures for Aircraft Applications
httpwwwreinforcedplasticscom
httpwwwcentennialofflightgovessayEvolution_of_TechnologycompositesTech40htm
Automotive
Composite material is used in a number of applications in the automotive
industry due to its temperature resistance rigidity and fatigue strength
The benefits of using composites include greater fuel efficiency
corrosion resistance light weight and strength Composites also provide
a low-cost way to help keep designs looking fresh
Composites are used in
- interior parts (cockpit trimming seats instrument panels)
- exterior structure (body panels openings underbody frontrear
modules)
- engine compartment and fuelmechanical area parts (axles and
suspensions fuel and exhaust systems)
- electrical and electronic components
Lamborghinis Sesto Element carbon fiber
ldquoFat men cannot run as fast as thin men but we build most of our vehicles as though dead-weight fat increased speedhellip I cannot
imagine where the delusion that weight means strength
came fromhelliprdquo mdashHenry Ford
The mix of automotive materials is changing showing a boost for FRP in helping original
equipment manufacturers meet fuel economy and emissions challenges
(Source 2011 DuPont AutomotiveSAE survey of design engineers performed by Signet Research Inc)
Source
httpwwwtoraycomcsrhighlight2009hig_001_01html
The MonoCell tub for the McLaren MP4-12C supercar is moulded as a single
piece and weighs less than 80 kg (176 lbs)
COMPOSITES IN MARINE
TRIMARAN BOAT
AMERICA NAVYINDONESIAN NAVY
Visby Class corvette
Total length is 72 meters
The beam is 1040 meters
The displacement is 600 metric tones
fully equipped the worlds largest CRP
construction
The design of the Visby aims to minimize
the optical and infrared signature above
water acoustic and hydroa coustic
signature underwater electrical potential
and magnetic signature pressure signature
radar cross section and actively emitted
signals
A stealth corvette of the YS 2000 design
has a detection range of 13km in rough
seas and 22km in calm sea without
jamming In a jammed environment the
Visby would be detected at a range of 8km
in rough sea and 11km in calm sea
The material provides high strength and
rigidity low weight good shock resistance
low radar and magnetic signature
1996
Visby is a class of stealth corvettes for the Swedish Navy
ldquoReduced 50 of a Conventional Steelrdquo
Source
Hull Construction with composite materials for ships over 100m in length 2002
Massachusetts Institute of Technology
httpwwwnaval-technologycomprojectsvisby
YACHTS
KAL YUDISTIRAMARATHON 100 ADMIRAL YACHT
LOA 3050 MWidth 6 MFuel Tank 8000 LWater Tank 3000 LIce Box 500 LAccommodation Max 35 Personnel
2 x CATERPILLAR 3412E 1200 HPMARINE DIESEL ENGINE
PC 40 ndash KRI Krait 827Department of Indonesian Navy
LOA 40 MWidth 73 MPower 190Weapon Twin Cannon Barrels
127 mm Heavy Machine GunSpeed Knot 25 KnotDisplacement 105 tonAccommodation 23 personnel
PATROL BOAT
Rigid Inflatable BoatPATROL BOAT
Yachts
36m Luxury Yacht Moonraker
36m Luxury Yacht GoldenEye
50m Luxury Yacht Casino
Royale
45m Luxury Yacht Seashaw
Boat Parts
Barovans for Seismic Sweep
Centrifugal Liftfan House for Surface Effect
Ships
Composite Boat PropellersRTM
Deckhouses for Pilot Boats
Fairing Parts for Submarines
Flybridges for Motor yachts
Light Weight Gangway
MTB Launcher Mock-up
Pleasure Boats
12m Sailboat
12m Sail-Catamaranone-off
Canoes
Dragonfly 1000Catamaran Sailboat
Fantasy 37Sailboat
Farr 60Luxury Sailboat
EurodingyOlympic Dingy Class for
Woman
Hydrolift F23 Racing Boats
Kajacs
Najad 42Sailboat
Najad 520Sailboat
Najad 441Sailboat
Najad 391Sailboat
Nordwest 900Motorboat
Nordwest 1100Motorboat
Quatro 44Motorboat
Racemaster Competition Boats
Storebro 420
Storebro 345
Sweden Yacht 370Sailboat
Sweden Yacht 69Sailboat
Windy 41Motorboat
X-632Sailboat
X-362Sailboat
Commercial Boats
175m High Speed AmbulancePassenger Boat
19m High Speed Passenger Boat
20m High Speed Passenger Boat
364m Surface Effect Passenger Ship
45m Surface Effect Passenger Ship
120m Hull Structural Parts HSSS Catamaran Ferry
APPENDIX
Marine Vessel
1188m Fast Attack Vessel FMV 90 E
20m SAV-Surface Auxiliary Vessels
34m Personnel TransportCoast Guard Vessel
40ft Experimental SES
40m Landsort-Class Mine Hunters
54m Mine Counter Measure Vehicles SES
74m Coastal Patrol Boats
Fishing Boats
30 GT
12 GT
10 GT
5 GT
WISEWings In Surface Effect
HOVERCRAFT
Designed specifically for the tourist and transport industries the
Pioneer Mk3 hovercraft is amphibious and comfortably seats 25
passengers plus 1-crew The air-conditioned cabin allows for
maximum visibility for all aboard The Pioneer Mk3 is robust and
dynamic in its performance
Commercial hovercraft
Mk3 AirLift Hovercraft - 1215m
Power is economicaly provided by one Deutz diesel engine of
330kW (442hp) to cruise easily at 40 knots with much higher
speeds available according to the surface conditions The hull is
manufactured from fibreglassPVC foam composite sandwich
the windows are glass and the skirt is urethane coated nylon A
Military version is available with increased payload and systems
redundancy Power for the Military version comes from two Steyr
diesel engines with a total installed power of 320kW (429hp) All
transmission electrical hydraulic and air systems are duplicated
for maximum redundancy The increased performance of the
Military version comes from the reduced engine weight of the twin
Steyr installation cf the Deutz installation
Source
httpwwwnauticexpocomprodairlift-hovercraftcommercial-hovercrafts-25251-142868html
HOVERFLIGHT
BALLISTIC amp UNIT DEFENCED
Triaxis Composites Collaboration with Institute of Aeronautics and Space in the development of Missile Nose Cone
Polymer composites is the evolution of the military defence
Thin steel was the helmet material of
WWII and remained the principal material until around the 1980rsquos
The advantages of using steel
included a simple technology for manufacture of the helmets low cost and reasonably good
impact protection However these helmets were found to provide only marginal protection
against fragments
During the Vietnam War the US Army experimented with fiber-reinforced inserts in the
helmets These inserts improved ballistic protection but at the same time added weight and
reduced the air space between the head and the helmet
By the early part of the 1980rsquos the US military had developed the first all-composite
100 fiber-reinforced helmet This development resulted in even better ballistic protection
without altering the weight of the helmet Other improvements included better head coverage and
more space for ventilation
Source
Composites Armor - A difficult but huge market
by A Brent Strong Brigham Young University
MILITARY VEHICLES
HIGH SPEED TRAIN SHINKANSEN
Advanced Composites provide lightweight solutions for railway vehicles
saving as much as 50-80 of the weight compared with traditional
components
A lower overall weight translates into less stress faster acceleration and
higher speeds as well as reduced starting and stopping inertia Today
these are important criteria in global high-speed and metropolitan
railway projects
Fire smoke and toxic fumes are key safety criteria for interior
components of railway carriages Any material selected for an interior
component must meet international fire retardant standards
for Rail Interiors and Exteriors
Ceiling Panels Stairs
Seating Vestibules
Window Panels Door Pillars
Partition WallsDiffusers
Gangway and Cabinet Panels Cabin and
Desk panels
Door Pillars Lavatory Modules (standard and
Front and Rear EndsRoof Panels
Nose Cones Under Fairings
Source
httpwwwpctaerail_compositesphp
101
SKY BUS
2009
Europe is the world leader in offshore wind with
828 wind turbines and a cumulative capacity of 2056 MW spread across 38 offshore wind farms in 9
European countries
The UK and Denmark are the current leaders with a 44 and 30 share respectively In 2009
five countries built new offshore wind farms
UK (284 MW)
Demark (230 MW)
Sweden (30 MW)
Germany (30 MW)
Norway (23 MW)
2010
Asia leads the growth in global wind power which grew 358 GW in 2010 bringing
total global capacity to 1944 GW ndash up 225 from 2009
the Global Wind Energy Council (GWEC)
Asia accounted for 19 GW of new global wind power installations driven by China which installed 165
GW
ldquoChina now has 423 GW of wind powerrdquo
ldquoThis puts China firmly on a path to reach 200 GW of installed wind power by 2020 At the same
time China has become the worldrsquos largest producer of wind energy equipmentrdquo
Source
httpwwwreinforcedplasticscomview15655asia-leads-global-wind-power-growth
httpimgdeusmcomdesignnews288288605-Sandia_Sizes_up_Wind_Turbine_Blade_Design_C_largegif
WIND ENERGY
Marine Current Turbines
Source
httpwwwsiemenscompressenpressreleasepress=enpressrelease2011solar-hydroex201111005htm
httpwwwmarineturbinescom
A commercial marine current turbine consists of
two rotors which are fixed on a structure within the
sea current The twin rotors rotate with the
movement of the tidal flow and the blades pitch
through 180 degrees to optimally track tidal current
(Press picture Marine Current Turbines)
Wave Star Energys Multi-point Absorber
CFRP COLUMN REINFORCEMENT
INDUSTRIAL TANKS
107
INDUSTRIAL PIPES
PRESSURE TANKS
109
ldquoLetrsquos Make with Compositesrdquo
9
Berdasarkan jenis penguat
bull Particle-reinforced composites
ndash Large-particle composites (Cermets tungsten carbida in cobalt semen beton bertulang)
ndash Dispersed-strenghtened composites (alumina in aluminium ThoriaThO2 in Nickel alloy)
bull Fiber-reinforced composites konstruksi kaku kuat dan ringan
ndash Discontinuous (Short) fiber composites
ndash Continuous (long) fiber composites
bull Structural-reinforced composites
ndash Laminar composites (kayu multipleks laminate carbon epoxy)
ndash Sandwich composites konstruksi ringan dengan kekakuan dan kekuatan bending yang tinggi (Honeycomb-carbon epoxy composites dinding kardus corrugated paper - paper)
KLASIFIKASI MATERIAL KOMPOSIT
10
Berdasarkan jenis matriks
bull Polymer matrix composites (PMC) Paling populer dengan beragam aplikasi
- Carbon fibre reinforced polymer
- Glass fibre reinforced polymer
- Metal fibre reinforced polymer
bull Metal matrix composites (MMC) Aerospace dan komponen mesin mobil
- Boron or carbon fibre reinforced Aluminium
- Alumina particle reinforced Aluminium
bull Ceramic matrix composites (CMC) Heat exhanger sistem pelindung panas komponen dengan lingkungan korosif dan erosif
- Zirconia in alumina
- Carbon fibre reinforced carbon
KLASIFIKASI MATERIAL KOMPOSIT
SERAT
(FIBER) +RESIN
(MATRIX) = COMPOSITES
bull GLASS (KACA)
bull CARBON
bull ARAMID
bull Fiberglass Reinforced Plastics
(FRP)
bull Carbon Fiber Reinforced Plastics
(CFRP)
bull Aramid Fiber Reinforced Plastics
POLYMER TECHNOLOGY COMPOSITES
bull POLYESTER
bull VINYLESTER
bull EPOXY
bull POLYPROPYLENE
bull POLYAMID
COMPOSITES BUATAN (ENGINEERED COMPOSITES) SEHARI-HARI
BETON = TULANGAN BESI + RESIN SEMEN
The Importance of Lightness for
Environmental Friendly Products
Mass Reduction for Less Energy Consumption
MATERIAL COMPOSITES
Thermoset
type
Density r
(kgm3)
Stiffnes
s E
(Gpa)
Tensile
strength
s (MPa)
Strain to
failure e
()
Tg 0C
Thermal
conductivity
k (Wm0C)
Specific
Heat Cp
(kJkg0C)
Thermal
expansion coeff
a (x106 0C-1)
Polyester 1100-1230 31-46 50-75 10-65 70- 017-022 13-23 55-100
Vinylester 1120-1130 31-33 70-81 30-80 70- - - -
Epoxy 1100-1200 26-38 60-85 15-80 65-175 017-020 105 45-65
Phenolic 1000-1250 30-40 60-80 18 300 012-024 14-18 25-60
PUR 1200 07 30-40 400-450 135 017-021 13-23 70-100
BMI 1200-1320 32-50 48-110 15-33 230-345 - - -
Polyimide 1430-1890 31-49 100-110 15-30 325-370 01-034 105-15 25-80
Al 2800 72 540 18 - 130 096 236
Steel 7790 205 640 25 - 54 046 11
MATRIKS POLIMER THERMOSET
Variasi sifat yang lebar disebabkan oleh adanya formulasi kimia yang berbeda dan penambahan aditif
Jenis Glass Fiber S Glass E Glass C Glass A Glass dll
Terms
Glass Type
S Glass E Glass C Glass A Glass
Silica (SiO2) Content 67 55 64 72
Al2O3 Content 23 14 6 1
Melting Point (Celcius) 915 836 745 745
Tensile Strength 665 500 440 440
Modulus Elastisitas 124 105 100 -
Application AEROSPACE BOAT CHEMICAL TANK CHEMICAL TANK
JENIS SERAT GLASS
CHINA
JENIS SERAT GLASS
C GLASS Calcium borosilicate glasses
used for CHEMICAL stability in corrosive
acid environments
E GLASS Alumina-calcium-borosilicate
glasses with a maximum alkali used as
general purpose fibers where STRENGTH
and high ELECTICAL RESISTIVITY are
required It manifests better electrical
insulation and strongly resists attack by
water More than 50 of the glass fibers
used for reinforcement is E-glass
C Glass
E Glass
C amp E GLASS
SUMBER AGY TECHNICAL PAPER HIGH STRENGTH GLASS FIBER
FAKTA
C GLASS 1 BOROS RESIN
2 KEKUATAN
KURANG
FAKTA
E GLASS 1 HEMAT RESIN
2 KEKUATAN BAIK
3 TAHAN LAMA
FAKTA
TEBAL BUKAN BERARTI KUAT
UNSUR MATRIX (RESIN)
TIDAK ADA KEKUATAN
ldquoMore than 50 of the glass fibers used for
reinforcement is E-glassrdquo
C glass E glass
E glass
C glass
KAIN WOVEN ROVING HASIL LAMINASI
JENIS SERAT GLASS
Kekuatan composites ditentukan oleh
1 Kekuatan amp Sifat Fiber
2 Kekuatan amp Sifat Resin
3 Fraksi Rasio Perbandingan Volume Fiber
dan Resin dalam Composites
rarr tergantung dari Proses Manufaktur
4 Geometri dan Orientasi Arah Fiber dalam
Composites
KEKUATAN COMPOSITES
PROSES MATERIAL
Proses Produksi Kain Fiberglass
Biji Kaca Benang Benang Kaca Kain Fiberglass
PROSES MATERIAL
Glass Beads
Glass Fiber Glass Roving YarnGlass Fabric
FIBERGLASS
PRODUK
MATERIAL DAN PRODUK FIBERGLASS
+
Resin + Additives
PERPADUAN COMPOSITES
BENANG KACA Potongan Serat Kaca CSM
CSM - CHOPPED STRAND MAT
chopped binder
Kain Fiberglass Generasi Pertama
BahanPengikat
SenyawaPada Resin
JENIS FIBERGLASS
Glass Roving Yarn Chopped Strand
ADVANTAGES DISADVANTAGES
Steel
1048707 Low cost 1048707 Corrodes easily
1048707 Ductile under ambient conditions
1048707 Has no lower fatigue limit for welded structures
1048707 Virtually isotropic 1048707 Heavy
1048707 Easily formed and fabricated 1048707 Brittle at low temperatures
1048707 Easily obtained (low relative cost) 1048707 Magnetic
1048707 Easily alloyed or heat treated for special operations
1048707 Easily repaired
1048707 Good fire resistance
1048707 Behaviour is well understood
Alumunium Alloy
1048707 Light weight 1048707 Poor fatigue properties
1048707 Corrosion resistant 1048707 Poor performance in fire
1048707 Easily formed1048707 Low melting point and softening temperature
1048707 Easily fabricated 1048707 High relative cost
1048707 Readily available 1048707 Strength and stiffness less than steel
1048707 Ductile
1048707 Non magnetic
FRP
1048707 Low magnetic properties
1048707 Low electrical conductivity (glass- reinforced plastics)
1048707 Resistance to corrosion
1048707 Resistance to rot and marine growth
1048707 Relatively high sonar transparency
1048707 Good strength to weight ratio
1048707 Good fatigue properties
1048707 Maintenance of properties at low temperatures
1048707 Availability
1048707 Can be manufactured to near net-shape
1048707 Stiffness and strength can be tailored to structural requirements
1048707 Excellent thermal insulation
1048707 Light weight
STEEL vs ALUMUNIUM vs COMPOSITES
Source
1Maritime Platforms Division Aeronautical and
Maritime Research Laboratory (Seref Aksu
Stuart Cannon Craig Gardiner and Matthew
Gudze
2 Metal Corrosion can be defined as the
destructive attack of a metal through interaction
with its environment
(httpwwwcorrosionistcomCorrosion_Fundament
alhtm)
28
Serat rarr penguat
Polimer matriks rarr pengikat
bull Sifat mekanik yang cukup baik
bull Viskositas dan temperatur pengerjaan rendah rarr mudah
dimanufaktur
bull Ketahanan korosi yang baik
bull Media perpindahan gaya rarr distribusi beban dari serat ke serat
bull Ulet rarr Melindungi serat yang getas
bull Size effect rarr Kekuatan dan kekakuan sangat tinggi
bull Aspect ratio (ld) tinggi rarr luas permukaan besar
bull Fleksibel rarr variasi teknik manufaktur
bull Serat dapat diatur sesuai dengan arah pembebanan
29
Advantages Polimer Composites
Kekuatan dan kekakuan spesifik yang tinggi FRCP vs material lain rarr kompetitif jika berat dipertimbangkan
Material Berat jenis
r (kgm3)
Kekakuan
E (GPa)
Kekuatan
tarik su
(MPa)
Kekakuan
spesifik
Er
Kekuatan
spesifik sur
Baja 7800 208 400 27 005
Aluminium 2700 70 200 259 007
Nylon 1100 25 80 23 007
Beton 2400 40 20 166 0008
Random
FRPC
1800 20 300 111 0006
Alligned FRPC
( serat)
1600 200 1500 125 094
Alligned FRCP
( serat)
1600 3 50 19 0001
Tensile Strength amp Modulus of Common Structural Materials
Densities of Common Structural Materials
Specific Tensile Strength amp Modulus of Common Structural Materials
Typical Properties of Common Structural Materials
Kesimpulan COMPOSITES = RINGAN amp KUAT
Jadi secara keseluruhan kekuatan composites
ditentukan oleh
1 Kekuatan amp Sifat Fiber
2 Kekuatan amp Sifat Resin
3 Fraksi Rasio Perbandingan Volume Fiber
dan Resin dalam Composites
4 Geometri dan Orientasi Arah Fiber dalam
Composites
PRODUKSI ANAK NEGERI
Proses Produksi Kain Fiberglass
Biji Kaca Benang Benang Kaca Kain Fiberglass
PROSES MATERIAL
Glass Beads
Glass Fiber Glass Roving YarnGlass Fabric
Proses Produksi Kain Fiberglass
Biji Kaca Benang Benang Kaca Kain Fiberglass
Glass Beads
Glass Fiber Glass Roving YarnGlass Fabric
PROSES MATERIAL
Benang Kaca Potongan Serat Kaca Chopped Strand Mat
CSM - Chopped Strand Mat
chopped binder
Produk Fiberglass Generasi Pertama
Bahan Pengikat
Senyawa Pada Resin
Glass Roving Yarn Chopped Strand
JENIS FIBERGLASS
Benang Kaca Woven Roving
WR - Woven Roving
Tenun Weaving
Produk Fiberglass Generasi Kedua
Glass Roving Yarn
JENIS FIBERGLASS
Multiaxial
MAX - Multiaxial
warp knitting
Produk Fiberglass Generasi Ketiga
Benang Kaca
Glass Roving Yarn
JENIS FIBERGLASS
MAX - Multiaxial Fabric
Fleece (optional)
Lapisan
MULTIAXIAL PROSES
Karakteristik CSM
bull Glass Content 30
bull Resin Content 70
bull Tensile Force
Chopped Strand Mat
JENIS FIBERGLASS
Karakteristik Woven Roving
bull Glass Content 45
bull Resin Content 55
Woven Roving
Resin
|
|
|
|
|
|
|
|
|
|
|
|
|
|
bull Kekuatan Tarik
JENIS FIBERGLASS
No Resin Rich Area
Karakteristik Multiaxial
bull Glass Content 60
bull Resin Content 40
Produk Fiberglass Ketiga MULTIAXIAL
JENIS FIBERGLASS
Perbedaan Woven Roving dan Multiaxial ndash Tampak Samping
JENIS FIBERGLASS
WR FRP
8 Ply WR 800
8 Ply CSM 450
Glass Weight 1 kg
Composite Weight 15kgm2
CSM FRP
22 Ply CSM 450
Glass Weight 1 kg
Composite Weight 18 kgm2
MULTIAXIAL FRP
13 Ply DB 800
Glass Weight 1 kg
Composite Weight
13 kgm2
JENIS FIBERGLASS
Multiaxial
FRP
Woven Roving
FRP
Chopped Strands Mat FRP
MULTIAXIAL
FAKTA
TEBAL BUKAN BERARTI KUAT
UNSUR MATRIX (RESIN)
TIDAK ADA KEKUATAN
ldquoMore than 50 of the glass fibers used for reinforcement is
E-glassrdquo
KarakteristikKekuatan
CSM WR MAX
Kekuatan Tarik 175 MPa 250 MPa 425 MPa
CSM 142
WR 70
KEKUATAN TARIK
Properties CSM Lamination WR Lamination MAX Lamination
Fabric Weight (kgm2) 1 1 1
Composite Weight (kgm2) 18 15 13
Resin usage (kgm2) 15 1 08
Amount of Fabric 22 Ply 16 Ply 13 Ply
Thickness 15 mm 12 mm 10 mm
Tensile Strength (Mpa) 125 1796 400
Tensile Strength (Nmmsup2) 28463 30958 4576
Processing Time High Med Low
Labour Cost High Med Low
MULTIAXIAL
Total Penggunaan Resin -51
Total Berat Kapal -40
Kekuatan Bangunan Kapal +59
Efisiensi Tenaga Kerja
Waktu Pengerjaan Lebih Cepat
KEUNGGULAN MATERIAL
Resapan Resin Lebih Baik amp Merata
Lapisan Lebih Sedikit
Meningkatkan Kekuatan Kapal
KEUNGGULAN MATERIAL
TRIAXIAL
DBL series DBT series
BIAXIAL
LT series DB series
UNIDIRECTIONAL
L series T series
QUADRIAXIAL
DBLT series
JENIS MULTIAXIAL
UNIDIRECTIONAL
DCMU 900 E ndash
KHUSUS UNTUK MEMPERKUAT BENDING KAPAL
PEMASANGAN KHUSUS PADA KEEL DAN TULANGAN
JENIS MULTIAXIAL UNTUK KAPAL
TRIAXIAL
DBL 600 ndash
APLIKASI PADA INDUSTRI PENERBANGAN
PEMASANGAN KHUSUS PADA
SAMBUNGAN BADAN DAN SAYAP
PESAWAT
JENIS MULTIAXIAL UNTUK PESAWAT
QUADRAXIAL
DBLT 800 ndash
APLIKASI PADA INDUSTRI ENERGI
DITERAPKAN UNTUK KEBUTUHAN PEMBANGKIT
LISTRIK ENERGI ANGIN
MULTIAXIAL UNTUK ENERGI
INDUSTRI KIMIA OLAHRAGA AUTOMOTIF
MULTIAXIAL UNTUK INDUSTRI LAINNYA
COMPOSITES
GUNAKAN MATERIAL FIBERGLASS
YANG SUDAH DISERTIFIKASI
BKI
FIBERGLASS UNTUK PEMBANGUNAN BAKAP
PERATURAN MENTERI PERHUBUNGAN
NOMOR PM 7 TAHUN 2013
TENTANG KEWAJIBAN KLASIFIKASI BAGI KAPAL BERBENDERA INDONESIA
PADA BADAN KLASIFIKASI
BADAN SERTIFIKASI MARITIM
Biro Klasifikasi IndonesiaDet Norske Veritas Germanischer Lloyds
PERATURAN BKI
Untuk Kapal Non-Metal
2006
PERSYARATAN MINIMUM
kekuatan material yang
harus digunakan
untuk membangun
Kapal Fiberglass
PEMBESARAN
Table 21
FIBERGLASS TRIAXIS COMPOSITES
TELAH BERSERTIFIKASI BKI
Biro Klasifikasi Indonesia
65
TEKNIK MANUFAKTUR
COMPOSITES
Wet hand lay-up
1) Peletakan
Dry Reinforcement
bull Dry reinforcement dan resin (+ katalis) ditaruh pada permukaan cetakan
2) Pemasukanpenekanan resin
bull Resin ditekan untuk meng-impregnasi serat dengan menggunakan rol
3) Pengulangan proses untuk lapisan lain
bull Beberapa lapisan dapat ditambahkan secara bertahap
4) Resin curing
bull Reaksi dimulai komponen dilepaskan setelah komponen mengeras
(fully cured)
Wet hand lay-up
Manufaktur komponen dapat dikerjakan dengan menggunakan beberapa lapis komposit
dengan memperhatikan kompatibilitas material dan tahapan curing Modifikasi proses dapat
dilakukan seperti
Vacuum bagging
setelah lay-up
Glass Roving
Bulk Resin
Catalyst
3) De-molding
2) Resin Cure
bull Curing dimulai dan komponen dilepaskan setelah pengerasan selesai
bull Serat gelas resin dan katalis dimasukkan kedalam spray gun
1) Spray-up
bull Campuran disemprotkan pada permukaan cetakan
Spray-up
69
Penyemprotan bakal komponen
Komponen
dilepaskan
dari cetakan
Full dispensing
system Chopper Roving
Atomised resin
and catalyst
Spray-up
Prepreg
1) LaminateAssembly 5) De-molding
3) Resin Melts Layup Consolidates
bull Prepreg serat yang sudah diimpregnasi oleh resin+katalis dalam kondisi padat
bull Lapisan prepreg digunting sesuai bentuk yang diinginkan kemudian diletakkan pada permukaan cetakan
sesuai bentuk komponen yang diinginkan Lay-up mudah dilakukan karena sifat ldquotackynessrdquo dari prepreg
2) Applied Vacuum Pressure and Heat
bull Tekanan dan panas diberikan resin mencair terjadi konsolidasi pada komponen
4) Resin Cures
bull Temperatur dinaikkan untuk memulai curing
Prepreg
Variasi proses Autoclave
Komponen dalam
vacuum-bag
bull Campuran resin (+katalis) dan chopped glass strands diperoleh dalam bentuk premixed compound Bulk molding
Compound (BMC) dalam bentuk adonan atau Sheet molding Compound (SMC) dalam bentuk lembaran
bull Ketika panas dan tekanan diberikan oleh cetakan compound mengalir sesuai bentuk komponen yang diinginkan
1) Placement of Charge
5) De-molding3) Squeeze to final dimensions
2) Mould Closure4) Resin Cure
bull Curing dimulai komponen dilepaskan setelah terjadi pengerasan yang cukup
Compression Molding
bull Preform atau dry reinforcement dimasukkan kedalam cetakan sesuai dengan bentuk komponen yang
diinginkan
bull Resin mengalir dengan penekanan atau pem-vakuman dan meng-impregnasi preform dan
mendorongmengeluarkan udara yang ada dalam preform
1) Preform Manufacture
2) Preform Compression
5) De-molding3) Resin Injection
4) Resin Cure
bull Curing terjadi cetakan dibuka setelah terjadi pengerasan yang mencukupi
Liquid Molding (RTM VARI VARTM)
Pultrusion
bull Dry roving or fabrics ditarik melalui bak berisi
campuran resin dan katalis
bull Campuran yang basah ditarik melalui cetakan
bull Sisa resin keluar cetakan
bull Pemanasan dilakukan untuk proses curing
bull Pendinginan dilakukan untuk mempercepat siklus
produksi
Cut-off
Cooling
Die sections
Resin bath
Fibre creel
Filament Winding
bull Dry roving ditarik melalui bak berisi campuran resin dan katalis
bull Wet roving digulungkan dalam keadaan tegang kepada mandrel
bull Kontrol mekanik dari pembawa serat mengatur orientasi peletakan serat pada
mandrel
INDUSTRI COMPOSITES
AEROSPACE
HISTORY
1950 ndash Boeing
1960 ndash F14 Tomcat
1981 ndash AV-8B Harrier
Source
Low-Cost Composite Materials and Structures for Aircraft Applications
httpwwwreinforcedplasticscom
httpwwwcentennialofflightgovessayEvolution_of_TechnologycompositesTech40htm
Automotive
Composite material is used in a number of applications in the automotive
industry due to its temperature resistance rigidity and fatigue strength
The benefits of using composites include greater fuel efficiency
corrosion resistance light weight and strength Composites also provide
a low-cost way to help keep designs looking fresh
Composites are used in
- interior parts (cockpit trimming seats instrument panels)
- exterior structure (body panels openings underbody frontrear
modules)
- engine compartment and fuelmechanical area parts (axles and
suspensions fuel and exhaust systems)
- electrical and electronic components
Lamborghinis Sesto Element carbon fiber
ldquoFat men cannot run as fast as thin men but we build most of our vehicles as though dead-weight fat increased speedhellip I cannot
imagine where the delusion that weight means strength
came fromhelliprdquo mdashHenry Ford
The mix of automotive materials is changing showing a boost for FRP in helping original
equipment manufacturers meet fuel economy and emissions challenges
(Source 2011 DuPont AutomotiveSAE survey of design engineers performed by Signet Research Inc)
Source
httpwwwtoraycomcsrhighlight2009hig_001_01html
The MonoCell tub for the McLaren MP4-12C supercar is moulded as a single
piece and weighs less than 80 kg (176 lbs)
COMPOSITES IN MARINE
TRIMARAN BOAT
AMERICA NAVYINDONESIAN NAVY
Visby Class corvette
Total length is 72 meters
The beam is 1040 meters
The displacement is 600 metric tones
fully equipped the worlds largest CRP
construction
The design of the Visby aims to minimize
the optical and infrared signature above
water acoustic and hydroa coustic
signature underwater electrical potential
and magnetic signature pressure signature
radar cross section and actively emitted
signals
A stealth corvette of the YS 2000 design
has a detection range of 13km in rough
seas and 22km in calm sea without
jamming In a jammed environment the
Visby would be detected at a range of 8km
in rough sea and 11km in calm sea
The material provides high strength and
rigidity low weight good shock resistance
low radar and magnetic signature
1996
Visby is a class of stealth corvettes for the Swedish Navy
ldquoReduced 50 of a Conventional Steelrdquo
Source
Hull Construction with composite materials for ships over 100m in length 2002
Massachusetts Institute of Technology
httpwwwnaval-technologycomprojectsvisby
YACHTS
KAL YUDISTIRAMARATHON 100 ADMIRAL YACHT
LOA 3050 MWidth 6 MFuel Tank 8000 LWater Tank 3000 LIce Box 500 LAccommodation Max 35 Personnel
2 x CATERPILLAR 3412E 1200 HPMARINE DIESEL ENGINE
PC 40 ndash KRI Krait 827Department of Indonesian Navy
LOA 40 MWidth 73 MPower 190Weapon Twin Cannon Barrels
127 mm Heavy Machine GunSpeed Knot 25 KnotDisplacement 105 tonAccommodation 23 personnel
PATROL BOAT
Rigid Inflatable BoatPATROL BOAT
Yachts
36m Luxury Yacht Moonraker
36m Luxury Yacht GoldenEye
50m Luxury Yacht Casino
Royale
45m Luxury Yacht Seashaw
Boat Parts
Barovans for Seismic Sweep
Centrifugal Liftfan House for Surface Effect
Ships
Composite Boat PropellersRTM
Deckhouses for Pilot Boats
Fairing Parts for Submarines
Flybridges for Motor yachts
Light Weight Gangway
MTB Launcher Mock-up
Pleasure Boats
12m Sailboat
12m Sail-Catamaranone-off
Canoes
Dragonfly 1000Catamaran Sailboat
Fantasy 37Sailboat
Farr 60Luxury Sailboat
EurodingyOlympic Dingy Class for
Woman
Hydrolift F23 Racing Boats
Kajacs
Najad 42Sailboat
Najad 520Sailboat
Najad 441Sailboat
Najad 391Sailboat
Nordwest 900Motorboat
Nordwest 1100Motorboat
Quatro 44Motorboat
Racemaster Competition Boats
Storebro 420
Storebro 345
Sweden Yacht 370Sailboat
Sweden Yacht 69Sailboat
Windy 41Motorboat
X-632Sailboat
X-362Sailboat
Commercial Boats
175m High Speed AmbulancePassenger Boat
19m High Speed Passenger Boat
20m High Speed Passenger Boat
364m Surface Effect Passenger Ship
45m Surface Effect Passenger Ship
120m Hull Structural Parts HSSS Catamaran Ferry
APPENDIX
Marine Vessel
1188m Fast Attack Vessel FMV 90 E
20m SAV-Surface Auxiliary Vessels
34m Personnel TransportCoast Guard Vessel
40ft Experimental SES
40m Landsort-Class Mine Hunters
54m Mine Counter Measure Vehicles SES
74m Coastal Patrol Boats
Fishing Boats
30 GT
12 GT
10 GT
5 GT
WISEWings In Surface Effect
HOVERCRAFT
Designed specifically for the tourist and transport industries the
Pioneer Mk3 hovercraft is amphibious and comfortably seats 25
passengers plus 1-crew The air-conditioned cabin allows for
maximum visibility for all aboard The Pioneer Mk3 is robust and
dynamic in its performance
Commercial hovercraft
Mk3 AirLift Hovercraft - 1215m
Power is economicaly provided by one Deutz diesel engine of
330kW (442hp) to cruise easily at 40 knots with much higher
speeds available according to the surface conditions The hull is
manufactured from fibreglassPVC foam composite sandwich
the windows are glass and the skirt is urethane coated nylon A
Military version is available with increased payload and systems
redundancy Power for the Military version comes from two Steyr
diesel engines with a total installed power of 320kW (429hp) All
transmission electrical hydraulic and air systems are duplicated
for maximum redundancy The increased performance of the
Military version comes from the reduced engine weight of the twin
Steyr installation cf the Deutz installation
Source
httpwwwnauticexpocomprodairlift-hovercraftcommercial-hovercrafts-25251-142868html
HOVERFLIGHT
BALLISTIC amp UNIT DEFENCED
Triaxis Composites Collaboration with Institute of Aeronautics and Space in the development of Missile Nose Cone
Polymer composites is the evolution of the military defence
Thin steel was the helmet material of
WWII and remained the principal material until around the 1980rsquos
The advantages of using steel
included a simple technology for manufacture of the helmets low cost and reasonably good
impact protection However these helmets were found to provide only marginal protection
against fragments
During the Vietnam War the US Army experimented with fiber-reinforced inserts in the
helmets These inserts improved ballistic protection but at the same time added weight and
reduced the air space between the head and the helmet
By the early part of the 1980rsquos the US military had developed the first all-composite
100 fiber-reinforced helmet This development resulted in even better ballistic protection
without altering the weight of the helmet Other improvements included better head coverage and
more space for ventilation
Source
Composites Armor - A difficult but huge market
by A Brent Strong Brigham Young University
MILITARY VEHICLES
HIGH SPEED TRAIN SHINKANSEN
Advanced Composites provide lightweight solutions for railway vehicles
saving as much as 50-80 of the weight compared with traditional
components
A lower overall weight translates into less stress faster acceleration and
higher speeds as well as reduced starting and stopping inertia Today
these are important criteria in global high-speed and metropolitan
railway projects
Fire smoke and toxic fumes are key safety criteria for interior
components of railway carriages Any material selected for an interior
component must meet international fire retardant standards
for Rail Interiors and Exteriors
Ceiling Panels Stairs
Seating Vestibules
Window Panels Door Pillars
Partition WallsDiffusers
Gangway and Cabinet Panels Cabin and
Desk panels
Door Pillars Lavatory Modules (standard and
Front and Rear EndsRoof Panels
Nose Cones Under Fairings
Source
httpwwwpctaerail_compositesphp
101
SKY BUS
2009
Europe is the world leader in offshore wind with
828 wind turbines and a cumulative capacity of 2056 MW spread across 38 offshore wind farms in 9
European countries
The UK and Denmark are the current leaders with a 44 and 30 share respectively In 2009
five countries built new offshore wind farms
UK (284 MW)
Demark (230 MW)
Sweden (30 MW)
Germany (30 MW)
Norway (23 MW)
2010
Asia leads the growth in global wind power which grew 358 GW in 2010 bringing
total global capacity to 1944 GW ndash up 225 from 2009
the Global Wind Energy Council (GWEC)
Asia accounted for 19 GW of new global wind power installations driven by China which installed 165
GW
ldquoChina now has 423 GW of wind powerrdquo
ldquoThis puts China firmly on a path to reach 200 GW of installed wind power by 2020 At the same
time China has become the worldrsquos largest producer of wind energy equipmentrdquo
Source
httpwwwreinforcedplasticscomview15655asia-leads-global-wind-power-growth
httpimgdeusmcomdesignnews288288605-Sandia_Sizes_up_Wind_Turbine_Blade_Design_C_largegif
WIND ENERGY
Marine Current Turbines
Source
httpwwwsiemenscompressenpressreleasepress=enpressrelease2011solar-hydroex201111005htm
httpwwwmarineturbinescom
A commercial marine current turbine consists of
two rotors which are fixed on a structure within the
sea current The twin rotors rotate with the
movement of the tidal flow and the blades pitch
through 180 degrees to optimally track tidal current
(Press picture Marine Current Turbines)
Wave Star Energys Multi-point Absorber
CFRP COLUMN REINFORCEMENT
INDUSTRIAL TANKS
107
INDUSTRIAL PIPES
PRESSURE TANKS
109
ldquoLetrsquos Make with Compositesrdquo
10
Berdasarkan jenis matriks
bull Polymer matrix composites (PMC) Paling populer dengan beragam aplikasi
- Carbon fibre reinforced polymer
- Glass fibre reinforced polymer
- Metal fibre reinforced polymer
bull Metal matrix composites (MMC) Aerospace dan komponen mesin mobil
- Boron or carbon fibre reinforced Aluminium
- Alumina particle reinforced Aluminium
bull Ceramic matrix composites (CMC) Heat exhanger sistem pelindung panas komponen dengan lingkungan korosif dan erosif
- Zirconia in alumina
- Carbon fibre reinforced carbon
KLASIFIKASI MATERIAL KOMPOSIT
SERAT
(FIBER) +RESIN
(MATRIX) = COMPOSITES
bull GLASS (KACA)
bull CARBON
bull ARAMID
bull Fiberglass Reinforced Plastics
(FRP)
bull Carbon Fiber Reinforced Plastics
(CFRP)
bull Aramid Fiber Reinforced Plastics
POLYMER TECHNOLOGY COMPOSITES
bull POLYESTER
bull VINYLESTER
bull EPOXY
bull POLYPROPYLENE
bull POLYAMID
COMPOSITES BUATAN (ENGINEERED COMPOSITES) SEHARI-HARI
BETON = TULANGAN BESI + RESIN SEMEN
The Importance of Lightness for
Environmental Friendly Products
Mass Reduction for Less Energy Consumption
MATERIAL COMPOSITES
Thermoset
type
Density r
(kgm3)
Stiffnes
s E
(Gpa)
Tensile
strength
s (MPa)
Strain to
failure e
()
Tg 0C
Thermal
conductivity
k (Wm0C)
Specific
Heat Cp
(kJkg0C)
Thermal
expansion coeff
a (x106 0C-1)
Polyester 1100-1230 31-46 50-75 10-65 70- 017-022 13-23 55-100
Vinylester 1120-1130 31-33 70-81 30-80 70- - - -
Epoxy 1100-1200 26-38 60-85 15-80 65-175 017-020 105 45-65
Phenolic 1000-1250 30-40 60-80 18 300 012-024 14-18 25-60
PUR 1200 07 30-40 400-450 135 017-021 13-23 70-100
BMI 1200-1320 32-50 48-110 15-33 230-345 - - -
Polyimide 1430-1890 31-49 100-110 15-30 325-370 01-034 105-15 25-80
Al 2800 72 540 18 - 130 096 236
Steel 7790 205 640 25 - 54 046 11
MATRIKS POLIMER THERMOSET
Variasi sifat yang lebar disebabkan oleh adanya formulasi kimia yang berbeda dan penambahan aditif
Jenis Glass Fiber S Glass E Glass C Glass A Glass dll
Terms
Glass Type
S Glass E Glass C Glass A Glass
Silica (SiO2) Content 67 55 64 72
Al2O3 Content 23 14 6 1
Melting Point (Celcius) 915 836 745 745
Tensile Strength 665 500 440 440
Modulus Elastisitas 124 105 100 -
Application AEROSPACE BOAT CHEMICAL TANK CHEMICAL TANK
JENIS SERAT GLASS
CHINA
JENIS SERAT GLASS
C GLASS Calcium borosilicate glasses
used for CHEMICAL stability in corrosive
acid environments
E GLASS Alumina-calcium-borosilicate
glasses with a maximum alkali used as
general purpose fibers where STRENGTH
and high ELECTICAL RESISTIVITY are
required It manifests better electrical
insulation and strongly resists attack by
water More than 50 of the glass fibers
used for reinforcement is E-glass
C Glass
E Glass
C amp E GLASS
SUMBER AGY TECHNICAL PAPER HIGH STRENGTH GLASS FIBER
FAKTA
C GLASS 1 BOROS RESIN
2 KEKUATAN
KURANG
FAKTA
E GLASS 1 HEMAT RESIN
2 KEKUATAN BAIK
3 TAHAN LAMA
FAKTA
TEBAL BUKAN BERARTI KUAT
UNSUR MATRIX (RESIN)
TIDAK ADA KEKUATAN
ldquoMore than 50 of the glass fibers used for
reinforcement is E-glassrdquo
C glass E glass
E glass
C glass
KAIN WOVEN ROVING HASIL LAMINASI
JENIS SERAT GLASS
Kekuatan composites ditentukan oleh
1 Kekuatan amp Sifat Fiber
2 Kekuatan amp Sifat Resin
3 Fraksi Rasio Perbandingan Volume Fiber
dan Resin dalam Composites
rarr tergantung dari Proses Manufaktur
4 Geometri dan Orientasi Arah Fiber dalam
Composites
KEKUATAN COMPOSITES
PROSES MATERIAL
Proses Produksi Kain Fiberglass
Biji Kaca Benang Benang Kaca Kain Fiberglass
PROSES MATERIAL
Glass Beads
Glass Fiber Glass Roving YarnGlass Fabric
FIBERGLASS
PRODUK
MATERIAL DAN PRODUK FIBERGLASS
+
Resin + Additives
PERPADUAN COMPOSITES
BENANG KACA Potongan Serat Kaca CSM
CSM - CHOPPED STRAND MAT
chopped binder
Kain Fiberglass Generasi Pertama
BahanPengikat
SenyawaPada Resin
JENIS FIBERGLASS
Glass Roving Yarn Chopped Strand
ADVANTAGES DISADVANTAGES
Steel
1048707 Low cost 1048707 Corrodes easily
1048707 Ductile under ambient conditions
1048707 Has no lower fatigue limit for welded structures
1048707 Virtually isotropic 1048707 Heavy
1048707 Easily formed and fabricated 1048707 Brittle at low temperatures
1048707 Easily obtained (low relative cost) 1048707 Magnetic
1048707 Easily alloyed or heat treated for special operations
1048707 Easily repaired
1048707 Good fire resistance
1048707 Behaviour is well understood
Alumunium Alloy
1048707 Light weight 1048707 Poor fatigue properties
1048707 Corrosion resistant 1048707 Poor performance in fire
1048707 Easily formed1048707 Low melting point and softening temperature
1048707 Easily fabricated 1048707 High relative cost
1048707 Readily available 1048707 Strength and stiffness less than steel
1048707 Ductile
1048707 Non magnetic
FRP
1048707 Low magnetic properties
1048707 Low electrical conductivity (glass- reinforced plastics)
1048707 Resistance to corrosion
1048707 Resistance to rot and marine growth
1048707 Relatively high sonar transparency
1048707 Good strength to weight ratio
1048707 Good fatigue properties
1048707 Maintenance of properties at low temperatures
1048707 Availability
1048707 Can be manufactured to near net-shape
1048707 Stiffness and strength can be tailored to structural requirements
1048707 Excellent thermal insulation
1048707 Light weight
STEEL vs ALUMUNIUM vs COMPOSITES
Source
1Maritime Platforms Division Aeronautical and
Maritime Research Laboratory (Seref Aksu
Stuart Cannon Craig Gardiner and Matthew
Gudze
2 Metal Corrosion can be defined as the
destructive attack of a metal through interaction
with its environment
(httpwwwcorrosionistcomCorrosion_Fundament
alhtm)
28
Serat rarr penguat
Polimer matriks rarr pengikat
bull Sifat mekanik yang cukup baik
bull Viskositas dan temperatur pengerjaan rendah rarr mudah
dimanufaktur
bull Ketahanan korosi yang baik
bull Media perpindahan gaya rarr distribusi beban dari serat ke serat
bull Ulet rarr Melindungi serat yang getas
bull Size effect rarr Kekuatan dan kekakuan sangat tinggi
bull Aspect ratio (ld) tinggi rarr luas permukaan besar
bull Fleksibel rarr variasi teknik manufaktur
bull Serat dapat diatur sesuai dengan arah pembebanan
29
Advantages Polimer Composites
Kekuatan dan kekakuan spesifik yang tinggi FRCP vs material lain rarr kompetitif jika berat dipertimbangkan
Material Berat jenis
r (kgm3)
Kekakuan
E (GPa)
Kekuatan
tarik su
(MPa)
Kekakuan
spesifik
Er
Kekuatan
spesifik sur
Baja 7800 208 400 27 005
Aluminium 2700 70 200 259 007
Nylon 1100 25 80 23 007
Beton 2400 40 20 166 0008
Random
FRPC
1800 20 300 111 0006
Alligned FRPC
( serat)
1600 200 1500 125 094
Alligned FRCP
( serat)
1600 3 50 19 0001
Tensile Strength amp Modulus of Common Structural Materials
Densities of Common Structural Materials
Specific Tensile Strength amp Modulus of Common Structural Materials
Typical Properties of Common Structural Materials
Kesimpulan COMPOSITES = RINGAN amp KUAT
Jadi secara keseluruhan kekuatan composites
ditentukan oleh
1 Kekuatan amp Sifat Fiber
2 Kekuatan amp Sifat Resin
3 Fraksi Rasio Perbandingan Volume Fiber
dan Resin dalam Composites
4 Geometri dan Orientasi Arah Fiber dalam
Composites
PRODUKSI ANAK NEGERI
Proses Produksi Kain Fiberglass
Biji Kaca Benang Benang Kaca Kain Fiberglass
PROSES MATERIAL
Glass Beads
Glass Fiber Glass Roving YarnGlass Fabric
Proses Produksi Kain Fiberglass
Biji Kaca Benang Benang Kaca Kain Fiberglass
Glass Beads
Glass Fiber Glass Roving YarnGlass Fabric
PROSES MATERIAL
Benang Kaca Potongan Serat Kaca Chopped Strand Mat
CSM - Chopped Strand Mat
chopped binder
Produk Fiberglass Generasi Pertama
Bahan Pengikat
Senyawa Pada Resin
Glass Roving Yarn Chopped Strand
JENIS FIBERGLASS
Benang Kaca Woven Roving
WR - Woven Roving
Tenun Weaving
Produk Fiberglass Generasi Kedua
Glass Roving Yarn
JENIS FIBERGLASS
Multiaxial
MAX - Multiaxial
warp knitting
Produk Fiberglass Generasi Ketiga
Benang Kaca
Glass Roving Yarn
JENIS FIBERGLASS
MAX - Multiaxial Fabric
Fleece (optional)
Lapisan
MULTIAXIAL PROSES
Karakteristik CSM
bull Glass Content 30
bull Resin Content 70
bull Tensile Force
Chopped Strand Mat
JENIS FIBERGLASS
Karakteristik Woven Roving
bull Glass Content 45
bull Resin Content 55
Woven Roving
Resin
|
|
|
|
|
|
|
|
|
|
|
|
|
|
bull Kekuatan Tarik
JENIS FIBERGLASS
No Resin Rich Area
Karakteristik Multiaxial
bull Glass Content 60
bull Resin Content 40
Produk Fiberglass Ketiga MULTIAXIAL
JENIS FIBERGLASS
Perbedaan Woven Roving dan Multiaxial ndash Tampak Samping
JENIS FIBERGLASS
WR FRP
8 Ply WR 800
8 Ply CSM 450
Glass Weight 1 kg
Composite Weight 15kgm2
CSM FRP
22 Ply CSM 450
Glass Weight 1 kg
Composite Weight 18 kgm2
MULTIAXIAL FRP
13 Ply DB 800
Glass Weight 1 kg
Composite Weight
13 kgm2
JENIS FIBERGLASS
Multiaxial
FRP
Woven Roving
FRP
Chopped Strands Mat FRP
MULTIAXIAL
FAKTA
TEBAL BUKAN BERARTI KUAT
UNSUR MATRIX (RESIN)
TIDAK ADA KEKUATAN
ldquoMore than 50 of the glass fibers used for reinforcement is
E-glassrdquo
KarakteristikKekuatan
CSM WR MAX
Kekuatan Tarik 175 MPa 250 MPa 425 MPa
CSM 142
WR 70
KEKUATAN TARIK
Properties CSM Lamination WR Lamination MAX Lamination
Fabric Weight (kgm2) 1 1 1
Composite Weight (kgm2) 18 15 13
Resin usage (kgm2) 15 1 08
Amount of Fabric 22 Ply 16 Ply 13 Ply
Thickness 15 mm 12 mm 10 mm
Tensile Strength (Mpa) 125 1796 400
Tensile Strength (Nmmsup2) 28463 30958 4576
Processing Time High Med Low
Labour Cost High Med Low
MULTIAXIAL
Total Penggunaan Resin -51
Total Berat Kapal -40
Kekuatan Bangunan Kapal +59
Efisiensi Tenaga Kerja
Waktu Pengerjaan Lebih Cepat
KEUNGGULAN MATERIAL
Resapan Resin Lebih Baik amp Merata
Lapisan Lebih Sedikit
Meningkatkan Kekuatan Kapal
KEUNGGULAN MATERIAL
TRIAXIAL
DBL series DBT series
BIAXIAL
LT series DB series
UNIDIRECTIONAL
L series T series
QUADRIAXIAL
DBLT series
JENIS MULTIAXIAL
UNIDIRECTIONAL
DCMU 900 E ndash
KHUSUS UNTUK MEMPERKUAT BENDING KAPAL
PEMASANGAN KHUSUS PADA KEEL DAN TULANGAN
JENIS MULTIAXIAL UNTUK KAPAL
TRIAXIAL
DBL 600 ndash
APLIKASI PADA INDUSTRI PENERBANGAN
PEMASANGAN KHUSUS PADA
SAMBUNGAN BADAN DAN SAYAP
PESAWAT
JENIS MULTIAXIAL UNTUK PESAWAT
QUADRAXIAL
DBLT 800 ndash
APLIKASI PADA INDUSTRI ENERGI
DITERAPKAN UNTUK KEBUTUHAN PEMBANGKIT
LISTRIK ENERGI ANGIN
MULTIAXIAL UNTUK ENERGI
INDUSTRI KIMIA OLAHRAGA AUTOMOTIF
MULTIAXIAL UNTUK INDUSTRI LAINNYA
COMPOSITES
GUNAKAN MATERIAL FIBERGLASS
YANG SUDAH DISERTIFIKASI
BKI
FIBERGLASS UNTUK PEMBANGUNAN BAKAP
PERATURAN MENTERI PERHUBUNGAN
NOMOR PM 7 TAHUN 2013
TENTANG KEWAJIBAN KLASIFIKASI BAGI KAPAL BERBENDERA INDONESIA
PADA BADAN KLASIFIKASI
BADAN SERTIFIKASI MARITIM
Biro Klasifikasi IndonesiaDet Norske Veritas Germanischer Lloyds
PERATURAN BKI
Untuk Kapal Non-Metal
2006
PERSYARATAN MINIMUM
kekuatan material yang
harus digunakan
untuk membangun
Kapal Fiberglass
PEMBESARAN
Table 21
FIBERGLASS TRIAXIS COMPOSITES
TELAH BERSERTIFIKASI BKI
Biro Klasifikasi Indonesia
65
TEKNIK MANUFAKTUR
COMPOSITES
Wet hand lay-up
1) Peletakan
Dry Reinforcement
bull Dry reinforcement dan resin (+ katalis) ditaruh pada permukaan cetakan
2) Pemasukanpenekanan resin
bull Resin ditekan untuk meng-impregnasi serat dengan menggunakan rol
3) Pengulangan proses untuk lapisan lain
bull Beberapa lapisan dapat ditambahkan secara bertahap
4) Resin curing
bull Reaksi dimulai komponen dilepaskan setelah komponen mengeras
(fully cured)
Wet hand lay-up
Manufaktur komponen dapat dikerjakan dengan menggunakan beberapa lapis komposit
dengan memperhatikan kompatibilitas material dan tahapan curing Modifikasi proses dapat
dilakukan seperti
Vacuum bagging
setelah lay-up
Glass Roving
Bulk Resin
Catalyst
3) De-molding
2) Resin Cure
bull Curing dimulai dan komponen dilepaskan setelah pengerasan selesai
bull Serat gelas resin dan katalis dimasukkan kedalam spray gun
1) Spray-up
bull Campuran disemprotkan pada permukaan cetakan
Spray-up
69
Penyemprotan bakal komponen
Komponen
dilepaskan
dari cetakan
Full dispensing
system Chopper Roving
Atomised resin
and catalyst
Spray-up
Prepreg
1) LaminateAssembly 5) De-molding
3) Resin Melts Layup Consolidates
bull Prepreg serat yang sudah diimpregnasi oleh resin+katalis dalam kondisi padat
bull Lapisan prepreg digunting sesuai bentuk yang diinginkan kemudian diletakkan pada permukaan cetakan
sesuai bentuk komponen yang diinginkan Lay-up mudah dilakukan karena sifat ldquotackynessrdquo dari prepreg
2) Applied Vacuum Pressure and Heat
bull Tekanan dan panas diberikan resin mencair terjadi konsolidasi pada komponen
4) Resin Cures
bull Temperatur dinaikkan untuk memulai curing
Prepreg
Variasi proses Autoclave
Komponen dalam
vacuum-bag
bull Campuran resin (+katalis) dan chopped glass strands diperoleh dalam bentuk premixed compound Bulk molding
Compound (BMC) dalam bentuk adonan atau Sheet molding Compound (SMC) dalam bentuk lembaran
bull Ketika panas dan tekanan diberikan oleh cetakan compound mengalir sesuai bentuk komponen yang diinginkan
1) Placement of Charge
5) De-molding3) Squeeze to final dimensions
2) Mould Closure4) Resin Cure
bull Curing dimulai komponen dilepaskan setelah terjadi pengerasan yang cukup
Compression Molding
bull Preform atau dry reinforcement dimasukkan kedalam cetakan sesuai dengan bentuk komponen yang
diinginkan
bull Resin mengalir dengan penekanan atau pem-vakuman dan meng-impregnasi preform dan
mendorongmengeluarkan udara yang ada dalam preform
1) Preform Manufacture
2) Preform Compression
5) De-molding3) Resin Injection
4) Resin Cure
bull Curing terjadi cetakan dibuka setelah terjadi pengerasan yang mencukupi
Liquid Molding (RTM VARI VARTM)
Pultrusion
bull Dry roving or fabrics ditarik melalui bak berisi
campuran resin dan katalis
bull Campuran yang basah ditarik melalui cetakan
bull Sisa resin keluar cetakan
bull Pemanasan dilakukan untuk proses curing
bull Pendinginan dilakukan untuk mempercepat siklus
produksi
Cut-off
Cooling
Die sections
Resin bath
Fibre creel
Filament Winding
bull Dry roving ditarik melalui bak berisi campuran resin dan katalis
bull Wet roving digulungkan dalam keadaan tegang kepada mandrel
bull Kontrol mekanik dari pembawa serat mengatur orientasi peletakan serat pada
mandrel
INDUSTRI COMPOSITES
AEROSPACE
HISTORY
1950 ndash Boeing
1960 ndash F14 Tomcat
1981 ndash AV-8B Harrier
Source
Low-Cost Composite Materials and Structures for Aircraft Applications
httpwwwreinforcedplasticscom
httpwwwcentennialofflightgovessayEvolution_of_TechnologycompositesTech40htm
Automotive
Composite material is used in a number of applications in the automotive
industry due to its temperature resistance rigidity and fatigue strength
The benefits of using composites include greater fuel efficiency
corrosion resistance light weight and strength Composites also provide
a low-cost way to help keep designs looking fresh
Composites are used in
- interior parts (cockpit trimming seats instrument panels)
- exterior structure (body panels openings underbody frontrear
modules)
- engine compartment and fuelmechanical area parts (axles and
suspensions fuel and exhaust systems)
- electrical and electronic components
Lamborghinis Sesto Element carbon fiber
ldquoFat men cannot run as fast as thin men but we build most of our vehicles as though dead-weight fat increased speedhellip I cannot
imagine where the delusion that weight means strength
came fromhelliprdquo mdashHenry Ford
The mix of automotive materials is changing showing a boost for FRP in helping original
equipment manufacturers meet fuel economy and emissions challenges
(Source 2011 DuPont AutomotiveSAE survey of design engineers performed by Signet Research Inc)
Source
httpwwwtoraycomcsrhighlight2009hig_001_01html
The MonoCell tub for the McLaren MP4-12C supercar is moulded as a single
piece and weighs less than 80 kg (176 lbs)
COMPOSITES IN MARINE
TRIMARAN BOAT
AMERICA NAVYINDONESIAN NAVY
Visby Class corvette
Total length is 72 meters
The beam is 1040 meters
The displacement is 600 metric tones
fully equipped the worlds largest CRP
construction
The design of the Visby aims to minimize
the optical and infrared signature above
water acoustic and hydroa coustic
signature underwater electrical potential
and magnetic signature pressure signature
radar cross section and actively emitted
signals
A stealth corvette of the YS 2000 design
has a detection range of 13km in rough
seas and 22km in calm sea without
jamming In a jammed environment the
Visby would be detected at a range of 8km
in rough sea and 11km in calm sea
The material provides high strength and
rigidity low weight good shock resistance
low radar and magnetic signature
1996
Visby is a class of stealth corvettes for the Swedish Navy
ldquoReduced 50 of a Conventional Steelrdquo
Source
Hull Construction with composite materials for ships over 100m in length 2002
Massachusetts Institute of Technology
httpwwwnaval-technologycomprojectsvisby
YACHTS
KAL YUDISTIRAMARATHON 100 ADMIRAL YACHT
LOA 3050 MWidth 6 MFuel Tank 8000 LWater Tank 3000 LIce Box 500 LAccommodation Max 35 Personnel
2 x CATERPILLAR 3412E 1200 HPMARINE DIESEL ENGINE
PC 40 ndash KRI Krait 827Department of Indonesian Navy
LOA 40 MWidth 73 MPower 190Weapon Twin Cannon Barrels
127 mm Heavy Machine GunSpeed Knot 25 KnotDisplacement 105 tonAccommodation 23 personnel
PATROL BOAT
Rigid Inflatable BoatPATROL BOAT
Yachts
36m Luxury Yacht Moonraker
36m Luxury Yacht GoldenEye
50m Luxury Yacht Casino
Royale
45m Luxury Yacht Seashaw
Boat Parts
Barovans for Seismic Sweep
Centrifugal Liftfan House for Surface Effect
Ships
Composite Boat PropellersRTM
Deckhouses for Pilot Boats
Fairing Parts for Submarines
Flybridges for Motor yachts
Light Weight Gangway
MTB Launcher Mock-up
Pleasure Boats
12m Sailboat
12m Sail-Catamaranone-off
Canoes
Dragonfly 1000Catamaran Sailboat
Fantasy 37Sailboat
Farr 60Luxury Sailboat
EurodingyOlympic Dingy Class for
Woman
Hydrolift F23 Racing Boats
Kajacs
Najad 42Sailboat
Najad 520Sailboat
Najad 441Sailboat
Najad 391Sailboat
Nordwest 900Motorboat
Nordwest 1100Motorboat
Quatro 44Motorboat
Racemaster Competition Boats
Storebro 420
Storebro 345
Sweden Yacht 370Sailboat
Sweden Yacht 69Sailboat
Windy 41Motorboat
X-632Sailboat
X-362Sailboat
Commercial Boats
175m High Speed AmbulancePassenger Boat
19m High Speed Passenger Boat
20m High Speed Passenger Boat
364m Surface Effect Passenger Ship
45m Surface Effect Passenger Ship
120m Hull Structural Parts HSSS Catamaran Ferry
APPENDIX
Marine Vessel
1188m Fast Attack Vessel FMV 90 E
20m SAV-Surface Auxiliary Vessels
34m Personnel TransportCoast Guard Vessel
40ft Experimental SES
40m Landsort-Class Mine Hunters
54m Mine Counter Measure Vehicles SES
74m Coastal Patrol Boats
Fishing Boats
30 GT
12 GT
10 GT
5 GT
WISEWings In Surface Effect
HOVERCRAFT
Designed specifically for the tourist and transport industries the
Pioneer Mk3 hovercraft is amphibious and comfortably seats 25
passengers plus 1-crew The air-conditioned cabin allows for
maximum visibility for all aboard The Pioneer Mk3 is robust and
dynamic in its performance
Commercial hovercraft
Mk3 AirLift Hovercraft - 1215m
Power is economicaly provided by one Deutz diesel engine of
330kW (442hp) to cruise easily at 40 knots with much higher
speeds available according to the surface conditions The hull is
manufactured from fibreglassPVC foam composite sandwich
the windows are glass and the skirt is urethane coated nylon A
Military version is available with increased payload and systems
redundancy Power for the Military version comes from two Steyr
diesel engines with a total installed power of 320kW (429hp) All
transmission electrical hydraulic and air systems are duplicated
for maximum redundancy The increased performance of the
Military version comes from the reduced engine weight of the twin
Steyr installation cf the Deutz installation
Source
httpwwwnauticexpocomprodairlift-hovercraftcommercial-hovercrafts-25251-142868html
HOVERFLIGHT
BALLISTIC amp UNIT DEFENCED
Triaxis Composites Collaboration with Institute of Aeronautics and Space in the development of Missile Nose Cone
Polymer composites is the evolution of the military defence
Thin steel was the helmet material of
WWII and remained the principal material until around the 1980rsquos
The advantages of using steel
included a simple technology for manufacture of the helmets low cost and reasonably good
impact protection However these helmets were found to provide only marginal protection
against fragments
During the Vietnam War the US Army experimented with fiber-reinforced inserts in the
helmets These inserts improved ballistic protection but at the same time added weight and
reduced the air space between the head and the helmet
By the early part of the 1980rsquos the US military had developed the first all-composite
100 fiber-reinforced helmet This development resulted in even better ballistic protection
without altering the weight of the helmet Other improvements included better head coverage and
more space for ventilation
Source
Composites Armor - A difficult but huge market
by A Brent Strong Brigham Young University
MILITARY VEHICLES
HIGH SPEED TRAIN SHINKANSEN
Advanced Composites provide lightweight solutions for railway vehicles
saving as much as 50-80 of the weight compared with traditional
components
A lower overall weight translates into less stress faster acceleration and
higher speeds as well as reduced starting and stopping inertia Today
these are important criteria in global high-speed and metropolitan
railway projects
Fire smoke and toxic fumes are key safety criteria for interior
components of railway carriages Any material selected for an interior
component must meet international fire retardant standards
for Rail Interiors and Exteriors
Ceiling Panels Stairs
Seating Vestibules
Window Panels Door Pillars
Partition WallsDiffusers
Gangway and Cabinet Panels Cabin and
Desk panels
Door Pillars Lavatory Modules (standard and
Front and Rear EndsRoof Panels
Nose Cones Under Fairings
Source
httpwwwpctaerail_compositesphp
101
SKY BUS
2009
Europe is the world leader in offshore wind with
828 wind turbines and a cumulative capacity of 2056 MW spread across 38 offshore wind farms in 9
European countries
The UK and Denmark are the current leaders with a 44 and 30 share respectively In 2009
five countries built new offshore wind farms
UK (284 MW)
Demark (230 MW)
Sweden (30 MW)
Germany (30 MW)
Norway (23 MW)
2010
Asia leads the growth in global wind power which grew 358 GW in 2010 bringing
total global capacity to 1944 GW ndash up 225 from 2009
the Global Wind Energy Council (GWEC)
Asia accounted for 19 GW of new global wind power installations driven by China which installed 165
GW
ldquoChina now has 423 GW of wind powerrdquo
ldquoThis puts China firmly on a path to reach 200 GW of installed wind power by 2020 At the same
time China has become the worldrsquos largest producer of wind energy equipmentrdquo
Source
httpwwwreinforcedplasticscomview15655asia-leads-global-wind-power-growth
httpimgdeusmcomdesignnews288288605-Sandia_Sizes_up_Wind_Turbine_Blade_Design_C_largegif
WIND ENERGY
Marine Current Turbines
Source
httpwwwsiemenscompressenpressreleasepress=enpressrelease2011solar-hydroex201111005htm
httpwwwmarineturbinescom
A commercial marine current turbine consists of
two rotors which are fixed on a structure within the
sea current The twin rotors rotate with the
movement of the tidal flow and the blades pitch
through 180 degrees to optimally track tidal current
(Press picture Marine Current Turbines)
Wave Star Energys Multi-point Absorber
CFRP COLUMN REINFORCEMENT
INDUSTRIAL TANKS
107
INDUSTRIAL PIPES
PRESSURE TANKS
109
ldquoLetrsquos Make with Compositesrdquo
SERAT
(FIBER) +RESIN
(MATRIX) = COMPOSITES
bull GLASS (KACA)
bull CARBON
bull ARAMID
bull Fiberglass Reinforced Plastics
(FRP)
bull Carbon Fiber Reinforced Plastics
(CFRP)
bull Aramid Fiber Reinforced Plastics
POLYMER TECHNOLOGY COMPOSITES
bull POLYESTER
bull VINYLESTER
bull EPOXY
bull POLYPROPYLENE
bull POLYAMID
COMPOSITES BUATAN (ENGINEERED COMPOSITES) SEHARI-HARI
BETON = TULANGAN BESI + RESIN SEMEN
The Importance of Lightness for
Environmental Friendly Products
Mass Reduction for Less Energy Consumption
MATERIAL COMPOSITES
Thermoset
type
Density r
(kgm3)
Stiffnes
s E
(Gpa)
Tensile
strength
s (MPa)
Strain to
failure e
()
Tg 0C
Thermal
conductivity
k (Wm0C)
Specific
Heat Cp
(kJkg0C)
Thermal
expansion coeff
a (x106 0C-1)
Polyester 1100-1230 31-46 50-75 10-65 70- 017-022 13-23 55-100
Vinylester 1120-1130 31-33 70-81 30-80 70- - - -
Epoxy 1100-1200 26-38 60-85 15-80 65-175 017-020 105 45-65
Phenolic 1000-1250 30-40 60-80 18 300 012-024 14-18 25-60
PUR 1200 07 30-40 400-450 135 017-021 13-23 70-100
BMI 1200-1320 32-50 48-110 15-33 230-345 - - -
Polyimide 1430-1890 31-49 100-110 15-30 325-370 01-034 105-15 25-80
Al 2800 72 540 18 - 130 096 236
Steel 7790 205 640 25 - 54 046 11
MATRIKS POLIMER THERMOSET
Variasi sifat yang lebar disebabkan oleh adanya formulasi kimia yang berbeda dan penambahan aditif
Jenis Glass Fiber S Glass E Glass C Glass A Glass dll
Terms
Glass Type
S Glass E Glass C Glass A Glass
Silica (SiO2) Content 67 55 64 72
Al2O3 Content 23 14 6 1
Melting Point (Celcius) 915 836 745 745
Tensile Strength 665 500 440 440
Modulus Elastisitas 124 105 100 -
Application AEROSPACE BOAT CHEMICAL TANK CHEMICAL TANK
JENIS SERAT GLASS
CHINA
JENIS SERAT GLASS
C GLASS Calcium borosilicate glasses
used for CHEMICAL stability in corrosive
acid environments
E GLASS Alumina-calcium-borosilicate
glasses with a maximum alkali used as
general purpose fibers where STRENGTH
and high ELECTICAL RESISTIVITY are
required It manifests better electrical
insulation and strongly resists attack by
water More than 50 of the glass fibers
used for reinforcement is E-glass
C Glass
E Glass
C amp E GLASS
SUMBER AGY TECHNICAL PAPER HIGH STRENGTH GLASS FIBER
FAKTA
C GLASS 1 BOROS RESIN
2 KEKUATAN
KURANG
FAKTA
E GLASS 1 HEMAT RESIN
2 KEKUATAN BAIK
3 TAHAN LAMA
FAKTA
TEBAL BUKAN BERARTI KUAT
UNSUR MATRIX (RESIN)
TIDAK ADA KEKUATAN
ldquoMore than 50 of the glass fibers used for
reinforcement is E-glassrdquo
C glass E glass
E glass
C glass
KAIN WOVEN ROVING HASIL LAMINASI
JENIS SERAT GLASS
Kekuatan composites ditentukan oleh
1 Kekuatan amp Sifat Fiber
2 Kekuatan amp Sifat Resin
3 Fraksi Rasio Perbandingan Volume Fiber
dan Resin dalam Composites
rarr tergantung dari Proses Manufaktur
4 Geometri dan Orientasi Arah Fiber dalam
Composites
KEKUATAN COMPOSITES
PROSES MATERIAL
Proses Produksi Kain Fiberglass
Biji Kaca Benang Benang Kaca Kain Fiberglass
PROSES MATERIAL
Glass Beads
Glass Fiber Glass Roving YarnGlass Fabric
FIBERGLASS
PRODUK
MATERIAL DAN PRODUK FIBERGLASS
+
Resin + Additives
PERPADUAN COMPOSITES
BENANG KACA Potongan Serat Kaca CSM
CSM - CHOPPED STRAND MAT
chopped binder
Kain Fiberglass Generasi Pertama
BahanPengikat
SenyawaPada Resin
JENIS FIBERGLASS
Glass Roving Yarn Chopped Strand
ADVANTAGES DISADVANTAGES
Steel
1048707 Low cost 1048707 Corrodes easily
1048707 Ductile under ambient conditions
1048707 Has no lower fatigue limit for welded structures
1048707 Virtually isotropic 1048707 Heavy
1048707 Easily formed and fabricated 1048707 Brittle at low temperatures
1048707 Easily obtained (low relative cost) 1048707 Magnetic
1048707 Easily alloyed or heat treated for special operations
1048707 Easily repaired
1048707 Good fire resistance
1048707 Behaviour is well understood
Alumunium Alloy
1048707 Light weight 1048707 Poor fatigue properties
1048707 Corrosion resistant 1048707 Poor performance in fire
1048707 Easily formed1048707 Low melting point and softening temperature
1048707 Easily fabricated 1048707 High relative cost
1048707 Readily available 1048707 Strength and stiffness less than steel
1048707 Ductile
1048707 Non magnetic
FRP
1048707 Low magnetic properties
1048707 Low electrical conductivity (glass- reinforced plastics)
1048707 Resistance to corrosion
1048707 Resistance to rot and marine growth
1048707 Relatively high sonar transparency
1048707 Good strength to weight ratio
1048707 Good fatigue properties
1048707 Maintenance of properties at low temperatures
1048707 Availability
1048707 Can be manufactured to near net-shape
1048707 Stiffness and strength can be tailored to structural requirements
1048707 Excellent thermal insulation
1048707 Light weight
STEEL vs ALUMUNIUM vs COMPOSITES
Source
1Maritime Platforms Division Aeronautical and
Maritime Research Laboratory (Seref Aksu
Stuart Cannon Craig Gardiner and Matthew
Gudze
2 Metal Corrosion can be defined as the
destructive attack of a metal through interaction
with its environment
(httpwwwcorrosionistcomCorrosion_Fundament
alhtm)
28
Serat rarr penguat
Polimer matriks rarr pengikat
bull Sifat mekanik yang cukup baik
bull Viskositas dan temperatur pengerjaan rendah rarr mudah
dimanufaktur
bull Ketahanan korosi yang baik
bull Media perpindahan gaya rarr distribusi beban dari serat ke serat
bull Ulet rarr Melindungi serat yang getas
bull Size effect rarr Kekuatan dan kekakuan sangat tinggi
bull Aspect ratio (ld) tinggi rarr luas permukaan besar
bull Fleksibel rarr variasi teknik manufaktur
bull Serat dapat diatur sesuai dengan arah pembebanan
29
Advantages Polimer Composites
Kekuatan dan kekakuan spesifik yang tinggi FRCP vs material lain rarr kompetitif jika berat dipertimbangkan
Material Berat jenis
r (kgm3)
Kekakuan
E (GPa)
Kekuatan
tarik su
(MPa)
Kekakuan
spesifik
Er
Kekuatan
spesifik sur
Baja 7800 208 400 27 005
Aluminium 2700 70 200 259 007
Nylon 1100 25 80 23 007
Beton 2400 40 20 166 0008
Random
FRPC
1800 20 300 111 0006
Alligned FRPC
( serat)
1600 200 1500 125 094
Alligned FRCP
( serat)
1600 3 50 19 0001
Tensile Strength amp Modulus of Common Structural Materials
Densities of Common Structural Materials
Specific Tensile Strength amp Modulus of Common Structural Materials
Typical Properties of Common Structural Materials
Kesimpulan COMPOSITES = RINGAN amp KUAT
Jadi secara keseluruhan kekuatan composites
ditentukan oleh
1 Kekuatan amp Sifat Fiber
2 Kekuatan amp Sifat Resin
3 Fraksi Rasio Perbandingan Volume Fiber
dan Resin dalam Composites
4 Geometri dan Orientasi Arah Fiber dalam
Composites
PRODUKSI ANAK NEGERI
Proses Produksi Kain Fiberglass
Biji Kaca Benang Benang Kaca Kain Fiberglass
PROSES MATERIAL
Glass Beads
Glass Fiber Glass Roving YarnGlass Fabric
Proses Produksi Kain Fiberglass
Biji Kaca Benang Benang Kaca Kain Fiberglass
Glass Beads
Glass Fiber Glass Roving YarnGlass Fabric
PROSES MATERIAL
Benang Kaca Potongan Serat Kaca Chopped Strand Mat
CSM - Chopped Strand Mat
chopped binder
Produk Fiberglass Generasi Pertama
Bahan Pengikat
Senyawa Pada Resin
Glass Roving Yarn Chopped Strand
JENIS FIBERGLASS
Benang Kaca Woven Roving
WR - Woven Roving
Tenun Weaving
Produk Fiberglass Generasi Kedua
Glass Roving Yarn
JENIS FIBERGLASS
Multiaxial
MAX - Multiaxial
warp knitting
Produk Fiberglass Generasi Ketiga
Benang Kaca
Glass Roving Yarn
JENIS FIBERGLASS
MAX - Multiaxial Fabric
Fleece (optional)
Lapisan
MULTIAXIAL PROSES
Karakteristik CSM
bull Glass Content 30
bull Resin Content 70
bull Tensile Force
Chopped Strand Mat
JENIS FIBERGLASS
Karakteristik Woven Roving
bull Glass Content 45
bull Resin Content 55
Woven Roving
Resin
|
|
|
|
|
|
|
|
|
|
|
|
|
|
bull Kekuatan Tarik
JENIS FIBERGLASS
No Resin Rich Area
Karakteristik Multiaxial
bull Glass Content 60
bull Resin Content 40
Produk Fiberglass Ketiga MULTIAXIAL
JENIS FIBERGLASS
Perbedaan Woven Roving dan Multiaxial ndash Tampak Samping
JENIS FIBERGLASS
WR FRP
8 Ply WR 800
8 Ply CSM 450
Glass Weight 1 kg
Composite Weight 15kgm2
CSM FRP
22 Ply CSM 450
Glass Weight 1 kg
Composite Weight 18 kgm2
MULTIAXIAL FRP
13 Ply DB 800
Glass Weight 1 kg
Composite Weight
13 kgm2
JENIS FIBERGLASS
Multiaxial
FRP
Woven Roving
FRP
Chopped Strands Mat FRP
MULTIAXIAL
FAKTA
TEBAL BUKAN BERARTI KUAT
UNSUR MATRIX (RESIN)
TIDAK ADA KEKUATAN
ldquoMore than 50 of the glass fibers used for reinforcement is
E-glassrdquo
KarakteristikKekuatan
CSM WR MAX
Kekuatan Tarik 175 MPa 250 MPa 425 MPa
CSM 142
WR 70
KEKUATAN TARIK
Properties CSM Lamination WR Lamination MAX Lamination
Fabric Weight (kgm2) 1 1 1
Composite Weight (kgm2) 18 15 13
Resin usage (kgm2) 15 1 08
Amount of Fabric 22 Ply 16 Ply 13 Ply
Thickness 15 mm 12 mm 10 mm
Tensile Strength (Mpa) 125 1796 400
Tensile Strength (Nmmsup2) 28463 30958 4576
Processing Time High Med Low
Labour Cost High Med Low
MULTIAXIAL
Total Penggunaan Resin -51
Total Berat Kapal -40
Kekuatan Bangunan Kapal +59
Efisiensi Tenaga Kerja
Waktu Pengerjaan Lebih Cepat
KEUNGGULAN MATERIAL
Resapan Resin Lebih Baik amp Merata
Lapisan Lebih Sedikit
Meningkatkan Kekuatan Kapal
KEUNGGULAN MATERIAL
TRIAXIAL
DBL series DBT series
BIAXIAL
LT series DB series
UNIDIRECTIONAL
L series T series
QUADRIAXIAL
DBLT series
JENIS MULTIAXIAL
UNIDIRECTIONAL
DCMU 900 E ndash
KHUSUS UNTUK MEMPERKUAT BENDING KAPAL
PEMASANGAN KHUSUS PADA KEEL DAN TULANGAN
JENIS MULTIAXIAL UNTUK KAPAL
TRIAXIAL
DBL 600 ndash
APLIKASI PADA INDUSTRI PENERBANGAN
PEMASANGAN KHUSUS PADA
SAMBUNGAN BADAN DAN SAYAP
PESAWAT
JENIS MULTIAXIAL UNTUK PESAWAT
QUADRAXIAL
DBLT 800 ndash
APLIKASI PADA INDUSTRI ENERGI
DITERAPKAN UNTUK KEBUTUHAN PEMBANGKIT
LISTRIK ENERGI ANGIN
MULTIAXIAL UNTUK ENERGI
INDUSTRI KIMIA OLAHRAGA AUTOMOTIF
MULTIAXIAL UNTUK INDUSTRI LAINNYA
COMPOSITES
GUNAKAN MATERIAL FIBERGLASS
YANG SUDAH DISERTIFIKASI
BKI
FIBERGLASS UNTUK PEMBANGUNAN BAKAP
PERATURAN MENTERI PERHUBUNGAN
NOMOR PM 7 TAHUN 2013
TENTANG KEWAJIBAN KLASIFIKASI BAGI KAPAL BERBENDERA INDONESIA
PADA BADAN KLASIFIKASI
BADAN SERTIFIKASI MARITIM
Biro Klasifikasi IndonesiaDet Norske Veritas Germanischer Lloyds
PERATURAN BKI
Untuk Kapal Non-Metal
2006
PERSYARATAN MINIMUM
kekuatan material yang
harus digunakan
untuk membangun
Kapal Fiberglass
PEMBESARAN
Table 21
FIBERGLASS TRIAXIS COMPOSITES
TELAH BERSERTIFIKASI BKI
Biro Klasifikasi Indonesia
65
TEKNIK MANUFAKTUR
COMPOSITES
Wet hand lay-up
1) Peletakan
Dry Reinforcement
bull Dry reinforcement dan resin (+ katalis) ditaruh pada permukaan cetakan
2) Pemasukanpenekanan resin
bull Resin ditekan untuk meng-impregnasi serat dengan menggunakan rol
3) Pengulangan proses untuk lapisan lain
bull Beberapa lapisan dapat ditambahkan secara bertahap
4) Resin curing
bull Reaksi dimulai komponen dilepaskan setelah komponen mengeras
(fully cured)
Wet hand lay-up
Manufaktur komponen dapat dikerjakan dengan menggunakan beberapa lapis komposit
dengan memperhatikan kompatibilitas material dan tahapan curing Modifikasi proses dapat
dilakukan seperti
Vacuum bagging
setelah lay-up
Glass Roving
Bulk Resin
Catalyst
3) De-molding
2) Resin Cure
bull Curing dimulai dan komponen dilepaskan setelah pengerasan selesai
bull Serat gelas resin dan katalis dimasukkan kedalam spray gun
1) Spray-up
bull Campuran disemprotkan pada permukaan cetakan
Spray-up
69
Penyemprotan bakal komponen
Komponen
dilepaskan
dari cetakan
Full dispensing
system Chopper Roving
Atomised resin
and catalyst
Spray-up
Prepreg
1) LaminateAssembly 5) De-molding
3) Resin Melts Layup Consolidates
bull Prepreg serat yang sudah diimpregnasi oleh resin+katalis dalam kondisi padat
bull Lapisan prepreg digunting sesuai bentuk yang diinginkan kemudian diletakkan pada permukaan cetakan
sesuai bentuk komponen yang diinginkan Lay-up mudah dilakukan karena sifat ldquotackynessrdquo dari prepreg
2) Applied Vacuum Pressure and Heat
bull Tekanan dan panas diberikan resin mencair terjadi konsolidasi pada komponen
4) Resin Cures
bull Temperatur dinaikkan untuk memulai curing
Prepreg
Variasi proses Autoclave
Komponen dalam
vacuum-bag
bull Campuran resin (+katalis) dan chopped glass strands diperoleh dalam bentuk premixed compound Bulk molding
Compound (BMC) dalam bentuk adonan atau Sheet molding Compound (SMC) dalam bentuk lembaran
bull Ketika panas dan tekanan diberikan oleh cetakan compound mengalir sesuai bentuk komponen yang diinginkan
1) Placement of Charge
5) De-molding3) Squeeze to final dimensions
2) Mould Closure4) Resin Cure
bull Curing dimulai komponen dilepaskan setelah terjadi pengerasan yang cukup
Compression Molding
bull Preform atau dry reinforcement dimasukkan kedalam cetakan sesuai dengan bentuk komponen yang
diinginkan
bull Resin mengalir dengan penekanan atau pem-vakuman dan meng-impregnasi preform dan
mendorongmengeluarkan udara yang ada dalam preform
1) Preform Manufacture
2) Preform Compression
5) De-molding3) Resin Injection
4) Resin Cure
bull Curing terjadi cetakan dibuka setelah terjadi pengerasan yang mencukupi
Liquid Molding (RTM VARI VARTM)
Pultrusion
bull Dry roving or fabrics ditarik melalui bak berisi
campuran resin dan katalis
bull Campuran yang basah ditarik melalui cetakan
bull Sisa resin keluar cetakan
bull Pemanasan dilakukan untuk proses curing
bull Pendinginan dilakukan untuk mempercepat siklus
produksi
Cut-off
Cooling
Die sections
Resin bath
Fibre creel
Filament Winding
bull Dry roving ditarik melalui bak berisi campuran resin dan katalis
bull Wet roving digulungkan dalam keadaan tegang kepada mandrel
bull Kontrol mekanik dari pembawa serat mengatur orientasi peletakan serat pada
mandrel
INDUSTRI COMPOSITES
AEROSPACE
HISTORY
1950 ndash Boeing
1960 ndash F14 Tomcat
1981 ndash AV-8B Harrier
Source
Low-Cost Composite Materials and Structures for Aircraft Applications
httpwwwreinforcedplasticscom
httpwwwcentennialofflightgovessayEvolution_of_TechnologycompositesTech40htm
Automotive
Composite material is used in a number of applications in the automotive
industry due to its temperature resistance rigidity and fatigue strength
The benefits of using composites include greater fuel efficiency
corrosion resistance light weight and strength Composites also provide
a low-cost way to help keep designs looking fresh
Composites are used in
- interior parts (cockpit trimming seats instrument panels)
- exterior structure (body panels openings underbody frontrear
modules)
- engine compartment and fuelmechanical area parts (axles and
suspensions fuel and exhaust systems)
- electrical and electronic components
Lamborghinis Sesto Element carbon fiber
ldquoFat men cannot run as fast as thin men but we build most of our vehicles as though dead-weight fat increased speedhellip I cannot
imagine where the delusion that weight means strength
came fromhelliprdquo mdashHenry Ford
The mix of automotive materials is changing showing a boost for FRP in helping original
equipment manufacturers meet fuel economy and emissions challenges
(Source 2011 DuPont AutomotiveSAE survey of design engineers performed by Signet Research Inc)
Source
httpwwwtoraycomcsrhighlight2009hig_001_01html
The MonoCell tub for the McLaren MP4-12C supercar is moulded as a single
piece and weighs less than 80 kg (176 lbs)
COMPOSITES IN MARINE
TRIMARAN BOAT
AMERICA NAVYINDONESIAN NAVY
Visby Class corvette
Total length is 72 meters
The beam is 1040 meters
The displacement is 600 metric tones
fully equipped the worlds largest CRP
construction
The design of the Visby aims to minimize
the optical and infrared signature above
water acoustic and hydroa coustic
signature underwater electrical potential
and magnetic signature pressure signature
radar cross section and actively emitted
signals
A stealth corvette of the YS 2000 design
has a detection range of 13km in rough
seas and 22km in calm sea without
jamming In a jammed environment the
Visby would be detected at a range of 8km
in rough sea and 11km in calm sea
The material provides high strength and
rigidity low weight good shock resistance
low radar and magnetic signature
1996
Visby is a class of stealth corvettes for the Swedish Navy
ldquoReduced 50 of a Conventional Steelrdquo
Source
Hull Construction with composite materials for ships over 100m in length 2002
Massachusetts Institute of Technology
httpwwwnaval-technologycomprojectsvisby
YACHTS
KAL YUDISTIRAMARATHON 100 ADMIRAL YACHT
LOA 3050 MWidth 6 MFuel Tank 8000 LWater Tank 3000 LIce Box 500 LAccommodation Max 35 Personnel
2 x CATERPILLAR 3412E 1200 HPMARINE DIESEL ENGINE
PC 40 ndash KRI Krait 827Department of Indonesian Navy
LOA 40 MWidth 73 MPower 190Weapon Twin Cannon Barrels
127 mm Heavy Machine GunSpeed Knot 25 KnotDisplacement 105 tonAccommodation 23 personnel
PATROL BOAT
Rigid Inflatable BoatPATROL BOAT
Yachts
36m Luxury Yacht Moonraker
36m Luxury Yacht GoldenEye
50m Luxury Yacht Casino
Royale
45m Luxury Yacht Seashaw
Boat Parts
Barovans for Seismic Sweep
Centrifugal Liftfan House for Surface Effect
Ships
Composite Boat PropellersRTM
Deckhouses for Pilot Boats
Fairing Parts for Submarines
Flybridges for Motor yachts
Light Weight Gangway
MTB Launcher Mock-up
Pleasure Boats
12m Sailboat
12m Sail-Catamaranone-off
Canoes
Dragonfly 1000Catamaran Sailboat
Fantasy 37Sailboat
Farr 60Luxury Sailboat
EurodingyOlympic Dingy Class for
Woman
Hydrolift F23 Racing Boats
Kajacs
Najad 42Sailboat
Najad 520Sailboat
Najad 441Sailboat
Najad 391Sailboat
Nordwest 900Motorboat
Nordwest 1100Motorboat
Quatro 44Motorboat
Racemaster Competition Boats
Storebro 420
Storebro 345
Sweden Yacht 370Sailboat
Sweden Yacht 69Sailboat
Windy 41Motorboat
X-632Sailboat
X-362Sailboat
Commercial Boats
175m High Speed AmbulancePassenger Boat
19m High Speed Passenger Boat
20m High Speed Passenger Boat
364m Surface Effect Passenger Ship
45m Surface Effect Passenger Ship
120m Hull Structural Parts HSSS Catamaran Ferry
APPENDIX
Marine Vessel
1188m Fast Attack Vessel FMV 90 E
20m SAV-Surface Auxiliary Vessels
34m Personnel TransportCoast Guard Vessel
40ft Experimental SES
40m Landsort-Class Mine Hunters
54m Mine Counter Measure Vehicles SES
74m Coastal Patrol Boats
Fishing Boats
30 GT
12 GT
10 GT
5 GT
WISEWings In Surface Effect
HOVERCRAFT
Designed specifically for the tourist and transport industries the
Pioneer Mk3 hovercraft is amphibious and comfortably seats 25
passengers plus 1-crew The air-conditioned cabin allows for
maximum visibility for all aboard The Pioneer Mk3 is robust and
dynamic in its performance
Commercial hovercraft
Mk3 AirLift Hovercraft - 1215m
Power is economicaly provided by one Deutz diesel engine of
330kW (442hp) to cruise easily at 40 knots with much higher
speeds available according to the surface conditions The hull is
manufactured from fibreglassPVC foam composite sandwich
the windows are glass and the skirt is urethane coated nylon A
Military version is available with increased payload and systems
redundancy Power for the Military version comes from two Steyr
diesel engines with a total installed power of 320kW (429hp) All
transmission electrical hydraulic and air systems are duplicated
for maximum redundancy The increased performance of the
Military version comes from the reduced engine weight of the twin
Steyr installation cf the Deutz installation
Source
httpwwwnauticexpocomprodairlift-hovercraftcommercial-hovercrafts-25251-142868html
HOVERFLIGHT
BALLISTIC amp UNIT DEFENCED
Triaxis Composites Collaboration with Institute of Aeronautics and Space in the development of Missile Nose Cone
Polymer composites is the evolution of the military defence
Thin steel was the helmet material of
WWII and remained the principal material until around the 1980rsquos
The advantages of using steel
included a simple technology for manufacture of the helmets low cost and reasonably good
impact protection However these helmets were found to provide only marginal protection
against fragments
During the Vietnam War the US Army experimented with fiber-reinforced inserts in the
helmets These inserts improved ballistic protection but at the same time added weight and
reduced the air space between the head and the helmet
By the early part of the 1980rsquos the US military had developed the first all-composite
100 fiber-reinforced helmet This development resulted in even better ballistic protection
without altering the weight of the helmet Other improvements included better head coverage and
more space for ventilation
Source
Composites Armor - A difficult but huge market
by A Brent Strong Brigham Young University
MILITARY VEHICLES
HIGH SPEED TRAIN SHINKANSEN
Advanced Composites provide lightweight solutions for railway vehicles
saving as much as 50-80 of the weight compared with traditional
components
A lower overall weight translates into less stress faster acceleration and
higher speeds as well as reduced starting and stopping inertia Today
these are important criteria in global high-speed and metropolitan
railway projects
Fire smoke and toxic fumes are key safety criteria for interior
components of railway carriages Any material selected for an interior
component must meet international fire retardant standards
for Rail Interiors and Exteriors
Ceiling Panels Stairs
Seating Vestibules
Window Panels Door Pillars
Partition WallsDiffusers
Gangway and Cabinet Panels Cabin and
Desk panels
Door Pillars Lavatory Modules (standard and
Front and Rear EndsRoof Panels
Nose Cones Under Fairings
Source
httpwwwpctaerail_compositesphp
101
SKY BUS
2009
Europe is the world leader in offshore wind with
828 wind turbines and a cumulative capacity of 2056 MW spread across 38 offshore wind farms in 9
European countries
The UK and Denmark are the current leaders with a 44 and 30 share respectively In 2009
five countries built new offshore wind farms
UK (284 MW)
Demark (230 MW)
Sweden (30 MW)
Germany (30 MW)
Norway (23 MW)
2010
Asia leads the growth in global wind power which grew 358 GW in 2010 bringing
total global capacity to 1944 GW ndash up 225 from 2009
the Global Wind Energy Council (GWEC)
Asia accounted for 19 GW of new global wind power installations driven by China which installed 165
GW
ldquoChina now has 423 GW of wind powerrdquo
ldquoThis puts China firmly on a path to reach 200 GW of installed wind power by 2020 At the same
time China has become the worldrsquos largest producer of wind energy equipmentrdquo
Source
httpwwwreinforcedplasticscomview15655asia-leads-global-wind-power-growth
httpimgdeusmcomdesignnews288288605-Sandia_Sizes_up_Wind_Turbine_Blade_Design_C_largegif
WIND ENERGY
Marine Current Turbines
Source
httpwwwsiemenscompressenpressreleasepress=enpressrelease2011solar-hydroex201111005htm
httpwwwmarineturbinescom
A commercial marine current turbine consists of
two rotors which are fixed on a structure within the
sea current The twin rotors rotate with the
movement of the tidal flow and the blades pitch
through 180 degrees to optimally track tidal current
(Press picture Marine Current Turbines)
Wave Star Energys Multi-point Absorber
CFRP COLUMN REINFORCEMENT
INDUSTRIAL TANKS
107
INDUSTRIAL PIPES
PRESSURE TANKS
109
ldquoLetrsquos Make with Compositesrdquo
COMPOSITES BUATAN (ENGINEERED COMPOSITES) SEHARI-HARI
BETON = TULANGAN BESI + RESIN SEMEN
The Importance of Lightness for
Environmental Friendly Products
Mass Reduction for Less Energy Consumption
MATERIAL COMPOSITES
Thermoset
type
Density r
(kgm3)
Stiffnes
s E
(Gpa)
Tensile
strength
s (MPa)
Strain to
failure e
()
Tg 0C
Thermal
conductivity
k (Wm0C)
Specific
Heat Cp
(kJkg0C)
Thermal
expansion coeff
a (x106 0C-1)
Polyester 1100-1230 31-46 50-75 10-65 70- 017-022 13-23 55-100
Vinylester 1120-1130 31-33 70-81 30-80 70- - - -
Epoxy 1100-1200 26-38 60-85 15-80 65-175 017-020 105 45-65
Phenolic 1000-1250 30-40 60-80 18 300 012-024 14-18 25-60
PUR 1200 07 30-40 400-450 135 017-021 13-23 70-100
BMI 1200-1320 32-50 48-110 15-33 230-345 - - -
Polyimide 1430-1890 31-49 100-110 15-30 325-370 01-034 105-15 25-80
Al 2800 72 540 18 - 130 096 236
Steel 7790 205 640 25 - 54 046 11
MATRIKS POLIMER THERMOSET
Variasi sifat yang lebar disebabkan oleh adanya formulasi kimia yang berbeda dan penambahan aditif
Jenis Glass Fiber S Glass E Glass C Glass A Glass dll
Terms
Glass Type
S Glass E Glass C Glass A Glass
Silica (SiO2) Content 67 55 64 72
Al2O3 Content 23 14 6 1
Melting Point (Celcius) 915 836 745 745
Tensile Strength 665 500 440 440
Modulus Elastisitas 124 105 100 -
Application AEROSPACE BOAT CHEMICAL TANK CHEMICAL TANK
JENIS SERAT GLASS
CHINA
JENIS SERAT GLASS
C GLASS Calcium borosilicate glasses
used for CHEMICAL stability in corrosive
acid environments
E GLASS Alumina-calcium-borosilicate
glasses with a maximum alkali used as
general purpose fibers where STRENGTH
and high ELECTICAL RESISTIVITY are
required It manifests better electrical
insulation and strongly resists attack by
water More than 50 of the glass fibers
used for reinforcement is E-glass
C Glass
E Glass
C amp E GLASS
SUMBER AGY TECHNICAL PAPER HIGH STRENGTH GLASS FIBER
FAKTA
C GLASS 1 BOROS RESIN
2 KEKUATAN
KURANG
FAKTA
E GLASS 1 HEMAT RESIN
2 KEKUATAN BAIK
3 TAHAN LAMA
FAKTA
TEBAL BUKAN BERARTI KUAT
UNSUR MATRIX (RESIN)
TIDAK ADA KEKUATAN
ldquoMore than 50 of the glass fibers used for
reinforcement is E-glassrdquo
C glass E glass
E glass
C glass
KAIN WOVEN ROVING HASIL LAMINASI
JENIS SERAT GLASS
Kekuatan composites ditentukan oleh
1 Kekuatan amp Sifat Fiber
2 Kekuatan amp Sifat Resin
3 Fraksi Rasio Perbandingan Volume Fiber
dan Resin dalam Composites
rarr tergantung dari Proses Manufaktur
4 Geometri dan Orientasi Arah Fiber dalam
Composites
KEKUATAN COMPOSITES
PROSES MATERIAL
Proses Produksi Kain Fiberglass
Biji Kaca Benang Benang Kaca Kain Fiberglass
PROSES MATERIAL
Glass Beads
Glass Fiber Glass Roving YarnGlass Fabric
FIBERGLASS
PRODUK
MATERIAL DAN PRODUK FIBERGLASS
+
Resin + Additives
PERPADUAN COMPOSITES
BENANG KACA Potongan Serat Kaca CSM
CSM - CHOPPED STRAND MAT
chopped binder
Kain Fiberglass Generasi Pertama
BahanPengikat
SenyawaPada Resin
JENIS FIBERGLASS
Glass Roving Yarn Chopped Strand
ADVANTAGES DISADVANTAGES
Steel
1048707 Low cost 1048707 Corrodes easily
1048707 Ductile under ambient conditions
1048707 Has no lower fatigue limit for welded structures
1048707 Virtually isotropic 1048707 Heavy
1048707 Easily formed and fabricated 1048707 Brittle at low temperatures
1048707 Easily obtained (low relative cost) 1048707 Magnetic
1048707 Easily alloyed or heat treated for special operations
1048707 Easily repaired
1048707 Good fire resistance
1048707 Behaviour is well understood
Alumunium Alloy
1048707 Light weight 1048707 Poor fatigue properties
1048707 Corrosion resistant 1048707 Poor performance in fire
1048707 Easily formed1048707 Low melting point and softening temperature
1048707 Easily fabricated 1048707 High relative cost
1048707 Readily available 1048707 Strength and stiffness less than steel
1048707 Ductile
1048707 Non magnetic
FRP
1048707 Low magnetic properties
1048707 Low electrical conductivity (glass- reinforced plastics)
1048707 Resistance to corrosion
1048707 Resistance to rot and marine growth
1048707 Relatively high sonar transparency
1048707 Good strength to weight ratio
1048707 Good fatigue properties
1048707 Maintenance of properties at low temperatures
1048707 Availability
1048707 Can be manufactured to near net-shape
1048707 Stiffness and strength can be tailored to structural requirements
1048707 Excellent thermal insulation
1048707 Light weight
STEEL vs ALUMUNIUM vs COMPOSITES
Source
1Maritime Platforms Division Aeronautical and
Maritime Research Laboratory (Seref Aksu
Stuart Cannon Craig Gardiner and Matthew
Gudze
2 Metal Corrosion can be defined as the
destructive attack of a metal through interaction
with its environment
(httpwwwcorrosionistcomCorrosion_Fundament
alhtm)
28
Serat rarr penguat
Polimer matriks rarr pengikat
bull Sifat mekanik yang cukup baik
bull Viskositas dan temperatur pengerjaan rendah rarr mudah
dimanufaktur
bull Ketahanan korosi yang baik
bull Media perpindahan gaya rarr distribusi beban dari serat ke serat
bull Ulet rarr Melindungi serat yang getas
bull Size effect rarr Kekuatan dan kekakuan sangat tinggi
bull Aspect ratio (ld) tinggi rarr luas permukaan besar
bull Fleksibel rarr variasi teknik manufaktur
bull Serat dapat diatur sesuai dengan arah pembebanan
29
Advantages Polimer Composites
Kekuatan dan kekakuan spesifik yang tinggi FRCP vs material lain rarr kompetitif jika berat dipertimbangkan
Material Berat jenis
r (kgm3)
Kekakuan
E (GPa)
Kekuatan
tarik su
(MPa)
Kekakuan
spesifik
Er
Kekuatan
spesifik sur
Baja 7800 208 400 27 005
Aluminium 2700 70 200 259 007
Nylon 1100 25 80 23 007
Beton 2400 40 20 166 0008
Random
FRPC
1800 20 300 111 0006
Alligned FRPC
( serat)
1600 200 1500 125 094
Alligned FRCP
( serat)
1600 3 50 19 0001
Tensile Strength amp Modulus of Common Structural Materials
Densities of Common Structural Materials
Specific Tensile Strength amp Modulus of Common Structural Materials
Typical Properties of Common Structural Materials
Kesimpulan COMPOSITES = RINGAN amp KUAT
Jadi secara keseluruhan kekuatan composites
ditentukan oleh
1 Kekuatan amp Sifat Fiber
2 Kekuatan amp Sifat Resin
3 Fraksi Rasio Perbandingan Volume Fiber
dan Resin dalam Composites
4 Geometri dan Orientasi Arah Fiber dalam
Composites
PRODUKSI ANAK NEGERI
Proses Produksi Kain Fiberglass
Biji Kaca Benang Benang Kaca Kain Fiberglass
PROSES MATERIAL
Glass Beads
Glass Fiber Glass Roving YarnGlass Fabric
Proses Produksi Kain Fiberglass
Biji Kaca Benang Benang Kaca Kain Fiberglass
Glass Beads
Glass Fiber Glass Roving YarnGlass Fabric
PROSES MATERIAL
Benang Kaca Potongan Serat Kaca Chopped Strand Mat
CSM - Chopped Strand Mat
chopped binder
Produk Fiberglass Generasi Pertama
Bahan Pengikat
Senyawa Pada Resin
Glass Roving Yarn Chopped Strand
JENIS FIBERGLASS
Benang Kaca Woven Roving
WR - Woven Roving
Tenun Weaving
Produk Fiberglass Generasi Kedua
Glass Roving Yarn
JENIS FIBERGLASS
Multiaxial
MAX - Multiaxial
warp knitting
Produk Fiberglass Generasi Ketiga
Benang Kaca
Glass Roving Yarn
JENIS FIBERGLASS
MAX - Multiaxial Fabric
Fleece (optional)
Lapisan
MULTIAXIAL PROSES
Karakteristik CSM
bull Glass Content 30
bull Resin Content 70
bull Tensile Force
Chopped Strand Mat
JENIS FIBERGLASS
Karakteristik Woven Roving
bull Glass Content 45
bull Resin Content 55
Woven Roving
Resin
|
|
|
|
|
|
|
|
|
|
|
|
|
|
bull Kekuatan Tarik
JENIS FIBERGLASS
No Resin Rich Area
Karakteristik Multiaxial
bull Glass Content 60
bull Resin Content 40
Produk Fiberglass Ketiga MULTIAXIAL
JENIS FIBERGLASS
Perbedaan Woven Roving dan Multiaxial ndash Tampak Samping
JENIS FIBERGLASS
WR FRP
8 Ply WR 800
8 Ply CSM 450
Glass Weight 1 kg
Composite Weight 15kgm2
CSM FRP
22 Ply CSM 450
Glass Weight 1 kg
Composite Weight 18 kgm2
MULTIAXIAL FRP
13 Ply DB 800
Glass Weight 1 kg
Composite Weight
13 kgm2
JENIS FIBERGLASS
Multiaxial
FRP
Woven Roving
FRP
Chopped Strands Mat FRP
MULTIAXIAL
FAKTA
TEBAL BUKAN BERARTI KUAT
UNSUR MATRIX (RESIN)
TIDAK ADA KEKUATAN
ldquoMore than 50 of the glass fibers used for reinforcement is
E-glassrdquo
KarakteristikKekuatan
CSM WR MAX
Kekuatan Tarik 175 MPa 250 MPa 425 MPa
CSM 142
WR 70
KEKUATAN TARIK
Properties CSM Lamination WR Lamination MAX Lamination
Fabric Weight (kgm2) 1 1 1
Composite Weight (kgm2) 18 15 13
Resin usage (kgm2) 15 1 08
Amount of Fabric 22 Ply 16 Ply 13 Ply
Thickness 15 mm 12 mm 10 mm
Tensile Strength (Mpa) 125 1796 400
Tensile Strength (Nmmsup2) 28463 30958 4576
Processing Time High Med Low
Labour Cost High Med Low
MULTIAXIAL
Total Penggunaan Resin -51
Total Berat Kapal -40
Kekuatan Bangunan Kapal +59
Efisiensi Tenaga Kerja
Waktu Pengerjaan Lebih Cepat
KEUNGGULAN MATERIAL
Resapan Resin Lebih Baik amp Merata
Lapisan Lebih Sedikit
Meningkatkan Kekuatan Kapal
KEUNGGULAN MATERIAL
TRIAXIAL
DBL series DBT series
BIAXIAL
LT series DB series
UNIDIRECTIONAL
L series T series
QUADRIAXIAL
DBLT series
JENIS MULTIAXIAL
UNIDIRECTIONAL
DCMU 900 E ndash
KHUSUS UNTUK MEMPERKUAT BENDING KAPAL
PEMASANGAN KHUSUS PADA KEEL DAN TULANGAN
JENIS MULTIAXIAL UNTUK KAPAL
TRIAXIAL
DBL 600 ndash
APLIKASI PADA INDUSTRI PENERBANGAN
PEMASANGAN KHUSUS PADA
SAMBUNGAN BADAN DAN SAYAP
PESAWAT
JENIS MULTIAXIAL UNTUK PESAWAT
QUADRAXIAL
DBLT 800 ndash
APLIKASI PADA INDUSTRI ENERGI
DITERAPKAN UNTUK KEBUTUHAN PEMBANGKIT
LISTRIK ENERGI ANGIN
MULTIAXIAL UNTUK ENERGI
INDUSTRI KIMIA OLAHRAGA AUTOMOTIF
MULTIAXIAL UNTUK INDUSTRI LAINNYA
COMPOSITES
GUNAKAN MATERIAL FIBERGLASS
YANG SUDAH DISERTIFIKASI
BKI
FIBERGLASS UNTUK PEMBANGUNAN BAKAP
PERATURAN MENTERI PERHUBUNGAN
NOMOR PM 7 TAHUN 2013
TENTANG KEWAJIBAN KLASIFIKASI BAGI KAPAL BERBENDERA INDONESIA
PADA BADAN KLASIFIKASI
BADAN SERTIFIKASI MARITIM
Biro Klasifikasi IndonesiaDet Norske Veritas Germanischer Lloyds
PERATURAN BKI
Untuk Kapal Non-Metal
2006
PERSYARATAN MINIMUM
kekuatan material yang
harus digunakan
untuk membangun
Kapal Fiberglass
PEMBESARAN
Table 21
FIBERGLASS TRIAXIS COMPOSITES
TELAH BERSERTIFIKASI BKI
Biro Klasifikasi Indonesia
65
TEKNIK MANUFAKTUR
COMPOSITES
Wet hand lay-up
1) Peletakan
Dry Reinforcement
bull Dry reinforcement dan resin (+ katalis) ditaruh pada permukaan cetakan
2) Pemasukanpenekanan resin
bull Resin ditekan untuk meng-impregnasi serat dengan menggunakan rol
3) Pengulangan proses untuk lapisan lain
bull Beberapa lapisan dapat ditambahkan secara bertahap
4) Resin curing
bull Reaksi dimulai komponen dilepaskan setelah komponen mengeras
(fully cured)
Wet hand lay-up
Manufaktur komponen dapat dikerjakan dengan menggunakan beberapa lapis komposit
dengan memperhatikan kompatibilitas material dan tahapan curing Modifikasi proses dapat
dilakukan seperti
Vacuum bagging
setelah lay-up
Glass Roving
Bulk Resin
Catalyst
3) De-molding
2) Resin Cure
bull Curing dimulai dan komponen dilepaskan setelah pengerasan selesai
bull Serat gelas resin dan katalis dimasukkan kedalam spray gun
1) Spray-up
bull Campuran disemprotkan pada permukaan cetakan
Spray-up
69
Penyemprotan bakal komponen
Komponen
dilepaskan
dari cetakan
Full dispensing
system Chopper Roving
Atomised resin
and catalyst
Spray-up
Prepreg
1) LaminateAssembly 5) De-molding
3) Resin Melts Layup Consolidates
bull Prepreg serat yang sudah diimpregnasi oleh resin+katalis dalam kondisi padat
bull Lapisan prepreg digunting sesuai bentuk yang diinginkan kemudian diletakkan pada permukaan cetakan
sesuai bentuk komponen yang diinginkan Lay-up mudah dilakukan karena sifat ldquotackynessrdquo dari prepreg
2) Applied Vacuum Pressure and Heat
bull Tekanan dan panas diberikan resin mencair terjadi konsolidasi pada komponen
4) Resin Cures
bull Temperatur dinaikkan untuk memulai curing
Prepreg
Variasi proses Autoclave
Komponen dalam
vacuum-bag
bull Campuran resin (+katalis) dan chopped glass strands diperoleh dalam bentuk premixed compound Bulk molding
Compound (BMC) dalam bentuk adonan atau Sheet molding Compound (SMC) dalam bentuk lembaran
bull Ketika panas dan tekanan diberikan oleh cetakan compound mengalir sesuai bentuk komponen yang diinginkan
1) Placement of Charge
5) De-molding3) Squeeze to final dimensions
2) Mould Closure4) Resin Cure
bull Curing dimulai komponen dilepaskan setelah terjadi pengerasan yang cukup
Compression Molding
bull Preform atau dry reinforcement dimasukkan kedalam cetakan sesuai dengan bentuk komponen yang
diinginkan
bull Resin mengalir dengan penekanan atau pem-vakuman dan meng-impregnasi preform dan
mendorongmengeluarkan udara yang ada dalam preform
1) Preform Manufacture
2) Preform Compression
5) De-molding3) Resin Injection
4) Resin Cure
bull Curing terjadi cetakan dibuka setelah terjadi pengerasan yang mencukupi
Liquid Molding (RTM VARI VARTM)
Pultrusion
bull Dry roving or fabrics ditarik melalui bak berisi
campuran resin dan katalis
bull Campuran yang basah ditarik melalui cetakan
bull Sisa resin keluar cetakan
bull Pemanasan dilakukan untuk proses curing
bull Pendinginan dilakukan untuk mempercepat siklus
produksi
Cut-off
Cooling
Die sections
Resin bath
Fibre creel
Filament Winding
bull Dry roving ditarik melalui bak berisi campuran resin dan katalis
bull Wet roving digulungkan dalam keadaan tegang kepada mandrel
bull Kontrol mekanik dari pembawa serat mengatur orientasi peletakan serat pada
mandrel
INDUSTRI COMPOSITES
AEROSPACE
HISTORY
1950 ndash Boeing
1960 ndash F14 Tomcat
1981 ndash AV-8B Harrier
Source
Low-Cost Composite Materials and Structures for Aircraft Applications
httpwwwreinforcedplasticscom
httpwwwcentennialofflightgovessayEvolution_of_TechnologycompositesTech40htm
Automotive
Composite material is used in a number of applications in the automotive
industry due to its temperature resistance rigidity and fatigue strength
The benefits of using composites include greater fuel efficiency
corrosion resistance light weight and strength Composites also provide
a low-cost way to help keep designs looking fresh
Composites are used in
- interior parts (cockpit trimming seats instrument panels)
- exterior structure (body panels openings underbody frontrear
modules)
- engine compartment and fuelmechanical area parts (axles and
suspensions fuel and exhaust systems)
- electrical and electronic components
Lamborghinis Sesto Element carbon fiber
ldquoFat men cannot run as fast as thin men but we build most of our vehicles as though dead-weight fat increased speedhellip I cannot
imagine where the delusion that weight means strength
came fromhelliprdquo mdashHenry Ford
The mix of automotive materials is changing showing a boost for FRP in helping original
equipment manufacturers meet fuel economy and emissions challenges
(Source 2011 DuPont AutomotiveSAE survey of design engineers performed by Signet Research Inc)
Source
httpwwwtoraycomcsrhighlight2009hig_001_01html
The MonoCell tub for the McLaren MP4-12C supercar is moulded as a single
piece and weighs less than 80 kg (176 lbs)
COMPOSITES IN MARINE
TRIMARAN BOAT
AMERICA NAVYINDONESIAN NAVY
Visby Class corvette
Total length is 72 meters
The beam is 1040 meters
The displacement is 600 metric tones
fully equipped the worlds largest CRP
construction
The design of the Visby aims to minimize
the optical and infrared signature above
water acoustic and hydroa coustic
signature underwater electrical potential
and magnetic signature pressure signature
radar cross section and actively emitted
signals
A stealth corvette of the YS 2000 design
has a detection range of 13km in rough
seas and 22km in calm sea without
jamming In a jammed environment the
Visby would be detected at a range of 8km
in rough sea and 11km in calm sea
The material provides high strength and
rigidity low weight good shock resistance
low radar and magnetic signature
1996
Visby is a class of stealth corvettes for the Swedish Navy
ldquoReduced 50 of a Conventional Steelrdquo
Source
Hull Construction with composite materials for ships over 100m in length 2002
Massachusetts Institute of Technology
httpwwwnaval-technologycomprojectsvisby
YACHTS
KAL YUDISTIRAMARATHON 100 ADMIRAL YACHT
LOA 3050 MWidth 6 MFuel Tank 8000 LWater Tank 3000 LIce Box 500 LAccommodation Max 35 Personnel
2 x CATERPILLAR 3412E 1200 HPMARINE DIESEL ENGINE
PC 40 ndash KRI Krait 827Department of Indonesian Navy
LOA 40 MWidth 73 MPower 190Weapon Twin Cannon Barrels
127 mm Heavy Machine GunSpeed Knot 25 KnotDisplacement 105 tonAccommodation 23 personnel
PATROL BOAT
Rigid Inflatable BoatPATROL BOAT
Yachts
36m Luxury Yacht Moonraker
36m Luxury Yacht GoldenEye
50m Luxury Yacht Casino
Royale
45m Luxury Yacht Seashaw
Boat Parts
Barovans for Seismic Sweep
Centrifugal Liftfan House for Surface Effect
Ships
Composite Boat PropellersRTM
Deckhouses for Pilot Boats
Fairing Parts for Submarines
Flybridges for Motor yachts
Light Weight Gangway
MTB Launcher Mock-up
Pleasure Boats
12m Sailboat
12m Sail-Catamaranone-off
Canoes
Dragonfly 1000Catamaran Sailboat
Fantasy 37Sailboat
Farr 60Luxury Sailboat
EurodingyOlympic Dingy Class for
Woman
Hydrolift F23 Racing Boats
Kajacs
Najad 42Sailboat
Najad 520Sailboat
Najad 441Sailboat
Najad 391Sailboat
Nordwest 900Motorboat
Nordwest 1100Motorboat
Quatro 44Motorboat
Racemaster Competition Boats
Storebro 420
Storebro 345
Sweden Yacht 370Sailboat
Sweden Yacht 69Sailboat
Windy 41Motorboat
X-632Sailboat
X-362Sailboat
Commercial Boats
175m High Speed AmbulancePassenger Boat
19m High Speed Passenger Boat
20m High Speed Passenger Boat
364m Surface Effect Passenger Ship
45m Surface Effect Passenger Ship
120m Hull Structural Parts HSSS Catamaran Ferry
APPENDIX
Marine Vessel
1188m Fast Attack Vessel FMV 90 E
20m SAV-Surface Auxiliary Vessels
34m Personnel TransportCoast Guard Vessel
40ft Experimental SES
40m Landsort-Class Mine Hunters
54m Mine Counter Measure Vehicles SES
74m Coastal Patrol Boats
Fishing Boats
30 GT
12 GT
10 GT
5 GT
WISEWings In Surface Effect
HOVERCRAFT
Designed specifically for the tourist and transport industries the
Pioneer Mk3 hovercraft is amphibious and comfortably seats 25
passengers plus 1-crew The air-conditioned cabin allows for
maximum visibility for all aboard The Pioneer Mk3 is robust and
dynamic in its performance
Commercial hovercraft
Mk3 AirLift Hovercraft - 1215m
Power is economicaly provided by one Deutz diesel engine of
330kW (442hp) to cruise easily at 40 knots with much higher
speeds available according to the surface conditions The hull is
manufactured from fibreglassPVC foam composite sandwich
the windows are glass and the skirt is urethane coated nylon A
Military version is available with increased payload and systems
redundancy Power for the Military version comes from two Steyr
diesel engines with a total installed power of 320kW (429hp) All
transmission electrical hydraulic and air systems are duplicated
for maximum redundancy The increased performance of the
Military version comes from the reduced engine weight of the twin
Steyr installation cf the Deutz installation
Source
httpwwwnauticexpocomprodairlift-hovercraftcommercial-hovercrafts-25251-142868html
HOVERFLIGHT
BALLISTIC amp UNIT DEFENCED
Triaxis Composites Collaboration with Institute of Aeronautics and Space in the development of Missile Nose Cone
Polymer composites is the evolution of the military defence
Thin steel was the helmet material of
WWII and remained the principal material until around the 1980rsquos
The advantages of using steel
included a simple technology for manufacture of the helmets low cost and reasonably good
impact protection However these helmets were found to provide only marginal protection
against fragments
During the Vietnam War the US Army experimented with fiber-reinforced inserts in the
helmets These inserts improved ballistic protection but at the same time added weight and
reduced the air space between the head and the helmet
By the early part of the 1980rsquos the US military had developed the first all-composite
100 fiber-reinforced helmet This development resulted in even better ballistic protection
without altering the weight of the helmet Other improvements included better head coverage and
more space for ventilation
Source
Composites Armor - A difficult but huge market
by A Brent Strong Brigham Young University
MILITARY VEHICLES
HIGH SPEED TRAIN SHINKANSEN
Advanced Composites provide lightweight solutions for railway vehicles
saving as much as 50-80 of the weight compared with traditional
components
A lower overall weight translates into less stress faster acceleration and
higher speeds as well as reduced starting and stopping inertia Today
these are important criteria in global high-speed and metropolitan
railway projects
Fire smoke and toxic fumes are key safety criteria for interior
components of railway carriages Any material selected for an interior
component must meet international fire retardant standards
for Rail Interiors and Exteriors
Ceiling Panels Stairs
Seating Vestibules
Window Panels Door Pillars
Partition WallsDiffusers
Gangway and Cabinet Panels Cabin and
Desk panels
Door Pillars Lavatory Modules (standard and
Front and Rear EndsRoof Panels
Nose Cones Under Fairings
Source
httpwwwpctaerail_compositesphp
101
SKY BUS
2009
Europe is the world leader in offshore wind with
828 wind turbines and a cumulative capacity of 2056 MW spread across 38 offshore wind farms in 9
European countries
The UK and Denmark are the current leaders with a 44 and 30 share respectively In 2009
five countries built new offshore wind farms
UK (284 MW)
Demark (230 MW)
Sweden (30 MW)
Germany (30 MW)
Norway (23 MW)
2010
Asia leads the growth in global wind power which grew 358 GW in 2010 bringing
total global capacity to 1944 GW ndash up 225 from 2009
the Global Wind Energy Council (GWEC)
Asia accounted for 19 GW of new global wind power installations driven by China which installed 165
GW
ldquoChina now has 423 GW of wind powerrdquo
ldquoThis puts China firmly on a path to reach 200 GW of installed wind power by 2020 At the same
time China has become the worldrsquos largest producer of wind energy equipmentrdquo
Source
httpwwwreinforcedplasticscomview15655asia-leads-global-wind-power-growth
httpimgdeusmcomdesignnews288288605-Sandia_Sizes_up_Wind_Turbine_Blade_Design_C_largegif
WIND ENERGY
Marine Current Turbines
Source
httpwwwsiemenscompressenpressreleasepress=enpressrelease2011solar-hydroex201111005htm
httpwwwmarineturbinescom
A commercial marine current turbine consists of
two rotors which are fixed on a structure within the
sea current The twin rotors rotate with the
movement of the tidal flow and the blades pitch
through 180 degrees to optimally track tidal current
(Press picture Marine Current Turbines)
Wave Star Energys Multi-point Absorber
CFRP COLUMN REINFORCEMENT
INDUSTRIAL TANKS
107
INDUSTRIAL PIPES
PRESSURE TANKS
109
ldquoLetrsquos Make with Compositesrdquo
The Importance of Lightness for
Environmental Friendly Products
Mass Reduction for Less Energy Consumption
MATERIAL COMPOSITES
Thermoset
type
Density r
(kgm3)
Stiffnes
s E
(Gpa)
Tensile
strength
s (MPa)
Strain to
failure e
()
Tg 0C
Thermal
conductivity
k (Wm0C)
Specific
Heat Cp
(kJkg0C)
Thermal
expansion coeff
a (x106 0C-1)
Polyester 1100-1230 31-46 50-75 10-65 70- 017-022 13-23 55-100
Vinylester 1120-1130 31-33 70-81 30-80 70- - - -
Epoxy 1100-1200 26-38 60-85 15-80 65-175 017-020 105 45-65
Phenolic 1000-1250 30-40 60-80 18 300 012-024 14-18 25-60
PUR 1200 07 30-40 400-450 135 017-021 13-23 70-100
BMI 1200-1320 32-50 48-110 15-33 230-345 - - -
Polyimide 1430-1890 31-49 100-110 15-30 325-370 01-034 105-15 25-80
Al 2800 72 540 18 - 130 096 236
Steel 7790 205 640 25 - 54 046 11
MATRIKS POLIMER THERMOSET
Variasi sifat yang lebar disebabkan oleh adanya formulasi kimia yang berbeda dan penambahan aditif
Jenis Glass Fiber S Glass E Glass C Glass A Glass dll
Terms
Glass Type
S Glass E Glass C Glass A Glass
Silica (SiO2) Content 67 55 64 72
Al2O3 Content 23 14 6 1
Melting Point (Celcius) 915 836 745 745
Tensile Strength 665 500 440 440
Modulus Elastisitas 124 105 100 -
Application AEROSPACE BOAT CHEMICAL TANK CHEMICAL TANK
JENIS SERAT GLASS
CHINA
JENIS SERAT GLASS
C GLASS Calcium borosilicate glasses
used for CHEMICAL stability in corrosive
acid environments
E GLASS Alumina-calcium-borosilicate
glasses with a maximum alkali used as
general purpose fibers where STRENGTH
and high ELECTICAL RESISTIVITY are
required It manifests better electrical
insulation and strongly resists attack by
water More than 50 of the glass fibers
used for reinforcement is E-glass
C Glass
E Glass
C amp E GLASS
SUMBER AGY TECHNICAL PAPER HIGH STRENGTH GLASS FIBER
FAKTA
C GLASS 1 BOROS RESIN
2 KEKUATAN
KURANG
FAKTA
E GLASS 1 HEMAT RESIN
2 KEKUATAN BAIK
3 TAHAN LAMA
FAKTA
TEBAL BUKAN BERARTI KUAT
UNSUR MATRIX (RESIN)
TIDAK ADA KEKUATAN
ldquoMore than 50 of the glass fibers used for
reinforcement is E-glassrdquo
C glass E glass
E glass
C glass
KAIN WOVEN ROVING HASIL LAMINASI
JENIS SERAT GLASS
Kekuatan composites ditentukan oleh
1 Kekuatan amp Sifat Fiber
2 Kekuatan amp Sifat Resin
3 Fraksi Rasio Perbandingan Volume Fiber
dan Resin dalam Composites
rarr tergantung dari Proses Manufaktur
4 Geometri dan Orientasi Arah Fiber dalam
Composites
KEKUATAN COMPOSITES
PROSES MATERIAL
Proses Produksi Kain Fiberglass
Biji Kaca Benang Benang Kaca Kain Fiberglass
PROSES MATERIAL
Glass Beads
Glass Fiber Glass Roving YarnGlass Fabric
FIBERGLASS
PRODUK
MATERIAL DAN PRODUK FIBERGLASS
+
Resin + Additives
PERPADUAN COMPOSITES
BENANG KACA Potongan Serat Kaca CSM
CSM - CHOPPED STRAND MAT
chopped binder
Kain Fiberglass Generasi Pertama
BahanPengikat
SenyawaPada Resin
JENIS FIBERGLASS
Glass Roving Yarn Chopped Strand
ADVANTAGES DISADVANTAGES
Steel
1048707 Low cost 1048707 Corrodes easily
1048707 Ductile under ambient conditions
1048707 Has no lower fatigue limit for welded structures
1048707 Virtually isotropic 1048707 Heavy
1048707 Easily formed and fabricated 1048707 Brittle at low temperatures
1048707 Easily obtained (low relative cost) 1048707 Magnetic
1048707 Easily alloyed or heat treated for special operations
1048707 Easily repaired
1048707 Good fire resistance
1048707 Behaviour is well understood
Alumunium Alloy
1048707 Light weight 1048707 Poor fatigue properties
1048707 Corrosion resistant 1048707 Poor performance in fire
1048707 Easily formed1048707 Low melting point and softening temperature
1048707 Easily fabricated 1048707 High relative cost
1048707 Readily available 1048707 Strength and stiffness less than steel
1048707 Ductile
1048707 Non magnetic
FRP
1048707 Low magnetic properties
1048707 Low electrical conductivity (glass- reinforced plastics)
1048707 Resistance to corrosion
1048707 Resistance to rot and marine growth
1048707 Relatively high sonar transparency
1048707 Good strength to weight ratio
1048707 Good fatigue properties
1048707 Maintenance of properties at low temperatures
1048707 Availability
1048707 Can be manufactured to near net-shape
1048707 Stiffness and strength can be tailored to structural requirements
1048707 Excellent thermal insulation
1048707 Light weight
STEEL vs ALUMUNIUM vs COMPOSITES
Source
1Maritime Platforms Division Aeronautical and
Maritime Research Laboratory (Seref Aksu
Stuart Cannon Craig Gardiner and Matthew
Gudze
2 Metal Corrosion can be defined as the
destructive attack of a metal through interaction
with its environment
(httpwwwcorrosionistcomCorrosion_Fundament
alhtm)
28
Serat rarr penguat
Polimer matriks rarr pengikat
bull Sifat mekanik yang cukup baik
bull Viskositas dan temperatur pengerjaan rendah rarr mudah
dimanufaktur
bull Ketahanan korosi yang baik
bull Media perpindahan gaya rarr distribusi beban dari serat ke serat
bull Ulet rarr Melindungi serat yang getas
bull Size effect rarr Kekuatan dan kekakuan sangat tinggi
bull Aspect ratio (ld) tinggi rarr luas permukaan besar
bull Fleksibel rarr variasi teknik manufaktur
bull Serat dapat diatur sesuai dengan arah pembebanan
29
Advantages Polimer Composites
Kekuatan dan kekakuan spesifik yang tinggi FRCP vs material lain rarr kompetitif jika berat dipertimbangkan
Material Berat jenis
r (kgm3)
Kekakuan
E (GPa)
Kekuatan
tarik su
(MPa)
Kekakuan
spesifik
Er
Kekuatan
spesifik sur
Baja 7800 208 400 27 005
Aluminium 2700 70 200 259 007
Nylon 1100 25 80 23 007
Beton 2400 40 20 166 0008
Random
FRPC
1800 20 300 111 0006
Alligned FRPC
( serat)
1600 200 1500 125 094
Alligned FRCP
( serat)
1600 3 50 19 0001
Tensile Strength amp Modulus of Common Structural Materials
Densities of Common Structural Materials
Specific Tensile Strength amp Modulus of Common Structural Materials
Typical Properties of Common Structural Materials
Kesimpulan COMPOSITES = RINGAN amp KUAT
Jadi secara keseluruhan kekuatan composites
ditentukan oleh
1 Kekuatan amp Sifat Fiber
2 Kekuatan amp Sifat Resin
3 Fraksi Rasio Perbandingan Volume Fiber
dan Resin dalam Composites
4 Geometri dan Orientasi Arah Fiber dalam
Composites
PRODUKSI ANAK NEGERI
Proses Produksi Kain Fiberglass
Biji Kaca Benang Benang Kaca Kain Fiberglass
PROSES MATERIAL
Glass Beads
Glass Fiber Glass Roving YarnGlass Fabric
Proses Produksi Kain Fiberglass
Biji Kaca Benang Benang Kaca Kain Fiberglass
Glass Beads
Glass Fiber Glass Roving YarnGlass Fabric
PROSES MATERIAL
Benang Kaca Potongan Serat Kaca Chopped Strand Mat
CSM - Chopped Strand Mat
chopped binder
Produk Fiberglass Generasi Pertama
Bahan Pengikat
Senyawa Pada Resin
Glass Roving Yarn Chopped Strand
JENIS FIBERGLASS
Benang Kaca Woven Roving
WR - Woven Roving
Tenun Weaving
Produk Fiberglass Generasi Kedua
Glass Roving Yarn
JENIS FIBERGLASS
Multiaxial
MAX - Multiaxial
warp knitting
Produk Fiberglass Generasi Ketiga
Benang Kaca
Glass Roving Yarn
JENIS FIBERGLASS
MAX - Multiaxial Fabric
Fleece (optional)
Lapisan
MULTIAXIAL PROSES
Karakteristik CSM
bull Glass Content 30
bull Resin Content 70
bull Tensile Force
Chopped Strand Mat
JENIS FIBERGLASS
Karakteristik Woven Roving
bull Glass Content 45
bull Resin Content 55
Woven Roving
Resin
|
|
|
|
|
|
|
|
|
|
|
|
|
|
bull Kekuatan Tarik
JENIS FIBERGLASS
No Resin Rich Area
Karakteristik Multiaxial
bull Glass Content 60
bull Resin Content 40
Produk Fiberglass Ketiga MULTIAXIAL
JENIS FIBERGLASS
Perbedaan Woven Roving dan Multiaxial ndash Tampak Samping
JENIS FIBERGLASS
WR FRP
8 Ply WR 800
8 Ply CSM 450
Glass Weight 1 kg
Composite Weight 15kgm2
CSM FRP
22 Ply CSM 450
Glass Weight 1 kg
Composite Weight 18 kgm2
MULTIAXIAL FRP
13 Ply DB 800
Glass Weight 1 kg
Composite Weight
13 kgm2
JENIS FIBERGLASS
Multiaxial
FRP
Woven Roving
FRP
Chopped Strands Mat FRP
MULTIAXIAL
FAKTA
TEBAL BUKAN BERARTI KUAT
UNSUR MATRIX (RESIN)
TIDAK ADA KEKUATAN
ldquoMore than 50 of the glass fibers used for reinforcement is
E-glassrdquo
KarakteristikKekuatan
CSM WR MAX
Kekuatan Tarik 175 MPa 250 MPa 425 MPa
CSM 142
WR 70
KEKUATAN TARIK
Properties CSM Lamination WR Lamination MAX Lamination
Fabric Weight (kgm2) 1 1 1
Composite Weight (kgm2) 18 15 13
Resin usage (kgm2) 15 1 08
Amount of Fabric 22 Ply 16 Ply 13 Ply
Thickness 15 mm 12 mm 10 mm
Tensile Strength (Mpa) 125 1796 400
Tensile Strength (Nmmsup2) 28463 30958 4576
Processing Time High Med Low
Labour Cost High Med Low
MULTIAXIAL
Total Penggunaan Resin -51
Total Berat Kapal -40
Kekuatan Bangunan Kapal +59
Efisiensi Tenaga Kerja
Waktu Pengerjaan Lebih Cepat
KEUNGGULAN MATERIAL
Resapan Resin Lebih Baik amp Merata
Lapisan Lebih Sedikit
Meningkatkan Kekuatan Kapal
KEUNGGULAN MATERIAL
TRIAXIAL
DBL series DBT series
BIAXIAL
LT series DB series
UNIDIRECTIONAL
L series T series
QUADRIAXIAL
DBLT series
JENIS MULTIAXIAL
UNIDIRECTIONAL
DCMU 900 E ndash
KHUSUS UNTUK MEMPERKUAT BENDING KAPAL
PEMASANGAN KHUSUS PADA KEEL DAN TULANGAN
JENIS MULTIAXIAL UNTUK KAPAL
TRIAXIAL
DBL 600 ndash
APLIKASI PADA INDUSTRI PENERBANGAN
PEMASANGAN KHUSUS PADA
SAMBUNGAN BADAN DAN SAYAP
PESAWAT
JENIS MULTIAXIAL UNTUK PESAWAT
QUADRAXIAL
DBLT 800 ndash
APLIKASI PADA INDUSTRI ENERGI
DITERAPKAN UNTUK KEBUTUHAN PEMBANGKIT
LISTRIK ENERGI ANGIN
MULTIAXIAL UNTUK ENERGI
INDUSTRI KIMIA OLAHRAGA AUTOMOTIF
MULTIAXIAL UNTUK INDUSTRI LAINNYA
COMPOSITES
GUNAKAN MATERIAL FIBERGLASS
YANG SUDAH DISERTIFIKASI
BKI
FIBERGLASS UNTUK PEMBANGUNAN BAKAP
PERATURAN MENTERI PERHUBUNGAN
NOMOR PM 7 TAHUN 2013
TENTANG KEWAJIBAN KLASIFIKASI BAGI KAPAL BERBENDERA INDONESIA
PADA BADAN KLASIFIKASI
BADAN SERTIFIKASI MARITIM
Biro Klasifikasi IndonesiaDet Norske Veritas Germanischer Lloyds
PERATURAN BKI
Untuk Kapal Non-Metal
2006
PERSYARATAN MINIMUM
kekuatan material yang
harus digunakan
untuk membangun
Kapal Fiberglass
PEMBESARAN
Table 21
FIBERGLASS TRIAXIS COMPOSITES
TELAH BERSERTIFIKASI BKI
Biro Klasifikasi Indonesia
65
TEKNIK MANUFAKTUR
COMPOSITES
Wet hand lay-up
1) Peletakan
Dry Reinforcement
bull Dry reinforcement dan resin (+ katalis) ditaruh pada permukaan cetakan
2) Pemasukanpenekanan resin
bull Resin ditekan untuk meng-impregnasi serat dengan menggunakan rol
3) Pengulangan proses untuk lapisan lain
bull Beberapa lapisan dapat ditambahkan secara bertahap
4) Resin curing
bull Reaksi dimulai komponen dilepaskan setelah komponen mengeras
(fully cured)
Wet hand lay-up
Manufaktur komponen dapat dikerjakan dengan menggunakan beberapa lapis komposit
dengan memperhatikan kompatibilitas material dan tahapan curing Modifikasi proses dapat
dilakukan seperti
Vacuum bagging
setelah lay-up
Glass Roving
Bulk Resin
Catalyst
3) De-molding
2) Resin Cure
bull Curing dimulai dan komponen dilepaskan setelah pengerasan selesai
bull Serat gelas resin dan katalis dimasukkan kedalam spray gun
1) Spray-up
bull Campuran disemprotkan pada permukaan cetakan
Spray-up
69
Penyemprotan bakal komponen
Komponen
dilepaskan
dari cetakan
Full dispensing
system Chopper Roving
Atomised resin
and catalyst
Spray-up
Prepreg
1) LaminateAssembly 5) De-molding
3) Resin Melts Layup Consolidates
bull Prepreg serat yang sudah diimpregnasi oleh resin+katalis dalam kondisi padat
bull Lapisan prepreg digunting sesuai bentuk yang diinginkan kemudian diletakkan pada permukaan cetakan
sesuai bentuk komponen yang diinginkan Lay-up mudah dilakukan karena sifat ldquotackynessrdquo dari prepreg
2) Applied Vacuum Pressure and Heat
bull Tekanan dan panas diberikan resin mencair terjadi konsolidasi pada komponen
4) Resin Cures
bull Temperatur dinaikkan untuk memulai curing
Prepreg
Variasi proses Autoclave
Komponen dalam
vacuum-bag
bull Campuran resin (+katalis) dan chopped glass strands diperoleh dalam bentuk premixed compound Bulk molding
Compound (BMC) dalam bentuk adonan atau Sheet molding Compound (SMC) dalam bentuk lembaran
bull Ketika panas dan tekanan diberikan oleh cetakan compound mengalir sesuai bentuk komponen yang diinginkan
1) Placement of Charge
5) De-molding3) Squeeze to final dimensions
2) Mould Closure4) Resin Cure
bull Curing dimulai komponen dilepaskan setelah terjadi pengerasan yang cukup
Compression Molding
bull Preform atau dry reinforcement dimasukkan kedalam cetakan sesuai dengan bentuk komponen yang
diinginkan
bull Resin mengalir dengan penekanan atau pem-vakuman dan meng-impregnasi preform dan
mendorongmengeluarkan udara yang ada dalam preform
1) Preform Manufacture
2) Preform Compression
5) De-molding3) Resin Injection
4) Resin Cure
bull Curing terjadi cetakan dibuka setelah terjadi pengerasan yang mencukupi
Liquid Molding (RTM VARI VARTM)
Pultrusion
bull Dry roving or fabrics ditarik melalui bak berisi
campuran resin dan katalis
bull Campuran yang basah ditarik melalui cetakan
bull Sisa resin keluar cetakan
bull Pemanasan dilakukan untuk proses curing
bull Pendinginan dilakukan untuk mempercepat siklus
produksi
Cut-off
Cooling
Die sections
Resin bath
Fibre creel
Filament Winding
bull Dry roving ditarik melalui bak berisi campuran resin dan katalis
bull Wet roving digulungkan dalam keadaan tegang kepada mandrel
bull Kontrol mekanik dari pembawa serat mengatur orientasi peletakan serat pada
mandrel
INDUSTRI COMPOSITES
AEROSPACE
HISTORY
1950 ndash Boeing
1960 ndash F14 Tomcat
1981 ndash AV-8B Harrier
Source
Low-Cost Composite Materials and Structures for Aircraft Applications
httpwwwreinforcedplasticscom
httpwwwcentennialofflightgovessayEvolution_of_TechnologycompositesTech40htm
Automotive
Composite material is used in a number of applications in the automotive
industry due to its temperature resistance rigidity and fatigue strength
The benefits of using composites include greater fuel efficiency
corrosion resistance light weight and strength Composites also provide
a low-cost way to help keep designs looking fresh
Composites are used in
- interior parts (cockpit trimming seats instrument panels)
- exterior structure (body panels openings underbody frontrear
modules)
- engine compartment and fuelmechanical area parts (axles and
suspensions fuel and exhaust systems)
- electrical and electronic components
Lamborghinis Sesto Element carbon fiber
ldquoFat men cannot run as fast as thin men but we build most of our vehicles as though dead-weight fat increased speedhellip I cannot
imagine where the delusion that weight means strength
came fromhelliprdquo mdashHenry Ford
The mix of automotive materials is changing showing a boost for FRP in helping original
equipment manufacturers meet fuel economy and emissions challenges
(Source 2011 DuPont AutomotiveSAE survey of design engineers performed by Signet Research Inc)
Source
httpwwwtoraycomcsrhighlight2009hig_001_01html
The MonoCell tub for the McLaren MP4-12C supercar is moulded as a single
piece and weighs less than 80 kg (176 lbs)
COMPOSITES IN MARINE
TRIMARAN BOAT
AMERICA NAVYINDONESIAN NAVY
Visby Class corvette
Total length is 72 meters
The beam is 1040 meters
The displacement is 600 metric tones
fully equipped the worlds largest CRP
construction
The design of the Visby aims to minimize
the optical and infrared signature above
water acoustic and hydroa coustic
signature underwater electrical potential
and magnetic signature pressure signature
radar cross section and actively emitted
signals
A stealth corvette of the YS 2000 design
has a detection range of 13km in rough
seas and 22km in calm sea without
jamming In a jammed environment the
Visby would be detected at a range of 8km
in rough sea and 11km in calm sea
The material provides high strength and
rigidity low weight good shock resistance
low radar and magnetic signature
1996
Visby is a class of stealth corvettes for the Swedish Navy
ldquoReduced 50 of a Conventional Steelrdquo
Source
Hull Construction with composite materials for ships over 100m in length 2002
Massachusetts Institute of Technology
httpwwwnaval-technologycomprojectsvisby
YACHTS
KAL YUDISTIRAMARATHON 100 ADMIRAL YACHT
LOA 3050 MWidth 6 MFuel Tank 8000 LWater Tank 3000 LIce Box 500 LAccommodation Max 35 Personnel
2 x CATERPILLAR 3412E 1200 HPMARINE DIESEL ENGINE
PC 40 ndash KRI Krait 827Department of Indonesian Navy
LOA 40 MWidth 73 MPower 190Weapon Twin Cannon Barrels
127 mm Heavy Machine GunSpeed Knot 25 KnotDisplacement 105 tonAccommodation 23 personnel
PATROL BOAT
Rigid Inflatable BoatPATROL BOAT
Yachts
36m Luxury Yacht Moonraker
36m Luxury Yacht GoldenEye
50m Luxury Yacht Casino
Royale
45m Luxury Yacht Seashaw
Boat Parts
Barovans for Seismic Sweep
Centrifugal Liftfan House for Surface Effect
Ships
Composite Boat PropellersRTM
Deckhouses for Pilot Boats
Fairing Parts for Submarines
Flybridges for Motor yachts
Light Weight Gangway
MTB Launcher Mock-up
Pleasure Boats
12m Sailboat
12m Sail-Catamaranone-off
Canoes
Dragonfly 1000Catamaran Sailboat
Fantasy 37Sailboat
Farr 60Luxury Sailboat
EurodingyOlympic Dingy Class for
Woman
Hydrolift F23 Racing Boats
Kajacs
Najad 42Sailboat
Najad 520Sailboat
Najad 441Sailboat
Najad 391Sailboat
Nordwest 900Motorboat
Nordwest 1100Motorboat
Quatro 44Motorboat
Racemaster Competition Boats
Storebro 420
Storebro 345
Sweden Yacht 370Sailboat
Sweden Yacht 69Sailboat
Windy 41Motorboat
X-632Sailboat
X-362Sailboat
Commercial Boats
175m High Speed AmbulancePassenger Boat
19m High Speed Passenger Boat
20m High Speed Passenger Boat
364m Surface Effect Passenger Ship
45m Surface Effect Passenger Ship
120m Hull Structural Parts HSSS Catamaran Ferry
APPENDIX
Marine Vessel
1188m Fast Attack Vessel FMV 90 E
20m SAV-Surface Auxiliary Vessels
34m Personnel TransportCoast Guard Vessel
40ft Experimental SES
40m Landsort-Class Mine Hunters
54m Mine Counter Measure Vehicles SES
74m Coastal Patrol Boats
Fishing Boats
30 GT
12 GT
10 GT
5 GT
WISEWings In Surface Effect
HOVERCRAFT
Designed specifically for the tourist and transport industries the
Pioneer Mk3 hovercraft is amphibious and comfortably seats 25
passengers plus 1-crew The air-conditioned cabin allows for
maximum visibility for all aboard The Pioneer Mk3 is robust and
dynamic in its performance
Commercial hovercraft
Mk3 AirLift Hovercraft - 1215m
Power is economicaly provided by one Deutz diesel engine of
330kW (442hp) to cruise easily at 40 knots with much higher
speeds available according to the surface conditions The hull is
manufactured from fibreglassPVC foam composite sandwich
the windows are glass and the skirt is urethane coated nylon A
Military version is available with increased payload and systems
redundancy Power for the Military version comes from two Steyr
diesel engines with a total installed power of 320kW (429hp) All
transmission electrical hydraulic and air systems are duplicated
for maximum redundancy The increased performance of the
Military version comes from the reduced engine weight of the twin
Steyr installation cf the Deutz installation
Source
httpwwwnauticexpocomprodairlift-hovercraftcommercial-hovercrafts-25251-142868html
HOVERFLIGHT
BALLISTIC amp UNIT DEFENCED
Triaxis Composites Collaboration with Institute of Aeronautics and Space in the development of Missile Nose Cone
Polymer composites is the evolution of the military defence
Thin steel was the helmet material of
WWII and remained the principal material until around the 1980rsquos
The advantages of using steel
included a simple technology for manufacture of the helmets low cost and reasonably good
impact protection However these helmets were found to provide only marginal protection
against fragments
During the Vietnam War the US Army experimented with fiber-reinforced inserts in the
helmets These inserts improved ballistic protection but at the same time added weight and
reduced the air space between the head and the helmet
By the early part of the 1980rsquos the US military had developed the first all-composite
100 fiber-reinforced helmet This development resulted in even better ballistic protection
without altering the weight of the helmet Other improvements included better head coverage and
more space for ventilation
Source
Composites Armor - A difficult but huge market
by A Brent Strong Brigham Young University
MILITARY VEHICLES
HIGH SPEED TRAIN SHINKANSEN
Advanced Composites provide lightweight solutions for railway vehicles
saving as much as 50-80 of the weight compared with traditional
components
A lower overall weight translates into less stress faster acceleration and
higher speeds as well as reduced starting and stopping inertia Today
these are important criteria in global high-speed and metropolitan
railway projects
Fire smoke and toxic fumes are key safety criteria for interior
components of railway carriages Any material selected for an interior
component must meet international fire retardant standards
for Rail Interiors and Exteriors
Ceiling Panels Stairs
Seating Vestibules
Window Panels Door Pillars
Partition WallsDiffusers
Gangway and Cabinet Panels Cabin and
Desk panels
Door Pillars Lavatory Modules (standard and
Front and Rear EndsRoof Panels
Nose Cones Under Fairings
Source
httpwwwpctaerail_compositesphp
101
SKY BUS
2009
Europe is the world leader in offshore wind with
828 wind turbines and a cumulative capacity of 2056 MW spread across 38 offshore wind farms in 9
European countries
The UK and Denmark are the current leaders with a 44 and 30 share respectively In 2009
five countries built new offshore wind farms
UK (284 MW)
Demark (230 MW)
Sweden (30 MW)
Germany (30 MW)
Norway (23 MW)
2010
Asia leads the growth in global wind power which grew 358 GW in 2010 bringing
total global capacity to 1944 GW ndash up 225 from 2009
the Global Wind Energy Council (GWEC)
Asia accounted for 19 GW of new global wind power installations driven by China which installed 165
GW
ldquoChina now has 423 GW of wind powerrdquo
ldquoThis puts China firmly on a path to reach 200 GW of installed wind power by 2020 At the same
time China has become the worldrsquos largest producer of wind energy equipmentrdquo
Source
httpwwwreinforcedplasticscomview15655asia-leads-global-wind-power-growth
httpimgdeusmcomdesignnews288288605-Sandia_Sizes_up_Wind_Turbine_Blade_Design_C_largegif
WIND ENERGY
Marine Current Turbines
Source
httpwwwsiemenscompressenpressreleasepress=enpressrelease2011solar-hydroex201111005htm
httpwwwmarineturbinescom
A commercial marine current turbine consists of
two rotors which are fixed on a structure within the
sea current The twin rotors rotate with the
movement of the tidal flow and the blades pitch
through 180 degrees to optimally track tidal current
(Press picture Marine Current Turbines)
Wave Star Energys Multi-point Absorber
CFRP COLUMN REINFORCEMENT
INDUSTRIAL TANKS
107
INDUSTRIAL PIPES
PRESSURE TANKS
109
ldquoLetrsquos Make with Compositesrdquo
Mass Reduction for Less Energy Consumption
MATERIAL COMPOSITES
Thermoset
type
Density r
(kgm3)
Stiffnes
s E
(Gpa)
Tensile
strength
s (MPa)
Strain to
failure e
()
Tg 0C
Thermal
conductivity
k (Wm0C)
Specific
Heat Cp
(kJkg0C)
Thermal
expansion coeff
a (x106 0C-1)
Polyester 1100-1230 31-46 50-75 10-65 70- 017-022 13-23 55-100
Vinylester 1120-1130 31-33 70-81 30-80 70- - - -
Epoxy 1100-1200 26-38 60-85 15-80 65-175 017-020 105 45-65
Phenolic 1000-1250 30-40 60-80 18 300 012-024 14-18 25-60
PUR 1200 07 30-40 400-450 135 017-021 13-23 70-100
BMI 1200-1320 32-50 48-110 15-33 230-345 - - -
Polyimide 1430-1890 31-49 100-110 15-30 325-370 01-034 105-15 25-80
Al 2800 72 540 18 - 130 096 236
Steel 7790 205 640 25 - 54 046 11
MATRIKS POLIMER THERMOSET
Variasi sifat yang lebar disebabkan oleh adanya formulasi kimia yang berbeda dan penambahan aditif
Jenis Glass Fiber S Glass E Glass C Glass A Glass dll
Terms
Glass Type
S Glass E Glass C Glass A Glass
Silica (SiO2) Content 67 55 64 72
Al2O3 Content 23 14 6 1
Melting Point (Celcius) 915 836 745 745
Tensile Strength 665 500 440 440
Modulus Elastisitas 124 105 100 -
Application AEROSPACE BOAT CHEMICAL TANK CHEMICAL TANK
JENIS SERAT GLASS
CHINA
JENIS SERAT GLASS
C GLASS Calcium borosilicate glasses
used for CHEMICAL stability in corrosive
acid environments
E GLASS Alumina-calcium-borosilicate
glasses with a maximum alkali used as
general purpose fibers where STRENGTH
and high ELECTICAL RESISTIVITY are
required It manifests better electrical
insulation and strongly resists attack by
water More than 50 of the glass fibers
used for reinforcement is E-glass
C Glass
E Glass
C amp E GLASS
SUMBER AGY TECHNICAL PAPER HIGH STRENGTH GLASS FIBER
FAKTA
C GLASS 1 BOROS RESIN
2 KEKUATAN
KURANG
FAKTA
E GLASS 1 HEMAT RESIN
2 KEKUATAN BAIK
3 TAHAN LAMA
FAKTA
TEBAL BUKAN BERARTI KUAT
UNSUR MATRIX (RESIN)
TIDAK ADA KEKUATAN
ldquoMore than 50 of the glass fibers used for
reinforcement is E-glassrdquo
C glass E glass
E glass
C glass
KAIN WOVEN ROVING HASIL LAMINASI
JENIS SERAT GLASS
Kekuatan composites ditentukan oleh
1 Kekuatan amp Sifat Fiber
2 Kekuatan amp Sifat Resin
3 Fraksi Rasio Perbandingan Volume Fiber
dan Resin dalam Composites
rarr tergantung dari Proses Manufaktur
4 Geometri dan Orientasi Arah Fiber dalam
Composites
KEKUATAN COMPOSITES
PROSES MATERIAL
Proses Produksi Kain Fiberglass
Biji Kaca Benang Benang Kaca Kain Fiberglass
PROSES MATERIAL
Glass Beads
Glass Fiber Glass Roving YarnGlass Fabric
FIBERGLASS
PRODUK
MATERIAL DAN PRODUK FIBERGLASS
+
Resin + Additives
PERPADUAN COMPOSITES
BENANG KACA Potongan Serat Kaca CSM
CSM - CHOPPED STRAND MAT
chopped binder
Kain Fiberglass Generasi Pertama
BahanPengikat
SenyawaPada Resin
JENIS FIBERGLASS
Glass Roving Yarn Chopped Strand
ADVANTAGES DISADVANTAGES
Steel
1048707 Low cost 1048707 Corrodes easily
1048707 Ductile under ambient conditions
1048707 Has no lower fatigue limit for welded structures
1048707 Virtually isotropic 1048707 Heavy
1048707 Easily formed and fabricated 1048707 Brittle at low temperatures
1048707 Easily obtained (low relative cost) 1048707 Magnetic
1048707 Easily alloyed or heat treated for special operations
1048707 Easily repaired
1048707 Good fire resistance
1048707 Behaviour is well understood
Alumunium Alloy
1048707 Light weight 1048707 Poor fatigue properties
1048707 Corrosion resistant 1048707 Poor performance in fire
1048707 Easily formed1048707 Low melting point and softening temperature
1048707 Easily fabricated 1048707 High relative cost
1048707 Readily available 1048707 Strength and stiffness less than steel
1048707 Ductile
1048707 Non magnetic
FRP
1048707 Low magnetic properties
1048707 Low electrical conductivity (glass- reinforced plastics)
1048707 Resistance to corrosion
1048707 Resistance to rot and marine growth
1048707 Relatively high sonar transparency
1048707 Good strength to weight ratio
1048707 Good fatigue properties
1048707 Maintenance of properties at low temperatures
1048707 Availability
1048707 Can be manufactured to near net-shape
1048707 Stiffness and strength can be tailored to structural requirements
1048707 Excellent thermal insulation
1048707 Light weight
STEEL vs ALUMUNIUM vs COMPOSITES
Source
1Maritime Platforms Division Aeronautical and
Maritime Research Laboratory (Seref Aksu
Stuart Cannon Craig Gardiner and Matthew
Gudze
2 Metal Corrosion can be defined as the
destructive attack of a metal through interaction
with its environment
(httpwwwcorrosionistcomCorrosion_Fundament
alhtm)
28
Serat rarr penguat
Polimer matriks rarr pengikat
bull Sifat mekanik yang cukup baik
bull Viskositas dan temperatur pengerjaan rendah rarr mudah
dimanufaktur
bull Ketahanan korosi yang baik
bull Media perpindahan gaya rarr distribusi beban dari serat ke serat
bull Ulet rarr Melindungi serat yang getas
bull Size effect rarr Kekuatan dan kekakuan sangat tinggi
bull Aspect ratio (ld) tinggi rarr luas permukaan besar
bull Fleksibel rarr variasi teknik manufaktur
bull Serat dapat diatur sesuai dengan arah pembebanan
29
Advantages Polimer Composites
Kekuatan dan kekakuan spesifik yang tinggi FRCP vs material lain rarr kompetitif jika berat dipertimbangkan
Material Berat jenis
r (kgm3)
Kekakuan
E (GPa)
Kekuatan
tarik su
(MPa)
Kekakuan
spesifik
Er
Kekuatan
spesifik sur
Baja 7800 208 400 27 005
Aluminium 2700 70 200 259 007
Nylon 1100 25 80 23 007
Beton 2400 40 20 166 0008
Random
FRPC
1800 20 300 111 0006
Alligned FRPC
( serat)
1600 200 1500 125 094
Alligned FRCP
( serat)
1600 3 50 19 0001
Tensile Strength amp Modulus of Common Structural Materials
Densities of Common Structural Materials
Specific Tensile Strength amp Modulus of Common Structural Materials
Typical Properties of Common Structural Materials
Kesimpulan COMPOSITES = RINGAN amp KUAT
Jadi secara keseluruhan kekuatan composites
ditentukan oleh
1 Kekuatan amp Sifat Fiber
2 Kekuatan amp Sifat Resin
3 Fraksi Rasio Perbandingan Volume Fiber
dan Resin dalam Composites
4 Geometri dan Orientasi Arah Fiber dalam
Composites
PRODUKSI ANAK NEGERI
Proses Produksi Kain Fiberglass
Biji Kaca Benang Benang Kaca Kain Fiberglass
PROSES MATERIAL
Glass Beads
Glass Fiber Glass Roving YarnGlass Fabric
Proses Produksi Kain Fiberglass
Biji Kaca Benang Benang Kaca Kain Fiberglass
Glass Beads
Glass Fiber Glass Roving YarnGlass Fabric
PROSES MATERIAL
Benang Kaca Potongan Serat Kaca Chopped Strand Mat
CSM - Chopped Strand Mat
chopped binder
Produk Fiberglass Generasi Pertama
Bahan Pengikat
Senyawa Pada Resin
Glass Roving Yarn Chopped Strand
JENIS FIBERGLASS
Benang Kaca Woven Roving
WR - Woven Roving
Tenun Weaving
Produk Fiberglass Generasi Kedua
Glass Roving Yarn
JENIS FIBERGLASS
Multiaxial
MAX - Multiaxial
warp knitting
Produk Fiberglass Generasi Ketiga
Benang Kaca
Glass Roving Yarn
JENIS FIBERGLASS
MAX - Multiaxial Fabric
Fleece (optional)
Lapisan
MULTIAXIAL PROSES
Karakteristik CSM
bull Glass Content 30
bull Resin Content 70
bull Tensile Force
Chopped Strand Mat
JENIS FIBERGLASS
Karakteristik Woven Roving
bull Glass Content 45
bull Resin Content 55
Woven Roving
Resin
|
|
|
|
|
|
|
|
|
|
|
|
|
|
bull Kekuatan Tarik
JENIS FIBERGLASS
No Resin Rich Area
Karakteristik Multiaxial
bull Glass Content 60
bull Resin Content 40
Produk Fiberglass Ketiga MULTIAXIAL
JENIS FIBERGLASS
Perbedaan Woven Roving dan Multiaxial ndash Tampak Samping
JENIS FIBERGLASS
WR FRP
8 Ply WR 800
8 Ply CSM 450
Glass Weight 1 kg
Composite Weight 15kgm2
CSM FRP
22 Ply CSM 450
Glass Weight 1 kg
Composite Weight 18 kgm2
MULTIAXIAL FRP
13 Ply DB 800
Glass Weight 1 kg
Composite Weight
13 kgm2
JENIS FIBERGLASS
Multiaxial
FRP
Woven Roving
FRP
Chopped Strands Mat FRP
MULTIAXIAL
FAKTA
TEBAL BUKAN BERARTI KUAT
UNSUR MATRIX (RESIN)
TIDAK ADA KEKUATAN
ldquoMore than 50 of the glass fibers used for reinforcement is
E-glassrdquo
KarakteristikKekuatan
CSM WR MAX
Kekuatan Tarik 175 MPa 250 MPa 425 MPa
CSM 142
WR 70
KEKUATAN TARIK
Properties CSM Lamination WR Lamination MAX Lamination
Fabric Weight (kgm2) 1 1 1
Composite Weight (kgm2) 18 15 13
Resin usage (kgm2) 15 1 08
Amount of Fabric 22 Ply 16 Ply 13 Ply
Thickness 15 mm 12 mm 10 mm
Tensile Strength (Mpa) 125 1796 400
Tensile Strength (Nmmsup2) 28463 30958 4576
Processing Time High Med Low
Labour Cost High Med Low
MULTIAXIAL
Total Penggunaan Resin -51
Total Berat Kapal -40
Kekuatan Bangunan Kapal +59
Efisiensi Tenaga Kerja
Waktu Pengerjaan Lebih Cepat
KEUNGGULAN MATERIAL
Resapan Resin Lebih Baik amp Merata
Lapisan Lebih Sedikit
Meningkatkan Kekuatan Kapal
KEUNGGULAN MATERIAL
TRIAXIAL
DBL series DBT series
BIAXIAL
LT series DB series
UNIDIRECTIONAL
L series T series
QUADRIAXIAL
DBLT series
JENIS MULTIAXIAL
UNIDIRECTIONAL
DCMU 900 E ndash
KHUSUS UNTUK MEMPERKUAT BENDING KAPAL
PEMASANGAN KHUSUS PADA KEEL DAN TULANGAN
JENIS MULTIAXIAL UNTUK KAPAL
TRIAXIAL
DBL 600 ndash
APLIKASI PADA INDUSTRI PENERBANGAN
PEMASANGAN KHUSUS PADA
SAMBUNGAN BADAN DAN SAYAP
PESAWAT
JENIS MULTIAXIAL UNTUK PESAWAT
QUADRAXIAL
DBLT 800 ndash
APLIKASI PADA INDUSTRI ENERGI
DITERAPKAN UNTUK KEBUTUHAN PEMBANGKIT
LISTRIK ENERGI ANGIN
MULTIAXIAL UNTUK ENERGI
INDUSTRI KIMIA OLAHRAGA AUTOMOTIF
MULTIAXIAL UNTUK INDUSTRI LAINNYA
COMPOSITES
GUNAKAN MATERIAL FIBERGLASS
YANG SUDAH DISERTIFIKASI
BKI
FIBERGLASS UNTUK PEMBANGUNAN BAKAP
PERATURAN MENTERI PERHUBUNGAN
NOMOR PM 7 TAHUN 2013
TENTANG KEWAJIBAN KLASIFIKASI BAGI KAPAL BERBENDERA INDONESIA
PADA BADAN KLASIFIKASI
BADAN SERTIFIKASI MARITIM
Biro Klasifikasi IndonesiaDet Norske Veritas Germanischer Lloyds
PERATURAN BKI
Untuk Kapal Non-Metal
2006
PERSYARATAN MINIMUM
kekuatan material yang
harus digunakan
untuk membangun
Kapal Fiberglass
PEMBESARAN
Table 21
FIBERGLASS TRIAXIS COMPOSITES
TELAH BERSERTIFIKASI BKI
Biro Klasifikasi Indonesia
65
TEKNIK MANUFAKTUR
COMPOSITES
Wet hand lay-up
1) Peletakan
Dry Reinforcement
bull Dry reinforcement dan resin (+ katalis) ditaruh pada permukaan cetakan
2) Pemasukanpenekanan resin
bull Resin ditekan untuk meng-impregnasi serat dengan menggunakan rol
3) Pengulangan proses untuk lapisan lain
bull Beberapa lapisan dapat ditambahkan secara bertahap
4) Resin curing
bull Reaksi dimulai komponen dilepaskan setelah komponen mengeras
(fully cured)
Wet hand lay-up
Manufaktur komponen dapat dikerjakan dengan menggunakan beberapa lapis komposit
dengan memperhatikan kompatibilitas material dan tahapan curing Modifikasi proses dapat
dilakukan seperti
Vacuum bagging
setelah lay-up
Glass Roving
Bulk Resin
Catalyst
3) De-molding
2) Resin Cure
bull Curing dimulai dan komponen dilepaskan setelah pengerasan selesai
bull Serat gelas resin dan katalis dimasukkan kedalam spray gun
1) Spray-up
bull Campuran disemprotkan pada permukaan cetakan
Spray-up
69
Penyemprotan bakal komponen
Komponen
dilepaskan
dari cetakan
Full dispensing
system Chopper Roving
Atomised resin
and catalyst
Spray-up
Prepreg
1) LaminateAssembly 5) De-molding
3) Resin Melts Layup Consolidates
bull Prepreg serat yang sudah diimpregnasi oleh resin+katalis dalam kondisi padat
bull Lapisan prepreg digunting sesuai bentuk yang diinginkan kemudian diletakkan pada permukaan cetakan
sesuai bentuk komponen yang diinginkan Lay-up mudah dilakukan karena sifat ldquotackynessrdquo dari prepreg
2) Applied Vacuum Pressure and Heat
bull Tekanan dan panas diberikan resin mencair terjadi konsolidasi pada komponen
4) Resin Cures
bull Temperatur dinaikkan untuk memulai curing
Prepreg
Variasi proses Autoclave
Komponen dalam
vacuum-bag
bull Campuran resin (+katalis) dan chopped glass strands diperoleh dalam bentuk premixed compound Bulk molding
Compound (BMC) dalam bentuk adonan atau Sheet molding Compound (SMC) dalam bentuk lembaran
bull Ketika panas dan tekanan diberikan oleh cetakan compound mengalir sesuai bentuk komponen yang diinginkan
1) Placement of Charge
5) De-molding3) Squeeze to final dimensions
2) Mould Closure4) Resin Cure
bull Curing dimulai komponen dilepaskan setelah terjadi pengerasan yang cukup
Compression Molding
bull Preform atau dry reinforcement dimasukkan kedalam cetakan sesuai dengan bentuk komponen yang
diinginkan
bull Resin mengalir dengan penekanan atau pem-vakuman dan meng-impregnasi preform dan
mendorongmengeluarkan udara yang ada dalam preform
1) Preform Manufacture
2) Preform Compression
5) De-molding3) Resin Injection
4) Resin Cure
bull Curing terjadi cetakan dibuka setelah terjadi pengerasan yang mencukupi
Liquid Molding (RTM VARI VARTM)
Pultrusion
bull Dry roving or fabrics ditarik melalui bak berisi
campuran resin dan katalis
bull Campuran yang basah ditarik melalui cetakan
bull Sisa resin keluar cetakan
bull Pemanasan dilakukan untuk proses curing
bull Pendinginan dilakukan untuk mempercepat siklus
produksi
Cut-off
Cooling
Die sections
Resin bath
Fibre creel
Filament Winding
bull Dry roving ditarik melalui bak berisi campuran resin dan katalis
bull Wet roving digulungkan dalam keadaan tegang kepada mandrel
bull Kontrol mekanik dari pembawa serat mengatur orientasi peletakan serat pada
mandrel
INDUSTRI COMPOSITES
AEROSPACE
HISTORY
1950 ndash Boeing
1960 ndash F14 Tomcat
1981 ndash AV-8B Harrier
Source
Low-Cost Composite Materials and Structures for Aircraft Applications
httpwwwreinforcedplasticscom
httpwwwcentennialofflightgovessayEvolution_of_TechnologycompositesTech40htm
Automotive
Composite material is used in a number of applications in the automotive
industry due to its temperature resistance rigidity and fatigue strength
The benefits of using composites include greater fuel efficiency
corrosion resistance light weight and strength Composites also provide
a low-cost way to help keep designs looking fresh
Composites are used in
- interior parts (cockpit trimming seats instrument panels)
- exterior structure (body panels openings underbody frontrear
modules)
- engine compartment and fuelmechanical area parts (axles and
suspensions fuel and exhaust systems)
- electrical and electronic components
Lamborghinis Sesto Element carbon fiber
ldquoFat men cannot run as fast as thin men but we build most of our vehicles as though dead-weight fat increased speedhellip I cannot
imagine where the delusion that weight means strength
came fromhelliprdquo mdashHenry Ford
The mix of automotive materials is changing showing a boost for FRP in helping original
equipment manufacturers meet fuel economy and emissions challenges
(Source 2011 DuPont AutomotiveSAE survey of design engineers performed by Signet Research Inc)
Source
httpwwwtoraycomcsrhighlight2009hig_001_01html
The MonoCell tub for the McLaren MP4-12C supercar is moulded as a single
piece and weighs less than 80 kg (176 lbs)
COMPOSITES IN MARINE
TRIMARAN BOAT
AMERICA NAVYINDONESIAN NAVY
Visby Class corvette
Total length is 72 meters
The beam is 1040 meters
The displacement is 600 metric tones
fully equipped the worlds largest CRP
construction
The design of the Visby aims to minimize
the optical and infrared signature above
water acoustic and hydroa coustic
signature underwater electrical potential
and magnetic signature pressure signature
radar cross section and actively emitted
signals
A stealth corvette of the YS 2000 design
has a detection range of 13km in rough
seas and 22km in calm sea without
jamming In a jammed environment the
Visby would be detected at a range of 8km
in rough sea and 11km in calm sea
The material provides high strength and
rigidity low weight good shock resistance
low radar and magnetic signature
1996
Visby is a class of stealth corvettes for the Swedish Navy
ldquoReduced 50 of a Conventional Steelrdquo
Source
Hull Construction with composite materials for ships over 100m in length 2002
Massachusetts Institute of Technology
httpwwwnaval-technologycomprojectsvisby
YACHTS
KAL YUDISTIRAMARATHON 100 ADMIRAL YACHT
LOA 3050 MWidth 6 MFuel Tank 8000 LWater Tank 3000 LIce Box 500 LAccommodation Max 35 Personnel
2 x CATERPILLAR 3412E 1200 HPMARINE DIESEL ENGINE
PC 40 ndash KRI Krait 827Department of Indonesian Navy
LOA 40 MWidth 73 MPower 190Weapon Twin Cannon Barrels
127 mm Heavy Machine GunSpeed Knot 25 KnotDisplacement 105 tonAccommodation 23 personnel
PATROL BOAT
Rigid Inflatable BoatPATROL BOAT
Yachts
36m Luxury Yacht Moonraker
36m Luxury Yacht GoldenEye
50m Luxury Yacht Casino
Royale
45m Luxury Yacht Seashaw
Boat Parts
Barovans for Seismic Sweep
Centrifugal Liftfan House for Surface Effect
Ships
Composite Boat PropellersRTM
Deckhouses for Pilot Boats
Fairing Parts for Submarines
Flybridges for Motor yachts
Light Weight Gangway
MTB Launcher Mock-up
Pleasure Boats
12m Sailboat
12m Sail-Catamaranone-off
Canoes
Dragonfly 1000Catamaran Sailboat
Fantasy 37Sailboat
Farr 60Luxury Sailboat
EurodingyOlympic Dingy Class for
Woman
Hydrolift F23 Racing Boats
Kajacs
Najad 42Sailboat
Najad 520Sailboat
Najad 441Sailboat
Najad 391Sailboat
Nordwest 900Motorboat
Nordwest 1100Motorboat
Quatro 44Motorboat
Racemaster Competition Boats
Storebro 420
Storebro 345
Sweden Yacht 370Sailboat
Sweden Yacht 69Sailboat
Windy 41Motorboat
X-632Sailboat
X-362Sailboat
Commercial Boats
175m High Speed AmbulancePassenger Boat
19m High Speed Passenger Boat
20m High Speed Passenger Boat
364m Surface Effect Passenger Ship
45m Surface Effect Passenger Ship
120m Hull Structural Parts HSSS Catamaran Ferry
APPENDIX
Marine Vessel
1188m Fast Attack Vessel FMV 90 E
20m SAV-Surface Auxiliary Vessels
34m Personnel TransportCoast Guard Vessel
40ft Experimental SES
40m Landsort-Class Mine Hunters
54m Mine Counter Measure Vehicles SES
74m Coastal Patrol Boats
Fishing Boats
30 GT
12 GT
10 GT
5 GT
WISEWings In Surface Effect
HOVERCRAFT
Designed specifically for the tourist and transport industries the
Pioneer Mk3 hovercraft is amphibious and comfortably seats 25
passengers plus 1-crew The air-conditioned cabin allows for
maximum visibility for all aboard The Pioneer Mk3 is robust and
dynamic in its performance
Commercial hovercraft
Mk3 AirLift Hovercraft - 1215m
Power is economicaly provided by one Deutz diesel engine of
330kW (442hp) to cruise easily at 40 knots with much higher
speeds available according to the surface conditions The hull is
manufactured from fibreglassPVC foam composite sandwich
the windows are glass and the skirt is urethane coated nylon A
Military version is available with increased payload and systems
redundancy Power for the Military version comes from two Steyr
diesel engines with a total installed power of 320kW (429hp) All
transmission electrical hydraulic and air systems are duplicated
for maximum redundancy The increased performance of the
Military version comes from the reduced engine weight of the twin
Steyr installation cf the Deutz installation
Source
httpwwwnauticexpocomprodairlift-hovercraftcommercial-hovercrafts-25251-142868html
HOVERFLIGHT
BALLISTIC amp UNIT DEFENCED
Triaxis Composites Collaboration with Institute of Aeronautics and Space in the development of Missile Nose Cone
Polymer composites is the evolution of the military defence
Thin steel was the helmet material of
WWII and remained the principal material until around the 1980rsquos
The advantages of using steel
included a simple technology for manufacture of the helmets low cost and reasonably good
impact protection However these helmets were found to provide only marginal protection
against fragments
During the Vietnam War the US Army experimented with fiber-reinforced inserts in the
helmets These inserts improved ballistic protection but at the same time added weight and
reduced the air space between the head and the helmet
By the early part of the 1980rsquos the US military had developed the first all-composite
100 fiber-reinforced helmet This development resulted in even better ballistic protection
without altering the weight of the helmet Other improvements included better head coverage and
more space for ventilation
Source
Composites Armor - A difficult but huge market
by A Brent Strong Brigham Young University
MILITARY VEHICLES
HIGH SPEED TRAIN SHINKANSEN
Advanced Composites provide lightweight solutions for railway vehicles
saving as much as 50-80 of the weight compared with traditional
components
A lower overall weight translates into less stress faster acceleration and
higher speeds as well as reduced starting and stopping inertia Today
these are important criteria in global high-speed and metropolitan
railway projects
Fire smoke and toxic fumes are key safety criteria for interior
components of railway carriages Any material selected for an interior
component must meet international fire retardant standards
for Rail Interiors and Exteriors
Ceiling Panels Stairs
Seating Vestibules
Window Panels Door Pillars
Partition WallsDiffusers
Gangway and Cabinet Panels Cabin and
Desk panels
Door Pillars Lavatory Modules (standard and
Front and Rear EndsRoof Panels
Nose Cones Under Fairings
Source
httpwwwpctaerail_compositesphp
101
SKY BUS
2009
Europe is the world leader in offshore wind with
828 wind turbines and a cumulative capacity of 2056 MW spread across 38 offshore wind farms in 9
European countries
The UK and Denmark are the current leaders with a 44 and 30 share respectively In 2009
five countries built new offshore wind farms
UK (284 MW)
Demark (230 MW)
Sweden (30 MW)
Germany (30 MW)
Norway (23 MW)
2010
Asia leads the growth in global wind power which grew 358 GW in 2010 bringing
total global capacity to 1944 GW ndash up 225 from 2009
the Global Wind Energy Council (GWEC)
Asia accounted for 19 GW of new global wind power installations driven by China which installed 165
GW
ldquoChina now has 423 GW of wind powerrdquo
ldquoThis puts China firmly on a path to reach 200 GW of installed wind power by 2020 At the same
time China has become the worldrsquos largest producer of wind energy equipmentrdquo
Source
httpwwwreinforcedplasticscomview15655asia-leads-global-wind-power-growth
httpimgdeusmcomdesignnews288288605-Sandia_Sizes_up_Wind_Turbine_Blade_Design_C_largegif
WIND ENERGY
Marine Current Turbines
Source
httpwwwsiemenscompressenpressreleasepress=enpressrelease2011solar-hydroex201111005htm
httpwwwmarineturbinescom
A commercial marine current turbine consists of
two rotors which are fixed on a structure within the
sea current The twin rotors rotate with the
movement of the tidal flow and the blades pitch
through 180 degrees to optimally track tidal current
(Press picture Marine Current Turbines)
Wave Star Energys Multi-point Absorber
CFRP COLUMN REINFORCEMENT
INDUSTRIAL TANKS
107
INDUSTRIAL PIPES
PRESSURE TANKS
109
ldquoLetrsquos Make with Compositesrdquo
MATERIAL COMPOSITES
Thermoset
type
Density r
(kgm3)
Stiffnes
s E
(Gpa)
Tensile
strength
s (MPa)
Strain to
failure e
()
Tg 0C
Thermal
conductivity
k (Wm0C)
Specific
Heat Cp
(kJkg0C)
Thermal
expansion coeff
a (x106 0C-1)
Polyester 1100-1230 31-46 50-75 10-65 70- 017-022 13-23 55-100
Vinylester 1120-1130 31-33 70-81 30-80 70- - - -
Epoxy 1100-1200 26-38 60-85 15-80 65-175 017-020 105 45-65
Phenolic 1000-1250 30-40 60-80 18 300 012-024 14-18 25-60
PUR 1200 07 30-40 400-450 135 017-021 13-23 70-100
BMI 1200-1320 32-50 48-110 15-33 230-345 - - -
Polyimide 1430-1890 31-49 100-110 15-30 325-370 01-034 105-15 25-80
Al 2800 72 540 18 - 130 096 236
Steel 7790 205 640 25 - 54 046 11
MATRIKS POLIMER THERMOSET
Variasi sifat yang lebar disebabkan oleh adanya formulasi kimia yang berbeda dan penambahan aditif
Jenis Glass Fiber S Glass E Glass C Glass A Glass dll
Terms
Glass Type
S Glass E Glass C Glass A Glass
Silica (SiO2) Content 67 55 64 72
Al2O3 Content 23 14 6 1
Melting Point (Celcius) 915 836 745 745
Tensile Strength 665 500 440 440
Modulus Elastisitas 124 105 100 -
Application AEROSPACE BOAT CHEMICAL TANK CHEMICAL TANK
JENIS SERAT GLASS
CHINA
JENIS SERAT GLASS
C GLASS Calcium borosilicate glasses
used for CHEMICAL stability in corrosive
acid environments
E GLASS Alumina-calcium-borosilicate
glasses with a maximum alkali used as
general purpose fibers where STRENGTH
and high ELECTICAL RESISTIVITY are
required It manifests better electrical
insulation and strongly resists attack by
water More than 50 of the glass fibers
used for reinforcement is E-glass
C Glass
E Glass
C amp E GLASS
SUMBER AGY TECHNICAL PAPER HIGH STRENGTH GLASS FIBER
FAKTA
C GLASS 1 BOROS RESIN
2 KEKUATAN
KURANG
FAKTA
E GLASS 1 HEMAT RESIN
2 KEKUATAN BAIK
3 TAHAN LAMA
FAKTA
TEBAL BUKAN BERARTI KUAT
UNSUR MATRIX (RESIN)
TIDAK ADA KEKUATAN
ldquoMore than 50 of the glass fibers used for
reinforcement is E-glassrdquo
C glass E glass
E glass
C glass
KAIN WOVEN ROVING HASIL LAMINASI
JENIS SERAT GLASS
Kekuatan composites ditentukan oleh
1 Kekuatan amp Sifat Fiber
2 Kekuatan amp Sifat Resin
3 Fraksi Rasio Perbandingan Volume Fiber
dan Resin dalam Composites
rarr tergantung dari Proses Manufaktur
4 Geometri dan Orientasi Arah Fiber dalam
Composites
KEKUATAN COMPOSITES
PROSES MATERIAL
Proses Produksi Kain Fiberglass
Biji Kaca Benang Benang Kaca Kain Fiberglass
PROSES MATERIAL
Glass Beads
Glass Fiber Glass Roving YarnGlass Fabric
FIBERGLASS
PRODUK
MATERIAL DAN PRODUK FIBERGLASS
+
Resin + Additives
PERPADUAN COMPOSITES
BENANG KACA Potongan Serat Kaca CSM
CSM - CHOPPED STRAND MAT
chopped binder
Kain Fiberglass Generasi Pertama
BahanPengikat
SenyawaPada Resin
JENIS FIBERGLASS
Glass Roving Yarn Chopped Strand
ADVANTAGES DISADVANTAGES
Steel
1048707 Low cost 1048707 Corrodes easily
1048707 Ductile under ambient conditions
1048707 Has no lower fatigue limit for welded structures
1048707 Virtually isotropic 1048707 Heavy
1048707 Easily formed and fabricated 1048707 Brittle at low temperatures
1048707 Easily obtained (low relative cost) 1048707 Magnetic
1048707 Easily alloyed or heat treated for special operations
1048707 Easily repaired
1048707 Good fire resistance
1048707 Behaviour is well understood
Alumunium Alloy
1048707 Light weight 1048707 Poor fatigue properties
1048707 Corrosion resistant 1048707 Poor performance in fire
1048707 Easily formed1048707 Low melting point and softening temperature
1048707 Easily fabricated 1048707 High relative cost
1048707 Readily available 1048707 Strength and stiffness less than steel
1048707 Ductile
1048707 Non magnetic
FRP
1048707 Low magnetic properties
1048707 Low electrical conductivity (glass- reinforced plastics)
1048707 Resistance to corrosion
1048707 Resistance to rot and marine growth
1048707 Relatively high sonar transparency
1048707 Good strength to weight ratio
1048707 Good fatigue properties
1048707 Maintenance of properties at low temperatures
1048707 Availability
1048707 Can be manufactured to near net-shape
1048707 Stiffness and strength can be tailored to structural requirements
1048707 Excellent thermal insulation
1048707 Light weight
STEEL vs ALUMUNIUM vs COMPOSITES
Source
1Maritime Platforms Division Aeronautical and
Maritime Research Laboratory (Seref Aksu
Stuart Cannon Craig Gardiner and Matthew
Gudze
2 Metal Corrosion can be defined as the
destructive attack of a metal through interaction
with its environment
(httpwwwcorrosionistcomCorrosion_Fundament
alhtm)
28
Serat rarr penguat
Polimer matriks rarr pengikat
bull Sifat mekanik yang cukup baik
bull Viskositas dan temperatur pengerjaan rendah rarr mudah
dimanufaktur
bull Ketahanan korosi yang baik
bull Media perpindahan gaya rarr distribusi beban dari serat ke serat
bull Ulet rarr Melindungi serat yang getas
bull Size effect rarr Kekuatan dan kekakuan sangat tinggi
bull Aspect ratio (ld) tinggi rarr luas permukaan besar
bull Fleksibel rarr variasi teknik manufaktur
bull Serat dapat diatur sesuai dengan arah pembebanan
29
Advantages Polimer Composites
Kekuatan dan kekakuan spesifik yang tinggi FRCP vs material lain rarr kompetitif jika berat dipertimbangkan
Material Berat jenis
r (kgm3)
Kekakuan
E (GPa)
Kekuatan
tarik su
(MPa)
Kekakuan
spesifik
Er
Kekuatan
spesifik sur
Baja 7800 208 400 27 005
Aluminium 2700 70 200 259 007
Nylon 1100 25 80 23 007
Beton 2400 40 20 166 0008
Random
FRPC
1800 20 300 111 0006
Alligned FRPC
( serat)
1600 200 1500 125 094
Alligned FRCP
( serat)
1600 3 50 19 0001
Tensile Strength amp Modulus of Common Structural Materials
Densities of Common Structural Materials
Specific Tensile Strength amp Modulus of Common Structural Materials
Typical Properties of Common Structural Materials
Kesimpulan COMPOSITES = RINGAN amp KUAT
Jadi secara keseluruhan kekuatan composites
ditentukan oleh
1 Kekuatan amp Sifat Fiber
2 Kekuatan amp Sifat Resin
3 Fraksi Rasio Perbandingan Volume Fiber
dan Resin dalam Composites
4 Geometri dan Orientasi Arah Fiber dalam
Composites
PRODUKSI ANAK NEGERI
Proses Produksi Kain Fiberglass
Biji Kaca Benang Benang Kaca Kain Fiberglass
PROSES MATERIAL
Glass Beads
Glass Fiber Glass Roving YarnGlass Fabric
Proses Produksi Kain Fiberglass
Biji Kaca Benang Benang Kaca Kain Fiberglass
Glass Beads
Glass Fiber Glass Roving YarnGlass Fabric
PROSES MATERIAL
Benang Kaca Potongan Serat Kaca Chopped Strand Mat
CSM - Chopped Strand Mat
chopped binder
Produk Fiberglass Generasi Pertama
Bahan Pengikat
Senyawa Pada Resin
Glass Roving Yarn Chopped Strand
JENIS FIBERGLASS
Benang Kaca Woven Roving
WR - Woven Roving
Tenun Weaving
Produk Fiberglass Generasi Kedua
Glass Roving Yarn
JENIS FIBERGLASS
Multiaxial
MAX - Multiaxial
warp knitting
Produk Fiberglass Generasi Ketiga
Benang Kaca
Glass Roving Yarn
JENIS FIBERGLASS
MAX - Multiaxial Fabric
Fleece (optional)
Lapisan
MULTIAXIAL PROSES
Karakteristik CSM
bull Glass Content 30
bull Resin Content 70
bull Tensile Force
Chopped Strand Mat
JENIS FIBERGLASS
Karakteristik Woven Roving
bull Glass Content 45
bull Resin Content 55
Woven Roving
Resin
|
|
|
|
|
|
|
|
|
|
|
|
|
|
bull Kekuatan Tarik
JENIS FIBERGLASS
No Resin Rich Area
Karakteristik Multiaxial
bull Glass Content 60
bull Resin Content 40
Produk Fiberglass Ketiga MULTIAXIAL
JENIS FIBERGLASS
Perbedaan Woven Roving dan Multiaxial ndash Tampak Samping
JENIS FIBERGLASS
WR FRP
8 Ply WR 800
8 Ply CSM 450
Glass Weight 1 kg
Composite Weight 15kgm2
CSM FRP
22 Ply CSM 450
Glass Weight 1 kg
Composite Weight 18 kgm2
MULTIAXIAL FRP
13 Ply DB 800
Glass Weight 1 kg
Composite Weight
13 kgm2
JENIS FIBERGLASS
Multiaxial
FRP
Woven Roving
FRP
Chopped Strands Mat FRP
MULTIAXIAL
FAKTA
TEBAL BUKAN BERARTI KUAT
UNSUR MATRIX (RESIN)
TIDAK ADA KEKUATAN
ldquoMore than 50 of the glass fibers used for reinforcement is
E-glassrdquo
KarakteristikKekuatan
CSM WR MAX
Kekuatan Tarik 175 MPa 250 MPa 425 MPa
CSM 142
WR 70
KEKUATAN TARIK
Properties CSM Lamination WR Lamination MAX Lamination
Fabric Weight (kgm2) 1 1 1
Composite Weight (kgm2) 18 15 13
Resin usage (kgm2) 15 1 08
Amount of Fabric 22 Ply 16 Ply 13 Ply
Thickness 15 mm 12 mm 10 mm
Tensile Strength (Mpa) 125 1796 400
Tensile Strength (Nmmsup2) 28463 30958 4576
Processing Time High Med Low
Labour Cost High Med Low
MULTIAXIAL
Total Penggunaan Resin -51
Total Berat Kapal -40
Kekuatan Bangunan Kapal +59
Efisiensi Tenaga Kerja
Waktu Pengerjaan Lebih Cepat
KEUNGGULAN MATERIAL
Resapan Resin Lebih Baik amp Merata
Lapisan Lebih Sedikit
Meningkatkan Kekuatan Kapal
KEUNGGULAN MATERIAL
TRIAXIAL
DBL series DBT series
BIAXIAL
LT series DB series
UNIDIRECTIONAL
L series T series
QUADRIAXIAL
DBLT series
JENIS MULTIAXIAL
UNIDIRECTIONAL
DCMU 900 E ndash
KHUSUS UNTUK MEMPERKUAT BENDING KAPAL
PEMASANGAN KHUSUS PADA KEEL DAN TULANGAN
JENIS MULTIAXIAL UNTUK KAPAL
TRIAXIAL
DBL 600 ndash
APLIKASI PADA INDUSTRI PENERBANGAN
PEMASANGAN KHUSUS PADA
SAMBUNGAN BADAN DAN SAYAP
PESAWAT
JENIS MULTIAXIAL UNTUK PESAWAT
QUADRAXIAL
DBLT 800 ndash
APLIKASI PADA INDUSTRI ENERGI
DITERAPKAN UNTUK KEBUTUHAN PEMBANGKIT
LISTRIK ENERGI ANGIN
MULTIAXIAL UNTUK ENERGI
INDUSTRI KIMIA OLAHRAGA AUTOMOTIF
MULTIAXIAL UNTUK INDUSTRI LAINNYA
COMPOSITES
GUNAKAN MATERIAL FIBERGLASS
YANG SUDAH DISERTIFIKASI
BKI
FIBERGLASS UNTUK PEMBANGUNAN BAKAP
PERATURAN MENTERI PERHUBUNGAN
NOMOR PM 7 TAHUN 2013
TENTANG KEWAJIBAN KLASIFIKASI BAGI KAPAL BERBENDERA INDONESIA
PADA BADAN KLASIFIKASI
BADAN SERTIFIKASI MARITIM
Biro Klasifikasi IndonesiaDet Norske Veritas Germanischer Lloyds
PERATURAN BKI
Untuk Kapal Non-Metal
2006
PERSYARATAN MINIMUM
kekuatan material yang
harus digunakan
untuk membangun
Kapal Fiberglass
PEMBESARAN
Table 21
FIBERGLASS TRIAXIS COMPOSITES
TELAH BERSERTIFIKASI BKI
Biro Klasifikasi Indonesia
65
TEKNIK MANUFAKTUR
COMPOSITES
Wet hand lay-up
1) Peletakan
Dry Reinforcement
bull Dry reinforcement dan resin (+ katalis) ditaruh pada permukaan cetakan
2) Pemasukanpenekanan resin
bull Resin ditekan untuk meng-impregnasi serat dengan menggunakan rol
3) Pengulangan proses untuk lapisan lain
bull Beberapa lapisan dapat ditambahkan secara bertahap
4) Resin curing
bull Reaksi dimulai komponen dilepaskan setelah komponen mengeras
(fully cured)
Wet hand lay-up
Manufaktur komponen dapat dikerjakan dengan menggunakan beberapa lapis komposit
dengan memperhatikan kompatibilitas material dan tahapan curing Modifikasi proses dapat
dilakukan seperti
Vacuum bagging
setelah lay-up
Glass Roving
Bulk Resin
Catalyst
3) De-molding
2) Resin Cure
bull Curing dimulai dan komponen dilepaskan setelah pengerasan selesai
bull Serat gelas resin dan katalis dimasukkan kedalam spray gun
1) Spray-up
bull Campuran disemprotkan pada permukaan cetakan
Spray-up
69
Penyemprotan bakal komponen
Komponen
dilepaskan
dari cetakan
Full dispensing
system Chopper Roving
Atomised resin
and catalyst
Spray-up
Prepreg
1) LaminateAssembly 5) De-molding
3) Resin Melts Layup Consolidates
bull Prepreg serat yang sudah diimpregnasi oleh resin+katalis dalam kondisi padat
bull Lapisan prepreg digunting sesuai bentuk yang diinginkan kemudian diletakkan pada permukaan cetakan
sesuai bentuk komponen yang diinginkan Lay-up mudah dilakukan karena sifat ldquotackynessrdquo dari prepreg
2) Applied Vacuum Pressure and Heat
bull Tekanan dan panas diberikan resin mencair terjadi konsolidasi pada komponen
4) Resin Cures
bull Temperatur dinaikkan untuk memulai curing
Prepreg
Variasi proses Autoclave
Komponen dalam
vacuum-bag
bull Campuran resin (+katalis) dan chopped glass strands diperoleh dalam bentuk premixed compound Bulk molding
Compound (BMC) dalam bentuk adonan atau Sheet molding Compound (SMC) dalam bentuk lembaran
bull Ketika panas dan tekanan diberikan oleh cetakan compound mengalir sesuai bentuk komponen yang diinginkan
1) Placement of Charge
5) De-molding3) Squeeze to final dimensions
2) Mould Closure4) Resin Cure
bull Curing dimulai komponen dilepaskan setelah terjadi pengerasan yang cukup
Compression Molding
bull Preform atau dry reinforcement dimasukkan kedalam cetakan sesuai dengan bentuk komponen yang
diinginkan
bull Resin mengalir dengan penekanan atau pem-vakuman dan meng-impregnasi preform dan
mendorongmengeluarkan udara yang ada dalam preform
1) Preform Manufacture
2) Preform Compression
5) De-molding3) Resin Injection
4) Resin Cure
bull Curing terjadi cetakan dibuka setelah terjadi pengerasan yang mencukupi
Liquid Molding (RTM VARI VARTM)
Pultrusion
bull Dry roving or fabrics ditarik melalui bak berisi
campuran resin dan katalis
bull Campuran yang basah ditarik melalui cetakan
bull Sisa resin keluar cetakan
bull Pemanasan dilakukan untuk proses curing
bull Pendinginan dilakukan untuk mempercepat siklus
produksi
Cut-off
Cooling
Die sections
Resin bath
Fibre creel
Filament Winding
bull Dry roving ditarik melalui bak berisi campuran resin dan katalis
bull Wet roving digulungkan dalam keadaan tegang kepada mandrel
bull Kontrol mekanik dari pembawa serat mengatur orientasi peletakan serat pada
mandrel
INDUSTRI COMPOSITES
AEROSPACE
HISTORY
1950 ndash Boeing
1960 ndash F14 Tomcat
1981 ndash AV-8B Harrier
Source
Low-Cost Composite Materials and Structures for Aircraft Applications
httpwwwreinforcedplasticscom
httpwwwcentennialofflightgovessayEvolution_of_TechnologycompositesTech40htm
Automotive
Composite material is used in a number of applications in the automotive
industry due to its temperature resistance rigidity and fatigue strength
The benefits of using composites include greater fuel efficiency
corrosion resistance light weight and strength Composites also provide
a low-cost way to help keep designs looking fresh
Composites are used in
- interior parts (cockpit trimming seats instrument panels)
- exterior structure (body panels openings underbody frontrear
modules)
- engine compartment and fuelmechanical area parts (axles and
suspensions fuel and exhaust systems)
- electrical and electronic components
Lamborghinis Sesto Element carbon fiber
ldquoFat men cannot run as fast as thin men but we build most of our vehicles as though dead-weight fat increased speedhellip I cannot
imagine where the delusion that weight means strength
came fromhelliprdquo mdashHenry Ford
The mix of automotive materials is changing showing a boost for FRP in helping original
equipment manufacturers meet fuel economy and emissions challenges
(Source 2011 DuPont AutomotiveSAE survey of design engineers performed by Signet Research Inc)
Source
httpwwwtoraycomcsrhighlight2009hig_001_01html
The MonoCell tub for the McLaren MP4-12C supercar is moulded as a single
piece and weighs less than 80 kg (176 lbs)
COMPOSITES IN MARINE
TRIMARAN BOAT
AMERICA NAVYINDONESIAN NAVY
Visby Class corvette
Total length is 72 meters
The beam is 1040 meters
The displacement is 600 metric tones
fully equipped the worlds largest CRP
construction
The design of the Visby aims to minimize
the optical and infrared signature above
water acoustic and hydroa coustic
signature underwater electrical potential
and magnetic signature pressure signature
radar cross section and actively emitted
signals
A stealth corvette of the YS 2000 design
has a detection range of 13km in rough
seas and 22km in calm sea without
jamming In a jammed environment the
Visby would be detected at a range of 8km
in rough sea and 11km in calm sea
The material provides high strength and
rigidity low weight good shock resistance
low radar and magnetic signature
1996
Visby is a class of stealth corvettes for the Swedish Navy
ldquoReduced 50 of a Conventional Steelrdquo
Source
Hull Construction with composite materials for ships over 100m in length 2002
Massachusetts Institute of Technology
httpwwwnaval-technologycomprojectsvisby
YACHTS
KAL YUDISTIRAMARATHON 100 ADMIRAL YACHT
LOA 3050 MWidth 6 MFuel Tank 8000 LWater Tank 3000 LIce Box 500 LAccommodation Max 35 Personnel
2 x CATERPILLAR 3412E 1200 HPMARINE DIESEL ENGINE
PC 40 ndash KRI Krait 827Department of Indonesian Navy
LOA 40 MWidth 73 MPower 190Weapon Twin Cannon Barrels
127 mm Heavy Machine GunSpeed Knot 25 KnotDisplacement 105 tonAccommodation 23 personnel
PATROL BOAT
Rigid Inflatable BoatPATROL BOAT
Yachts
36m Luxury Yacht Moonraker
36m Luxury Yacht GoldenEye
50m Luxury Yacht Casino
Royale
45m Luxury Yacht Seashaw
Boat Parts
Barovans for Seismic Sweep
Centrifugal Liftfan House for Surface Effect
Ships
Composite Boat PropellersRTM
Deckhouses for Pilot Boats
Fairing Parts for Submarines
Flybridges for Motor yachts
Light Weight Gangway
MTB Launcher Mock-up
Pleasure Boats
12m Sailboat
12m Sail-Catamaranone-off
Canoes
Dragonfly 1000Catamaran Sailboat
Fantasy 37Sailboat
Farr 60Luxury Sailboat
EurodingyOlympic Dingy Class for
Woman
Hydrolift F23 Racing Boats
Kajacs
Najad 42Sailboat
Najad 520Sailboat
Najad 441Sailboat
Najad 391Sailboat
Nordwest 900Motorboat
Nordwest 1100Motorboat
Quatro 44Motorboat
Racemaster Competition Boats
Storebro 420
Storebro 345
Sweden Yacht 370Sailboat
Sweden Yacht 69Sailboat
Windy 41Motorboat
X-632Sailboat
X-362Sailboat
Commercial Boats
175m High Speed AmbulancePassenger Boat
19m High Speed Passenger Boat
20m High Speed Passenger Boat
364m Surface Effect Passenger Ship
45m Surface Effect Passenger Ship
120m Hull Structural Parts HSSS Catamaran Ferry
APPENDIX
Marine Vessel
1188m Fast Attack Vessel FMV 90 E
20m SAV-Surface Auxiliary Vessels
34m Personnel TransportCoast Guard Vessel
40ft Experimental SES
40m Landsort-Class Mine Hunters
54m Mine Counter Measure Vehicles SES
74m Coastal Patrol Boats
Fishing Boats
30 GT
12 GT
10 GT
5 GT
WISEWings In Surface Effect
HOVERCRAFT
Designed specifically for the tourist and transport industries the
Pioneer Mk3 hovercraft is amphibious and comfortably seats 25
passengers plus 1-crew The air-conditioned cabin allows for
maximum visibility for all aboard The Pioneer Mk3 is robust and
dynamic in its performance
Commercial hovercraft
Mk3 AirLift Hovercraft - 1215m
Power is economicaly provided by one Deutz diesel engine of
330kW (442hp) to cruise easily at 40 knots with much higher
speeds available according to the surface conditions The hull is
manufactured from fibreglassPVC foam composite sandwich
the windows are glass and the skirt is urethane coated nylon A
Military version is available with increased payload and systems
redundancy Power for the Military version comes from two Steyr
diesel engines with a total installed power of 320kW (429hp) All
transmission electrical hydraulic and air systems are duplicated
for maximum redundancy The increased performance of the
Military version comes from the reduced engine weight of the twin
Steyr installation cf the Deutz installation
Source
httpwwwnauticexpocomprodairlift-hovercraftcommercial-hovercrafts-25251-142868html
HOVERFLIGHT
BALLISTIC amp UNIT DEFENCED
Triaxis Composites Collaboration with Institute of Aeronautics and Space in the development of Missile Nose Cone
Polymer composites is the evolution of the military defence
Thin steel was the helmet material of
WWII and remained the principal material until around the 1980rsquos
The advantages of using steel
included a simple technology for manufacture of the helmets low cost and reasonably good
impact protection However these helmets were found to provide only marginal protection
against fragments
During the Vietnam War the US Army experimented with fiber-reinforced inserts in the
helmets These inserts improved ballistic protection but at the same time added weight and
reduced the air space between the head and the helmet
By the early part of the 1980rsquos the US military had developed the first all-composite
100 fiber-reinforced helmet This development resulted in even better ballistic protection
without altering the weight of the helmet Other improvements included better head coverage and
more space for ventilation
Source
Composites Armor - A difficult but huge market
by A Brent Strong Brigham Young University
MILITARY VEHICLES
HIGH SPEED TRAIN SHINKANSEN
Advanced Composites provide lightweight solutions for railway vehicles
saving as much as 50-80 of the weight compared with traditional
components
A lower overall weight translates into less stress faster acceleration and
higher speeds as well as reduced starting and stopping inertia Today
these are important criteria in global high-speed and metropolitan
railway projects
Fire smoke and toxic fumes are key safety criteria for interior
components of railway carriages Any material selected for an interior
component must meet international fire retardant standards
for Rail Interiors and Exteriors
Ceiling Panels Stairs
Seating Vestibules
Window Panels Door Pillars
Partition WallsDiffusers
Gangway and Cabinet Panels Cabin and
Desk panels
Door Pillars Lavatory Modules (standard and
Front and Rear EndsRoof Panels
Nose Cones Under Fairings
Source
httpwwwpctaerail_compositesphp
101
SKY BUS
2009
Europe is the world leader in offshore wind with
828 wind turbines and a cumulative capacity of 2056 MW spread across 38 offshore wind farms in 9
European countries
The UK and Denmark are the current leaders with a 44 and 30 share respectively In 2009
five countries built new offshore wind farms
UK (284 MW)
Demark (230 MW)
Sweden (30 MW)
Germany (30 MW)
Norway (23 MW)
2010
Asia leads the growth in global wind power which grew 358 GW in 2010 bringing
total global capacity to 1944 GW ndash up 225 from 2009
the Global Wind Energy Council (GWEC)
Asia accounted for 19 GW of new global wind power installations driven by China which installed 165
GW
ldquoChina now has 423 GW of wind powerrdquo
ldquoThis puts China firmly on a path to reach 200 GW of installed wind power by 2020 At the same
time China has become the worldrsquos largest producer of wind energy equipmentrdquo
Source
httpwwwreinforcedplasticscomview15655asia-leads-global-wind-power-growth
httpimgdeusmcomdesignnews288288605-Sandia_Sizes_up_Wind_Turbine_Blade_Design_C_largegif
WIND ENERGY
Marine Current Turbines
Source
httpwwwsiemenscompressenpressreleasepress=enpressrelease2011solar-hydroex201111005htm
httpwwwmarineturbinescom
A commercial marine current turbine consists of
two rotors which are fixed on a structure within the
sea current The twin rotors rotate with the
movement of the tidal flow and the blades pitch
through 180 degrees to optimally track tidal current
(Press picture Marine Current Turbines)
Wave Star Energys Multi-point Absorber
CFRP COLUMN REINFORCEMENT
INDUSTRIAL TANKS
107
INDUSTRIAL PIPES
PRESSURE TANKS
109
ldquoLetrsquos Make with Compositesrdquo
Thermoset
type
Density r
(kgm3)
Stiffnes
s E
(Gpa)
Tensile
strength
s (MPa)
Strain to
failure e
()
Tg 0C
Thermal
conductivity
k (Wm0C)
Specific
Heat Cp
(kJkg0C)
Thermal
expansion coeff
a (x106 0C-1)
Polyester 1100-1230 31-46 50-75 10-65 70- 017-022 13-23 55-100
Vinylester 1120-1130 31-33 70-81 30-80 70- - - -
Epoxy 1100-1200 26-38 60-85 15-80 65-175 017-020 105 45-65
Phenolic 1000-1250 30-40 60-80 18 300 012-024 14-18 25-60
PUR 1200 07 30-40 400-450 135 017-021 13-23 70-100
BMI 1200-1320 32-50 48-110 15-33 230-345 - - -
Polyimide 1430-1890 31-49 100-110 15-30 325-370 01-034 105-15 25-80
Al 2800 72 540 18 - 130 096 236
Steel 7790 205 640 25 - 54 046 11
MATRIKS POLIMER THERMOSET
Variasi sifat yang lebar disebabkan oleh adanya formulasi kimia yang berbeda dan penambahan aditif
Jenis Glass Fiber S Glass E Glass C Glass A Glass dll
Terms
Glass Type
S Glass E Glass C Glass A Glass
Silica (SiO2) Content 67 55 64 72
Al2O3 Content 23 14 6 1
Melting Point (Celcius) 915 836 745 745
Tensile Strength 665 500 440 440
Modulus Elastisitas 124 105 100 -
Application AEROSPACE BOAT CHEMICAL TANK CHEMICAL TANK
JENIS SERAT GLASS
CHINA
JENIS SERAT GLASS
C GLASS Calcium borosilicate glasses
used for CHEMICAL stability in corrosive
acid environments
E GLASS Alumina-calcium-borosilicate
glasses with a maximum alkali used as
general purpose fibers where STRENGTH
and high ELECTICAL RESISTIVITY are
required It manifests better electrical
insulation and strongly resists attack by
water More than 50 of the glass fibers
used for reinforcement is E-glass
C Glass
E Glass
C amp E GLASS
SUMBER AGY TECHNICAL PAPER HIGH STRENGTH GLASS FIBER
FAKTA
C GLASS 1 BOROS RESIN
2 KEKUATAN
KURANG
FAKTA
E GLASS 1 HEMAT RESIN
2 KEKUATAN BAIK
3 TAHAN LAMA
FAKTA
TEBAL BUKAN BERARTI KUAT
UNSUR MATRIX (RESIN)
TIDAK ADA KEKUATAN
ldquoMore than 50 of the glass fibers used for
reinforcement is E-glassrdquo
C glass E glass
E glass
C glass
KAIN WOVEN ROVING HASIL LAMINASI
JENIS SERAT GLASS
Kekuatan composites ditentukan oleh
1 Kekuatan amp Sifat Fiber
2 Kekuatan amp Sifat Resin
3 Fraksi Rasio Perbandingan Volume Fiber
dan Resin dalam Composites
rarr tergantung dari Proses Manufaktur
4 Geometri dan Orientasi Arah Fiber dalam
Composites
KEKUATAN COMPOSITES
PROSES MATERIAL
Proses Produksi Kain Fiberglass
Biji Kaca Benang Benang Kaca Kain Fiberglass
PROSES MATERIAL
Glass Beads
Glass Fiber Glass Roving YarnGlass Fabric
FIBERGLASS
PRODUK
MATERIAL DAN PRODUK FIBERGLASS
+
Resin + Additives
PERPADUAN COMPOSITES
BENANG KACA Potongan Serat Kaca CSM
CSM - CHOPPED STRAND MAT
chopped binder
Kain Fiberglass Generasi Pertama
BahanPengikat
SenyawaPada Resin
JENIS FIBERGLASS
Glass Roving Yarn Chopped Strand
ADVANTAGES DISADVANTAGES
Steel
1048707 Low cost 1048707 Corrodes easily
1048707 Ductile under ambient conditions
1048707 Has no lower fatigue limit for welded structures
1048707 Virtually isotropic 1048707 Heavy
1048707 Easily formed and fabricated 1048707 Brittle at low temperatures
1048707 Easily obtained (low relative cost) 1048707 Magnetic
1048707 Easily alloyed or heat treated for special operations
1048707 Easily repaired
1048707 Good fire resistance
1048707 Behaviour is well understood
Alumunium Alloy
1048707 Light weight 1048707 Poor fatigue properties
1048707 Corrosion resistant 1048707 Poor performance in fire
1048707 Easily formed1048707 Low melting point and softening temperature
1048707 Easily fabricated 1048707 High relative cost
1048707 Readily available 1048707 Strength and stiffness less than steel
1048707 Ductile
1048707 Non magnetic
FRP
1048707 Low magnetic properties
1048707 Low electrical conductivity (glass- reinforced plastics)
1048707 Resistance to corrosion
1048707 Resistance to rot and marine growth
1048707 Relatively high sonar transparency
1048707 Good strength to weight ratio
1048707 Good fatigue properties
1048707 Maintenance of properties at low temperatures
1048707 Availability
1048707 Can be manufactured to near net-shape
1048707 Stiffness and strength can be tailored to structural requirements
1048707 Excellent thermal insulation
1048707 Light weight
STEEL vs ALUMUNIUM vs COMPOSITES
Source
1Maritime Platforms Division Aeronautical and
Maritime Research Laboratory (Seref Aksu
Stuart Cannon Craig Gardiner and Matthew
Gudze
2 Metal Corrosion can be defined as the
destructive attack of a metal through interaction
with its environment
(httpwwwcorrosionistcomCorrosion_Fundament
alhtm)
28
Serat rarr penguat
Polimer matriks rarr pengikat
bull Sifat mekanik yang cukup baik
bull Viskositas dan temperatur pengerjaan rendah rarr mudah
dimanufaktur
bull Ketahanan korosi yang baik
bull Media perpindahan gaya rarr distribusi beban dari serat ke serat
bull Ulet rarr Melindungi serat yang getas
bull Size effect rarr Kekuatan dan kekakuan sangat tinggi
bull Aspect ratio (ld) tinggi rarr luas permukaan besar
bull Fleksibel rarr variasi teknik manufaktur
bull Serat dapat diatur sesuai dengan arah pembebanan
29
Advantages Polimer Composites
Kekuatan dan kekakuan spesifik yang tinggi FRCP vs material lain rarr kompetitif jika berat dipertimbangkan
Material Berat jenis
r (kgm3)
Kekakuan
E (GPa)
Kekuatan
tarik su
(MPa)
Kekakuan
spesifik
Er
Kekuatan
spesifik sur
Baja 7800 208 400 27 005
Aluminium 2700 70 200 259 007
Nylon 1100 25 80 23 007
Beton 2400 40 20 166 0008
Random
FRPC
1800 20 300 111 0006
Alligned FRPC
( serat)
1600 200 1500 125 094
Alligned FRCP
( serat)
1600 3 50 19 0001
Tensile Strength amp Modulus of Common Structural Materials
Densities of Common Structural Materials
Specific Tensile Strength amp Modulus of Common Structural Materials
Typical Properties of Common Structural Materials
Kesimpulan COMPOSITES = RINGAN amp KUAT
Jadi secara keseluruhan kekuatan composites
ditentukan oleh
1 Kekuatan amp Sifat Fiber
2 Kekuatan amp Sifat Resin
3 Fraksi Rasio Perbandingan Volume Fiber
dan Resin dalam Composites
4 Geometri dan Orientasi Arah Fiber dalam
Composites
PRODUKSI ANAK NEGERI
Proses Produksi Kain Fiberglass
Biji Kaca Benang Benang Kaca Kain Fiberglass
PROSES MATERIAL
Glass Beads
Glass Fiber Glass Roving YarnGlass Fabric
Proses Produksi Kain Fiberglass
Biji Kaca Benang Benang Kaca Kain Fiberglass
Glass Beads
Glass Fiber Glass Roving YarnGlass Fabric
PROSES MATERIAL
Benang Kaca Potongan Serat Kaca Chopped Strand Mat
CSM - Chopped Strand Mat
chopped binder
Produk Fiberglass Generasi Pertama
Bahan Pengikat
Senyawa Pada Resin
Glass Roving Yarn Chopped Strand
JENIS FIBERGLASS
Benang Kaca Woven Roving
WR - Woven Roving
Tenun Weaving
Produk Fiberglass Generasi Kedua
Glass Roving Yarn
JENIS FIBERGLASS
Multiaxial
MAX - Multiaxial
warp knitting
Produk Fiberglass Generasi Ketiga
Benang Kaca
Glass Roving Yarn
JENIS FIBERGLASS
MAX - Multiaxial Fabric
Fleece (optional)
Lapisan
MULTIAXIAL PROSES
Karakteristik CSM
bull Glass Content 30
bull Resin Content 70
bull Tensile Force
Chopped Strand Mat
JENIS FIBERGLASS
Karakteristik Woven Roving
bull Glass Content 45
bull Resin Content 55
Woven Roving
Resin
|
|
|
|
|
|
|
|
|
|
|
|
|
|
bull Kekuatan Tarik
JENIS FIBERGLASS
No Resin Rich Area
Karakteristik Multiaxial
bull Glass Content 60
bull Resin Content 40
Produk Fiberglass Ketiga MULTIAXIAL
JENIS FIBERGLASS
Perbedaan Woven Roving dan Multiaxial ndash Tampak Samping
JENIS FIBERGLASS
WR FRP
8 Ply WR 800
8 Ply CSM 450
Glass Weight 1 kg
Composite Weight 15kgm2
CSM FRP
22 Ply CSM 450
Glass Weight 1 kg
Composite Weight 18 kgm2
MULTIAXIAL FRP
13 Ply DB 800
Glass Weight 1 kg
Composite Weight
13 kgm2
JENIS FIBERGLASS
Multiaxial
FRP
Woven Roving
FRP
Chopped Strands Mat FRP
MULTIAXIAL
FAKTA
TEBAL BUKAN BERARTI KUAT
UNSUR MATRIX (RESIN)
TIDAK ADA KEKUATAN
ldquoMore than 50 of the glass fibers used for reinforcement is
E-glassrdquo
KarakteristikKekuatan
CSM WR MAX
Kekuatan Tarik 175 MPa 250 MPa 425 MPa
CSM 142
WR 70
KEKUATAN TARIK
Properties CSM Lamination WR Lamination MAX Lamination
Fabric Weight (kgm2) 1 1 1
Composite Weight (kgm2) 18 15 13
Resin usage (kgm2) 15 1 08
Amount of Fabric 22 Ply 16 Ply 13 Ply
Thickness 15 mm 12 mm 10 mm
Tensile Strength (Mpa) 125 1796 400
Tensile Strength (Nmmsup2) 28463 30958 4576
Processing Time High Med Low
Labour Cost High Med Low
MULTIAXIAL
Total Penggunaan Resin -51
Total Berat Kapal -40
Kekuatan Bangunan Kapal +59
Efisiensi Tenaga Kerja
Waktu Pengerjaan Lebih Cepat
KEUNGGULAN MATERIAL
Resapan Resin Lebih Baik amp Merata
Lapisan Lebih Sedikit
Meningkatkan Kekuatan Kapal
KEUNGGULAN MATERIAL
TRIAXIAL
DBL series DBT series
BIAXIAL
LT series DB series
UNIDIRECTIONAL
L series T series
QUADRIAXIAL
DBLT series
JENIS MULTIAXIAL
UNIDIRECTIONAL
DCMU 900 E ndash
KHUSUS UNTUK MEMPERKUAT BENDING KAPAL
PEMASANGAN KHUSUS PADA KEEL DAN TULANGAN
JENIS MULTIAXIAL UNTUK KAPAL
TRIAXIAL
DBL 600 ndash
APLIKASI PADA INDUSTRI PENERBANGAN
PEMASANGAN KHUSUS PADA
SAMBUNGAN BADAN DAN SAYAP
PESAWAT
JENIS MULTIAXIAL UNTUK PESAWAT
QUADRAXIAL
DBLT 800 ndash
APLIKASI PADA INDUSTRI ENERGI
DITERAPKAN UNTUK KEBUTUHAN PEMBANGKIT
LISTRIK ENERGI ANGIN
MULTIAXIAL UNTUK ENERGI
INDUSTRI KIMIA OLAHRAGA AUTOMOTIF
MULTIAXIAL UNTUK INDUSTRI LAINNYA
COMPOSITES
GUNAKAN MATERIAL FIBERGLASS
YANG SUDAH DISERTIFIKASI
BKI
FIBERGLASS UNTUK PEMBANGUNAN BAKAP
PERATURAN MENTERI PERHUBUNGAN
NOMOR PM 7 TAHUN 2013
TENTANG KEWAJIBAN KLASIFIKASI BAGI KAPAL BERBENDERA INDONESIA
PADA BADAN KLASIFIKASI
BADAN SERTIFIKASI MARITIM
Biro Klasifikasi IndonesiaDet Norske Veritas Germanischer Lloyds
PERATURAN BKI
Untuk Kapal Non-Metal
2006
PERSYARATAN MINIMUM
kekuatan material yang
harus digunakan
untuk membangun
Kapal Fiberglass
PEMBESARAN
Table 21
FIBERGLASS TRIAXIS COMPOSITES
TELAH BERSERTIFIKASI BKI
Biro Klasifikasi Indonesia
65
TEKNIK MANUFAKTUR
COMPOSITES
Wet hand lay-up
1) Peletakan
Dry Reinforcement
bull Dry reinforcement dan resin (+ katalis) ditaruh pada permukaan cetakan
2) Pemasukanpenekanan resin
bull Resin ditekan untuk meng-impregnasi serat dengan menggunakan rol
3) Pengulangan proses untuk lapisan lain
bull Beberapa lapisan dapat ditambahkan secara bertahap
4) Resin curing
bull Reaksi dimulai komponen dilepaskan setelah komponen mengeras
(fully cured)
Wet hand lay-up
Manufaktur komponen dapat dikerjakan dengan menggunakan beberapa lapis komposit
dengan memperhatikan kompatibilitas material dan tahapan curing Modifikasi proses dapat
dilakukan seperti
Vacuum bagging
setelah lay-up
Glass Roving
Bulk Resin
Catalyst
3) De-molding
2) Resin Cure
bull Curing dimulai dan komponen dilepaskan setelah pengerasan selesai
bull Serat gelas resin dan katalis dimasukkan kedalam spray gun
1) Spray-up
bull Campuran disemprotkan pada permukaan cetakan
Spray-up
69
Penyemprotan bakal komponen
Komponen
dilepaskan
dari cetakan
Full dispensing
system Chopper Roving
Atomised resin
and catalyst
Spray-up
Prepreg
1) LaminateAssembly 5) De-molding
3) Resin Melts Layup Consolidates
bull Prepreg serat yang sudah diimpregnasi oleh resin+katalis dalam kondisi padat
bull Lapisan prepreg digunting sesuai bentuk yang diinginkan kemudian diletakkan pada permukaan cetakan
sesuai bentuk komponen yang diinginkan Lay-up mudah dilakukan karena sifat ldquotackynessrdquo dari prepreg
2) Applied Vacuum Pressure and Heat
bull Tekanan dan panas diberikan resin mencair terjadi konsolidasi pada komponen
4) Resin Cures
bull Temperatur dinaikkan untuk memulai curing
Prepreg
Variasi proses Autoclave
Komponen dalam
vacuum-bag
bull Campuran resin (+katalis) dan chopped glass strands diperoleh dalam bentuk premixed compound Bulk molding
Compound (BMC) dalam bentuk adonan atau Sheet molding Compound (SMC) dalam bentuk lembaran
bull Ketika panas dan tekanan diberikan oleh cetakan compound mengalir sesuai bentuk komponen yang diinginkan
1) Placement of Charge
5) De-molding3) Squeeze to final dimensions
2) Mould Closure4) Resin Cure
bull Curing dimulai komponen dilepaskan setelah terjadi pengerasan yang cukup
Compression Molding
bull Preform atau dry reinforcement dimasukkan kedalam cetakan sesuai dengan bentuk komponen yang
diinginkan
bull Resin mengalir dengan penekanan atau pem-vakuman dan meng-impregnasi preform dan
mendorongmengeluarkan udara yang ada dalam preform
1) Preform Manufacture
2) Preform Compression
5) De-molding3) Resin Injection
4) Resin Cure
bull Curing terjadi cetakan dibuka setelah terjadi pengerasan yang mencukupi
Liquid Molding (RTM VARI VARTM)
Pultrusion
bull Dry roving or fabrics ditarik melalui bak berisi
campuran resin dan katalis
bull Campuran yang basah ditarik melalui cetakan
bull Sisa resin keluar cetakan
bull Pemanasan dilakukan untuk proses curing
bull Pendinginan dilakukan untuk mempercepat siklus
produksi
Cut-off
Cooling
Die sections
Resin bath
Fibre creel
Filament Winding
bull Dry roving ditarik melalui bak berisi campuran resin dan katalis
bull Wet roving digulungkan dalam keadaan tegang kepada mandrel
bull Kontrol mekanik dari pembawa serat mengatur orientasi peletakan serat pada
mandrel
INDUSTRI COMPOSITES
AEROSPACE
HISTORY
1950 ndash Boeing
1960 ndash F14 Tomcat
1981 ndash AV-8B Harrier
Source
Low-Cost Composite Materials and Structures for Aircraft Applications
httpwwwreinforcedplasticscom
httpwwwcentennialofflightgovessayEvolution_of_TechnologycompositesTech40htm
Automotive
Composite material is used in a number of applications in the automotive
industry due to its temperature resistance rigidity and fatigue strength
The benefits of using composites include greater fuel efficiency
corrosion resistance light weight and strength Composites also provide
a low-cost way to help keep designs looking fresh
Composites are used in
- interior parts (cockpit trimming seats instrument panels)
- exterior structure (body panels openings underbody frontrear
modules)
- engine compartment and fuelmechanical area parts (axles and
suspensions fuel and exhaust systems)
- electrical and electronic components
Lamborghinis Sesto Element carbon fiber
ldquoFat men cannot run as fast as thin men but we build most of our vehicles as though dead-weight fat increased speedhellip I cannot
imagine where the delusion that weight means strength
came fromhelliprdquo mdashHenry Ford
The mix of automotive materials is changing showing a boost for FRP in helping original
equipment manufacturers meet fuel economy and emissions challenges
(Source 2011 DuPont AutomotiveSAE survey of design engineers performed by Signet Research Inc)
Source
httpwwwtoraycomcsrhighlight2009hig_001_01html
The MonoCell tub for the McLaren MP4-12C supercar is moulded as a single
piece and weighs less than 80 kg (176 lbs)
COMPOSITES IN MARINE
TRIMARAN BOAT
AMERICA NAVYINDONESIAN NAVY
Visby Class corvette
Total length is 72 meters
The beam is 1040 meters
The displacement is 600 metric tones
fully equipped the worlds largest CRP
construction
The design of the Visby aims to minimize
the optical and infrared signature above
water acoustic and hydroa coustic
signature underwater electrical potential
and magnetic signature pressure signature
radar cross section and actively emitted
signals
A stealth corvette of the YS 2000 design
has a detection range of 13km in rough
seas and 22km in calm sea without
jamming In a jammed environment the
Visby would be detected at a range of 8km
in rough sea and 11km in calm sea
The material provides high strength and
rigidity low weight good shock resistance
low radar and magnetic signature
1996
Visby is a class of stealth corvettes for the Swedish Navy
ldquoReduced 50 of a Conventional Steelrdquo
Source
Hull Construction with composite materials for ships over 100m in length 2002
Massachusetts Institute of Technology
httpwwwnaval-technologycomprojectsvisby
YACHTS
KAL YUDISTIRAMARATHON 100 ADMIRAL YACHT
LOA 3050 MWidth 6 MFuel Tank 8000 LWater Tank 3000 LIce Box 500 LAccommodation Max 35 Personnel
2 x CATERPILLAR 3412E 1200 HPMARINE DIESEL ENGINE
PC 40 ndash KRI Krait 827Department of Indonesian Navy
LOA 40 MWidth 73 MPower 190Weapon Twin Cannon Barrels
127 mm Heavy Machine GunSpeed Knot 25 KnotDisplacement 105 tonAccommodation 23 personnel
PATROL BOAT
Rigid Inflatable BoatPATROL BOAT
Yachts
36m Luxury Yacht Moonraker
36m Luxury Yacht GoldenEye
50m Luxury Yacht Casino
Royale
45m Luxury Yacht Seashaw
Boat Parts
Barovans for Seismic Sweep
Centrifugal Liftfan House for Surface Effect
Ships
Composite Boat PropellersRTM
Deckhouses for Pilot Boats
Fairing Parts for Submarines
Flybridges for Motor yachts
Light Weight Gangway
MTB Launcher Mock-up
Pleasure Boats
12m Sailboat
12m Sail-Catamaranone-off
Canoes
Dragonfly 1000Catamaran Sailboat
Fantasy 37Sailboat
Farr 60Luxury Sailboat
EurodingyOlympic Dingy Class for
Woman
Hydrolift F23 Racing Boats
Kajacs
Najad 42Sailboat
Najad 520Sailboat
Najad 441Sailboat
Najad 391Sailboat
Nordwest 900Motorboat
Nordwest 1100Motorboat
Quatro 44Motorboat
Racemaster Competition Boats
Storebro 420
Storebro 345
Sweden Yacht 370Sailboat
Sweden Yacht 69Sailboat
Windy 41Motorboat
X-632Sailboat
X-362Sailboat
Commercial Boats
175m High Speed AmbulancePassenger Boat
19m High Speed Passenger Boat
20m High Speed Passenger Boat
364m Surface Effect Passenger Ship
45m Surface Effect Passenger Ship
120m Hull Structural Parts HSSS Catamaran Ferry
APPENDIX
Marine Vessel
1188m Fast Attack Vessel FMV 90 E
20m SAV-Surface Auxiliary Vessels
34m Personnel TransportCoast Guard Vessel
40ft Experimental SES
40m Landsort-Class Mine Hunters
54m Mine Counter Measure Vehicles SES
74m Coastal Patrol Boats
Fishing Boats
30 GT
12 GT
10 GT
5 GT
WISEWings In Surface Effect
HOVERCRAFT
Designed specifically for the tourist and transport industries the
Pioneer Mk3 hovercraft is amphibious and comfortably seats 25
passengers plus 1-crew The air-conditioned cabin allows for
maximum visibility for all aboard The Pioneer Mk3 is robust and
dynamic in its performance
Commercial hovercraft
Mk3 AirLift Hovercraft - 1215m
Power is economicaly provided by one Deutz diesel engine of
330kW (442hp) to cruise easily at 40 knots with much higher
speeds available according to the surface conditions The hull is
manufactured from fibreglassPVC foam composite sandwich
the windows are glass and the skirt is urethane coated nylon A
Military version is available with increased payload and systems
redundancy Power for the Military version comes from two Steyr
diesel engines with a total installed power of 320kW (429hp) All
transmission electrical hydraulic and air systems are duplicated
for maximum redundancy The increased performance of the
Military version comes from the reduced engine weight of the twin
Steyr installation cf the Deutz installation
Source
httpwwwnauticexpocomprodairlift-hovercraftcommercial-hovercrafts-25251-142868html
HOVERFLIGHT
BALLISTIC amp UNIT DEFENCED
Triaxis Composites Collaboration with Institute of Aeronautics and Space in the development of Missile Nose Cone
Polymer composites is the evolution of the military defence
Thin steel was the helmet material of
WWII and remained the principal material until around the 1980rsquos
The advantages of using steel
included a simple technology for manufacture of the helmets low cost and reasonably good
impact protection However these helmets were found to provide only marginal protection
against fragments
During the Vietnam War the US Army experimented with fiber-reinforced inserts in the
helmets These inserts improved ballistic protection but at the same time added weight and
reduced the air space between the head and the helmet
By the early part of the 1980rsquos the US military had developed the first all-composite
100 fiber-reinforced helmet This development resulted in even better ballistic protection
without altering the weight of the helmet Other improvements included better head coverage and
more space for ventilation
Source
Composites Armor - A difficult but huge market
by A Brent Strong Brigham Young University
MILITARY VEHICLES
HIGH SPEED TRAIN SHINKANSEN
Advanced Composites provide lightweight solutions for railway vehicles
saving as much as 50-80 of the weight compared with traditional
components
A lower overall weight translates into less stress faster acceleration and
higher speeds as well as reduced starting and stopping inertia Today
these are important criteria in global high-speed and metropolitan
railway projects
Fire smoke and toxic fumes are key safety criteria for interior
components of railway carriages Any material selected for an interior
component must meet international fire retardant standards
for Rail Interiors and Exteriors
Ceiling Panels Stairs
Seating Vestibules
Window Panels Door Pillars
Partition WallsDiffusers
Gangway and Cabinet Panels Cabin and
Desk panels
Door Pillars Lavatory Modules (standard and
Front and Rear EndsRoof Panels
Nose Cones Under Fairings
Source
httpwwwpctaerail_compositesphp
101
SKY BUS
2009
Europe is the world leader in offshore wind with
828 wind turbines and a cumulative capacity of 2056 MW spread across 38 offshore wind farms in 9
European countries
The UK and Denmark are the current leaders with a 44 and 30 share respectively In 2009
five countries built new offshore wind farms
UK (284 MW)
Demark (230 MW)
Sweden (30 MW)
Germany (30 MW)
Norway (23 MW)
2010
Asia leads the growth in global wind power which grew 358 GW in 2010 bringing
total global capacity to 1944 GW ndash up 225 from 2009
the Global Wind Energy Council (GWEC)
Asia accounted for 19 GW of new global wind power installations driven by China which installed 165
GW
ldquoChina now has 423 GW of wind powerrdquo
ldquoThis puts China firmly on a path to reach 200 GW of installed wind power by 2020 At the same
time China has become the worldrsquos largest producer of wind energy equipmentrdquo
Source
httpwwwreinforcedplasticscomview15655asia-leads-global-wind-power-growth
httpimgdeusmcomdesignnews288288605-Sandia_Sizes_up_Wind_Turbine_Blade_Design_C_largegif
WIND ENERGY
Marine Current Turbines
Source
httpwwwsiemenscompressenpressreleasepress=enpressrelease2011solar-hydroex201111005htm
httpwwwmarineturbinescom
A commercial marine current turbine consists of
two rotors which are fixed on a structure within the
sea current The twin rotors rotate with the
movement of the tidal flow and the blades pitch
through 180 degrees to optimally track tidal current
(Press picture Marine Current Turbines)
Wave Star Energys Multi-point Absorber
CFRP COLUMN REINFORCEMENT
INDUSTRIAL TANKS
107
INDUSTRIAL PIPES
PRESSURE TANKS
109
ldquoLetrsquos Make with Compositesrdquo
Jenis Glass Fiber S Glass E Glass C Glass A Glass dll
Terms
Glass Type
S Glass E Glass C Glass A Glass
Silica (SiO2) Content 67 55 64 72
Al2O3 Content 23 14 6 1
Melting Point (Celcius) 915 836 745 745
Tensile Strength 665 500 440 440
Modulus Elastisitas 124 105 100 -
Application AEROSPACE BOAT CHEMICAL TANK CHEMICAL TANK
JENIS SERAT GLASS
CHINA
JENIS SERAT GLASS
C GLASS Calcium borosilicate glasses
used for CHEMICAL stability in corrosive
acid environments
E GLASS Alumina-calcium-borosilicate
glasses with a maximum alkali used as
general purpose fibers where STRENGTH
and high ELECTICAL RESISTIVITY are
required It manifests better electrical
insulation and strongly resists attack by
water More than 50 of the glass fibers
used for reinforcement is E-glass
C Glass
E Glass
C amp E GLASS
SUMBER AGY TECHNICAL PAPER HIGH STRENGTH GLASS FIBER
FAKTA
C GLASS 1 BOROS RESIN
2 KEKUATAN
KURANG
FAKTA
E GLASS 1 HEMAT RESIN
2 KEKUATAN BAIK
3 TAHAN LAMA
FAKTA
TEBAL BUKAN BERARTI KUAT
UNSUR MATRIX (RESIN)
TIDAK ADA KEKUATAN
ldquoMore than 50 of the glass fibers used for
reinforcement is E-glassrdquo
C glass E glass
E glass
C glass
KAIN WOVEN ROVING HASIL LAMINASI
JENIS SERAT GLASS
Kekuatan composites ditentukan oleh
1 Kekuatan amp Sifat Fiber
2 Kekuatan amp Sifat Resin
3 Fraksi Rasio Perbandingan Volume Fiber
dan Resin dalam Composites
rarr tergantung dari Proses Manufaktur
4 Geometri dan Orientasi Arah Fiber dalam
Composites
KEKUATAN COMPOSITES
PROSES MATERIAL
Proses Produksi Kain Fiberglass
Biji Kaca Benang Benang Kaca Kain Fiberglass
PROSES MATERIAL
Glass Beads
Glass Fiber Glass Roving YarnGlass Fabric
FIBERGLASS
PRODUK
MATERIAL DAN PRODUK FIBERGLASS
+
Resin + Additives
PERPADUAN COMPOSITES
BENANG KACA Potongan Serat Kaca CSM
CSM - CHOPPED STRAND MAT
chopped binder
Kain Fiberglass Generasi Pertama
BahanPengikat
SenyawaPada Resin
JENIS FIBERGLASS
Glass Roving Yarn Chopped Strand
ADVANTAGES DISADVANTAGES
Steel
1048707 Low cost 1048707 Corrodes easily
1048707 Ductile under ambient conditions
1048707 Has no lower fatigue limit for welded structures
1048707 Virtually isotropic 1048707 Heavy
1048707 Easily formed and fabricated 1048707 Brittle at low temperatures
1048707 Easily obtained (low relative cost) 1048707 Magnetic
1048707 Easily alloyed or heat treated for special operations
1048707 Easily repaired
1048707 Good fire resistance
1048707 Behaviour is well understood
Alumunium Alloy
1048707 Light weight 1048707 Poor fatigue properties
1048707 Corrosion resistant 1048707 Poor performance in fire
1048707 Easily formed1048707 Low melting point and softening temperature
1048707 Easily fabricated 1048707 High relative cost
1048707 Readily available 1048707 Strength and stiffness less than steel
1048707 Ductile
1048707 Non magnetic
FRP
1048707 Low magnetic properties
1048707 Low electrical conductivity (glass- reinforced plastics)
1048707 Resistance to corrosion
1048707 Resistance to rot and marine growth
1048707 Relatively high sonar transparency
1048707 Good strength to weight ratio
1048707 Good fatigue properties
1048707 Maintenance of properties at low temperatures
1048707 Availability
1048707 Can be manufactured to near net-shape
1048707 Stiffness and strength can be tailored to structural requirements
1048707 Excellent thermal insulation
1048707 Light weight
STEEL vs ALUMUNIUM vs COMPOSITES
Source
1Maritime Platforms Division Aeronautical and
Maritime Research Laboratory (Seref Aksu
Stuart Cannon Craig Gardiner and Matthew
Gudze
2 Metal Corrosion can be defined as the
destructive attack of a metal through interaction
with its environment
(httpwwwcorrosionistcomCorrosion_Fundament
alhtm)
28
Serat rarr penguat
Polimer matriks rarr pengikat
bull Sifat mekanik yang cukup baik
bull Viskositas dan temperatur pengerjaan rendah rarr mudah
dimanufaktur
bull Ketahanan korosi yang baik
bull Media perpindahan gaya rarr distribusi beban dari serat ke serat
bull Ulet rarr Melindungi serat yang getas
bull Size effect rarr Kekuatan dan kekakuan sangat tinggi
bull Aspect ratio (ld) tinggi rarr luas permukaan besar
bull Fleksibel rarr variasi teknik manufaktur
bull Serat dapat diatur sesuai dengan arah pembebanan
29
Advantages Polimer Composites
Kekuatan dan kekakuan spesifik yang tinggi FRCP vs material lain rarr kompetitif jika berat dipertimbangkan
Material Berat jenis
r (kgm3)
Kekakuan
E (GPa)
Kekuatan
tarik su
(MPa)
Kekakuan
spesifik
Er
Kekuatan
spesifik sur
Baja 7800 208 400 27 005
Aluminium 2700 70 200 259 007
Nylon 1100 25 80 23 007
Beton 2400 40 20 166 0008
Random
FRPC
1800 20 300 111 0006
Alligned FRPC
( serat)
1600 200 1500 125 094
Alligned FRCP
( serat)
1600 3 50 19 0001
Tensile Strength amp Modulus of Common Structural Materials
Densities of Common Structural Materials
Specific Tensile Strength amp Modulus of Common Structural Materials
Typical Properties of Common Structural Materials
Kesimpulan COMPOSITES = RINGAN amp KUAT
Jadi secara keseluruhan kekuatan composites
ditentukan oleh
1 Kekuatan amp Sifat Fiber
2 Kekuatan amp Sifat Resin
3 Fraksi Rasio Perbandingan Volume Fiber
dan Resin dalam Composites
4 Geometri dan Orientasi Arah Fiber dalam
Composites
PRODUKSI ANAK NEGERI
Proses Produksi Kain Fiberglass
Biji Kaca Benang Benang Kaca Kain Fiberglass
PROSES MATERIAL
Glass Beads
Glass Fiber Glass Roving YarnGlass Fabric
Proses Produksi Kain Fiberglass
Biji Kaca Benang Benang Kaca Kain Fiberglass
Glass Beads
Glass Fiber Glass Roving YarnGlass Fabric
PROSES MATERIAL
Benang Kaca Potongan Serat Kaca Chopped Strand Mat
CSM - Chopped Strand Mat
chopped binder
Produk Fiberglass Generasi Pertama
Bahan Pengikat
Senyawa Pada Resin
Glass Roving Yarn Chopped Strand
JENIS FIBERGLASS
Benang Kaca Woven Roving
WR - Woven Roving
Tenun Weaving
Produk Fiberglass Generasi Kedua
Glass Roving Yarn
JENIS FIBERGLASS
Multiaxial
MAX - Multiaxial
warp knitting
Produk Fiberglass Generasi Ketiga
Benang Kaca
Glass Roving Yarn
JENIS FIBERGLASS
MAX - Multiaxial Fabric
Fleece (optional)
Lapisan
MULTIAXIAL PROSES
Karakteristik CSM
bull Glass Content 30
bull Resin Content 70
bull Tensile Force
Chopped Strand Mat
JENIS FIBERGLASS
Karakteristik Woven Roving
bull Glass Content 45
bull Resin Content 55
Woven Roving
Resin
|
|
|
|
|
|
|
|
|
|
|
|
|
|
bull Kekuatan Tarik
JENIS FIBERGLASS
No Resin Rich Area
Karakteristik Multiaxial
bull Glass Content 60
bull Resin Content 40
Produk Fiberglass Ketiga MULTIAXIAL
JENIS FIBERGLASS
Perbedaan Woven Roving dan Multiaxial ndash Tampak Samping
JENIS FIBERGLASS
WR FRP
8 Ply WR 800
8 Ply CSM 450
Glass Weight 1 kg
Composite Weight 15kgm2
CSM FRP
22 Ply CSM 450
Glass Weight 1 kg
Composite Weight 18 kgm2
MULTIAXIAL FRP
13 Ply DB 800
Glass Weight 1 kg
Composite Weight
13 kgm2
JENIS FIBERGLASS
Multiaxial
FRP
Woven Roving
FRP
Chopped Strands Mat FRP
MULTIAXIAL
FAKTA
TEBAL BUKAN BERARTI KUAT
UNSUR MATRIX (RESIN)
TIDAK ADA KEKUATAN
ldquoMore than 50 of the glass fibers used for reinforcement is
E-glassrdquo
KarakteristikKekuatan
CSM WR MAX
Kekuatan Tarik 175 MPa 250 MPa 425 MPa
CSM 142
WR 70
KEKUATAN TARIK
Properties CSM Lamination WR Lamination MAX Lamination
Fabric Weight (kgm2) 1 1 1
Composite Weight (kgm2) 18 15 13
Resin usage (kgm2) 15 1 08
Amount of Fabric 22 Ply 16 Ply 13 Ply
Thickness 15 mm 12 mm 10 mm
Tensile Strength (Mpa) 125 1796 400
Tensile Strength (Nmmsup2) 28463 30958 4576
Processing Time High Med Low
Labour Cost High Med Low
MULTIAXIAL
Total Penggunaan Resin -51
Total Berat Kapal -40
Kekuatan Bangunan Kapal +59
Efisiensi Tenaga Kerja
Waktu Pengerjaan Lebih Cepat
KEUNGGULAN MATERIAL
Resapan Resin Lebih Baik amp Merata
Lapisan Lebih Sedikit
Meningkatkan Kekuatan Kapal
KEUNGGULAN MATERIAL
TRIAXIAL
DBL series DBT series
BIAXIAL
LT series DB series
UNIDIRECTIONAL
L series T series
QUADRIAXIAL
DBLT series
JENIS MULTIAXIAL
UNIDIRECTIONAL
DCMU 900 E ndash
KHUSUS UNTUK MEMPERKUAT BENDING KAPAL
PEMASANGAN KHUSUS PADA KEEL DAN TULANGAN
JENIS MULTIAXIAL UNTUK KAPAL
TRIAXIAL
DBL 600 ndash
APLIKASI PADA INDUSTRI PENERBANGAN
PEMASANGAN KHUSUS PADA
SAMBUNGAN BADAN DAN SAYAP
PESAWAT
JENIS MULTIAXIAL UNTUK PESAWAT
QUADRAXIAL
DBLT 800 ndash
APLIKASI PADA INDUSTRI ENERGI
DITERAPKAN UNTUK KEBUTUHAN PEMBANGKIT
LISTRIK ENERGI ANGIN
MULTIAXIAL UNTUK ENERGI
INDUSTRI KIMIA OLAHRAGA AUTOMOTIF
MULTIAXIAL UNTUK INDUSTRI LAINNYA
COMPOSITES
GUNAKAN MATERIAL FIBERGLASS
YANG SUDAH DISERTIFIKASI
BKI
FIBERGLASS UNTUK PEMBANGUNAN BAKAP
PERATURAN MENTERI PERHUBUNGAN
NOMOR PM 7 TAHUN 2013
TENTANG KEWAJIBAN KLASIFIKASI BAGI KAPAL BERBENDERA INDONESIA
PADA BADAN KLASIFIKASI
BADAN SERTIFIKASI MARITIM
Biro Klasifikasi IndonesiaDet Norske Veritas Germanischer Lloyds
PERATURAN BKI
Untuk Kapal Non-Metal
2006
PERSYARATAN MINIMUM
kekuatan material yang
harus digunakan
untuk membangun
Kapal Fiberglass
PEMBESARAN
Table 21
FIBERGLASS TRIAXIS COMPOSITES
TELAH BERSERTIFIKASI BKI
Biro Klasifikasi Indonesia
65
TEKNIK MANUFAKTUR
COMPOSITES
Wet hand lay-up
1) Peletakan
Dry Reinforcement
bull Dry reinforcement dan resin (+ katalis) ditaruh pada permukaan cetakan
2) Pemasukanpenekanan resin
bull Resin ditekan untuk meng-impregnasi serat dengan menggunakan rol
3) Pengulangan proses untuk lapisan lain
bull Beberapa lapisan dapat ditambahkan secara bertahap
4) Resin curing
bull Reaksi dimulai komponen dilepaskan setelah komponen mengeras
(fully cured)
Wet hand lay-up
Manufaktur komponen dapat dikerjakan dengan menggunakan beberapa lapis komposit
dengan memperhatikan kompatibilitas material dan tahapan curing Modifikasi proses dapat
dilakukan seperti
Vacuum bagging
setelah lay-up
Glass Roving
Bulk Resin
Catalyst
3) De-molding
2) Resin Cure
bull Curing dimulai dan komponen dilepaskan setelah pengerasan selesai
bull Serat gelas resin dan katalis dimasukkan kedalam spray gun
1) Spray-up
bull Campuran disemprotkan pada permukaan cetakan
Spray-up
69
Penyemprotan bakal komponen
Komponen
dilepaskan
dari cetakan
Full dispensing
system Chopper Roving
Atomised resin
and catalyst
Spray-up
Prepreg
1) LaminateAssembly 5) De-molding
3) Resin Melts Layup Consolidates
bull Prepreg serat yang sudah diimpregnasi oleh resin+katalis dalam kondisi padat
bull Lapisan prepreg digunting sesuai bentuk yang diinginkan kemudian diletakkan pada permukaan cetakan
sesuai bentuk komponen yang diinginkan Lay-up mudah dilakukan karena sifat ldquotackynessrdquo dari prepreg
2) Applied Vacuum Pressure and Heat
bull Tekanan dan panas diberikan resin mencair terjadi konsolidasi pada komponen
4) Resin Cures
bull Temperatur dinaikkan untuk memulai curing
Prepreg
Variasi proses Autoclave
Komponen dalam
vacuum-bag
bull Campuran resin (+katalis) dan chopped glass strands diperoleh dalam bentuk premixed compound Bulk molding
Compound (BMC) dalam bentuk adonan atau Sheet molding Compound (SMC) dalam bentuk lembaran
bull Ketika panas dan tekanan diberikan oleh cetakan compound mengalir sesuai bentuk komponen yang diinginkan
1) Placement of Charge
5) De-molding3) Squeeze to final dimensions
2) Mould Closure4) Resin Cure
bull Curing dimulai komponen dilepaskan setelah terjadi pengerasan yang cukup
Compression Molding
bull Preform atau dry reinforcement dimasukkan kedalam cetakan sesuai dengan bentuk komponen yang
diinginkan
bull Resin mengalir dengan penekanan atau pem-vakuman dan meng-impregnasi preform dan
mendorongmengeluarkan udara yang ada dalam preform
1) Preform Manufacture
2) Preform Compression
5) De-molding3) Resin Injection
4) Resin Cure
bull Curing terjadi cetakan dibuka setelah terjadi pengerasan yang mencukupi
Liquid Molding (RTM VARI VARTM)
Pultrusion
bull Dry roving or fabrics ditarik melalui bak berisi
campuran resin dan katalis
bull Campuran yang basah ditarik melalui cetakan
bull Sisa resin keluar cetakan
bull Pemanasan dilakukan untuk proses curing
bull Pendinginan dilakukan untuk mempercepat siklus
produksi
Cut-off
Cooling
Die sections
Resin bath
Fibre creel
Filament Winding
bull Dry roving ditarik melalui bak berisi campuran resin dan katalis
bull Wet roving digulungkan dalam keadaan tegang kepada mandrel
bull Kontrol mekanik dari pembawa serat mengatur orientasi peletakan serat pada
mandrel
INDUSTRI COMPOSITES
AEROSPACE
HISTORY
1950 ndash Boeing
1960 ndash F14 Tomcat
1981 ndash AV-8B Harrier
Source
Low-Cost Composite Materials and Structures for Aircraft Applications
httpwwwreinforcedplasticscom
httpwwwcentennialofflightgovessayEvolution_of_TechnologycompositesTech40htm
Automotive
Composite material is used in a number of applications in the automotive
industry due to its temperature resistance rigidity and fatigue strength
The benefits of using composites include greater fuel efficiency
corrosion resistance light weight and strength Composites also provide
a low-cost way to help keep designs looking fresh
Composites are used in
- interior parts (cockpit trimming seats instrument panels)
- exterior structure (body panels openings underbody frontrear
modules)
- engine compartment and fuelmechanical area parts (axles and
suspensions fuel and exhaust systems)
- electrical and electronic components
Lamborghinis Sesto Element carbon fiber
ldquoFat men cannot run as fast as thin men but we build most of our vehicles as though dead-weight fat increased speedhellip I cannot
imagine where the delusion that weight means strength
came fromhelliprdquo mdashHenry Ford
The mix of automotive materials is changing showing a boost for FRP in helping original
equipment manufacturers meet fuel economy and emissions challenges
(Source 2011 DuPont AutomotiveSAE survey of design engineers performed by Signet Research Inc)
Source
httpwwwtoraycomcsrhighlight2009hig_001_01html
The MonoCell tub for the McLaren MP4-12C supercar is moulded as a single
piece and weighs less than 80 kg (176 lbs)
COMPOSITES IN MARINE
TRIMARAN BOAT
AMERICA NAVYINDONESIAN NAVY
Visby Class corvette
Total length is 72 meters
The beam is 1040 meters
The displacement is 600 metric tones
fully equipped the worlds largest CRP
construction
The design of the Visby aims to minimize
the optical and infrared signature above
water acoustic and hydroa coustic
signature underwater electrical potential
and magnetic signature pressure signature
radar cross section and actively emitted
signals
A stealth corvette of the YS 2000 design
has a detection range of 13km in rough
seas and 22km in calm sea without
jamming In a jammed environment the
Visby would be detected at a range of 8km
in rough sea and 11km in calm sea
The material provides high strength and
rigidity low weight good shock resistance
low radar and magnetic signature
1996
Visby is a class of stealth corvettes for the Swedish Navy
ldquoReduced 50 of a Conventional Steelrdquo
Source
Hull Construction with composite materials for ships over 100m in length 2002
Massachusetts Institute of Technology
httpwwwnaval-technologycomprojectsvisby
YACHTS
KAL YUDISTIRAMARATHON 100 ADMIRAL YACHT
LOA 3050 MWidth 6 MFuel Tank 8000 LWater Tank 3000 LIce Box 500 LAccommodation Max 35 Personnel
2 x CATERPILLAR 3412E 1200 HPMARINE DIESEL ENGINE
PC 40 ndash KRI Krait 827Department of Indonesian Navy
LOA 40 MWidth 73 MPower 190Weapon Twin Cannon Barrels
127 mm Heavy Machine GunSpeed Knot 25 KnotDisplacement 105 tonAccommodation 23 personnel
PATROL BOAT
Rigid Inflatable BoatPATROL BOAT
Yachts
36m Luxury Yacht Moonraker
36m Luxury Yacht GoldenEye
50m Luxury Yacht Casino
Royale
45m Luxury Yacht Seashaw
Boat Parts
Barovans for Seismic Sweep
Centrifugal Liftfan House for Surface Effect
Ships
Composite Boat PropellersRTM
Deckhouses for Pilot Boats
Fairing Parts for Submarines
Flybridges for Motor yachts
Light Weight Gangway
MTB Launcher Mock-up
Pleasure Boats
12m Sailboat
12m Sail-Catamaranone-off
Canoes
Dragonfly 1000Catamaran Sailboat
Fantasy 37Sailboat
Farr 60Luxury Sailboat
EurodingyOlympic Dingy Class for
Woman
Hydrolift F23 Racing Boats
Kajacs
Najad 42Sailboat
Najad 520Sailboat
Najad 441Sailboat
Najad 391Sailboat
Nordwest 900Motorboat
Nordwest 1100Motorboat
Quatro 44Motorboat
Racemaster Competition Boats
Storebro 420
Storebro 345
Sweden Yacht 370Sailboat
Sweden Yacht 69Sailboat
Windy 41Motorboat
X-632Sailboat
X-362Sailboat
Commercial Boats
175m High Speed AmbulancePassenger Boat
19m High Speed Passenger Boat
20m High Speed Passenger Boat
364m Surface Effect Passenger Ship
45m Surface Effect Passenger Ship
120m Hull Structural Parts HSSS Catamaran Ferry
APPENDIX
Marine Vessel
1188m Fast Attack Vessel FMV 90 E
20m SAV-Surface Auxiliary Vessels
34m Personnel TransportCoast Guard Vessel
40ft Experimental SES
40m Landsort-Class Mine Hunters
54m Mine Counter Measure Vehicles SES
74m Coastal Patrol Boats
Fishing Boats
30 GT
12 GT
10 GT
5 GT
WISEWings In Surface Effect
HOVERCRAFT
Designed specifically for the tourist and transport industries the
Pioneer Mk3 hovercraft is amphibious and comfortably seats 25
passengers plus 1-crew The air-conditioned cabin allows for
maximum visibility for all aboard The Pioneer Mk3 is robust and
dynamic in its performance
Commercial hovercraft
Mk3 AirLift Hovercraft - 1215m
Power is economicaly provided by one Deutz diesel engine of
330kW (442hp) to cruise easily at 40 knots with much higher
speeds available according to the surface conditions The hull is
manufactured from fibreglassPVC foam composite sandwich
the windows are glass and the skirt is urethane coated nylon A
Military version is available with increased payload and systems
redundancy Power for the Military version comes from two Steyr
diesel engines with a total installed power of 320kW (429hp) All
transmission electrical hydraulic and air systems are duplicated
for maximum redundancy The increased performance of the
Military version comes from the reduced engine weight of the twin
Steyr installation cf the Deutz installation
Source
httpwwwnauticexpocomprodairlift-hovercraftcommercial-hovercrafts-25251-142868html
HOVERFLIGHT
BALLISTIC amp UNIT DEFENCED
Triaxis Composites Collaboration with Institute of Aeronautics and Space in the development of Missile Nose Cone
Polymer composites is the evolution of the military defence
Thin steel was the helmet material of
WWII and remained the principal material until around the 1980rsquos
The advantages of using steel
included a simple technology for manufacture of the helmets low cost and reasonably good
impact protection However these helmets were found to provide only marginal protection
against fragments
During the Vietnam War the US Army experimented with fiber-reinforced inserts in the
helmets These inserts improved ballistic protection but at the same time added weight and
reduced the air space between the head and the helmet
By the early part of the 1980rsquos the US military had developed the first all-composite
100 fiber-reinforced helmet This development resulted in even better ballistic protection
without altering the weight of the helmet Other improvements included better head coverage and
more space for ventilation
Source
Composites Armor - A difficult but huge market
by A Brent Strong Brigham Young University
MILITARY VEHICLES
HIGH SPEED TRAIN SHINKANSEN
Advanced Composites provide lightweight solutions for railway vehicles
saving as much as 50-80 of the weight compared with traditional
components
A lower overall weight translates into less stress faster acceleration and
higher speeds as well as reduced starting and stopping inertia Today
these are important criteria in global high-speed and metropolitan
railway projects
Fire smoke and toxic fumes are key safety criteria for interior
components of railway carriages Any material selected for an interior
component must meet international fire retardant standards
for Rail Interiors and Exteriors
Ceiling Panels Stairs
Seating Vestibules
Window Panels Door Pillars
Partition WallsDiffusers
Gangway and Cabinet Panels Cabin and
Desk panels
Door Pillars Lavatory Modules (standard and
Front and Rear EndsRoof Panels
Nose Cones Under Fairings
Source
httpwwwpctaerail_compositesphp
101
SKY BUS
2009
Europe is the world leader in offshore wind with
828 wind turbines and a cumulative capacity of 2056 MW spread across 38 offshore wind farms in 9
European countries
The UK and Denmark are the current leaders with a 44 and 30 share respectively In 2009
five countries built new offshore wind farms
UK (284 MW)
Demark (230 MW)
Sweden (30 MW)
Germany (30 MW)
Norway (23 MW)
2010
Asia leads the growth in global wind power which grew 358 GW in 2010 bringing
total global capacity to 1944 GW ndash up 225 from 2009
the Global Wind Energy Council (GWEC)
Asia accounted for 19 GW of new global wind power installations driven by China which installed 165
GW
ldquoChina now has 423 GW of wind powerrdquo
ldquoThis puts China firmly on a path to reach 200 GW of installed wind power by 2020 At the same
time China has become the worldrsquos largest producer of wind energy equipmentrdquo
Source
httpwwwreinforcedplasticscomview15655asia-leads-global-wind-power-growth
httpimgdeusmcomdesignnews288288605-Sandia_Sizes_up_Wind_Turbine_Blade_Design_C_largegif
WIND ENERGY
Marine Current Turbines
Source
httpwwwsiemenscompressenpressreleasepress=enpressrelease2011solar-hydroex201111005htm
httpwwwmarineturbinescom
A commercial marine current turbine consists of
two rotors which are fixed on a structure within the
sea current The twin rotors rotate with the
movement of the tidal flow and the blades pitch
through 180 degrees to optimally track tidal current
(Press picture Marine Current Turbines)
Wave Star Energys Multi-point Absorber
CFRP COLUMN REINFORCEMENT
INDUSTRIAL TANKS
107
INDUSTRIAL PIPES
PRESSURE TANKS
109
ldquoLetrsquos Make with Compositesrdquo
JENIS SERAT GLASS
C GLASS Calcium borosilicate glasses
used for CHEMICAL stability in corrosive
acid environments
E GLASS Alumina-calcium-borosilicate
glasses with a maximum alkali used as
general purpose fibers where STRENGTH
and high ELECTICAL RESISTIVITY are
required It manifests better electrical
insulation and strongly resists attack by
water More than 50 of the glass fibers
used for reinforcement is E-glass
C Glass
E Glass
C amp E GLASS
SUMBER AGY TECHNICAL PAPER HIGH STRENGTH GLASS FIBER
FAKTA
C GLASS 1 BOROS RESIN
2 KEKUATAN
KURANG
FAKTA
E GLASS 1 HEMAT RESIN
2 KEKUATAN BAIK
3 TAHAN LAMA
FAKTA
TEBAL BUKAN BERARTI KUAT
UNSUR MATRIX (RESIN)
TIDAK ADA KEKUATAN
ldquoMore than 50 of the glass fibers used for
reinforcement is E-glassrdquo
C glass E glass
E glass
C glass
KAIN WOVEN ROVING HASIL LAMINASI
JENIS SERAT GLASS
Kekuatan composites ditentukan oleh
1 Kekuatan amp Sifat Fiber
2 Kekuatan amp Sifat Resin
3 Fraksi Rasio Perbandingan Volume Fiber
dan Resin dalam Composites
rarr tergantung dari Proses Manufaktur
4 Geometri dan Orientasi Arah Fiber dalam
Composites
KEKUATAN COMPOSITES
PROSES MATERIAL
Proses Produksi Kain Fiberglass
Biji Kaca Benang Benang Kaca Kain Fiberglass
PROSES MATERIAL
Glass Beads
Glass Fiber Glass Roving YarnGlass Fabric
FIBERGLASS
PRODUK
MATERIAL DAN PRODUK FIBERGLASS
+
Resin + Additives
PERPADUAN COMPOSITES
BENANG KACA Potongan Serat Kaca CSM
CSM - CHOPPED STRAND MAT
chopped binder
Kain Fiberglass Generasi Pertama
BahanPengikat
SenyawaPada Resin
JENIS FIBERGLASS
Glass Roving Yarn Chopped Strand
ADVANTAGES DISADVANTAGES
Steel
1048707 Low cost 1048707 Corrodes easily
1048707 Ductile under ambient conditions
1048707 Has no lower fatigue limit for welded structures
1048707 Virtually isotropic 1048707 Heavy
1048707 Easily formed and fabricated 1048707 Brittle at low temperatures
1048707 Easily obtained (low relative cost) 1048707 Magnetic
1048707 Easily alloyed or heat treated for special operations
1048707 Easily repaired
1048707 Good fire resistance
1048707 Behaviour is well understood
Alumunium Alloy
1048707 Light weight 1048707 Poor fatigue properties
1048707 Corrosion resistant 1048707 Poor performance in fire
1048707 Easily formed1048707 Low melting point and softening temperature
1048707 Easily fabricated 1048707 High relative cost
1048707 Readily available 1048707 Strength and stiffness less than steel
1048707 Ductile
1048707 Non magnetic
FRP
1048707 Low magnetic properties
1048707 Low electrical conductivity (glass- reinforced plastics)
1048707 Resistance to corrosion
1048707 Resistance to rot and marine growth
1048707 Relatively high sonar transparency
1048707 Good strength to weight ratio
1048707 Good fatigue properties
1048707 Maintenance of properties at low temperatures
1048707 Availability
1048707 Can be manufactured to near net-shape
1048707 Stiffness and strength can be tailored to structural requirements
1048707 Excellent thermal insulation
1048707 Light weight
STEEL vs ALUMUNIUM vs COMPOSITES
Source
1Maritime Platforms Division Aeronautical and
Maritime Research Laboratory (Seref Aksu
Stuart Cannon Craig Gardiner and Matthew
Gudze
2 Metal Corrosion can be defined as the
destructive attack of a metal through interaction
with its environment
(httpwwwcorrosionistcomCorrosion_Fundament
alhtm)
28
Serat rarr penguat
Polimer matriks rarr pengikat
bull Sifat mekanik yang cukup baik
bull Viskositas dan temperatur pengerjaan rendah rarr mudah
dimanufaktur
bull Ketahanan korosi yang baik
bull Media perpindahan gaya rarr distribusi beban dari serat ke serat
bull Ulet rarr Melindungi serat yang getas
bull Size effect rarr Kekuatan dan kekakuan sangat tinggi
bull Aspect ratio (ld) tinggi rarr luas permukaan besar
bull Fleksibel rarr variasi teknik manufaktur
bull Serat dapat diatur sesuai dengan arah pembebanan
29
Advantages Polimer Composites
Kekuatan dan kekakuan spesifik yang tinggi FRCP vs material lain rarr kompetitif jika berat dipertimbangkan
Material Berat jenis
r (kgm3)
Kekakuan
E (GPa)
Kekuatan
tarik su
(MPa)
Kekakuan
spesifik
Er
Kekuatan
spesifik sur
Baja 7800 208 400 27 005
Aluminium 2700 70 200 259 007
Nylon 1100 25 80 23 007
Beton 2400 40 20 166 0008
Random
FRPC
1800 20 300 111 0006
Alligned FRPC
( serat)
1600 200 1500 125 094
Alligned FRCP
( serat)
1600 3 50 19 0001
Tensile Strength amp Modulus of Common Structural Materials
Densities of Common Structural Materials
Specific Tensile Strength amp Modulus of Common Structural Materials
Typical Properties of Common Structural Materials
Kesimpulan COMPOSITES = RINGAN amp KUAT
Jadi secara keseluruhan kekuatan composites
ditentukan oleh
1 Kekuatan amp Sifat Fiber
2 Kekuatan amp Sifat Resin
3 Fraksi Rasio Perbandingan Volume Fiber
dan Resin dalam Composites
4 Geometri dan Orientasi Arah Fiber dalam
Composites
PRODUKSI ANAK NEGERI
Proses Produksi Kain Fiberglass
Biji Kaca Benang Benang Kaca Kain Fiberglass
PROSES MATERIAL
Glass Beads
Glass Fiber Glass Roving YarnGlass Fabric
Proses Produksi Kain Fiberglass
Biji Kaca Benang Benang Kaca Kain Fiberglass
Glass Beads
Glass Fiber Glass Roving YarnGlass Fabric
PROSES MATERIAL
Benang Kaca Potongan Serat Kaca Chopped Strand Mat
CSM - Chopped Strand Mat
chopped binder
Produk Fiberglass Generasi Pertama
Bahan Pengikat
Senyawa Pada Resin
Glass Roving Yarn Chopped Strand
JENIS FIBERGLASS
Benang Kaca Woven Roving
WR - Woven Roving
Tenun Weaving
Produk Fiberglass Generasi Kedua
Glass Roving Yarn
JENIS FIBERGLASS
Multiaxial
MAX - Multiaxial
warp knitting
Produk Fiberglass Generasi Ketiga
Benang Kaca
Glass Roving Yarn
JENIS FIBERGLASS
MAX - Multiaxial Fabric
Fleece (optional)
Lapisan
MULTIAXIAL PROSES
Karakteristik CSM
bull Glass Content 30
bull Resin Content 70
bull Tensile Force
Chopped Strand Mat
JENIS FIBERGLASS
Karakteristik Woven Roving
bull Glass Content 45
bull Resin Content 55
Woven Roving
Resin
|
|
|
|
|
|
|
|
|
|
|
|
|
|
bull Kekuatan Tarik
JENIS FIBERGLASS
No Resin Rich Area
Karakteristik Multiaxial
bull Glass Content 60
bull Resin Content 40
Produk Fiberglass Ketiga MULTIAXIAL
JENIS FIBERGLASS
Perbedaan Woven Roving dan Multiaxial ndash Tampak Samping
JENIS FIBERGLASS
WR FRP
8 Ply WR 800
8 Ply CSM 450
Glass Weight 1 kg
Composite Weight 15kgm2
CSM FRP
22 Ply CSM 450
Glass Weight 1 kg
Composite Weight 18 kgm2
MULTIAXIAL FRP
13 Ply DB 800
Glass Weight 1 kg
Composite Weight
13 kgm2
JENIS FIBERGLASS
Multiaxial
FRP
Woven Roving
FRP
Chopped Strands Mat FRP
MULTIAXIAL
FAKTA
TEBAL BUKAN BERARTI KUAT
UNSUR MATRIX (RESIN)
TIDAK ADA KEKUATAN
ldquoMore than 50 of the glass fibers used for reinforcement is
E-glassrdquo
KarakteristikKekuatan
CSM WR MAX
Kekuatan Tarik 175 MPa 250 MPa 425 MPa
CSM 142
WR 70
KEKUATAN TARIK
Properties CSM Lamination WR Lamination MAX Lamination
Fabric Weight (kgm2) 1 1 1
Composite Weight (kgm2) 18 15 13
Resin usage (kgm2) 15 1 08
Amount of Fabric 22 Ply 16 Ply 13 Ply
Thickness 15 mm 12 mm 10 mm
Tensile Strength (Mpa) 125 1796 400
Tensile Strength (Nmmsup2) 28463 30958 4576
Processing Time High Med Low
Labour Cost High Med Low
MULTIAXIAL
Total Penggunaan Resin -51
Total Berat Kapal -40
Kekuatan Bangunan Kapal +59
Efisiensi Tenaga Kerja
Waktu Pengerjaan Lebih Cepat
KEUNGGULAN MATERIAL
Resapan Resin Lebih Baik amp Merata
Lapisan Lebih Sedikit
Meningkatkan Kekuatan Kapal
KEUNGGULAN MATERIAL
TRIAXIAL
DBL series DBT series
BIAXIAL
LT series DB series
UNIDIRECTIONAL
L series T series
QUADRIAXIAL
DBLT series
JENIS MULTIAXIAL
UNIDIRECTIONAL
DCMU 900 E ndash
KHUSUS UNTUK MEMPERKUAT BENDING KAPAL
PEMASANGAN KHUSUS PADA KEEL DAN TULANGAN
JENIS MULTIAXIAL UNTUK KAPAL
TRIAXIAL
DBL 600 ndash
APLIKASI PADA INDUSTRI PENERBANGAN
PEMASANGAN KHUSUS PADA
SAMBUNGAN BADAN DAN SAYAP
PESAWAT
JENIS MULTIAXIAL UNTUK PESAWAT
QUADRAXIAL
DBLT 800 ndash
APLIKASI PADA INDUSTRI ENERGI
DITERAPKAN UNTUK KEBUTUHAN PEMBANGKIT
LISTRIK ENERGI ANGIN
MULTIAXIAL UNTUK ENERGI
INDUSTRI KIMIA OLAHRAGA AUTOMOTIF
MULTIAXIAL UNTUK INDUSTRI LAINNYA
COMPOSITES
GUNAKAN MATERIAL FIBERGLASS
YANG SUDAH DISERTIFIKASI
BKI
FIBERGLASS UNTUK PEMBANGUNAN BAKAP
PERATURAN MENTERI PERHUBUNGAN
NOMOR PM 7 TAHUN 2013
TENTANG KEWAJIBAN KLASIFIKASI BAGI KAPAL BERBENDERA INDONESIA
PADA BADAN KLASIFIKASI
BADAN SERTIFIKASI MARITIM
Biro Klasifikasi IndonesiaDet Norske Veritas Germanischer Lloyds
PERATURAN BKI
Untuk Kapal Non-Metal
2006
PERSYARATAN MINIMUM
kekuatan material yang
harus digunakan
untuk membangun
Kapal Fiberglass
PEMBESARAN
Table 21
FIBERGLASS TRIAXIS COMPOSITES
TELAH BERSERTIFIKASI BKI
Biro Klasifikasi Indonesia
65
TEKNIK MANUFAKTUR
COMPOSITES
Wet hand lay-up
1) Peletakan
Dry Reinforcement
bull Dry reinforcement dan resin (+ katalis) ditaruh pada permukaan cetakan
2) Pemasukanpenekanan resin
bull Resin ditekan untuk meng-impregnasi serat dengan menggunakan rol
3) Pengulangan proses untuk lapisan lain
bull Beberapa lapisan dapat ditambahkan secara bertahap
4) Resin curing
bull Reaksi dimulai komponen dilepaskan setelah komponen mengeras
(fully cured)
Wet hand lay-up
Manufaktur komponen dapat dikerjakan dengan menggunakan beberapa lapis komposit
dengan memperhatikan kompatibilitas material dan tahapan curing Modifikasi proses dapat
dilakukan seperti
Vacuum bagging
setelah lay-up
Glass Roving
Bulk Resin
Catalyst
3) De-molding
2) Resin Cure
bull Curing dimulai dan komponen dilepaskan setelah pengerasan selesai
bull Serat gelas resin dan katalis dimasukkan kedalam spray gun
1) Spray-up
bull Campuran disemprotkan pada permukaan cetakan
Spray-up
69
Penyemprotan bakal komponen
Komponen
dilepaskan
dari cetakan
Full dispensing
system Chopper Roving
Atomised resin
and catalyst
Spray-up
Prepreg
1) LaminateAssembly 5) De-molding
3) Resin Melts Layup Consolidates
bull Prepreg serat yang sudah diimpregnasi oleh resin+katalis dalam kondisi padat
bull Lapisan prepreg digunting sesuai bentuk yang diinginkan kemudian diletakkan pada permukaan cetakan
sesuai bentuk komponen yang diinginkan Lay-up mudah dilakukan karena sifat ldquotackynessrdquo dari prepreg
2) Applied Vacuum Pressure and Heat
bull Tekanan dan panas diberikan resin mencair terjadi konsolidasi pada komponen
4) Resin Cures
bull Temperatur dinaikkan untuk memulai curing
Prepreg
Variasi proses Autoclave
Komponen dalam
vacuum-bag
bull Campuran resin (+katalis) dan chopped glass strands diperoleh dalam bentuk premixed compound Bulk molding
Compound (BMC) dalam bentuk adonan atau Sheet molding Compound (SMC) dalam bentuk lembaran
bull Ketika panas dan tekanan diberikan oleh cetakan compound mengalir sesuai bentuk komponen yang diinginkan
1) Placement of Charge
5) De-molding3) Squeeze to final dimensions
2) Mould Closure4) Resin Cure
bull Curing dimulai komponen dilepaskan setelah terjadi pengerasan yang cukup
Compression Molding
bull Preform atau dry reinforcement dimasukkan kedalam cetakan sesuai dengan bentuk komponen yang
diinginkan
bull Resin mengalir dengan penekanan atau pem-vakuman dan meng-impregnasi preform dan
mendorongmengeluarkan udara yang ada dalam preform
1) Preform Manufacture
2) Preform Compression
5) De-molding3) Resin Injection
4) Resin Cure
bull Curing terjadi cetakan dibuka setelah terjadi pengerasan yang mencukupi
Liquid Molding (RTM VARI VARTM)
Pultrusion
bull Dry roving or fabrics ditarik melalui bak berisi
campuran resin dan katalis
bull Campuran yang basah ditarik melalui cetakan
bull Sisa resin keluar cetakan
bull Pemanasan dilakukan untuk proses curing
bull Pendinginan dilakukan untuk mempercepat siklus
produksi
Cut-off
Cooling
Die sections
Resin bath
Fibre creel
Filament Winding
bull Dry roving ditarik melalui bak berisi campuran resin dan katalis
bull Wet roving digulungkan dalam keadaan tegang kepada mandrel
bull Kontrol mekanik dari pembawa serat mengatur orientasi peletakan serat pada
mandrel
INDUSTRI COMPOSITES
AEROSPACE
HISTORY
1950 ndash Boeing
1960 ndash F14 Tomcat
1981 ndash AV-8B Harrier
Source
Low-Cost Composite Materials and Structures for Aircraft Applications
httpwwwreinforcedplasticscom
httpwwwcentennialofflightgovessayEvolution_of_TechnologycompositesTech40htm
Automotive
Composite material is used in a number of applications in the automotive
industry due to its temperature resistance rigidity and fatigue strength
The benefits of using composites include greater fuel efficiency
corrosion resistance light weight and strength Composites also provide
a low-cost way to help keep designs looking fresh
Composites are used in
- interior parts (cockpit trimming seats instrument panels)
- exterior structure (body panels openings underbody frontrear
modules)
- engine compartment and fuelmechanical area parts (axles and
suspensions fuel and exhaust systems)
- electrical and electronic components
Lamborghinis Sesto Element carbon fiber
ldquoFat men cannot run as fast as thin men but we build most of our vehicles as though dead-weight fat increased speedhellip I cannot
imagine where the delusion that weight means strength
came fromhelliprdquo mdashHenry Ford
The mix of automotive materials is changing showing a boost for FRP in helping original
equipment manufacturers meet fuel economy and emissions challenges
(Source 2011 DuPont AutomotiveSAE survey of design engineers performed by Signet Research Inc)
Source
httpwwwtoraycomcsrhighlight2009hig_001_01html
The MonoCell tub for the McLaren MP4-12C supercar is moulded as a single
piece and weighs less than 80 kg (176 lbs)
COMPOSITES IN MARINE
TRIMARAN BOAT
AMERICA NAVYINDONESIAN NAVY
Visby Class corvette
Total length is 72 meters
The beam is 1040 meters
The displacement is 600 metric tones
fully equipped the worlds largest CRP
construction
The design of the Visby aims to minimize
the optical and infrared signature above
water acoustic and hydroa coustic
signature underwater electrical potential
and magnetic signature pressure signature
radar cross section and actively emitted
signals
A stealth corvette of the YS 2000 design
has a detection range of 13km in rough
seas and 22km in calm sea without
jamming In a jammed environment the
Visby would be detected at a range of 8km
in rough sea and 11km in calm sea
The material provides high strength and
rigidity low weight good shock resistance
low radar and magnetic signature
1996
Visby is a class of stealth corvettes for the Swedish Navy
ldquoReduced 50 of a Conventional Steelrdquo
Source
Hull Construction with composite materials for ships over 100m in length 2002
Massachusetts Institute of Technology
httpwwwnaval-technologycomprojectsvisby
YACHTS
KAL YUDISTIRAMARATHON 100 ADMIRAL YACHT
LOA 3050 MWidth 6 MFuel Tank 8000 LWater Tank 3000 LIce Box 500 LAccommodation Max 35 Personnel
2 x CATERPILLAR 3412E 1200 HPMARINE DIESEL ENGINE
PC 40 ndash KRI Krait 827Department of Indonesian Navy
LOA 40 MWidth 73 MPower 190Weapon Twin Cannon Barrels
127 mm Heavy Machine GunSpeed Knot 25 KnotDisplacement 105 tonAccommodation 23 personnel
PATROL BOAT
Rigid Inflatable BoatPATROL BOAT
Yachts
36m Luxury Yacht Moonraker
36m Luxury Yacht GoldenEye
50m Luxury Yacht Casino
Royale
45m Luxury Yacht Seashaw
Boat Parts
Barovans for Seismic Sweep
Centrifugal Liftfan House for Surface Effect
Ships
Composite Boat PropellersRTM
Deckhouses for Pilot Boats
Fairing Parts for Submarines
Flybridges for Motor yachts
Light Weight Gangway
MTB Launcher Mock-up
Pleasure Boats
12m Sailboat
12m Sail-Catamaranone-off
Canoes
Dragonfly 1000Catamaran Sailboat
Fantasy 37Sailboat
Farr 60Luxury Sailboat
EurodingyOlympic Dingy Class for
Woman
Hydrolift F23 Racing Boats
Kajacs
Najad 42Sailboat
Najad 520Sailboat
Najad 441Sailboat
Najad 391Sailboat
Nordwest 900Motorboat
Nordwest 1100Motorboat
Quatro 44Motorboat
Racemaster Competition Boats
Storebro 420
Storebro 345
Sweden Yacht 370Sailboat
Sweden Yacht 69Sailboat
Windy 41Motorboat
X-632Sailboat
X-362Sailboat
Commercial Boats
175m High Speed AmbulancePassenger Boat
19m High Speed Passenger Boat
20m High Speed Passenger Boat
364m Surface Effect Passenger Ship
45m Surface Effect Passenger Ship
120m Hull Structural Parts HSSS Catamaran Ferry
APPENDIX
Marine Vessel
1188m Fast Attack Vessel FMV 90 E
20m SAV-Surface Auxiliary Vessels
34m Personnel TransportCoast Guard Vessel
40ft Experimental SES
40m Landsort-Class Mine Hunters
54m Mine Counter Measure Vehicles SES
74m Coastal Patrol Boats
Fishing Boats
30 GT
12 GT
10 GT
5 GT
WISEWings In Surface Effect
HOVERCRAFT
Designed specifically for the tourist and transport industries the
Pioneer Mk3 hovercraft is amphibious and comfortably seats 25
passengers plus 1-crew The air-conditioned cabin allows for
maximum visibility for all aboard The Pioneer Mk3 is robust and
dynamic in its performance
Commercial hovercraft
Mk3 AirLift Hovercraft - 1215m
Power is economicaly provided by one Deutz diesel engine of
330kW (442hp) to cruise easily at 40 knots with much higher
speeds available according to the surface conditions The hull is
manufactured from fibreglassPVC foam composite sandwich
the windows are glass and the skirt is urethane coated nylon A
Military version is available with increased payload and systems
redundancy Power for the Military version comes from two Steyr
diesel engines with a total installed power of 320kW (429hp) All
transmission electrical hydraulic and air systems are duplicated
for maximum redundancy The increased performance of the
Military version comes from the reduced engine weight of the twin
Steyr installation cf the Deutz installation
Source
httpwwwnauticexpocomprodairlift-hovercraftcommercial-hovercrafts-25251-142868html
HOVERFLIGHT
BALLISTIC amp UNIT DEFENCED
Triaxis Composites Collaboration with Institute of Aeronautics and Space in the development of Missile Nose Cone
Polymer composites is the evolution of the military defence
Thin steel was the helmet material of
WWII and remained the principal material until around the 1980rsquos
The advantages of using steel
included a simple technology for manufacture of the helmets low cost and reasonably good
impact protection However these helmets were found to provide only marginal protection
against fragments
During the Vietnam War the US Army experimented with fiber-reinforced inserts in the
helmets These inserts improved ballistic protection but at the same time added weight and
reduced the air space between the head and the helmet
By the early part of the 1980rsquos the US military had developed the first all-composite
100 fiber-reinforced helmet This development resulted in even better ballistic protection
without altering the weight of the helmet Other improvements included better head coverage and
more space for ventilation
Source
Composites Armor - A difficult but huge market
by A Brent Strong Brigham Young University
MILITARY VEHICLES
HIGH SPEED TRAIN SHINKANSEN
Advanced Composites provide lightweight solutions for railway vehicles
saving as much as 50-80 of the weight compared with traditional
components
A lower overall weight translates into less stress faster acceleration and
higher speeds as well as reduced starting and stopping inertia Today
these are important criteria in global high-speed and metropolitan
railway projects
Fire smoke and toxic fumes are key safety criteria for interior
components of railway carriages Any material selected for an interior
component must meet international fire retardant standards
for Rail Interiors and Exteriors
Ceiling Panels Stairs
Seating Vestibules
Window Panels Door Pillars
Partition WallsDiffusers
Gangway and Cabinet Panels Cabin and
Desk panels
Door Pillars Lavatory Modules (standard and
Front and Rear EndsRoof Panels
Nose Cones Under Fairings
Source
httpwwwpctaerail_compositesphp
101
SKY BUS
2009
Europe is the world leader in offshore wind with
828 wind turbines and a cumulative capacity of 2056 MW spread across 38 offshore wind farms in 9
European countries
The UK and Denmark are the current leaders with a 44 and 30 share respectively In 2009
five countries built new offshore wind farms
UK (284 MW)
Demark (230 MW)
Sweden (30 MW)
Germany (30 MW)
Norway (23 MW)
2010
Asia leads the growth in global wind power which grew 358 GW in 2010 bringing
total global capacity to 1944 GW ndash up 225 from 2009
the Global Wind Energy Council (GWEC)
Asia accounted for 19 GW of new global wind power installations driven by China which installed 165
GW
ldquoChina now has 423 GW of wind powerrdquo
ldquoThis puts China firmly on a path to reach 200 GW of installed wind power by 2020 At the same
time China has become the worldrsquos largest producer of wind energy equipmentrdquo
Source
httpwwwreinforcedplasticscomview15655asia-leads-global-wind-power-growth
httpimgdeusmcomdesignnews288288605-Sandia_Sizes_up_Wind_Turbine_Blade_Design_C_largegif
WIND ENERGY
Marine Current Turbines
Source
httpwwwsiemenscompressenpressreleasepress=enpressrelease2011solar-hydroex201111005htm
httpwwwmarineturbinescom
A commercial marine current turbine consists of
two rotors which are fixed on a structure within the
sea current The twin rotors rotate with the
movement of the tidal flow and the blades pitch
through 180 degrees to optimally track tidal current
(Press picture Marine Current Turbines)
Wave Star Energys Multi-point Absorber
CFRP COLUMN REINFORCEMENT
INDUSTRIAL TANKS
107
INDUSTRIAL PIPES
PRESSURE TANKS
109
ldquoLetrsquos Make with Compositesrdquo
C GLASS Calcium borosilicate glasses
used for CHEMICAL stability in corrosive
acid environments
E GLASS Alumina-calcium-borosilicate
glasses with a maximum alkali used as
general purpose fibers where STRENGTH
and high ELECTICAL RESISTIVITY are
required It manifests better electrical
insulation and strongly resists attack by
water More than 50 of the glass fibers
used for reinforcement is E-glass
C Glass
E Glass
C amp E GLASS
SUMBER AGY TECHNICAL PAPER HIGH STRENGTH GLASS FIBER
FAKTA
C GLASS 1 BOROS RESIN
2 KEKUATAN
KURANG
FAKTA
E GLASS 1 HEMAT RESIN
2 KEKUATAN BAIK
3 TAHAN LAMA
FAKTA
TEBAL BUKAN BERARTI KUAT
UNSUR MATRIX (RESIN)
TIDAK ADA KEKUATAN
ldquoMore than 50 of the glass fibers used for
reinforcement is E-glassrdquo
C glass E glass
E glass
C glass
KAIN WOVEN ROVING HASIL LAMINASI
JENIS SERAT GLASS
Kekuatan composites ditentukan oleh
1 Kekuatan amp Sifat Fiber
2 Kekuatan amp Sifat Resin
3 Fraksi Rasio Perbandingan Volume Fiber
dan Resin dalam Composites
rarr tergantung dari Proses Manufaktur
4 Geometri dan Orientasi Arah Fiber dalam
Composites
KEKUATAN COMPOSITES
PROSES MATERIAL
Proses Produksi Kain Fiberglass
Biji Kaca Benang Benang Kaca Kain Fiberglass
PROSES MATERIAL
Glass Beads
Glass Fiber Glass Roving YarnGlass Fabric
FIBERGLASS
PRODUK
MATERIAL DAN PRODUK FIBERGLASS
+
Resin + Additives
PERPADUAN COMPOSITES
BENANG KACA Potongan Serat Kaca CSM
CSM - CHOPPED STRAND MAT
chopped binder
Kain Fiberglass Generasi Pertama
BahanPengikat
SenyawaPada Resin
JENIS FIBERGLASS
Glass Roving Yarn Chopped Strand
ADVANTAGES DISADVANTAGES
Steel
1048707 Low cost 1048707 Corrodes easily
1048707 Ductile under ambient conditions
1048707 Has no lower fatigue limit for welded structures
1048707 Virtually isotropic 1048707 Heavy
1048707 Easily formed and fabricated 1048707 Brittle at low temperatures
1048707 Easily obtained (low relative cost) 1048707 Magnetic
1048707 Easily alloyed or heat treated for special operations
1048707 Easily repaired
1048707 Good fire resistance
1048707 Behaviour is well understood
Alumunium Alloy
1048707 Light weight 1048707 Poor fatigue properties
1048707 Corrosion resistant 1048707 Poor performance in fire
1048707 Easily formed1048707 Low melting point and softening temperature
1048707 Easily fabricated 1048707 High relative cost
1048707 Readily available 1048707 Strength and stiffness less than steel
1048707 Ductile
1048707 Non magnetic
FRP
1048707 Low magnetic properties
1048707 Low electrical conductivity (glass- reinforced plastics)
1048707 Resistance to corrosion
1048707 Resistance to rot and marine growth
1048707 Relatively high sonar transparency
1048707 Good strength to weight ratio
1048707 Good fatigue properties
1048707 Maintenance of properties at low temperatures
1048707 Availability
1048707 Can be manufactured to near net-shape
1048707 Stiffness and strength can be tailored to structural requirements
1048707 Excellent thermal insulation
1048707 Light weight
STEEL vs ALUMUNIUM vs COMPOSITES
Source
1Maritime Platforms Division Aeronautical and
Maritime Research Laboratory (Seref Aksu
Stuart Cannon Craig Gardiner and Matthew
Gudze
2 Metal Corrosion can be defined as the
destructive attack of a metal through interaction
with its environment
(httpwwwcorrosionistcomCorrosion_Fundament
alhtm)
28
Serat rarr penguat
Polimer matriks rarr pengikat
bull Sifat mekanik yang cukup baik
bull Viskositas dan temperatur pengerjaan rendah rarr mudah
dimanufaktur
bull Ketahanan korosi yang baik
bull Media perpindahan gaya rarr distribusi beban dari serat ke serat
bull Ulet rarr Melindungi serat yang getas
bull Size effect rarr Kekuatan dan kekakuan sangat tinggi
bull Aspect ratio (ld) tinggi rarr luas permukaan besar
bull Fleksibel rarr variasi teknik manufaktur
bull Serat dapat diatur sesuai dengan arah pembebanan
29
Advantages Polimer Composites
Kekuatan dan kekakuan spesifik yang tinggi FRCP vs material lain rarr kompetitif jika berat dipertimbangkan
Material Berat jenis
r (kgm3)
Kekakuan
E (GPa)
Kekuatan
tarik su
(MPa)
Kekakuan
spesifik
Er
Kekuatan
spesifik sur
Baja 7800 208 400 27 005
Aluminium 2700 70 200 259 007
Nylon 1100 25 80 23 007
Beton 2400 40 20 166 0008
Random
FRPC
1800 20 300 111 0006
Alligned FRPC
( serat)
1600 200 1500 125 094
Alligned FRCP
( serat)
1600 3 50 19 0001
Tensile Strength amp Modulus of Common Structural Materials
Densities of Common Structural Materials
Specific Tensile Strength amp Modulus of Common Structural Materials
Typical Properties of Common Structural Materials
Kesimpulan COMPOSITES = RINGAN amp KUAT
Jadi secara keseluruhan kekuatan composites
ditentukan oleh
1 Kekuatan amp Sifat Fiber
2 Kekuatan amp Sifat Resin
3 Fraksi Rasio Perbandingan Volume Fiber
dan Resin dalam Composites
4 Geometri dan Orientasi Arah Fiber dalam
Composites
PRODUKSI ANAK NEGERI
Proses Produksi Kain Fiberglass
Biji Kaca Benang Benang Kaca Kain Fiberglass
PROSES MATERIAL
Glass Beads
Glass Fiber Glass Roving YarnGlass Fabric
Proses Produksi Kain Fiberglass
Biji Kaca Benang Benang Kaca Kain Fiberglass
Glass Beads
Glass Fiber Glass Roving YarnGlass Fabric
PROSES MATERIAL
Benang Kaca Potongan Serat Kaca Chopped Strand Mat
CSM - Chopped Strand Mat
chopped binder
Produk Fiberglass Generasi Pertama
Bahan Pengikat
Senyawa Pada Resin
Glass Roving Yarn Chopped Strand
JENIS FIBERGLASS
Benang Kaca Woven Roving
WR - Woven Roving
Tenun Weaving
Produk Fiberglass Generasi Kedua
Glass Roving Yarn
JENIS FIBERGLASS
Multiaxial
MAX - Multiaxial
warp knitting
Produk Fiberglass Generasi Ketiga
Benang Kaca
Glass Roving Yarn
JENIS FIBERGLASS
MAX - Multiaxial Fabric
Fleece (optional)
Lapisan
MULTIAXIAL PROSES
Karakteristik CSM
bull Glass Content 30
bull Resin Content 70
bull Tensile Force
Chopped Strand Mat
JENIS FIBERGLASS
Karakteristik Woven Roving
bull Glass Content 45
bull Resin Content 55
Woven Roving
Resin
|
|
|
|
|
|
|
|
|
|
|
|
|
|
bull Kekuatan Tarik
JENIS FIBERGLASS
No Resin Rich Area
Karakteristik Multiaxial
bull Glass Content 60
bull Resin Content 40
Produk Fiberglass Ketiga MULTIAXIAL
JENIS FIBERGLASS
Perbedaan Woven Roving dan Multiaxial ndash Tampak Samping
JENIS FIBERGLASS
WR FRP
8 Ply WR 800
8 Ply CSM 450
Glass Weight 1 kg
Composite Weight 15kgm2
CSM FRP
22 Ply CSM 450
Glass Weight 1 kg
Composite Weight 18 kgm2
MULTIAXIAL FRP
13 Ply DB 800
Glass Weight 1 kg
Composite Weight
13 kgm2
JENIS FIBERGLASS
Multiaxial
FRP
Woven Roving
FRP
Chopped Strands Mat FRP
MULTIAXIAL
FAKTA
TEBAL BUKAN BERARTI KUAT
UNSUR MATRIX (RESIN)
TIDAK ADA KEKUATAN
ldquoMore than 50 of the glass fibers used for reinforcement is
E-glassrdquo
KarakteristikKekuatan
CSM WR MAX
Kekuatan Tarik 175 MPa 250 MPa 425 MPa
CSM 142
WR 70
KEKUATAN TARIK
Properties CSM Lamination WR Lamination MAX Lamination
Fabric Weight (kgm2) 1 1 1
Composite Weight (kgm2) 18 15 13
Resin usage (kgm2) 15 1 08
Amount of Fabric 22 Ply 16 Ply 13 Ply
Thickness 15 mm 12 mm 10 mm
Tensile Strength (Mpa) 125 1796 400
Tensile Strength (Nmmsup2) 28463 30958 4576
Processing Time High Med Low
Labour Cost High Med Low
MULTIAXIAL
Total Penggunaan Resin -51
Total Berat Kapal -40
Kekuatan Bangunan Kapal +59
Efisiensi Tenaga Kerja
Waktu Pengerjaan Lebih Cepat
KEUNGGULAN MATERIAL
Resapan Resin Lebih Baik amp Merata
Lapisan Lebih Sedikit
Meningkatkan Kekuatan Kapal
KEUNGGULAN MATERIAL
TRIAXIAL
DBL series DBT series
BIAXIAL
LT series DB series
UNIDIRECTIONAL
L series T series
QUADRIAXIAL
DBLT series
JENIS MULTIAXIAL
UNIDIRECTIONAL
DCMU 900 E ndash
KHUSUS UNTUK MEMPERKUAT BENDING KAPAL
PEMASANGAN KHUSUS PADA KEEL DAN TULANGAN
JENIS MULTIAXIAL UNTUK KAPAL
TRIAXIAL
DBL 600 ndash
APLIKASI PADA INDUSTRI PENERBANGAN
PEMASANGAN KHUSUS PADA
SAMBUNGAN BADAN DAN SAYAP
PESAWAT
JENIS MULTIAXIAL UNTUK PESAWAT
QUADRAXIAL
DBLT 800 ndash
APLIKASI PADA INDUSTRI ENERGI
DITERAPKAN UNTUK KEBUTUHAN PEMBANGKIT
LISTRIK ENERGI ANGIN
MULTIAXIAL UNTUK ENERGI
INDUSTRI KIMIA OLAHRAGA AUTOMOTIF
MULTIAXIAL UNTUK INDUSTRI LAINNYA
COMPOSITES
GUNAKAN MATERIAL FIBERGLASS
YANG SUDAH DISERTIFIKASI
BKI
FIBERGLASS UNTUK PEMBANGUNAN BAKAP
PERATURAN MENTERI PERHUBUNGAN
NOMOR PM 7 TAHUN 2013
TENTANG KEWAJIBAN KLASIFIKASI BAGI KAPAL BERBENDERA INDONESIA
PADA BADAN KLASIFIKASI
BADAN SERTIFIKASI MARITIM
Biro Klasifikasi IndonesiaDet Norske Veritas Germanischer Lloyds
PERATURAN BKI
Untuk Kapal Non-Metal
2006
PERSYARATAN MINIMUM
kekuatan material yang
harus digunakan
untuk membangun
Kapal Fiberglass
PEMBESARAN
Table 21
FIBERGLASS TRIAXIS COMPOSITES
TELAH BERSERTIFIKASI BKI
Biro Klasifikasi Indonesia
65
TEKNIK MANUFAKTUR
COMPOSITES
Wet hand lay-up
1) Peletakan
Dry Reinforcement
bull Dry reinforcement dan resin (+ katalis) ditaruh pada permukaan cetakan
2) Pemasukanpenekanan resin
bull Resin ditekan untuk meng-impregnasi serat dengan menggunakan rol
3) Pengulangan proses untuk lapisan lain
bull Beberapa lapisan dapat ditambahkan secara bertahap
4) Resin curing
bull Reaksi dimulai komponen dilepaskan setelah komponen mengeras
(fully cured)
Wet hand lay-up
Manufaktur komponen dapat dikerjakan dengan menggunakan beberapa lapis komposit
dengan memperhatikan kompatibilitas material dan tahapan curing Modifikasi proses dapat
dilakukan seperti
Vacuum bagging
setelah lay-up
Glass Roving
Bulk Resin
Catalyst
3) De-molding
2) Resin Cure
bull Curing dimulai dan komponen dilepaskan setelah pengerasan selesai
bull Serat gelas resin dan katalis dimasukkan kedalam spray gun
1) Spray-up
bull Campuran disemprotkan pada permukaan cetakan
Spray-up
69
Penyemprotan bakal komponen
Komponen
dilepaskan
dari cetakan
Full dispensing
system Chopper Roving
Atomised resin
and catalyst
Spray-up
Prepreg
1) LaminateAssembly 5) De-molding
3) Resin Melts Layup Consolidates
bull Prepreg serat yang sudah diimpregnasi oleh resin+katalis dalam kondisi padat
bull Lapisan prepreg digunting sesuai bentuk yang diinginkan kemudian diletakkan pada permukaan cetakan
sesuai bentuk komponen yang diinginkan Lay-up mudah dilakukan karena sifat ldquotackynessrdquo dari prepreg
2) Applied Vacuum Pressure and Heat
bull Tekanan dan panas diberikan resin mencair terjadi konsolidasi pada komponen
4) Resin Cures
bull Temperatur dinaikkan untuk memulai curing
Prepreg
Variasi proses Autoclave
Komponen dalam
vacuum-bag
bull Campuran resin (+katalis) dan chopped glass strands diperoleh dalam bentuk premixed compound Bulk molding
Compound (BMC) dalam bentuk adonan atau Sheet molding Compound (SMC) dalam bentuk lembaran
bull Ketika panas dan tekanan diberikan oleh cetakan compound mengalir sesuai bentuk komponen yang diinginkan
1) Placement of Charge
5) De-molding3) Squeeze to final dimensions
2) Mould Closure4) Resin Cure
bull Curing dimulai komponen dilepaskan setelah terjadi pengerasan yang cukup
Compression Molding
bull Preform atau dry reinforcement dimasukkan kedalam cetakan sesuai dengan bentuk komponen yang
diinginkan
bull Resin mengalir dengan penekanan atau pem-vakuman dan meng-impregnasi preform dan
mendorongmengeluarkan udara yang ada dalam preform
1) Preform Manufacture
2) Preform Compression
5) De-molding3) Resin Injection
4) Resin Cure
bull Curing terjadi cetakan dibuka setelah terjadi pengerasan yang mencukupi
Liquid Molding (RTM VARI VARTM)
Pultrusion
bull Dry roving or fabrics ditarik melalui bak berisi
campuran resin dan katalis
bull Campuran yang basah ditarik melalui cetakan
bull Sisa resin keluar cetakan
bull Pemanasan dilakukan untuk proses curing
bull Pendinginan dilakukan untuk mempercepat siklus
produksi
Cut-off
Cooling
Die sections
Resin bath
Fibre creel
Filament Winding
bull Dry roving ditarik melalui bak berisi campuran resin dan katalis
bull Wet roving digulungkan dalam keadaan tegang kepada mandrel
bull Kontrol mekanik dari pembawa serat mengatur orientasi peletakan serat pada
mandrel
INDUSTRI COMPOSITES
AEROSPACE
HISTORY
1950 ndash Boeing
1960 ndash F14 Tomcat
1981 ndash AV-8B Harrier
Source
Low-Cost Composite Materials and Structures for Aircraft Applications
httpwwwreinforcedplasticscom
httpwwwcentennialofflightgovessayEvolution_of_TechnologycompositesTech40htm
Automotive
Composite material is used in a number of applications in the automotive
industry due to its temperature resistance rigidity and fatigue strength
The benefits of using composites include greater fuel efficiency
corrosion resistance light weight and strength Composites also provide
a low-cost way to help keep designs looking fresh
Composites are used in
- interior parts (cockpit trimming seats instrument panels)
- exterior structure (body panels openings underbody frontrear
modules)
- engine compartment and fuelmechanical area parts (axles and
suspensions fuel and exhaust systems)
- electrical and electronic components
Lamborghinis Sesto Element carbon fiber
ldquoFat men cannot run as fast as thin men but we build most of our vehicles as though dead-weight fat increased speedhellip I cannot
imagine where the delusion that weight means strength
came fromhelliprdquo mdashHenry Ford
The mix of automotive materials is changing showing a boost for FRP in helping original
equipment manufacturers meet fuel economy and emissions challenges
(Source 2011 DuPont AutomotiveSAE survey of design engineers performed by Signet Research Inc)
Source
httpwwwtoraycomcsrhighlight2009hig_001_01html
The MonoCell tub for the McLaren MP4-12C supercar is moulded as a single
piece and weighs less than 80 kg (176 lbs)
COMPOSITES IN MARINE
TRIMARAN BOAT
AMERICA NAVYINDONESIAN NAVY
Visby Class corvette
Total length is 72 meters
The beam is 1040 meters
The displacement is 600 metric tones
fully equipped the worlds largest CRP
construction
The design of the Visby aims to minimize
the optical and infrared signature above
water acoustic and hydroa coustic
signature underwater electrical potential
and magnetic signature pressure signature
radar cross section and actively emitted
signals
A stealth corvette of the YS 2000 design
has a detection range of 13km in rough
seas and 22km in calm sea without
jamming In a jammed environment the
Visby would be detected at a range of 8km
in rough sea and 11km in calm sea
The material provides high strength and
rigidity low weight good shock resistance
low radar and magnetic signature
1996
Visby is a class of stealth corvettes for the Swedish Navy
ldquoReduced 50 of a Conventional Steelrdquo
Source
Hull Construction with composite materials for ships over 100m in length 2002
Massachusetts Institute of Technology
httpwwwnaval-technologycomprojectsvisby
YACHTS
KAL YUDISTIRAMARATHON 100 ADMIRAL YACHT
LOA 3050 MWidth 6 MFuel Tank 8000 LWater Tank 3000 LIce Box 500 LAccommodation Max 35 Personnel
2 x CATERPILLAR 3412E 1200 HPMARINE DIESEL ENGINE
PC 40 ndash KRI Krait 827Department of Indonesian Navy
LOA 40 MWidth 73 MPower 190Weapon Twin Cannon Barrels
127 mm Heavy Machine GunSpeed Knot 25 KnotDisplacement 105 tonAccommodation 23 personnel
PATROL BOAT
Rigid Inflatable BoatPATROL BOAT
Yachts
36m Luxury Yacht Moonraker
36m Luxury Yacht GoldenEye
50m Luxury Yacht Casino
Royale
45m Luxury Yacht Seashaw
Boat Parts
Barovans for Seismic Sweep
Centrifugal Liftfan House for Surface Effect
Ships
Composite Boat PropellersRTM
Deckhouses for Pilot Boats
Fairing Parts for Submarines
Flybridges for Motor yachts
Light Weight Gangway
MTB Launcher Mock-up
Pleasure Boats
12m Sailboat
12m Sail-Catamaranone-off
Canoes
Dragonfly 1000Catamaran Sailboat
Fantasy 37Sailboat
Farr 60Luxury Sailboat
EurodingyOlympic Dingy Class for
Woman
Hydrolift F23 Racing Boats
Kajacs
Najad 42Sailboat
Najad 520Sailboat
Najad 441Sailboat
Najad 391Sailboat
Nordwest 900Motorboat
Nordwest 1100Motorboat
Quatro 44Motorboat
Racemaster Competition Boats
Storebro 420
Storebro 345
Sweden Yacht 370Sailboat
Sweden Yacht 69Sailboat
Windy 41Motorboat
X-632Sailboat
X-362Sailboat
Commercial Boats
175m High Speed AmbulancePassenger Boat
19m High Speed Passenger Boat
20m High Speed Passenger Boat
364m Surface Effect Passenger Ship
45m Surface Effect Passenger Ship
120m Hull Structural Parts HSSS Catamaran Ferry
APPENDIX
Marine Vessel
1188m Fast Attack Vessel FMV 90 E
20m SAV-Surface Auxiliary Vessels
34m Personnel TransportCoast Guard Vessel
40ft Experimental SES
40m Landsort-Class Mine Hunters
54m Mine Counter Measure Vehicles SES
74m Coastal Patrol Boats
Fishing Boats
30 GT
12 GT
10 GT
5 GT
WISEWings In Surface Effect
HOVERCRAFT
Designed specifically for the tourist and transport industries the
Pioneer Mk3 hovercraft is amphibious and comfortably seats 25
passengers plus 1-crew The air-conditioned cabin allows for
maximum visibility for all aboard The Pioneer Mk3 is robust and
dynamic in its performance
Commercial hovercraft
Mk3 AirLift Hovercraft - 1215m
Power is economicaly provided by one Deutz diesel engine of
330kW (442hp) to cruise easily at 40 knots with much higher
speeds available according to the surface conditions The hull is
manufactured from fibreglassPVC foam composite sandwich
the windows are glass and the skirt is urethane coated nylon A
Military version is available with increased payload and systems
redundancy Power for the Military version comes from two Steyr
diesel engines with a total installed power of 320kW (429hp) All
transmission electrical hydraulic and air systems are duplicated
for maximum redundancy The increased performance of the
Military version comes from the reduced engine weight of the twin
Steyr installation cf the Deutz installation
Source
httpwwwnauticexpocomprodairlift-hovercraftcommercial-hovercrafts-25251-142868html
HOVERFLIGHT
BALLISTIC amp UNIT DEFENCED
Triaxis Composites Collaboration with Institute of Aeronautics and Space in the development of Missile Nose Cone
Polymer composites is the evolution of the military defence
Thin steel was the helmet material of
WWII and remained the principal material until around the 1980rsquos
The advantages of using steel
included a simple technology for manufacture of the helmets low cost and reasonably good
impact protection However these helmets were found to provide only marginal protection
against fragments
During the Vietnam War the US Army experimented with fiber-reinforced inserts in the
helmets These inserts improved ballistic protection but at the same time added weight and
reduced the air space between the head and the helmet
By the early part of the 1980rsquos the US military had developed the first all-composite
100 fiber-reinforced helmet This development resulted in even better ballistic protection
without altering the weight of the helmet Other improvements included better head coverage and
more space for ventilation
Source
Composites Armor - A difficult but huge market
by A Brent Strong Brigham Young University
MILITARY VEHICLES
HIGH SPEED TRAIN SHINKANSEN
Advanced Composites provide lightweight solutions for railway vehicles
saving as much as 50-80 of the weight compared with traditional
components
A lower overall weight translates into less stress faster acceleration and
higher speeds as well as reduced starting and stopping inertia Today
these are important criteria in global high-speed and metropolitan
railway projects
Fire smoke and toxic fumes are key safety criteria for interior
components of railway carriages Any material selected for an interior
component must meet international fire retardant standards
for Rail Interiors and Exteriors
Ceiling Panels Stairs
Seating Vestibules
Window Panels Door Pillars
Partition WallsDiffusers
Gangway and Cabinet Panels Cabin and
Desk panels
Door Pillars Lavatory Modules (standard and
Front and Rear EndsRoof Panels
Nose Cones Under Fairings
Source
httpwwwpctaerail_compositesphp
101
SKY BUS
2009
Europe is the world leader in offshore wind with
828 wind turbines and a cumulative capacity of 2056 MW spread across 38 offshore wind farms in 9
European countries
The UK and Denmark are the current leaders with a 44 and 30 share respectively In 2009
five countries built new offshore wind farms
UK (284 MW)
Demark (230 MW)
Sweden (30 MW)
Germany (30 MW)
Norway (23 MW)
2010
Asia leads the growth in global wind power which grew 358 GW in 2010 bringing
total global capacity to 1944 GW ndash up 225 from 2009
the Global Wind Energy Council (GWEC)
Asia accounted for 19 GW of new global wind power installations driven by China which installed 165
GW
ldquoChina now has 423 GW of wind powerrdquo
ldquoThis puts China firmly on a path to reach 200 GW of installed wind power by 2020 At the same
time China has become the worldrsquos largest producer of wind energy equipmentrdquo
Source
httpwwwreinforcedplasticscomview15655asia-leads-global-wind-power-growth
httpimgdeusmcomdesignnews288288605-Sandia_Sizes_up_Wind_Turbine_Blade_Design_C_largegif
WIND ENERGY
Marine Current Turbines
Source
httpwwwsiemenscompressenpressreleasepress=enpressrelease2011solar-hydroex201111005htm
httpwwwmarineturbinescom
A commercial marine current turbine consists of
two rotors which are fixed on a structure within the
sea current The twin rotors rotate with the
movement of the tidal flow and the blades pitch
through 180 degrees to optimally track tidal current
(Press picture Marine Current Turbines)
Wave Star Energys Multi-point Absorber
CFRP COLUMN REINFORCEMENT
INDUSTRIAL TANKS
107
INDUSTRIAL PIPES
PRESSURE TANKS
109
ldquoLetrsquos Make with Compositesrdquo
FAKTA
C GLASS 1 BOROS RESIN
2 KEKUATAN
KURANG
FAKTA
E GLASS 1 HEMAT RESIN
2 KEKUATAN BAIK
3 TAHAN LAMA
FAKTA
TEBAL BUKAN BERARTI KUAT
UNSUR MATRIX (RESIN)
TIDAK ADA KEKUATAN
ldquoMore than 50 of the glass fibers used for
reinforcement is E-glassrdquo
C glass E glass
E glass
C glass
KAIN WOVEN ROVING HASIL LAMINASI
JENIS SERAT GLASS
Kekuatan composites ditentukan oleh
1 Kekuatan amp Sifat Fiber
2 Kekuatan amp Sifat Resin
3 Fraksi Rasio Perbandingan Volume Fiber
dan Resin dalam Composites
rarr tergantung dari Proses Manufaktur
4 Geometri dan Orientasi Arah Fiber dalam
Composites
KEKUATAN COMPOSITES
PROSES MATERIAL
Proses Produksi Kain Fiberglass
Biji Kaca Benang Benang Kaca Kain Fiberglass
PROSES MATERIAL
Glass Beads
Glass Fiber Glass Roving YarnGlass Fabric
FIBERGLASS
PRODUK
MATERIAL DAN PRODUK FIBERGLASS
+
Resin + Additives
PERPADUAN COMPOSITES
BENANG KACA Potongan Serat Kaca CSM
CSM - CHOPPED STRAND MAT
chopped binder
Kain Fiberglass Generasi Pertama
BahanPengikat
SenyawaPada Resin
JENIS FIBERGLASS
Glass Roving Yarn Chopped Strand
ADVANTAGES DISADVANTAGES
Steel
1048707 Low cost 1048707 Corrodes easily
1048707 Ductile under ambient conditions
1048707 Has no lower fatigue limit for welded structures
1048707 Virtually isotropic 1048707 Heavy
1048707 Easily formed and fabricated 1048707 Brittle at low temperatures
1048707 Easily obtained (low relative cost) 1048707 Magnetic
1048707 Easily alloyed or heat treated for special operations
1048707 Easily repaired
1048707 Good fire resistance
1048707 Behaviour is well understood
Alumunium Alloy
1048707 Light weight 1048707 Poor fatigue properties
1048707 Corrosion resistant 1048707 Poor performance in fire
1048707 Easily formed1048707 Low melting point and softening temperature
1048707 Easily fabricated 1048707 High relative cost
1048707 Readily available 1048707 Strength and stiffness less than steel
1048707 Ductile
1048707 Non magnetic
FRP
1048707 Low magnetic properties
1048707 Low electrical conductivity (glass- reinforced plastics)
1048707 Resistance to corrosion
1048707 Resistance to rot and marine growth
1048707 Relatively high sonar transparency
1048707 Good strength to weight ratio
1048707 Good fatigue properties
1048707 Maintenance of properties at low temperatures
1048707 Availability
1048707 Can be manufactured to near net-shape
1048707 Stiffness and strength can be tailored to structural requirements
1048707 Excellent thermal insulation
1048707 Light weight
STEEL vs ALUMUNIUM vs COMPOSITES
Source
1Maritime Platforms Division Aeronautical and
Maritime Research Laboratory (Seref Aksu
Stuart Cannon Craig Gardiner and Matthew
Gudze
2 Metal Corrosion can be defined as the
destructive attack of a metal through interaction
with its environment
(httpwwwcorrosionistcomCorrosion_Fundament
alhtm)
28
Serat rarr penguat
Polimer matriks rarr pengikat
bull Sifat mekanik yang cukup baik
bull Viskositas dan temperatur pengerjaan rendah rarr mudah
dimanufaktur
bull Ketahanan korosi yang baik
bull Media perpindahan gaya rarr distribusi beban dari serat ke serat
bull Ulet rarr Melindungi serat yang getas
bull Size effect rarr Kekuatan dan kekakuan sangat tinggi
bull Aspect ratio (ld) tinggi rarr luas permukaan besar
bull Fleksibel rarr variasi teknik manufaktur
bull Serat dapat diatur sesuai dengan arah pembebanan
29
Advantages Polimer Composites
Kekuatan dan kekakuan spesifik yang tinggi FRCP vs material lain rarr kompetitif jika berat dipertimbangkan
Material Berat jenis
r (kgm3)
Kekakuan
E (GPa)
Kekuatan
tarik su
(MPa)
Kekakuan
spesifik
Er
Kekuatan
spesifik sur
Baja 7800 208 400 27 005
Aluminium 2700 70 200 259 007
Nylon 1100 25 80 23 007
Beton 2400 40 20 166 0008
Random
FRPC
1800 20 300 111 0006
Alligned FRPC
( serat)
1600 200 1500 125 094
Alligned FRCP
( serat)
1600 3 50 19 0001
Tensile Strength amp Modulus of Common Structural Materials
Densities of Common Structural Materials
Specific Tensile Strength amp Modulus of Common Structural Materials
Typical Properties of Common Structural Materials
Kesimpulan COMPOSITES = RINGAN amp KUAT
Jadi secara keseluruhan kekuatan composites
ditentukan oleh
1 Kekuatan amp Sifat Fiber
2 Kekuatan amp Sifat Resin
3 Fraksi Rasio Perbandingan Volume Fiber
dan Resin dalam Composites
4 Geometri dan Orientasi Arah Fiber dalam
Composites
PRODUKSI ANAK NEGERI
Proses Produksi Kain Fiberglass
Biji Kaca Benang Benang Kaca Kain Fiberglass
PROSES MATERIAL
Glass Beads
Glass Fiber Glass Roving YarnGlass Fabric
Proses Produksi Kain Fiberglass
Biji Kaca Benang Benang Kaca Kain Fiberglass
Glass Beads
Glass Fiber Glass Roving YarnGlass Fabric
PROSES MATERIAL
Benang Kaca Potongan Serat Kaca Chopped Strand Mat
CSM - Chopped Strand Mat
chopped binder
Produk Fiberglass Generasi Pertama
Bahan Pengikat
Senyawa Pada Resin
Glass Roving Yarn Chopped Strand
JENIS FIBERGLASS
Benang Kaca Woven Roving
WR - Woven Roving
Tenun Weaving
Produk Fiberglass Generasi Kedua
Glass Roving Yarn
JENIS FIBERGLASS
Multiaxial
MAX - Multiaxial
warp knitting
Produk Fiberglass Generasi Ketiga
Benang Kaca
Glass Roving Yarn
JENIS FIBERGLASS
MAX - Multiaxial Fabric
Fleece (optional)
Lapisan
MULTIAXIAL PROSES
Karakteristik CSM
bull Glass Content 30
bull Resin Content 70
bull Tensile Force
Chopped Strand Mat
JENIS FIBERGLASS
Karakteristik Woven Roving
bull Glass Content 45
bull Resin Content 55
Woven Roving
Resin
|
|
|
|
|
|
|
|
|
|
|
|
|
|
bull Kekuatan Tarik
JENIS FIBERGLASS
No Resin Rich Area
Karakteristik Multiaxial
bull Glass Content 60
bull Resin Content 40
Produk Fiberglass Ketiga MULTIAXIAL
JENIS FIBERGLASS
Perbedaan Woven Roving dan Multiaxial ndash Tampak Samping
JENIS FIBERGLASS
WR FRP
8 Ply WR 800
8 Ply CSM 450
Glass Weight 1 kg
Composite Weight 15kgm2
CSM FRP
22 Ply CSM 450
Glass Weight 1 kg
Composite Weight 18 kgm2
MULTIAXIAL FRP
13 Ply DB 800
Glass Weight 1 kg
Composite Weight
13 kgm2
JENIS FIBERGLASS
Multiaxial
FRP
Woven Roving
FRP
Chopped Strands Mat FRP
MULTIAXIAL
FAKTA
TEBAL BUKAN BERARTI KUAT
UNSUR MATRIX (RESIN)
TIDAK ADA KEKUATAN
ldquoMore than 50 of the glass fibers used for reinforcement is
E-glassrdquo
KarakteristikKekuatan
CSM WR MAX
Kekuatan Tarik 175 MPa 250 MPa 425 MPa
CSM 142
WR 70
KEKUATAN TARIK
Properties CSM Lamination WR Lamination MAX Lamination
Fabric Weight (kgm2) 1 1 1
Composite Weight (kgm2) 18 15 13
Resin usage (kgm2) 15 1 08
Amount of Fabric 22 Ply 16 Ply 13 Ply
Thickness 15 mm 12 mm 10 mm
Tensile Strength (Mpa) 125 1796 400
Tensile Strength (Nmmsup2) 28463 30958 4576
Processing Time High Med Low
Labour Cost High Med Low
MULTIAXIAL
Total Penggunaan Resin -51
Total Berat Kapal -40
Kekuatan Bangunan Kapal +59
Efisiensi Tenaga Kerja
Waktu Pengerjaan Lebih Cepat
KEUNGGULAN MATERIAL
Resapan Resin Lebih Baik amp Merata
Lapisan Lebih Sedikit
Meningkatkan Kekuatan Kapal
KEUNGGULAN MATERIAL
TRIAXIAL
DBL series DBT series
BIAXIAL
LT series DB series
UNIDIRECTIONAL
L series T series
QUADRIAXIAL
DBLT series
JENIS MULTIAXIAL
UNIDIRECTIONAL
DCMU 900 E ndash
KHUSUS UNTUK MEMPERKUAT BENDING KAPAL
PEMASANGAN KHUSUS PADA KEEL DAN TULANGAN
JENIS MULTIAXIAL UNTUK KAPAL
TRIAXIAL
DBL 600 ndash
APLIKASI PADA INDUSTRI PENERBANGAN
PEMASANGAN KHUSUS PADA
SAMBUNGAN BADAN DAN SAYAP
PESAWAT
JENIS MULTIAXIAL UNTUK PESAWAT
QUADRAXIAL
DBLT 800 ndash
APLIKASI PADA INDUSTRI ENERGI
DITERAPKAN UNTUK KEBUTUHAN PEMBANGKIT
LISTRIK ENERGI ANGIN
MULTIAXIAL UNTUK ENERGI
INDUSTRI KIMIA OLAHRAGA AUTOMOTIF
MULTIAXIAL UNTUK INDUSTRI LAINNYA
COMPOSITES
GUNAKAN MATERIAL FIBERGLASS
YANG SUDAH DISERTIFIKASI
BKI
FIBERGLASS UNTUK PEMBANGUNAN BAKAP
PERATURAN MENTERI PERHUBUNGAN
NOMOR PM 7 TAHUN 2013
TENTANG KEWAJIBAN KLASIFIKASI BAGI KAPAL BERBENDERA INDONESIA
PADA BADAN KLASIFIKASI
BADAN SERTIFIKASI MARITIM
Biro Klasifikasi IndonesiaDet Norske Veritas Germanischer Lloyds
PERATURAN BKI
Untuk Kapal Non-Metal
2006
PERSYARATAN MINIMUM
kekuatan material yang
harus digunakan
untuk membangun
Kapal Fiberglass
PEMBESARAN
Table 21
FIBERGLASS TRIAXIS COMPOSITES
TELAH BERSERTIFIKASI BKI
Biro Klasifikasi Indonesia
65
TEKNIK MANUFAKTUR
COMPOSITES
Wet hand lay-up
1) Peletakan
Dry Reinforcement
bull Dry reinforcement dan resin (+ katalis) ditaruh pada permukaan cetakan
2) Pemasukanpenekanan resin
bull Resin ditekan untuk meng-impregnasi serat dengan menggunakan rol
3) Pengulangan proses untuk lapisan lain
bull Beberapa lapisan dapat ditambahkan secara bertahap
4) Resin curing
bull Reaksi dimulai komponen dilepaskan setelah komponen mengeras
(fully cured)
Wet hand lay-up
Manufaktur komponen dapat dikerjakan dengan menggunakan beberapa lapis komposit
dengan memperhatikan kompatibilitas material dan tahapan curing Modifikasi proses dapat
dilakukan seperti
Vacuum bagging
setelah lay-up
Glass Roving
Bulk Resin
Catalyst
3) De-molding
2) Resin Cure
bull Curing dimulai dan komponen dilepaskan setelah pengerasan selesai
bull Serat gelas resin dan katalis dimasukkan kedalam spray gun
1) Spray-up
bull Campuran disemprotkan pada permukaan cetakan
Spray-up
69
Penyemprotan bakal komponen
Komponen
dilepaskan
dari cetakan
Full dispensing
system Chopper Roving
Atomised resin
and catalyst
Spray-up
Prepreg
1) LaminateAssembly 5) De-molding
3) Resin Melts Layup Consolidates
bull Prepreg serat yang sudah diimpregnasi oleh resin+katalis dalam kondisi padat
bull Lapisan prepreg digunting sesuai bentuk yang diinginkan kemudian diletakkan pada permukaan cetakan
sesuai bentuk komponen yang diinginkan Lay-up mudah dilakukan karena sifat ldquotackynessrdquo dari prepreg
2) Applied Vacuum Pressure and Heat
bull Tekanan dan panas diberikan resin mencair terjadi konsolidasi pada komponen
4) Resin Cures
bull Temperatur dinaikkan untuk memulai curing
Prepreg
Variasi proses Autoclave
Komponen dalam
vacuum-bag
bull Campuran resin (+katalis) dan chopped glass strands diperoleh dalam bentuk premixed compound Bulk molding
Compound (BMC) dalam bentuk adonan atau Sheet molding Compound (SMC) dalam bentuk lembaran
bull Ketika panas dan tekanan diberikan oleh cetakan compound mengalir sesuai bentuk komponen yang diinginkan
1) Placement of Charge
5) De-molding3) Squeeze to final dimensions
2) Mould Closure4) Resin Cure
bull Curing dimulai komponen dilepaskan setelah terjadi pengerasan yang cukup
Compression Molding
bull Preform atau dry reinforcement dimasukkan kedalam cetakan sesuai dengan bentuk komponen yang
diinginkan
bull Resin mengalir dengan penekanan atau pem-vakuman dan meng-impregnasi preform dan
mendorongmengeluarkan udara yang ada dalam preform
1) Preform Manufacture
2) Preform Compression
5) De-molding3) Resin Injection
4) Resin Cure
bull Curing terjadi cetakan dibuka setelah terjadi pengerasan yang mencukupi
Liquid Molding (RTM VARI VARTM)
Pultrusion
bull Dry roving or fabrics ditarik melalui bak berisi
campuran resin dan katalis
bull Campuran yang basah ditarik melalui cetakan
bull Sisa resin keluar cetakan
bull Pemanasan dilakukan untuk proses curing
bull Pendinginan dilakukan untuk mempercepat siklus
produksi
Cut-off
Cooling
Die sections
Resin bath
Fibre creel
Filament Winding
bull Dry roving ditarik melalui bak berisi campuran resin dan katalis
bull Wet roving digulungkan dalam keadaan tegang kepada mandrel
bull Kontrol mekanik dari pembawa serat mengatur orientasi peletakan serat pada
mandrel
INDUSTRI COMPOSITES
AEROSPACE
HISTORY
1950 ndash Boeing
1960 ndash F14 Tomcat
1981 ndash AV-8B Harrier
Source
Low-Cost Composite Materials and Structures for Aircraft Applications
httpwwwreinforcedplasticscom
httpwwwcentennialofflightgovessayEvolution_of_TechnologycompositesTech40htm
Automotive
Composite material is used in a number of applications in the automotive
industry due to its temperature resistance rigidity and fatigue strength
The benefits of using composites include greater fuel efficiency
corrosion resistance light weight and strength Composites also provide
a low-cost way to help keep designs looking fresh
Composites are used in
- interior parts (cockpit trimming seats instrument panels)
- exterior structure (body panels openings underbody frontrear
modules)
- engine compartment and fuelmechanical area parts (axles and
suspensions fuel and exhaust systems)
- electrical and electronic components
Lamborghinis Sesto Element carbon fiber
ldquoFat men cannot run as fast as thin men but we build most of our vehicles as though dead-weight fat increased speedhellip I cannot
imagine where the delusion that weight means strength
came fromhelliprdquo mdashHenry Ford
The mix of automotive materials is changing showing a boost for FRP in helping original
equipment manufacturers meet fuel economy and emissions challenges
(Source 2011 DuPont AutomotiveSAE survey of design engineers performed by Signet Research Inc)
Source
httpwwwtoraycomcsrhighlight2009hig_001_01html
The MonoCell tub for the McLaren MP4-12C supercar is moulded as a single
piece and weighs less than 80 kg (176 lbs)
COMPOSITES IN MARINE
TRIMARAN BOAT
AMERICA NAVYINDONESIAN NAVY
Visby Class corvette
Total length is 72 meters
The beam is 1040 meters
The displacement is 600 metric tones
fully equipped the worlds largest CRP
construction
The design of the Visby aims to minimize
the optical and infrared signature above
water acoustic and hydroa coustic
signature underwater electrical potential
and magnetic signature pressure signature
radar cross section and actively emitted
signals
A stealth corvette of the YS 2000 design
has a detection range of 13km in rough
seas and 22km in calm sea without
jamming In a jammed environment the
Visby would be detected at a range of 8km
in rough sea and 11km in calm sea
The material provides high strength and
rigidity low weight good shock resistance
low radar and magnetic signature
1996
Visby is a class of stealth corvettes for the Swedish Navy
ldquoReduced 50 of a Conventional Steelrdquo
Source
Hull Construction with composite materials for ships over 100m in length 2002
Massachusetts Institute of Technology
httpwwwnaval-technologycomprojectsvisby
YACHTS
KAL YUDISTIRAMARATHON 100 ADMIRAL YACHT
LOA 3050 MWidth 6 MFuel Tank 8000 LWater Tank 3000 LIce Box 500 LAccommodation Max 35 Personnel
2 x CATERPILLAR 3412E 1200 HPMARINE DIESEL ENGINE
PC 40 ndash KRI Krait 827Department of Indonesian Navy
LOA 40 MWidth 73 MPower 190Weapon Twin Cannon Barrels
127 mm Heavy Machine GunSpeed Knot 25 KnotDisplacement 105 tonAccommodation 23 personnel
PATROL BOAT
Rigid Inflatable BoatPATROL BOAT
Yachts
36m Luxury Yacht Moonraker
36m Luxury Yacht GoldenEye
50m Luxury Yacht Casino
Royale
45m Luxury Yacht Seashaw
Boat Parts
Barovans for Seismic Sweep
Centrifugal Liftfan House for Surface Effect
Ships
Composite Boat PropellersRTM
Deckhouses for Pilot Boats
Fairing Parts for Submarines
Flybridges for Motor yachts
Light Weight Gangway
MTB Launcher Mock-up
Pleasure Boats
12m Sailboat
12m Sail-Catamaranone-off
Canoes
Dragonfly 1000Catamaran Sailboat
Fantasy 37Sailboat
Farr 60Luxury Sailboat
EurodingyOlympic Dingy Class for
Woman
Hydrolift F23 Racing Boats
Kajacs
Najad 42Sailboat
Najad 520Sailboat
Najad 441Sailboat
Najad 391Sailboat
Nordwest 900Motorboat
Nordwest 1100Motorboat
Quatro 44Motorboat
Racemaster Competition Boats
Storebro 420
Storebro 345
Sweden Yacht 370Sailboat
Sweden Yacht 69Sailboat
Windy 41Motorboat
X-632Sailboat
X-362Sailboat
Commercial Boats
175m High Speed AmbulancePassenger Boat
19m High Speed Passenger Boat
20m High Speed Passenger Boat
364m Surface Effect Passenger Ship
45m Surface Effect Passenger Ship
120m Hull Structural Parts HSSS Catamaran Ferry
APPENDIX
Marine Vessel
1188m Fast Attack Vessel FMV 90 E
20m SAV-Surface Auxiliary Vessels
34m Personnel TransportCoast Guard Vessel
40ft Experimental SES
40m Landsort-Class Mine Hunters
54m Mine Counter Measure Vehicles SES
74m Coastal Patrol Boats
Fishing Boats
30 GT
12 GT
10 GT
5 GT
WISEWings In Surface Effect
HOVERCRAFT
Designed specifically for the tourist and transport industries the
Pioneer Mk3 hovercraft is amphibious and comfortably seats 25
passengers plus 1-crew The air-conditioned cabin allows for
maximum visibility for all aboard The Pioneer Mk3 is robust and
dynamic in its performance
Commercial hovercraft
Mk3 AirLift Hovercraft - 1215m
Power is economicaly provided by one Deutz diesel engine of
330kW (442hp) to cruise easily at 40 knots with much higher
speeds available according to the surface conditions The hull is
manufactured from fibreglassPVC foam composite sandwich
the windows are glass and the skirt is urethane coated nylon A
Military version is available with increased payload and systems
redundancy Power for the Military version comes from two Steyr
diesel engines with a total installed power of 320kW (429hp) All
transmission electrical hydraulic and air systems are duplicated
for maximum redundancy The increased performance of the
Military version comes from the reduced engine weight of the twin
Steyr installation cf the Deutz installation
Source
httpwwwnauticexpocomprodairlift-hovercraftcommercial-hovercrafts-25251-142868html
HOVERFLIGHT
BALLISTIC amp UNIT DEFENCED
Triaxis Composites Collaboration with Institute of Aeronautics and Space in the development of Missile Nose Cone
Polymer composites is the evolution of the military defence
Thin steel was the helmet material of
WWII and remained the principal material until around the 1980rsquos
The advantages of using steel
included a simple technology for manufacture of the helmets low cost and reasonably good
impact protection However these helmets were found to provide only marginal protection
against fragments
During the Vietnam War the US Army experimented with fiber-reinforced inserts in the
helmets These inserts improved ballistic protection but at the same time added weight and
reduced the air space between the head and the helmet
By the early part of the 1980rsquos the US military had developed the first all-composite
100 fiber-reinforced helmet This development resulted in even better ballistic protection
without altering the weight of the helmet Other improvements included better head coverage and
more space for ventilation
Source
Composites Armor - A difficult but huge market
by A Brent Strong Brigham Young University
MILITARY VEHICLES
HIGH SPEED TRAIN SHINKANSEN
Advanced Composites provide lightweight solutions for railway vehicles
saving as much as 50-80 of the weight compared with traditional
components
A lower overall weight translates into less stress faster acceleration and
higher speeds as well as reduced starting and stopping inertia Today
these are important criteria in global high-speed and metropolitan
railway projects
Fire smoke and toxic fumes are key safety criteria for interior
components of railway carriages Any material selected for an interior
component must meet international fire retardant standards
for Rail Interiors and Exteriors
Ceiling Panels Stairs
Seating Vestibules
Window Panels Door Pillars
Partition WallsDiffusers
Gangway and Cabinet Panels Cabin and
Desk panels
Door Pillars Lavatory Modules (standard and
Front and Rear EndsRoof Panels
Nose Cones Under Fairings
Source
httpwwwpctaerail_compositesphp
101
SKY BUS
2009
Europe is the world leader in offshore wind with
828 wind turbines and a cumulative capacity of 2056 MW spread across 38 offshore wind farms in 9
European countries
The UK and Denmark are the current leaders with a 44 and 30 share respectively In 2009
five countries built new offshore wind farms
UK (284 MW)
Demark (230 MW)
Sweden (30 MW)
Germany (30 MW)
Norway (23 MW)
2010
Asia leads the growth in global wind power which grew 358 GW in 2010 bringing
total global capacity to 1944 GW ndash up 225 from 2009
the Global Wind Energy Council (GWEC)
Asia accounted for 19 GW of new global wind power installations driven by China which installed 165
GW
ldquoChina now has 423 GW of wind powerrdquo
ldquoThis puts China firmly on a path to reach 200 GW of installed wind power by 2020 At the same
time China has become the worldrsquos largest producer of wind energy equipmentrdquo
Source
httpwwwreinforcedplasticscomview15655asia-leads-global-wind-power-growth
httpimgdeusmcomdesignnews288288605-Sandia_Sizes_up_Wind_Turbine_Blade_Design_C_largegif
WIND ENERGY
Marine Current Turbines
Source
httpwwwsiemenscompressenpressreleasepress=enpressrelease2011solar-hydroex201111005htm
httpwwwmarineturbinescom
A commercial marine current turbine consists of
two rotors which are fixed on a structure within the
sea current The twin rotors rotate with the
movement of the tidal flow and the blades pitch
through 180 degrees to optimally track tidal current
(Press picture Marine Current Turbines)
Wave Star Energys Multi-point Absorber
CFRP COLUMN REINFORCEMENT
INDUSTRIAL TANKS
107
INDUSTRIAL PIPES
PRESSURE TANKS
109
ldquoLetrsquos Make with Compositesrdquo
C glass E glass
E glass
C glass
KAIN WOVEN ROVING HASIL LAMINASI
JENIS SERAT GLASS
Kekuatan composites ditentukan oleh
1 Kekuatan amp Sifat Fiber
2 Kekuatan amp Sifat Resin
3 Fraksi Rasio Perbandingan Volume Fiber
dan Resin dalam Composites
rarr tergantung dari Proses Manufaktur
4 Geometri dan Orientasi Arah Fiber dalam
Composites
KEKUATAN COMPOSITES
PROSES MATERIAL
Proses Produksi Kain Fiberglass
Biji Kaca Benang Benang Kaca Kain Fiberglass
PROSES MATERIAL
Glass Beads
Glass Fiber Glass Roving YarnGlass Fabric
FIBERGLASS
PRODUK
MATERIAL DAN PRODUK FIBERGLASS
+
Resin + Additives
PERPADUAN COMPOSITES
BENANG KACA Potongan Serat Kaca CSM
CSM - CHOPPED STRAND MAT
chopped binder
Kain Fiberglass Generasi Pertama
BahanPengikat
SenyawaPada Resin
JENIS FIBERGLASS
Glass Roving Yarn Chopped Strand
ADVANTAGES DISADVANTAGES
Steel
1048707 Low cost 1048707 Corrodes easily
1048707 Ductile under ambient conditions
1048707 Has no lower fatigue limit for welded structures
1048707 Virtually isotropic 1048707 Heavy
1048707 Easily formed and fabricated 1048707 Brittle at low temperatures
1048707 Easily obtained (low relative cost) 1048707 Magnetic
1048707 Easily alloyed or heat treated for special operations
1048707 Easily repaired
1048707 Good fire resistance
1048707 Behaviour is well understood
Alumunium Alloy
1048707 Light weight 1048707 Poor fatigue properties
1048707 Corrosion resistant 1048707 Poor performance in fire
1048707 Easily formed1048707 Low melting point and softening temperature
1048707 Easily fabricated 1048707 High relative cost
1048707 Readily available 1048707 Strength and stiffness less than steel
1048707 Ductile
1048707 Non magnetic
FRP
1048707 Low magnetic properties
1048707 Low electrical conductivity (glass- reinforced plastics)
1048707 Resistance to corrosion
1048707 Resistance to rot and marine growth
1048707 Relatively high sonar transparency
1048707 Good strength to weight ratio
1048707 Good fatigue properties
1048707 Maintenance of properties at low temperatures
1048707 Availability
1048707 Can be manufactured to near net-shape
1048707 Stiffness and strength can be tailored to structural requirements
1048707 Excellent thermal insulation
1048707 Light weight
STEEL vs ALUMUNIUM vs COMPOSITES
Source
1Maritime Platforms Division Aeronautical and
Maritime Research Laboratory (Seref Aksu
Stuart Cannon Craig Gardiner and Matthew
Gudze
2 Metal Corrosion can be defined as the
destructive attack of a metal through interaction
with its environment
(httpwwwcorrosionistcomCorrosion_Fundament
alhtm)
28
Serat rarr penguat
Polimer matriks rarr pengikat
bull Sifat mekanik yang cukup baik
bull Viskositas dan temperatur pengerjaan rendah rarr mudah
dimanufaktur
bull Ketahanan korosi yang baik
bull Media perpindahan gaya rarr distribusi beban dari serat ke serat
bull Ulet rarr Melindungi serat yang getas
bull Size effect rarr Kekuatan dan kekakuan sangat tinggi
bull Aspect ratio (ld) tinggi rarr luas permukaan besar
bull Fleksibel rarr variasi teknik manufaktur
bull Serat dapat diatur sesuai dengan arah pembebanan
29
Advantages Polimer Composites
Kekuatan dan kekakuan spesifik yang tinggi FRCP vs material lain rarr kompetitif jika berat dipertimbangkan
Material Berat jenis
r (kgm3)
Kekakuan
E (GPa)
Kekuatan
tarik su
(MPa)
Kekakuan
spesifik
Er
Kekuatan
spesifik sur
Baja 7800 208 400 27 005
Aluminium 2700 70 200 259 007
Nylon 1100 25 80 23 007
Beton 2400 40 20 166 0008
Random
FRPC
1800 20 300 111 0006
Alligned FRPC
( serat)
1600 200 1500 125 094
Alligned FRCP
( serat)
1600 3 50 19 0001
Tensile Strength amp Modulus of Common Structural Materials
Densities of Common Structural Materials
Specific Tensile Strength amp Modulus of Common Structural Materials
Typical Properties of Common Structural Materials
Kesimpulan COMPOSITES = RINGAN amp KUAT
Jadi secara keseluruhan kekuatan composites
ditentukan oleh
1 Kekuatan amp Sifat Fiber
2 Kekuatan amp Sifat Resin
3 Fraksi Rasio Perbandingan Volume Fiber
dan Resin dalam Composites
4 Geometri dan Orientasi Arah Fiber dalam
Composites
PRODUKSI ANAK NEGERI
Proses Produksi Kain Fiberglass
Biji Kaca Benang Benang Kaca Kain Fiberglass
PROSES MATERIAL
Glass Beads
Glass Fiber Glass Roving YarnGlass Fabric
Proses Produksi Kain Fiberglass
Biji Kaca Benang Benang Kaca Kain Fiberglass
Glass Beads
Glass Fiber Glass Roving YarnGlass Fabric
PROSES MATERIAL
Benang Kaca Potongan Serat Kaca Chopped Strand Mat
CSM - Chopped Strand Mat
chopped binder
Produk Fiberglass Generasi Pertama
Bahan Pengikat
Senyawa Pada Resin
Glass Roving Yarn Chopped Strand
JENIS FIBERGLASS
Benang Kaca Woven Roving
WR - Woven Roving
Tenun Weaving
Produk Fiberglass Generasi Kedua
Glass Roving Yarn
JENIS FIBERGLASS
Multiaxial
MAX - Multiaxial
warp knitting
Produk Fiberglass Generasi Ketiga
Benang Kaca
Glass Roving Yarn
JENIS FIBERGLASS
MAX - Multiaxial Fabric
Fleece (optional)
Lapisan
MULTIAXIAL PROSES
Karakteristik CSM
bull Glass Content 30
bull Resin Content 70
bull Tensile Force
Chopped Strand Mat
JENIS FIBERGLASS
Karakteristik Woven Roving
bull Glass Content 45
bull Resin Content 55
Woven Roving
Resin
|
|
|
|
|
|
|
|
|
|
|
|
|
|
bull Kekuatan Tarik
JENIS FIBERGLASS
No Resin Rich Area
Karakteristik Multiaxial
bull Glass Content 60
bull Resin Content 40
Produk Fiberglass Ketiga MULTIAXIAL
JENIS FIBERGLASS
Perbedaan Woven Roving dan Multiaxial ndash Tampak Samping
JENIS FIBERGLASS
WR FRP
8 Ply WR 800
8 Ply CSM 450
Glass Weight 1 kg
Composite Weight 15kgm2
CSM FRP
22 Ply CSM 450
Glass Weight 1 kg
Composite Weight 18 kgm2
MULTIAXIAL FRP
13 Ply DB 800
Glass Weight 1 kg
Composite Weight
13 kgm2
JENIS FIBERGLASS
Multiaxial
FRP
Woven Roving
FRP
Chopped Strands Mat FRP
MULTIAXIAL
FAKTA
TEBAL BUKAN BERARTI KUAT
UNSUR MATRIX (RESIN)
TIDAK ADA KEKUATAN
ldquoMore than 50 of the glass fibers used for reinforcement is
E-glassrdquo
KarakteristikKekuatan
CSM WR MAX
Kekuatan Tarik 175 MPa 250 MPa 425 MPa
CSM 142
WR 70
KEKUATAN TARIK
Properties CSM Lamination WR Lamination MAX Lamination
Fabric Weight (kgm2) 1 1 1
Composite Weight (kgm2) 18 15 13
Resin usage (kgm2) 15 1 08
Amount of Fabric 22 Ply 16 Ply 13 Ply
Thickness 15 mm 12 mm 10 mm
Tensile Strength (Mpa) 125 1796 400
Tensile Strength (Nmmsup2) 28463 30958 4576
Processing Time High Med Low
Labour Cost High Med Low
MULTIAXIAL
Total Penggunaan Resin -51
Total Berat Kapal -40
Kekuatan Bangunan Kapal +59
Efisiensi Tenaga Kerja
Waktu Pengerjaan Lebih Cepat
KEUNGGULAN MATERIAL
Resapan Resin Lebih Baik amp Merata
Lapisan Lebih Sedikit
Meningkatkan Kekuatan Kapal
KEUNGGULAN MATERIAL
TRIAXIAL
DBL series DBT series
BIAXIAL
LT series DB series
UNIDIRECTIONAL
L series T series
QUADRIAXIAL
DBLT series
JENIS MULTIAXIAL
UNIDIRECTIONAL
DCMU 900 E ndash
KHUSUS UNTUK MEMPERKUAT BENDING KAPAL
PEMASANGAN KHUSUS PADA KEEL DAN TULANGAN
JENIS MULTIAXIAL UNTUK KAPAL
TRIAXIAL
DBL 600 ndash
APLIKASI PADA INDUSTRI PENERBANGAN
PEMASANGAN KHUSUS PADA
SAMBUNGAN BADAN DAN SAYAP
PESAWAT
JENIS MULTIAXIAL UNTUK PESAWAT
QUADRAXIAL
DBLT 800 ndash
APLIKASI PADA INDUSTRI ENERGI
DITERAPKAN UNTUK KEBUTUHAN PEMBANGKIT
LISTRIK ENERGI ANGIN
MULTIAXIAL UNTUK ENERGI
INDUSTRI KIMIA OLAHRAGA AUTOMOTIF
MULTIAXIAL UNTUK INDUSTRI LAINNYA
COMPOSITES
GUNAKAN MATERIAL FIBERGLASS
YANG SUDAH DISERTIFIKASI
BKI
FIBERGLASS UNTUK PEMBANGUNAN BAKAP
PERATURAN MENTERI PERHUBUNGAN
NOMOR PM 7 TAHUN 2013
TENTANG KEWAJIBAN KLASIFIKASI BAGI KAPAL BERBENDERA INDONESIA
PADA BADAN KLASIFIKASI
BADAN SERTIFIKASI MARITIM
Biro Klasifikasi IndonesiaDet Norske Veritas Germanischer Lloyds
PERATURAN BKI
Untuk Kapal Non-Metal
2006
PERSYARATAN MINIMUM
kekuatan material yang
harus digunakan
untuk membangun
Kapal Fiberglass
PEMBESARAN
Table 21
FIBERGLASS TRIAXIS COMPOSITES
TELAH BERSERTIFIKASI BKI
Biro Klasifikasi Indonesia
65
TEKNIK MANUFAKTUR
COMPOSITES
Wet hand lay-up
1) Peletakan
Dry Reinforcement
bull Dry reinforcement dan resin (+ katalis) ditaruh pada permukaan cetakan
2) Pemasukanpenekanan resin
bull Resin ditekan untuk meng-impregnasi serat dengan menggunakan rol
3) Pengulangan proses untuk lapisan lain
bull Beberapa lapisan dapat ditambahkan secara bertahap
4) Resin curing
bull Reaksi dimulai komponen dilepaskan setelah komponen mengeras
(fully cured)
Wet hand lay-up
Manufaktur komponen dapat dikerjakan dengan menggunakan beberapa lapis komposit
dengan memperhatikan kompatibilitas material dan tahapan curing Modifikasi proses dapat
dilakukan seperti
Vacuum bagging
setelah lay-up
Glass Roving
Bulk Resin
Catalyst
3) De-molding
2) Resin Cure
bull Curing dimulai dan komponen dilepaskan setelah pengerasan selesai
bull Serat gelas resin dan katalis dimasukkan kedalam spray gun
1) Spray-up
bull Campuran disemprotkan pada permukaan cetakan
Spray-up
69
Penyemprotan bakal komponen
Komponen
dilepaskan
dari cetakan
Full dispensing
system Chopper Roving
Atomised resin
and catalyst
Spray-up
Prepreg
1) LaminateAssembly 5) De-molding
3) Resin Melts Layup Consolidates
bull Prepreg serat yang sudah diimpregnasi oleh resin+katalis dalam kondisi padat
bull Lapisan prepreg digunting sesuai bentuk yang diinginkan kemudian diletakkan pada permukaan cetakan
sesuai bentuk komponen yang diinginkan Lay-up mudah dilakukan karena sifat ldquotackynessrdquo dari prepreg
2) Applied Vacuum Pressure and Heat
bull Tekanan dan panas diberikan resin mencair terjadi konsolidasi pada komponen
4) Resin Cures
bull Temperatur dinaikkan untuk memulai curing
Prepreg
Variasi proses Autoclave
Komponen dalam
vacuum-bag
bull Campuran resin (+katalis) dan chopped glass strands diperoleh dalam bentuk premixed compound Bulk molding
Compound (BMC) dalam bentuk adonan atau Sheet molding Compound (SMC) dalam bentuk lembaran
bull Ketika panas dan tekanan diberikan oleh cetakan compound mengalir sesuai bentuk komponen yang diinginkan
1) Placement of Charge
5) De-molding3) Squeeze to final dimensions
2) Mould Closure4) Resin Cure
bull Curing dimulai komponen dilepaskan setelah terjadi pengerasan yang cukup
Compression Molding
bull Preform atau dry reinforcement dimasukkan kedalam cetakan sesuai dengan bentuk komponen yang
diinginkan
bull Resin mengalir dengan penekanan atau pem-vakuman dan meng-impregnasi preform dan
mendorongmengeluarkan udara yang ada dalam preform
1) Preform Manufacture
2) Preform Compression
5) De-molding3) Resin Injection
4) Resin Cure
bull Curing terjadi cetakan dibuka setelah terjadi pengerasan yang mencukupi
Liquid Molding (RTM VARI VARTM)
Pultrusion
bull Dry roving or fabrics ditarik melalui bak berisi
campuran resin dan katalis
bull Campuran yang basah ditarik melalui cetakan
bull Sisa resin keluar cetakan
bull Pemanasan dilakukan untuk proses curing
bull Pendinginan dilakukan untuk mempercepat siklus
produksi
Cut-off
Cooling
Die sections
Resin bath
Fibre creel
Filament Winding
bull Dry roving ditarik melalui bak berisi campuran resin dan katalis
bull Wet roving digulungkan dalam keadaan tegang kepada mandrel
bull Kontrol mekanik dari pembawa serat mengatur orientasi peletakan serat pada
mandrel
INDUSTRI COMPOSITES
AEROSPACE
HISTORY
1950 ndash Boeing
1960 ndash F14 Tomcat
1981 ndash AV-8B Harrier
Source
Low-Cost Composite Materials and Structures for Aircraft Applications
httpwwwreinforcedplasticscom
httpwwwcentennialofflightgovessayEvolution_of_TechnologycompositesTech40htm
Automotive
Composite material is used in a number of applications in the automotive
industry due to its temperature resistance rigidity and fatigue strength
The benefits of using composites include greater fuel efficiency
corrosion resistance light weight and strength Composites also provide
a low-cost way to help keep designs looking fresh
Composites are used in
- interior parts (cockpit trimming seats instrument panels)
- exterior structure (body panels openings underbody frontrear
modules)
- engine compartment and fuelmechanical area parts (axles and
suspensions fuel and exhaust systems)
- electrical and electronic components
Lamborghinis Sesto Element carbon fiber
ldquoFat men cannot run as fast as thin men but we build most of our vehicles as though dead-weight fat increased speedhellip I cannot
imagine where the delusion that weight means strength
came fromhelliprdquo mdashHenry Ford
The mix of automotive materials is changing showing a boost for FRP in helping original
equipment manufacturers meet fuel economy and emissions challenges
(Source 2011 DuPont AutomotiveSAE survey of design engineers performed by Signet Research Inc)
Source
httpwwwtoraycomcsrhighlight2009hig_001_01html
The MonoCell tub for the McLaren MP4-12C supercar is moulded as a single
piece and weighs less than 80 kg (176 lbs)
COMPOSITES IN MARINE
TRIMARAN BOAT
AMERICA NAVYINDONESIAN NAVY
Visby Class corvette
Total length is 72 meters
The beam is 1040 meters
The displacement is 600 metric tones
fully equipped the worlds largest CRP
construction
The design of the Visby aims to minimize
the optical and infrared signature above
water acoustic and hydroa coustic
signature underwater electrical potential
and magnetic signature pressure signature
radar cross section and actively emitted
signals
A stealth corvette of the YS 2000 design
has a detection range of 13km in rough
seas and 22km in calm sea without
jamming In a jammed environment the
Visby would be detected at a range of 8km
in rough sea and 11km in calm sea
The material provides high strength and
rigidity low weight good shock resistance
low radar and magnetic signature
1996
Visby is a class of stealth corvettes for the Swedish Navy
ldquoReduced 50 of a Conventional Steelrdquo
Source
Hull Construction with composite materials for ships over 100m in length 2002
Massachusetts Institute of Technology
httpwwwnaval-technologycomprojectsvisby
YACHTS
KAL YUDISTIRAMARATHON 100 ADMIRAL YACHT
LOA 3050 MWidth 6 MFuel Tank 8000 LWater Tank 3000 LIce Box 500 LAccommodation Max 35 Personnel
2 x CATERPILLAR 3412E 1200 HPMARINE DIESEL ENGINE
PC 40 ndash KRI Krait 827Department of Indonesian Navy
LOA 40 MWidth 73 MPower 190Weapon Twin Cannon Barrels
127 mm Heavy Machine GunSpeed Knot 25 KnotDisplacement 105 tonAccommodation 23 personnel
PATROL BOAT
Rigid Inflatable BoatPATROL BOAT
Yachts
36m Luxury Yacht Moonraker
36m Luxury Yacht GoldenEye
50m Luxury Yacht Casino
Royale
45m Luxury Yacht Seashaw
Boat Parts
Barovans for Seismic Sweep
Centrifugal Liftfan House for Surface Effect
Ships
Composite Boat PropellersRTM
Deckhouses for Pilot Boats
Fairing Parts for Submarines
Flybridges for Motor yachts
Light Weight Gangway
MTB Launcher Mock-up
Pleasure Boats
12m Sailboat
12m Sail-Catamaranone-off
Canoes
Dragonfly 1000Catamaran Sailboat
Fantasy 37Sailboat
Farr 60Luxury Sailboat
EurodingyOlympic Dingy Class for
Woman
Hydrolift F23 Racing Boats
Kajacs
Najad 42Sailboat
Najad 520Sailboat
Najad 441Sailboat
Najad 391Sailboat
Nordwest 900Motorboat
Nordwest 1100Motorboat
Quatro 44Motorboat
Racemaster Competition Boats
Storebro 420
Storebro 345
Sweden Yacht 370Sailboat
Sweden Yacht 69Sailboat
Windy 41Motorboat
X-632Sailboat
X-362Sailboat
Commercial Boats
175m High Speed AmbulancePassenger Boat
19m High Speed Passenger Boat
20m High Speed Passenger Boat
364m Surface Effect Passenger Ship
45m Surface Effect Passenger Ship
120m Hull Structural Parts HSSS Catamaran Ferry
APPENDIX
Marine Vessel
1188m Fast Attack Vessel FMV 90 E
20m SAV-Surface Auxiliary Vessels
34m Personnel TransportCoast Guard Vessel
40ft Experimental SES
40m Landsort-Class Mine Hunters
54m Mine Counter Measure Vehicles SES
74m Coastal Patrol Boats
Fishing Boats
30 GT
12 GT
10 GT
5 GT
WISEWings In Surface Effect
HOVERCRAFT
Designed specifically for the tourist and transport industries the
Pioneer Mk3 hovercraft is amphibious and comfortably seats 25
passengers plus 1-crew The air-conditioned cabin allows for
maximum visibility for all aboard The Pioneer Mk3 is robust and
dynamic in its performance
Commercial hovercraft
Mk3 AirLift Hovercraft - 1215m
Power is economicaly provided by one Deutz diesel engine of
330kW (442hp) to cruise easily at 40 knots with much higher
speeds available according to the surface conditions The hull is
manufactured from fibreglassPVC foam composite sandwich
the windows are glass and the skirt is urethane coated nylon A
Military version is available with increased payload and systems
redundancy Power for the Military version comes from two Steyr
diesel engines with a total installed power of 320kW (429hp) All
transmission electrical hydraulic and air systems are duplicated
for maximum redundancy The increased performance of the
Military version comes from the reduced engine weight of the twin
Steyr installation cf the Deutz installation
Source
httpwwwnauticexpocomprodairlift-hovercraftcommercial-hovercrafts-25251-142868html
HOVERFLIGHT
BALLISTIC amp UNIT DEFENCED
Triaxis Composites Collaboration with Institute of Aeronautics and Space in the development of Missile Nose Cone
Polymer composites is the evolution of the military defence
Thin steel was the helmet material of
WWII and remained the principal material until around the 1980rsquos
The advantages of using steel
included a simple technology for manufacture of the helmets low cost and reasonably good
impact protection However these helmets were found to provide only marginal protection
against fragments
During the Vietnam War the US Army experimented with fiber-reinforced inserts in the
helmets These inserts improved ballistic protection but at the same time added weight and
reduced the air space between the head and the helmet
By the early part of the 1980rsquos the US military had developed the first all-composite
100 fiber-reinforced helmet This development resulted in even better ballistic protection
without altering the weight of the helmet Other improvements included better head coverage and
more space for ventilation
Source
Composites Armor - A difficult but huge market
by A Brent Strong Brigham Young University
MILITARY VEHICLES
HIGH SPEED TRAIN SHINKANSEN
Advanced Composites provide lightweight solutions for railway vehicles
saving as much as 50-80 of the weight compared with traditional
components
A lower overall weight translates into less stress faster acceleration and
higher speeds as well as reduced starting and stopping inertia Today
these are important criteria in global high-speed and metropolitan
railway projects
Fire smoke and toxic fumes are key safety criteria for interior
components of railway carriages Any material selected for an interior
component must meet international fire retardant standards
for Rail Interiors and Exteriors
Ceiling Panels Stairs
Seating Vestibules
Window Panels Door Pillars
Partition WallsDiffusers
Gangway and Cabinet Panels Cabin and
Desk panels
Door Pillars Lavatory Modules (standard and
Front and Rear EndsRoof Panels
Nose Cones Under Fairings
Source
httpwwwpctaerail_compositesphp
101
SKY BUS
2009
Europe is the world leader in offshore wind with
828 wind turbines and a cumulative capacity of 2056 MW spread across 38 offshore wind farms in 9
European countries
The UK and Denmark are the current leaders with a 44 and 30 share respectively In 2009
five countries built new offshore wind farms
UK (284 MW)
Demark (230 MW)
Sweden (30 MW)
Germany (30 MW)
Norway (23 MW)
2010
Asia leads the growth in global wind power which grew 358 GW in 2010 bringing
total global capacity to 1944 GW ndash up 225 from 2009
the Global Wind Energy Council (GWEC)
Asia accounted for 19 GW of new global wind power installations driven by China which installed 165
GW
ldquoChina now has 423 GW of wind powerrdquo
ldquoThis puts China firmly on a path to reach 200 GW of installed wind power by 2020 At the same
time China has become the worldrsquos largest producer of wind energy equipmentrdquo
Source
httpwwwreinforcedplasticscomview15655asia-leads-global-wind-power-growth
httpimgdeusmcomdesignnews288288605-Sandia_Sizes_up_Wind_Turbine_Blade_Design_C_largegif
WIND ENERGY
Marine Current Turbines
Source
httpwwwsiemenscompressenpressreleasepress=enpressrelease2011solar-hydroex201111005htm
httpwwwmarineturbinescom
A commercial marine current turbine consists of
two rotors which are fixed on a structure within the
sea current The twin rotors rotate with the
movement of the tidal flow and the blades pitch
through 180 degrees to optimally track tidal current
(Press picture Marine Current Turbines)
Wave Star Energys Multi-point Absorber
CFRP COLUMN REINFORCEMENT
INDUSTRIAL TANKS
107
INDUSTRIAL PIPES
PRESSURE TANKS
109
ldquoLetrsquos Make with Compositesrdquo
Kekuatan composites ditentukan oleh
1 Kekuatan amp Sifat Fiber
2 Kekuatan amp Sifat Resin
3 Fraksi Rasio Perbandingan Volume Fiber
dan Resin dalam Composites
rarr tergantung dari Proses Manufaktur
4 Geometri dan Orientasi Arah Fiber dalam
Composites
KEKUATAN COMPOSITES
PROSES MATERIAL
Proses Produksi Kain Fiberglass
Biji Kaca Benang Benang Kaca Kain Fiberglass
PROSES MATERIAL
Glass Beads
Glass Fiber Glass Roving YarnGlass Fabric
FIBERGLASS
PRODUK
MATERIAL DAN PRODUK FIBERGLASS
+
Resin + Additives
PERPADUAN COMPOSITES
BENANG KACA Potongan Serat Kaca CSM
CSM - CHOPPED STRAND MAT
chopped binder
Kain Fiberglass Generasi Pertama
BahanPengikat
SenyawaPada Resin
JENIS FIBERGLASS
Glass Roving Yarn Chopped Strand
ADVANTAGES DISADVANTAGES
Steel
1048707 Low cost 1048707 Corrodes easily
1048707 Ductile under ambient conditions
1048707 Has no lower fatigue limit for welded structures
1048707 Virtually isotropic 1048707 Heavy
1048707 Easily formed and fabricated 1048707 Brittle at low temperatures
1048707 Easily obtained (low relative cost) 1048707 Magnetic
1048707 Easily alloyed or heat treated for special operations
1048707 Easily repaired
1048707 Good fire resistance
1048707 Behaviour is well understood
Alumunium Alloy
1048707 Light weight 1048707 Poor fatigue properties
1048707 Corrosion resistant 1048707 Poor performance in fire
1048707 Easily formed1048707 Low melting point and softening temperature
1048707 Easily fabricated 1048707 High relative cost
1048707 Readily available 1048707 Strength and stiffness less than steel
1048707 Ductile
1048707 Non magnetic
FRP
1048707 Low magnetic properties
1048707 Low electrical conductivity (glass- reinforced plastics)
1048707 Resistance to corrosion
1048707 Resistance to rot and marine growth
1048707 Relatively high sonar transparency
1048707 Good strength to weight ratio
1048707 Good fatigue properties
1048707 Maintenance of properties at low temperatures
1048707 Availability
1048707 Can be manufactured to near net-shape
1048707 Stiffness and strength can be tailored to structural requirements
1048707 Excellent thermal insulation
1048707 Light weight
STEEL vs ALUMUNIUM vs COMPOSITES
Source
1Maritime Platforms Division Aeronautical and
Maritime Research Laboratory (Seref Aksu
Stuart Cannon Craig Gardiner and Matthew
Gudze
2 Metal Corrosion can be defined as the
destructive attack of a metal through interaction
with its environment
(httpwwwcorrosionistcomCorrosion_Fundament
alhtm)
28
Serat rarr penguat
Polimer matriks rarr pengikat
bull Sifat mekanik yang cukup baik
bull Viskositas dan temperatur pengerjaan rendah rarr mudah
dimanufaktur
bull Ketahanan korosi yang baik
bull Media perpindahan gaya rarr distribusi beban dari serat ke serat
bull Ulet rarr Melindungi serat yang getas
bull Size effect rarr Kekuatan dan kekakuan sangat tinggi
bull Aspect ratio (ld) tinggi rarr luas permukaan besar
bull Fleksibel rarr variasi teknik manufaktur
bull Serat dapat diatur sesuai dengan arah pembebanan
29
Advantages Polimer Composites
Kekuatan dan kekakuan spesifik yang tinggi FRCP vs material lain rarr kompetitif jika berat dipertimbangkan
Material Berat jenis
r (kgm3)
Kekakuan
E (GPa)
Kekuatan
tarik su
(MPa)
Kekakuan
spesifik
Er
Kekuatan
spesifik sur
Baja 7800 208 400 27 005
Aluminium 2700 70 200 259 007
Nylon 1100 25 80 23 007
Beton 2400 40 20 166 0008
Random
FRPC
1800 20 300 111 0006
Alligned FRPC
( serat)
1600 200 1500 125 094
Alligned FRCP
( serat)
1600 3 50 19 0001
Tensile Strength amp Modulus of Common Structural Materials
Densities of Common Structural Materials
Specific Tensile Strength amp Modulus of Common Structural Materials
Typical Properties of Common Structural Materials
Kesimpulan COMPOSITES = RINGAN amp KUAT
Jadi secara keseluruhan kekuatan composites
ditentukan oleh
1 Kekuatan amp Sifat Fiber
2 Kekuatan amp Sifat Resin
3 Fraksi Rasio Perbandingan Volume Fiber
dan Resin dalam Composites
4 Geometri dan Orientasi Arah Fiber dalam
Composites
PRODUKSI ANAK NEGERI
Proses Produksi Kain Fiberglass
Biji Kaca Benang Benang Kaca Kain Fiberglass
PROSES MATERIAL
Glass Beads
Glass Fiber Glass Roving YarnGlass Fabric
Proses Produksi Kain Fiberglass
Biji Kaca Benang Benang Kaca Kain Fiberglass
Glass Beads
Glass Fiber Glass Roving YarnGlass Fabric
PROSES MATERIAL
Benang Kaca Potongan Serat Kaca Chopped Strand Mat
CSM - Chopped Strand Mat
chopped binder
Produk Fiberglass Generasi Pertama
Bahan Pengikat
Senyawa Pada Resin
Glass Roving Yarn Chopped Strand
JENIS FIBERGLASS
Benang Kaca Woven Roving
WR - Woven Roving
Tenun Weaving
Produk Fiberglass Generasi Kedua
Glass Roving Yarn
JENIS FIBERGLASS
Multiaxial
MAX - Multiaxial
warp knitting
Produk Fiberglass Generasi Ketiga
Benang Kaca
Glass Roving Yarn
JENIS FIBERGLASS
MAX - Multiaxial Fabric
Fleece (optional)
Lapisan
MULTIAXIAL PROSES
Karakteristik CSM
bull Glass Content 30
bull Resin Content 70
bull Tensile Force
Chopped Strand Mat
JENIS FIBERGLASS
Karakteristik Woven Roving
bull Glass Content 45
bull Resin Content 55
Woven Roving
Resin
|
|
|
|
|
|
|
|
|
|
|
|
|
|
bull Kekuatan Tarik
JENIS FIBERGLASS
No Resin Rich Area
Karakteristik Multiaxial
bull Glass Content 60
bull Resin Content 40
Produk Fiberglass Ketiga MULTIAXIAL
JENIS FIBERGLASS
Perbedaan Woven Roving dan Multiaxial ndash Tampak Samping
JENIS FIBERGLASS
WR FRP
8 Ply WR 800
8 Ply CSM 450
Glass Weight 1 kg
Composite Weight 15kgm2
CSM FRP
22 Ply CSM 450
Glass Weight 1 kg
Composite Weight 18 kgm2
MULTIAXIAL FRP
13 Ply DB 800
Glass Weight 1 kg
Composite Weight
13 kgm2
JENIS FIBERGLASS
Multiaxial
FRP
Woven Roving
FRP
Chopped Strands Mat FRP
MULTIAXIAL
FAKTA
TEBAL BUKAN BERARTI KUAT
UNSUR MATRIX (RESIN)
TIDAK ADA KEKUATAN
ldquoMore than 50 of the glass fibers used for reinforcement is
E-glassrdquo
KarakteristikKekuatan
CSM WR MAX
Kekuatan Tarik 175 MPa 250 MPa 425 MPa
CSM 142
WR 70
KEKUATAN TARIK
Properties CSM Lamination WR Lamination MAX Lamination
Fabric Weight (kgm2) 1 1 1
Composite Weight (kgm2) 18 15 13
Resin usage (kgm2) 15 1 08
Amount of Fabric 22 Ply 16 Ply 13 Ply
Thickness 15 mm 12 mm 10 mm
Tensile Strength (Mpa) 125 1796 400
Tensile Strength (Nmmsup2) 28463 30958 4576
Processing Time High Med Low
Labour Cost High Med Low
MULTIAXIAL
Total Penggunaan Resin -51
Total Berat Kapal -40
Kekuatan Bangunan Kapal +59
Efisiensi Tenaga Kerja
Waktu Pengerjaan Lebih Cepat
KEUNGGULAN MATERIAL
Resapan Resin Lebih Baik amp Merata
Lapisan Lebih Sedikit
Meningkatkan Kekuatan Kapal
KEUNGGULAN MATERIAL
TRIAXIAL
DBL series DBT series
BIAXIAL
LT series DB series
UNIDIRECTIONAL
L series T series
QUADRIAXIAL
DBLT series
JENIS MULTIAXIAL
UNIDIRECTIONAL
DCMU 900 E ndash
KHUSUS UNTUK MEMPERKUAT BENDING KAPAL
PEMASANGAN KHUSUS PADA KEEL DAN TULANGAN
JENIS MULTIAXIAL UNTUK KAPAL
TRIAXIAL
DBL 600 ndash
APLIKASI PADA INDUSTRI PENERBANGAN
PEMASANGAN KHUSUS PADA
SAMBUNGAN BADAN DAN SAYAP
PESAWAT
JENIS MULTIAXIAL UNTUK PESAWAT
QUADRAXIAL
DBLT 800 ndash
APLIKASI PADA INDUSTRI ENERGI
DITERAPKAN UNTUK KEBUTUHAN PEMBANGKIT
LISTRIK ENERGI ANGIN
MULTIAXIAL UNTUK ENERGI
INDUSTRI KIMIA OLAHRAGA AUTOMOTIF
MULTIAXIAL UNTUK INDUSTRI LAINNYA
COMPOSITES
GUNAKAN MATERIAL FIBERGLASS
YANG SUDAH DISERTIFIKASI
BKI
FIBERGLASS UNTUK PEMBANGUNAN BAKAP
PERATURAN MENTERI PERHUBUNGAN
NOMOR PM 7 TAHUN 2013
TENTANG KEWAJIBAN KLASIFIKASI BAGI KAPAL BERBENDERA INDONESIA
PADA BADAN KLASIFIKASI
BADAN SERTIFIKASI MARITIM
Biro Klasifikasi IndonesiaDet Norske Veritas Germanischer Lloyds
PERATURAN BKI
Untuk Kapal Non-Metal
2006
PERSYARATAN MINIMUM
kekuatan material yang
harus digunakan
untuk membangun
Kapal Fiberglass
PEMBESARAN
Table 21
FIBERGLASS TRIAXIS COMPOSITES
TELAH BERSERTIFIKASI BKI
Biro Klasifikasi Indonesia
65
TEKNIK MANUFAKTUR
COMPOSITES
Wet hand lay-up
1) Peletakan
Dry Reinforcement
bull Dry reinforcement dan resin (+ katalis) ditaruh pada permukaan cetakan
2) Pemasukanpenekanan resin
bull Resin ditekan untuk meng-impregnasi serat dengan menggunakan rol
3) Pengulangan proses untuk lapisan lain
bull Beberapa lapisan dapat ditambahkan secara bertahap
4) Resin curing
bull Reaksi dimulai komponen dilepaskan setelah komponen mengeras
(fully cured)
Wet hand lay-up
Manufaktur komponen dapat dikerjakan dengan menggunakan beberapa lapis komposit
dengan memperhatikan kompatibilitas material dan tahapan curing Modifikasi proses dapat
dilakukan seperti
Vacuum bagging
setelah lay-up
Glass Roving
Bulk Resin
Catalyst
3) De-molding
2) Resin Cure
bull Curing dimulai dan komponen dilepaskan setelah pengerasan selesai
bull Serat gelas resin dan katalis dimasukkan kedalam spray gun
1) Spray-up
bull Campuran disemprotkan pada permukaan cetakan
Spray-up
69
Penyemprotan bakal komponen
Komponen
dilepaskan
dari cetakan
Full dispensing
system Chopper Roving
Atomised resin
and catalyst
Spray-up
Prepreg
1) LaminateAssembly 5) De-molding
3) Resin Melts Layup Consolidates
bull Prepreg serat yang sudah diimpregnasi oleh resin+katalis dalam kondisi padat
bull Lapisan prepreg digunting sesuai bentuk yang diinginkan kemudian diletakkan pada permukaan cetakan
sesuai bentuk komponen yang diinginkan Lay-up mudah dilakukan karena sifat ldquotackynessrdquo dari prepreg
2) Applied Vacuum Pressure and Heat
bull Tekanan dan panas diberikan resin mencair terjadi konsolidasi pada komponen
4) Resin Cures
bull Temperatur dinaikkan untuk memulai curing
Prepreg
Variasi proses Autoclave
Komponen dalam
vacuum-bag
bull Campuran resin (+katalis) dan chopped glass strands diperoleh dalam bentuk premixed compound Bulk molding
Compound (BMC) dalam bentuk adonan atau Sheet molding Compound (SMC) dalam bentuk lembaran
bull Ketika panas dan tekanan diberikan oleh cetakan compound mengalir sesuai bentuk komponen yang diinginkan
1) Placement of Charge
5) De-molding3) Squeeze to final dimensions
2) Mould Closure4) Resin Cure
bull Curing dimulai komponen dilepaskan setelah terjadi pengerasan yang cukup
Compression Molding
bull Preform atau dry reinforcement dimasukkan kedalam cetakan sesuai dengan bentuk komponen yang
diinginkan
bull Resin mengalir dengan penekanan atau pem-vakuman dan meng-impregnasi preform dan
mendorongmengeluarkan udara yang ada dalam preform
1) Preform Manufacture
2) Preform Compression
5) De-molding3) Resin Injection
4) Resin Cure
bull Curing terjadi cetakan dibuka setelah terjadi pengerasan yang mencukupi
Liquid Molding (RTM VARI VARTM)
Pultrusion
bull Dry roving or fabrics ditarik melalui bak berisi
campuran resin dan katalis
bull Campuran yang basah ditarik melalui cetakan
bull Sisa resin keluar cetakan
bull Pemanasan dilakukan untuk proses curing
bull Pendinginan dilakukan untuk mempercepat siklus
produksi
Cut-off
Cooling
Die sections
Resin bath
Fibre creel
Filament Winding
bull Dry roving ditarik melalui bak berisi campuran resin dan katalis
bull Wet roving digulungkan dalam keadaan tegang kepada mandrel
bull Kontrol mekanik dari pembawa serat mengatur orientasi peletakan serat pada
mandrel
INDUSTRI COMPOSITES
AEROSPACE
HISTORY
1950 ndash Boeing
1960 ndash F14 Tomcat
1981 ndash AV-8B Harrier
Source
Low-Cost Composite Materials and Structures for Aircraft Applications
httpwwwreinforcedplasticscom
httpwwwcentennialofflightgovessayEvolution_of_TechnologycompositesTech40htm
Automotive
Composite material is used in a number of applications in the automotive
industry due to its temperature resistance rigidity and fatigue strength
The benefits of using composites include greater fuel efficiency
corrosion resistance light weight and strength Composites also provide
a low-cost way to help keep designs looking fresh
Composites are used in
- interior parts (cockpit trimming seats instrument panels)
- exterior structure (body panels openings underbody frontrear
modules)
- engine compartment and fuelmechanical area parts (axles and
suspensions fuel and exhaust systems)
- electrical and electronic components
Lamborghinis Sesto Element carbon fiber
ldquoFat men cannot run as fast as thin men but we build most of our vehicles as though dead-weight fat increased speedhellip I cannot
imagine where the delusion that weight means strength
came fromhelliprdquo mdashHenry Ford
The mix of automotive materials is changing showing a boost for FRP in helping original
equipment manufacturers meet fuel economy and emissions challenges
(Source 2011 DuPont AutomotiveSAE survey of design engineers performed by Signet Research Inc)
Source
httpwwwtoraycomcsrhighlight2009hig_001_01html
The MonoCell tub for the McLaren MP4-12C supercar is moulded as a single
piece and weighs less than 80 kg (176 lbs)
COMPOSITES IN MARINE
TRIMARAN BOAT
AMERICA NAVYINDONESIAN NAVY
Visby Class corvette
Total length is 72 meters
The beam is 1040 meters
The displacement is 600 metric tones
fully equipped the worlds largest CRP
construction
The design of the Visby aims to minimize
the optical and infrared signature above
water acoustic and hydroa coustic
signature underwater electrical potential
and magnetic signature pressure signature
radar cross section and actively emitted
signals
A stealth corvette of the YS 2000 design
has a detection range of 13km in rough
seas and 22km in calm sea without
jamming In a jammed environment the
Visby would be detected at a range of 8km
in rough sea and 11km in calm sea
The material provides high strength and
rigidity low weight good shock resistance
low radar and magnetic signature
1996
Visby is a class of stealth corvettes for the Swedish Navy
ldquoReduced 50 of a Conventional Steelrdquo
Source
Hull Construction with composite materials for ships over 100m in length 2002
Massachusetts Institute of Technology
httpwwwnaval-technologycomprojectsvisby
YACHTS
KAL YUDISTIRAMARATHON 100 ADMIRAL YACHT
LOA 3050 MWidth 6 MFuel Tank 8000 LWater Tank 3000 LIce Box 500 LAccommodation Max 35 Personnel
2 x CATERPILLAR 3412E 1200 HPMARINE DIESEL ENGINE
PC 40 ndash KRI Krait 827Department of Indonesian Navy
LOA 40 MWidth 73 MPower 190Weapon Twin Cannon Barrels
127 mm Heavy Machine GunSpeed Knot 25 KnotDisplacement 105 tonAccommodation 23 personnel
PATROL BOAT
Rigid Inflatable BoatPATROL BOAT
Yachts
36m Luxury Yacht Moonraker
36m Luxury Yacht GoldenEye
50m Luxury Yacht Casino
Royale
45m Luxury Yacht Seashaw
Boat Parts
Barovans for Seismic Sweep
Centrifugal Liftfan House for Surface Effect
Ships
Composite Boat PropellersRTM
Deckhouses for Pilot Boats
Fairing Parts for Submarines
Flybridges for Motor yachts
Light Weight Gangway
MTB Launcher Mock-up
Pleasure Boats
12m Sailboat
12m Sail-Catamaranone-off
Canoes
Dragonfly 1000Catamaran Sailboat
Fantasy 37Sailboat
Farr 60Luxury Sailboat
EurodingyOlympic Dingy Class for
Woman
Hydrolift F23 Racing Boats
Kajacs
Najad 42Sailboat
Najad 520Sailboat
Najad 441Sailboat
Najad 391Sailboat
Nordwest 900Motorboat
Nordwest 1100Motorboat
Quatro 44Motorboat
Racemaster Competition Boats
Storebro 420
Storebro 345
Sweden Yacht 370Sailboat
Sweden Yacht 69Sailboat
Windy 41Motorboat
X-632Sailboat
X-362Sailboat
Commercial Boats
175m High Speed AmbulancePassenger Boat
19m High Speed Passenger Boat
20m High Speed Passenger Boat
364m Surface Effect Passenger Ship
45m Surface Effect Passenger Ship
120m Hull Structural Parts HSSS Catamaran Ferry
APPENDIX
Marine Vessel
1188m Fast Attack Vessel FMV 90 E
20m SAV-Surface Auxiliary Vessels
34m Personnel TransportCoast Guard Vessel
40ft Experimental SES
40m Landsort-Class Mine Hunters
54m Mine Counter Measure Vehicles SES
74m Coastal Patrol Boats
Fishing Boats
30 GT
12 GT
10 GT
5 GT
WISEWings In Surface Effect
HOVERCRAFT
Designed specifically for the tourist and transport industries the
Pioneer Mk3 hovercraft is amphibious and comfortably seats 25
passengers plus 1-crew The air-conditioned cabin allows for
maximum visibility for all aboard The Pioneer Mk3 is robust and
dynamic in its performance
Commercial hovercraft
Mk3 AirLift Hovercraft - 1215m
Power is economicaly provided by one Deutz diesel engine of
330kW (442hp) to cruise easily at 40 knots with much higher
speeds available according to the surface conditions The hull is
manufactured from fibreglassPVC foam composite sandwich
the windows are glass and the skirt is urethane coated nylon A
Military version is available with increased payload and systems
redundancy Power for the Military version comes from two Steyr
diesel engines with a total installed power of 320kW (429hp) All
transmission electrical hydraulic and air systems are duplicated
for maximum redundancy The increased performance of the
Military version comes from the reduced engine weight of the twin
Steyr installation cf the Deutz installation
Source
httpwwwnauticexpocomprodairlift-hovercraftcommercial-hovercrafts-25251-142868html
HOVERFLIGHT
BALLISTIC amp UNIT DEFENCED
Triaxis Composites Collaboration with Institute of Aeronautics and Space in the development of Missile Nose Cone
Polymer composites is the evolution of the military defence
Thin steel was the helmet material of
WWII and remained the principal material until around the 1980rsquos
The advantages of using steel
included a simple technology for manufacture of the helmets low cost and reasonably good
impact protection However these helmets were found to provide only marginal protection
against fragments
During the Vietnam War the US Army experimented with fiber-reinforced inserts in the
helmets These inserts improved ballistic protection but at the same time added weight and
reduced the air space between the head and the helmet
By the early part of the 1980rsquos the US military had developed the first all-composite
100 fiber-reinforced helmet This development resulted in even better ballistic protection
without altering the weight of the helmet Other improvements included better head coverage and
more space for ventilation
Source
Composites Armor - A difficult but huge market
by A Brent Strong Brigham Young University
MILITARY VEHICLES
HIGH SPEED TRAIN SHINKANSEN
Advanced Composites provide lightweight solutions for railway vehicles
saving as much as 50-80 of the weight compared with traditional
components
A lower overall weight translates into less stress faster acceleration and
higher speeds as well as reduced starting and stopping inertia Today
these are important criteria in global high-speed and metropolitan
railway projects
Fire smoke and toxic fumes are key safety criteria for interior
components of railway carriages Any material selected for an interior
component must meet international fire retardant standards
for Rail Interiors and Exteriors
Ceiling Panels Stairs
Seating Vestibules
Window Panels Door Pillars
Partition WallsDiffusers
Gangway and Cabinet Panels Cabin and
Desk panels
Door Pillars Lavatory Modules (standard and
Front and Rear EndsRoof Panels
Nose Cones Under Fairings
Source
httpwwwpctaerail_compositesphp
101
SKY BUS
2009
Europe is the world leader in offshore wind with
828 wind turbines and a cumulative capacity of 2056 MW spread across 38 offshore wind farms in 9
European countries
The UK and Denmark are the current leaders with a 44 and 30 share respectively In 2009
five countries built new offshore wind farms
UK (284 MW)
Demark (230 MW)
Sweden (30 MW)
Germany (30 MW)
Norway (23 MW)
2010
Asia leads the growth in global wind power which grew 358 GW in 2010 bringing
total global capacity to 1944 GW ndash up 225 from 2009
the Global Wind Energy Council (GWEC)
Asia accounted for 19 GW of new global wind power installations driven by China which installed 165
GW
ldquoChina now has 423 GW of wind powerrdquo
ldquoThis puts China firmly on a path to reach 200 GW of installed wind power by 2020 At the same
time China has become the worldrsquos largest producer of wind energy equipmentrdquo
Source
httpwwwreinforcedplasticscomview15655asia-leads-global-wind-power-growth
httpimgdeusmcomdesignnews288288605-Sandia_Sizes_up_Wind_Turbine_Blade_Design_C_largegif
WIND ENERGY
Marine Current Turbines
Source
httpwwwsiemenscompressenpressreleasepress=enpressrelease2011solar-hydroex201111005htm
httpwwwmarineturbinescom
A commercial marine current turbine consists of
two rotors which are fixed on a structure within the
sea current The twin rotors rotate with the
movement of the tidal flow and the blades pitch
through 180 degrees to optimally track tidal current
(Press picture Marine Current Turbines)
Wave Star Energys Multi-point Absorber
CFRP COLUMN REINFORCEMENT
INDUSTRIAL TANKS
107
INDUSTRIAL PIPES
PRESSURE TANKS
109
ldquoLetrsquos Make with Compositesrdquo
PROSES MATERIAL
Proses Produksi Kain Fiberglass
Biji Kaca Benang Benang Kaca Kain Fiberglass
PROSES MATERIAL
Glass Beads
Glass Fiber Glass Roving YarnGlass Fabric
FIBERGLASS
PRODUK
MATERIAL DAN PRODUK FIBERGLASS
+
Resin + Additives
PERPADUAN COMPOSITES
BENANG KACA Potongan Serat Kaca CSM
CSM - CHOPPED STRAND MAT
chopped binder
Kain Fiberglass Generasi Pertama
BahanPengikat
SenyawaPada Resin
JENIS FIBERGLASS
Glass Roving Yarn Chopped Strand
ADVANTAGES DISADVANTAGES
Steel
1048707 Low cost 1048707 Corrodes easily
1048707 Ductile under ambient conditions
1048707 Has no lower fatigue limit for welded structures
1048707 Virtually isotropic 1048707 Heavy
1048707 Easily formed and fabricated 1048707 Brittle at low temperatures
1048707 Easily obtained (low relative cost) 1048707 Magnetic
1048707 Easily alloyed or heat treated for special operations
1048707 Easily repaired
1048707 Good fire resistance
1048707 Behaviour is well understood
Alumunium Alloy
1048707 Light weight 1048707 Poor fatigue properties
1048707 Corrosion resistant 1048707 Poor performance in fire
1048707 Easily formed1048707 Low melting point and softening temperature
1048707 Easily fabricated 1048707 High relative cost
1048707 Readily available 1048707 Strength and stiffness less than steel
1048707 Ductile
1048707 Non magnetic
FRP
1048707 Low magnetic properties
1048707 Low electrical conductivity (glass- reinforced plastics)
1048707 Resistance to corrosion
1048707 Resistance to rot and marine growth
1048707 Relatively high sonar transparency
1048707 Good strength to weight ratio
1048707 Good fatigue properties
1048707 Maintenance of properties at low temperatures
1048707 Availability
1048707 Can be manufactured to near net-shape
1048707 Stiffness and strength can be tailored to structural requirements
1048707 Excellent thermal insulation
1048707 Light weight
STEEL vs ALUMUNIUM vs COMPOSITES
Source
1Maritime Platforms Division Aeronautical and
Maritime Research Laboratory (Seref Aksu
Stuart Cannon Craig Gardiner and Matthew
Gudze
2 Metal Corrosion can be defined as the
destructive attack of a metal through interaction
with its environment
(httpwwwcorrosionistcomCorrosion_Fundament
alhtm)
28
Serat rarr penguat
Polimer matriks rarr pengikat
bull Sifat mekanik yang cukup baik
bull Viskositas dan temperatur pengerjaan rendah rarr mudah
dimanufaktur
bull Ketahanan korosi yang baik
bull Media perpindahan gaya rarr distribusi beban dari serat ke serat
bull Ulet rarr Melindungi serat yang getas
bull Size effect rarr Kekuatan dan kekakuan sangat tinggi
bull Aspect ratio (ld) tinggi rarr luas permukaan besar
bull Fleksibel rarr variasi teknik manufaktur
bull Serat dapat diatur sesuai dengan arah pembebanan
29
Advantages Polimer Composites
Kekuatan dan kekakuan spesifik yang tinggi FRCP vs material lain rarr kompetitif jika berat dipertimbangkan
Material Berat jenis
r (kgm3)
Kekakuan
E (GPa)
Kekuatan
tarik su
(MPa)
Kekakuan
spesifik
Er
Kekuatan
spesifik sur
Baja 7800 208 400 27 005
Aluminium 2700 70 200 259 007
Nylon 1100 25 80 23 007
Beton 2400 40 20 166 0008
Random
FRPC
1800 20 300 111 0006
Alligned FRPC
( serat)
1600 200 1500 125 094
Alligned FRCP
( serat)
1600 3 50 19 0001
Tensile Strength amp Modulus of Common Structural Materials
Densities of Common Structural Materials
Specific Tensile Strength amp Modulus of Common Structural Materials
Typical Properties of Common Structural Materials
Kesimpulan COMPOSITES = RINGAN amp KUAT
Jadi secara keseluruhan kekuatan composites
ditentukan oleh
1 Kekuatan amp Sifat Fiber
2 Kekuatan amp Sifat Resin
3 Fraksi Rasio Perbandingan Volume Fiber
dan Resin dalam Composites
4 Geometri dan Orientasi Arah Fiber dalam
Composites
PRODUKSI ANAK NEGERI
Proses Produksi Kain Fiberglass
Biji Kaca Benang Benang Kaca Kain Fiberglass
PROSES MATERIAL
Glass Beads
Glass Fiber Glass Roving YarnGlass Fabric
Proses Produksi Kain Fiberglass
Biji Kaca Benang Benang Kaca Kain Fiberglass
Glass Beads
Glass Fiber Glass Roving YarnGlass Fabric
PROSES MATERIAL
Benang Kaca Potongan Serat Kaca Chopped Strand Mat
CSM - Chopped Strand Mat
chopped binder
Produk Fiberglass Generasi Pertama
Bahan Pengikat
Senyawa Pada Resin
Glass Roving Yarn Chopped Strand
JENIS FIBERGLASS
Benang Kaca Woven Roving
WR - Woven Roving
Tenun Weaving
Produk Fiberglass Generasi Kedua
Glass Roving Yarn
JENIS FIBERGLASS
Multiaxial
MAX - Multiaxial
warp knitting
Produk Fiberglass Generasi Ketiga
Benang Kaca
Glass Roving Yarn
JENIS FIBERGLASS
MAX - Multiaxial Fabric
Fleece (optional)
Lapisan
MULTIAXIAL PROSES
Karakteristik CSM
bull Glass Content 30
bull Resin Content 70
bull Tensile Force
Chopped Strand Mat
JENIS FIBERGLASS
Karakteristik Woven Roving
bull Glass Content 45
bull Resin Content 55
Woven Roving
Resin
|
|
|
|
|
|
|
|
|
|
|
|
|
|
bull Kekuatan Tarik
JENIS FIBERGLASS
No Resin Rich Area
Karakteristik Multiaxial
bull Glass Content 60
bull Resin Content 40
Produk Fiberglass Ketiga MULTIAXIAL
JENIS FIBERGLASS
Perbedaan Woven Roving dan Multiaxial ndash Tampak Samping
JENIS FIBERGLASS
WR FRP
8 Ply WR 800
8 Ply CSM 450
Glass Weight 1 kg
Composite Weight 15kgm2
CSM FRP
22 Ply CSM 450
Glass Weight 1 kg
Composite Weight 18 kgm2
MULTIAXIAL FRP
13 Ply DB 800
Glass Weight 1 kg
Composite Weight
13 kgm2
JENIS FIBERGLASS
Multiaxial
FRP
Woven Roving
FRP
Chopped Strands Mat FRP
MULTIAXIAL
FAKTA
TEBAL BUKAN BERARTI KUAT
UNSUR MATRIX (RESIN)
TIDAK ADA KEKUATAN
ldquoMore than 50 of the glass fibers used for reinforcement is
E-glassrdquo
KarakteristikKekuatan
CSM WR MAX
Kekuatan Tarik 175 MPa 250 MPa 425 MPa
CSM 142
WR 70
KEKUATAN TARIK
Properties CSM Lamination WR Lamination MAX Lamination
Fabric Weight (kgm2) 1 1 1
Composite Weight (kgm2) 18 15 13
Resin usage (kgm2) 15 1 08
Amount of Fabric 22 Ply 16 Ply 13 Ply
Thickness 15 mm 12 mm 10 mm
Tensile Strength (Mpa) 125 1796 400
Tensile Strength (Nmmsup2) 28463 30958 4576
Processing Time High Med Low
Labour Cost High Med Low
MULTIAXIAL
Total Penggunaan Resin -51
Total Berat Kapal -40
Kekuatan Bangunan Kapal +59
Efisiensi Tenaga Kerja
Waktu Pengerjaan Lebih Cepat
KEUNGGULAN MATERIAL
Resapan Resin Lebih Baik amp Merata
Lapisan Lebih Sedikit
Meningkatkan Kekuatan Kapal
KEUNGGULAN MATERIAL
TRIAXIAL
DBL series DBT series
BIAXIAL
LT series DB series
UNIDIRECTIONAL
L series T series
QUADRIAXIAL
DBLT series
JENIS MULTIAXIAL
UNIDIRECTIONAL
DCMU 900 E ndash
KHUSUS UNTUK MEMPERKUAT BENDING KAPAL
PEMASANGAN KHUSUS PADA KEEL DAN TULANGAN
JENIS MULTIAXIAL UNTUK KAPAL
TRIAXIAL
DBL 600 ndash
APLIKASI PADA INDUSTRI PENERBANGAN
PEMASANGAN KHUSUS PADA
SAMBUNGAN BADAN DAN SAYAP
PESAWAT
JENIS MULTIAXIAL UNTUK PESAWAT
QUADRAXIAL
DBLT 800 ndash
APLIKASI PADA INDUSTRI ENERGI
DITERAPKAN UNTUK KEBUTUHAN PEMBANGKIT
LISTRIK ENERGI ANGIN
MULTIAXIAL UNTUK ENERGI
INDUSTRI KIMIA OLAHRAGA AUTOMOTIF
MULTIAXIAL UNTUK INDUSTRI LAINNYA
COMPOSITES
GUNAKAN MATERIAL FIBERGLASS
YANG SUDAH DISERTIFIKASI
BKI
FIBERGLASS UNTUK PEMBANGUNAN BAKAP
PERATURAN MENTERI PERHUBUNGAN
NOMOR PM 7 TAHUN 2013
TENTANG KEWAJIBAN KLASIFIKASI BAGI KAPAL BERBENDERA INDONESIA
PADA BADAN KLASIFIKASI
BADAN SERTIFIKASI MARITIM
Biro Klasifikasi IndonesiaDet Norske Veritas Germanischer Lloyds
PERATURAN BKI
Untuk Kapal Non-Metal
2006
PERSYARATAN MINIMUM
kekuatan material yang
harus digunakan
untuk membangun
Kapal Fiberglass
PEMBESARAN
Table 21
FIBERGLASS TRIAXIS COMPOSITES
TELAH BERSERTIFIKASI BKI
Biro Klasifikasi Indonesia
65
TEKNIK MANUFAKTUR
COMPOSITES
Wet hand lay-up
1) Peletakan
Dry Reinforcement
bull Dry reinforcement dan resin (+ katalis) ditaruh pada permukaan cetakan
2) Pemasukanpenekanan resin
bull Resin ditekan untuk meng-impregnasi serat dengan menggunakan rol
3) Pengulangan proses untuk lapisan lain
bull Beberapa lapisan dapat ditambahkan secara bertahap
4) Resin curing
bull Reaksi dimulai komponen dilepaskan setelah komponen mengeras
(fully cured)
Wet hand lay-up
Manufaktur komponen dapat dikerjakan dengan menggunakan beberapa lapis komposit
dengan memperhatikan kompatibilitas material dan tahapan curing Modifikasi proses dapat
dilakukan seperti
Vacuum bagging
setelah lay-up
Glass Roving
Bulk Resin
Catalyst
3) De-molding
2) Resin Cure
bull Curing dimulai dan komponen dilepaskan setelah pengerasan selesai
bull Serat gelas resin dan katalis dimasukkan kedalam spray gun
1) Spray-up
bull Campuran disemprotkan pada permukaan cetakan
Spray-up
69
Penyemprotan bakal komponen
Komponen
dilepaskan
dari cetakan
Full dispensing
system Chopper Roving
Atomised resin
and catalyst
Spray-up
Prepreg
1) LaminateAssembly 5) De-molding
3) Resin Melts Layup Consolidates
bull Prepreg serat yang sudah diimpregnasi oleh resin+katalis dalam kondisi padat
bull Lapisan prepreg digunting sesuai bentuk yang diinginkan kemudian diletakkan pada permukaan cetakan
sesuai bentuk komponen yang diinginkan Lay-up mudah dilakukan karena sifat ldquotackynessrdquo dari prepreg
2) Applied Vacuum Pressure and Heat
bull Tekanan dan panas diberikan resin mencair terjadi konsolidasi pada komponen
4) Resin Cures
bull Temperatur dinaikkan untuk memulai curing
Prepreg
Variasi proses Autoclave
Komponen dalam
vacuum-bag
bull Campuran resin (+katalis) dan chopped glass strands diperoleh dalam bentuk premixed compound Bulk molding
Compound (BMC) dalam bentuk adonan atau Sheet molding Compound (SMC) dalam bentuk lembaran
bull Ketika panas dan tekanan diberikan oleh cetakan compound mengalir sesuai bentuk komponen yang diinginkan
1) Placement of Charge
5) De-molding3) Squeeze to final dimensions
2) Mould Closure4) Resin Cure
bull Curing dimulai komponen dilepaskan setelah terjadi pengerasan yang cukup
Compression Molding
bull Preform atau dry reinforcement dimasukkan kedalam cetakan sesuai dengan bentuk komponen yang
diinginkan
bull Resin mengalir dengan penekanan atau pem-vakuman dan meng-impregnasi preform dan
mendorongmengeluarkan udara yang ada dalam preform
1) Preform Manufacture
2) Preform Compression
5) De-molding3) Resin Injection
4) Resin Cure
bull Curing terjadi cetakan dibuka setelah terjadi pengerasan yang mencukupi
Liquid Molding (RTM VARI VARTM)
Pultrusion
bull Dry roving or fabrics ditarik melalui bak berisi
campuran resin dan katalis
bull Campuran yang basah ditarik melalui cetakan
bull Sisa resin keluar cetakan
bull Pemanasan dilakukan untuk proses curing
bull Pendinginan dilakukan untuk mempercepat siklus
produksi
Cut-off
Cooling
Die sections
Resin bath
Fibre creel
Filament Winding
bull Dry roving ditarik melalui bak berisi campuran resin dan katalis
bull Wet roving digulungkan dalam keadaan tegang kepada mandrel
bull Kontrol mekanik dari pembawa serat mengatur orientasi peletakan serat pada
mandrel
INDUSTRI COMPOSITES
AEROSPACE
HISTORY
1950 ndash Boeing
1960 ndash F14 Tomcat
1981 ndash AV-8B Harrier
Source
Low-Cost Composite Materials and Structures for Aircraft Applications
httpwwwreinforcedplasticscom
httpwwwcentennialofflightgovessayEvolution_of_TechnologycompositesTech40htm
Automotive
Composite material is used in a number of applications in the automotive
industry due to its temperature resistance rigidity and fatigue strength
The benefits of using composites include greater fuel efficiency
corrosion resistance light weight and strength Composites also provide
a low-cost way to help keep designs looking fresh
Composites are used in
- interior parts (cockpit trimming seats instrument panels)
- exterior structure (body panels openings underbody frontrear
modules)
- engine compartment and fuelmechanical area parts (axles and
suspensions fuel and exhaust systems)
- electrical and electronic components
Lamborghinis Sesto Element carbon fiber
ldquoFat men cannot run as fast as thin men but we build most of our vehicles as though dead-weight fat increased speedhellip I cannot
imagine where the delusion that weight means strength
came fromhelliprdquo mdashHenry Ford
The mix of automotive materials is changing showing a boost for FRP in helping original
equipment manufacturers meet fuel economy and emissions challenges
(Source 2011 DuPont AutomotiveSAE survey of design engineers performed by Signet Research Inc)
Source
httpwwwtoraycomcsrhighlight2009hig_001_01html
The MonoCell tub for the McLaren MP4-12C supercar is moulded as a single
piece and weighs less than 80 kg (176 lbs)
COMPOSITES IN MARINE
TRIMARAN BOAT
AMERICA NAVYINDONESIAN NAVY
Visby Class corvette
Total length is 72 meters
The beam is 1040 meters
The displacement is 600 metric tones
fully equipped the worlds largest CRP
construction
The design of the Visby aims to minimize
the optical and infrared signature above
water acoustic and hydroa coustic
signature underwater electrical potential
and magnetic signature pressure signature
radar cross section and actively emitted
signals
A stealth corvette of the YS 2000 design
has a detection range of 13km in rough
seas and 22km in calm sea without
jamming In a jammed environment the
Visby would be detected at a range of 8km
in rough sea and 11km in calm sea
The material provides high strength and
rigidity low weight good shock resistance
low radar and magnetic signature
1996
Visby is a class of stealth corvettes for the Swedish Navy
ldquoReduced 50 of a Conventional Steelrdquo
Source
Hull Construction with composite materials for ships over 100m in length 2002
Massachusetts Institute of Technology
httpwwwnaval-technologycomprojectsvisby
YACHTS
KAL YUDISTIRAMARATHON 100 ADMIRAL YACHT
LOA 3050 MWidth 6 MFuel Tank 8000 LWater Tank 3000 LIce Box 500 LAccommodation Max 35 Personnel
2 x CATERPILLAR 3412E 1200 HPMARINE DIESEL ENGINE
PC 40 ndash KRI Krait 827Department of Indonesian Navy
LOA 40 MWidth 73 MPower 190Weapon Twin Cannon Barrels
127 mm Heavy Machine GunSpeed Knot 25 KnotDisplacement 105 tonAccommodation 23 personnel
PATROL BOAT
Rigid Inflatable BoatPATROL BOAT
Yachts
36m Luxury Yacht Moonraker
36m Luxury Yacht GoldenEye
50m Luxury Yacht Casino
Royale
45m Luxury Yacht Seashaw
Boat Parts
Barovans for Seismic Sweep
Centrifugal Liftfan House for Surface Effect
Ships
Composite Boat PropellersRTM
Deckhouses for Pilot Boats
Fairing Parts for Submarines
Flybridges for Motor yachts
Light Weight Gangway
MTB Launcher Mock-up
Pleasure Boats
12m Sailboat
12m Sail-Catamaranone-off
Canoes
Dragonfly 1000Catamaran Sailboat
Fantasy 37Sailboat
Farr 60Luxury Sailboat
EurodingyOlympic Dingy Class for
Woman
Hydrolift F23 Racing Boats
Kajacs
Najad 42Sailboat
Najad 520Sailboat
Najad 441Sailboat
Najad 391Sailboat
Nordwest 900Motorboat
Nordwest 1100Motorboat
Quatro 44Motorboat
Racemaster Competition Boats
Storebro 420
Storebro 345
Sweden Yacht 370Sailboat
Sweden Yacht 69Sailboat
Windy 41Motorboat
X-632Sailboat
X-362Sailboat
Commercial Boats
175m High Speed AmbulancePassenger Boat
19m High Speed Passenger Boat
20m High Speed Passenger Boat
364m Surface Effect Passenger Ship
45m Surface Effect Passenger Ship
120m Hull Structural Parts HSSS Catamaran Ferry
APPENDIX
Marine Vessel
1188m Fast Attack Vessel FMV 90 E
20m SAV-Surface Auxiliary Vessels
34m Personnel TransportCoast Guard Vessel
40ft Experimental SES
40m Landsort-Class Mine Hunters
54m Mine Counter Measure Vehicles SES
74m Coastal Patrol Boats
Fishing Boats
30 GT
12 GT
10 GT
5 GT
WISEWings In Surface Effect
HOVERCRAFT
Designed specifically for the tourist and transport industries the
Pioneer Mk3 hovercraft is amphibious and comfortably seats 25
passengers plus 1-crew The air-conditioned cabin allows for
maximum visibility for all aboard The Pioneer Mk3 is robust and
dynamic in its performance
Commercial hovercraft
Mk3 AirLift Hovercraft - 1215m
Power is economicaly provided by one Deutz diesel engine of
330kW (442hp) to cruise easily at 40 knots with much higher
speeds available according to the surface conditions The hull is
manufactured from fibreglassPVC foam composite sandwich
the windows are glass and the skirt is urethane coated nylon A
Military version is available with increased payload and systems
redundancy Power for the Military version comes from two Steyr
diesel engines with a total installed power of 320kW (429hp) All
transmission electrical hydraulic and air systems are duplicated
for maximum redundancy The increased performance of the
Military version comes from the reduced engine weight of the twin
Steyr installation cf the Deutz installation
Source
httpwwwnauticexpocomprodairlift-hovercraftcommercial-hovercrafts-25251-142868html
HOVERFLIGHT
BALLISTIC amp UNIT DEFENCED
Triaxis Composites Collaboration with Institute of Aeronautics and Space in the development of Missile Nose Cone
Polymer composites is the evolution of the military defence
Thin steel was the helmet material of
WWII and remained the principal material until around the 1980rsquos
The advantages of using steel
included a simple technology for manufacture of the helmets low cost and reasonably good
impact protection However these helmets were found to provide only marginal protection
against fragments
During the Vietnam War the US Army experimented with fiber-reinforced inserts in the
helmets These inserts improved ballistic protection but at the same time added weight and
reduced the air space between the head and the helmet
By the early part of the 1980rsquos the US military had developed the first all-composite
100 fiber-reinforced helmet This development resulted in even better ballistic protection
without altering the weight of the helmet Other improvements included better head coverage and
more space for ventilation
Source
Composites Armor - A difficult but huge market
by A Brent Strong Brigham Young University
MILITARY VEHICLES
HIGH SPEED TRAIN SHINKANSEN
Advanced Composites provide lightweight solutions for railway vehicles
saving as much as 50-80 of the weight compared with traditional
components
A lower overall weight translates into less stress faster acceleration and
higher speeds as well as reduced starting and stopping inertia Today
these are important criteria in global high-speed and metropolitan
railway projects
Fire smoke and toxic fumes are key safety criteria for interior
components of railway carriages Any material selected for an interior
component must meet international fire retardant standards
for Rail Interiors and Exteriors
Ceiling Panels Stairs
Seating Vestibules
Window Panels Door Pillars
Partition WallsDiffusers
Gangway and Cabinet Panels Cabin and
Desk panels
Door Pillars Lavatory Modules (standard and
Front and Rear EndsRoof Panels
Nose Cones Under Fairings
Source
httpwwwpctaerail_compositesphp
101
SKY BUS
2009
Europe is the world leader in offshore wind with
828 wind turbines and a cumulative capacity of 2056 MW spread across 38 offshore wind farms in 9
European countries
The UK and Denmark are the current leaders with a 44 and 30 share respectively In 2009
five countries built new offshore wind farms
UK (284 MW)
Demark (230 MW)
Sweden (30 MW)
Germany (30 MW)
Norway (23 MW)
2010
Asia leads the growth in global wind power which grew 358 GW in 2010 bringing
total global capacity to 1944 GW ndash up 225 from 2009
the Global Wind Energy Council (GWEC)
Asia accounted for 19 GW of new global wind power installations driven by China which installed 165
GW
ldquoChina now has 423 GW of wind powerrdquo
ldquoThis puts China firmly on a path to reach 200 GW of installed wind power by 2020 At the same
time China has become the worldrsquos largest producer of wind energy equipmentrdquo
Source
httpwwwreinforcedplasticscomview15655asia-leads-global-wind-power-growth
httpimgdeusmcomdesignnews288288605-Sandia_Sizes_up_Wind_Turbine_Blade_Design_C_largegif
WIND ENERGY
Marine Current Turbines
Source
httpwwwsiemenscompressenpressreleasepress=enpressrelease2011solar-hydroex201111005htm
httpwwwmarineturbinescom
A commercial marine current turbine consists of
two rotors which are fixed on a structure within the
sea current The twin rotors rotate with the
movement of the tidal flow and the blades pitch
through 180 degrees to optimally track tidal current
(Press picture Marine Current Turbines)
Wave Star Energys Multi-point Absorber
CFRP COLUMN REINFORCEMENT
INDUSTRIAL TANKS
107
INDUSTRIAL PIPES
PRESSURE TANKS
109
ldquoLetrsquos Make with Compositesrdquo
Proses Produksi Kain Fiberglass
Biji Kaca Benang Benang Kaca Kain Fiberglass
PROSES MATERIAL
Glass Beads
Glass Fiber Glass Roving YarnGlass Fabric
FIBERGLASS
PRODUK
MATERIAL DAN PRODUK FIBERGLASS
+
Resin + Additives
PERPADUAN COMPOSITES
BENANG KACA Potongan Serat Kaca CSM
CSM - CHOPPED STRAND MAT
chopped binder
Kain Fiberglass Generasi Pertama
BahanPengikat
SenyawaPada Resin
JENIS FIBERGLASS
Glass Roving Yarn Chopped Strand
ADVANTAGES DISADVANTAGES
Steel
1048707 Low cost 1048707 Corrodes easily
1048707 Ductile under ambient conditions
1048707 Has no lower fatigue limit for welded structures
1048707 Virtually isotropic 1048707 Heavy
1048707 Easily formed and fabricated 1048707 Brittle at low temperatures
1048707 Easily obtained (low relative cost) 1048707 Magnetic
1048707 Easily alloyed or heat treated for special operations
1048707 Easily repaired
1048707 Good fire resistance
1048707 Behaviour is well understood
Alumunium Alloy
1048707 Light weight 1048707 Poor fatigue properties
1048707 Corrosion resistant 1048707 Poor performance in fire
1048707 Easily formed1048707 Low melting point and softening temperature
1048707 Easily fabricated 1048707 High relative cost
1048707 Readily available 1048707 Strength and stiffness less than steel
1048707 Ductile
1048707 Non magnetic
FRP
1048707 Low magnetic properties
1048707 Low electrical conductivity (glass- reinforced plastics)
1048707 Resistance to corrosion
1048707 Resistance to rot and marine growth
1048707 Relatively high sonar transparency
1048707 Good strength to weight ratio
1048707 Good fatigue properties
1048707 Maintenance of properties at low temperatures
1048707 Availability
1048707 Can be manufactured to near net-shape
1048707 Stiffness and strength can be tailored to structural requirements
1048707 Excellent thermal insulation
1048707 Light weight
STEEL vs ALUMUNIUM vs COMPOSITES
Source
1Maritime Platforms Division Aeronautical and
Maritime Research Laboratory (Seref Aksu
Stuart Cannon Craig Gardiner and Matthew
Gudze
2 Metal Corrosion can be defined as the
destructive attack of a metal through interaction
with its environment
(httpwwwcorrosionistcomCorrosion_Fundament
alhtm)
28
Serat rarr penguat
Polimer matriks rarr pengikat
bull Sifat mekanik yang cukup baik
bull Viskositas dan temperatur pengerjaan rendah rarr mudah
dimanufaktur
bull Ketahanan korosi yang baik
bull Media perpindahan gaya rarr distribusi beban dari serat ke serat
bull Ulet rarr Melindungi serat yang getas
bull Size effect rarr Kekuatan dan kekakuan sangat tinggi
bull Aspect ratio (ld) tinggi rarr luas permukaan besar
bull Fleksibel rarr variasi teknik manufaktur
bull Serat dapat diatur sesuai dengan arah pembebanan
29
Advantages Polimer Composites
Kekuatan dan kekakuan spesifik yang tinggi FRCP vs material lain rarr kompetitif jika berat dipertimbangkan
Material Berat jenis
r (kgm3)
Kekakuan
E (GPa)
Kekuatan
tarik su
(MPa)
Kekakuan
spesifik
Er
Kekuatan
spesifik sur
Baja 7800 208 400 27 005
Aluminium 2700 70 200 259 007
Nylon 1100 25 80 23 007
Beton 2400 40 20 166 0008
Random
FRPC
1800 20 300 111 0006
Alligned FRPC
( serat)
1600 200 1500 125 094
Alligned FRCP
( serat)
1600 3 50 19 0001
Tensile Strength amp Modulus of Common Structural Materials
Densities of Common Structural Materials
Specific Tensile Strength amp Modulus of Common Structural Materials
Typical Properties of Common Structural Materials
Kesimpulan COMPOSITES = RINGAN amp KUAT
Jadi secara keseluruhan kekuatan composites
ditentukan oleh
1 Kekuatan amp Sifat Fiber
2 Kekuatan amp Sifat Resin
3 Fraksi Rasio Perbandingan Volume Fiber
dan Resin dalam Composites
4 Geometri dan Orientasi Arah Fiber dalam
Composites
PRODUKSI ANAK NEGERI
Proses Produksi Kain Fiberglass
Biji Kaca Benang Benang Kaca Kain Fiberglass
PROSES MATERIAL
Glass Beads
Glass Fiber Glass Roving YarnGlass Fabric
Proses Produksi Kain Fiberglass
Biji Kaca Benang Benang Kaca Kain Fiberglass
Glass Beads
Glass Fiber Glass Roving YarnGlass Fabric
PROSES MATERIAL
Benang Kaca Potongan Serat Kaca Chopped Strand Mat
CSM - Chopped Strand Mat
chopped binder
Produk Fiberglass Generasi Pertama
Bahan Pengikat
Senyawa Pada Resin
Glass Roving Yarn Chopped Strand
JENIS FIBERGLASS
Benang Kaca Woven Roving
WR - Woven Roving
Tenun Weaving
Produk Fiberglass Generasi Kedua
Glass Roving Yarn
JENIS FIBERGLASS
Multiaxial
MAX - Multiaxial
warp knitting
Produk Fiberglass Generasi Ketiga
Benang Kaca
Glass Roving Yarn
JENIS FIBERGLASS
MAX - Multiaxial Fabric
Fleece (optional)
Lapisan
MULTIAXIAL PROSES
Karakteristik CSM
bull Glass Content 30
bull Resin Content 70
bull Tensile Force
Chopped Strand Mat
JENIS FIBERGLASS
Karakteristik Woven Roving
bull Glass Content 45
bull Resin Content 55
Woven Roving
Resin
|
|
|
|
|
|
|
|
|
|
|
|
|
|
bull Kekuatan Tarik
JENIS FIBERGLASS
No Resin Rich Area
Karakteristik Multiaxial
bull Glass Content 60
bull Resin Content 40
Produk Fiberglass Ketiga MULTIAXIAL
JENIS FIBERGLASS
Perbedaan Woven Roving dan Multiaxial ndash Tampak Samping
JENIS FIBERGLASS
WR FRP
8 Ply WR 800
8 Ply CSM 450
Glass Weight 1 kg
Composite Weight 15kgm2
CSM FRP
22 Ply CSM 450
Glass Weight 1 kg
Composite Weight 18 kgm2
MULTIAXIAL FRP
13 Ply DB 800
Glass Weight 1 kg
Composite Weight
13 kgm2
JENIS FIBERGLASS
Multiaxial
FRP
Woven Roving
FRP
Chopped Strands Mat FRP
MULTIAXIAL
FAKTA
TEBAL BUKAN BERARTI KUAT
UNSUR MATRIX (RESIN)
TIDAK ADA KEKUATAN
ldquoMore than 50 of the glass fibers used for reinforcement is
E-glassrdquo
KarakteristikKekuatan
CSM WR MAX
Kekuatan Tarik 175 MPa 250 MPa 425 MPa
CSM 142
WR 70
KEKUATAN TARIK
Properties CSM Lamination WR Lamination MAX Lamination
Fabric Weight (kgm2) 1 1 1
Composite Weight (kgm2) 18 15 13
Resin usage (kgm2) 15 1 08
Amount of Fabric 22 Ply 16 Ply 13 Ply
Thickness 15 mm 12 mm 10 mm
Tensile Strength (Mpa) 125 1796 400
Tensile Strength (Nmmsup2) 28463 30958 4576
Processing Time High Med Low
Labour Cost High Med Low
MULTIAXIAL
Total Penggunaan Resin -51
Total Berat Kapal -40
Kekuatan Bangunan Kapal +59
Efisiensi Tenaga Kerja
Waktu Pengerjaan Lebih Cepat
KEUNGGULAN MATERIAL
Resapan Resin Lebih Baik amp Merata
Lapisan Lebih Sedikit
Meningkatkan Kekuatan Kapal
KEUNGGULAN MATERIAL
TRIAXIAL
DBL series DBT series
BIAXIAL
LT series DB series
UNIDIRECTIONAL
L series T series
QUADRIAXIAL
DBLT series
JENIS MULTIAXIAL
UNIDIRECTIONAL
DCMU 900 E ndash
KHUSUS UNTUK MEMPERKUAT BENDING KAPAL
PEMASANGAN KHUSUS PADA KEEL DAN TULANGAN
JENIS MULTIAXIAL UNTUK KAPAL
TRIAXIAL
DBL 600 ndash
APLIKASI PADA INDUSTRI PENERBANGAN
PEMASANGAN KHUSUS PADA
SAMBUNGAN BADAN DAN SAYAP
PESAWAT
JENIS MULTIAXIAL UNTUK PESAWAT
QUADRAXIAL
DBLT 800 ndash
APLIKASI PADA INDUSTRI ENERGI
DITERAPKAN UNTUK KEBUTUHAN PEMBANGKIT
LISTRIK ENERGI ANGIN
MULTIAXIAL UNTUK ENERGI
INDUSTRI KIMIA OLAHRAGA AUTOMOTIF
MULTIAXIAL UNTUK INDUSTRI LAINNYA
COMPOSITES
GUNAKAN MATERIAL FIBERGLASS
YANG SUDAH DISERTIFIKASI
BKI
FIBERGLASS UNTUK PEMBANGUNAN BAKAP
PERATURAN MENTERI PERHUBUNGAN
NOMOR PM 7 TAHUN 2013
TENTANG KEWAJIBAN KLASIFIKASI BAGI KAPAL BERBENDERA INDONESIA
PADA BADAN KLASIFIKASI
BADAN SERTIFIKASI MARITIM
Biro Klasifikasi IndonesiaDet Norske Veritas Germanischer Lloyds
PERATURAN BKI
Untuk Kapal Non-Metal
2006
PERSYARATAN MINIMUM
kekuatan material yang
harus digunakan
untuk membangun
Kapal Fiberglass
PEMBESARAN
Table 21
FIBERGLASS TRIAXIS COMPOSITES
TELAH BERSERTIFIKASI BKI
Biro Klasifikasi Indonesia
65
TEKNIK MANUFAKTUR
COMPOSITES
Wet hand lay-up
1) Peletakan
Dry Reinforcement
bull Dry reinforcement dan resin (+ katalis) ditaruh pada permukaan cetakan
2) Pemasukanpenekanan resin
bull Resin ditekan untuk meng-impregnasi serat dengan menggunakan rol
3) Pengulangan proses untuk lapisan lain
bull Beberapa lapisan dapat ditambahkan secara bertahap
4) Resin curing
bull Reaksi dimulai komponen dilepaskan setelah komponen mengeras
(fully cured)
Wet hand lay-up
Manufaktur komponen dapat dikerjakan dengan menggunakan beberapa lapis komposit
dengan memperhatikan kompatibilitas material dan tahapan curing Modifikasi proses dapat
dilakukan seperti
Vacuum bagging
setelah lay-up
Glass Roving
Bulk Resin
Catalyst
3) De-molding
2) Resin Cure
bull Curing dimulai dan komponen dilepaskan setelah pengerasan selesai
bull Serat gelas resin dan katalis dimasukkan kedalam spray gun
1) Spray-up
bull Campuran disemprotkan pada permukaan cetakan
Spray-up
69
Penyemprotan bakal komponen
Komponen
dilepaskan
dari cetakan
Full dispensing
system Chopper Roving
Atomised resin
and catalyst
Spray-up
Prepreg
1) LaminateAssembly 5) De-molding
3) Resin Melts Layup Consolidates
bull Prepreg serat yang sudah diimpregnasi oleh resin+katalis dalam kondisi padat
bull Lapisan prepreg digunting sesuai bentuk yang diinginkan kemudian diletakkan pada permukaan cetakan
sesuai bentuk komponen yang diinginkan Lay-up mudah dilakukan karena sifat ldquotackynessrdquo dari prepreg
2) Applied Vacuum Pressure and Heat
bull Tekanan dan panas diberikan resin mencair terjadi konsolidasi pada komponen
4) Resin Cures
bull Temperatur dinaikkan untuk memulai curing
Prepreg
Variasi proses Autoclave
Komponen dalam
vacuum-bag
bull Campuran resin (+katalis) dan chopped glass strands diperoleh dalam bentuk premixed compound Bulk molding
Compound (BMC) dalam bentuk adonan atau Sheet molding Compound (SMC) dalam bentuk lembaran
bull Ketika panas dan tekanan diberikan oleh cetakan compound mengalir sesuai bentuk komponen yang diinginkan
1) Placement of Charge
5) De-molding3) Squeeze to final dimensions
2) Mould Closure4) Resin Cure
bull Curing dimulai komponen dilepaskan setelah terjadi pengerasan yang cukup
Compression Molding
bull Preform atau dry reinforcement dimasukkan kedalam cetakan sesuai dengan bentuk komponen yang
diinginkan
bull Resin mengalir dengan penekanan atau pem-vakuman dan meng-impregnasi preform dan
mendorongmengeluarkan udara yang ada dalam preform
1) Preform Manufacture
2) Preform Compression
5) De-molding3) Resin Injection
4) Resin Cure
bull Curing terjadi cetakan dibuka setelah terjadi pengerasan yang mencukupi
Liquid Molding (RTM VARI VARTM)
Pultrusion
bull Dry roving or fabrics ditarik melalui bak berisi
campuran resin dan katalis
bull Campuran yang basah ditarik melalui cetakan
bull Sisa resin keluar cetakan
bull Pemanasan dilakukan untuk proses curing
bull Pendinginan dilakukan untuk mempercepat siklus
produksi
Cut-off
Cooling
Die sections
Resin bath
Fibre creel
Filament Winding
bull Dry roving ditarik melalui bak berisi campuran resin dan katalis
bull Wet roving digulungkan dalam keadaan tegang kepada mandrel
bull Kontrol mekanik dari pembawa serat mengatur orientasi peletakan serat pada
mandrel
INDUSTRI COMPOSITES
AEROSPACE
HISTORY
1950 ndash Boeing
1960 ndash F14 Tomcat
1981 ndash AV-8B Harrier
Source
Low-Cost Composite Materials and Structures for Aircraft Applications
httpwwwreinforcedplasticscom
httpwwwcentennialofflightgovessayEvolution_of_TechnologycompositesTech40htm
Automotive
Composite material is used in a number of applications in the automotive
industry due to its temperature resistance rigidity and fatigue strength
The benefits of using composites include greater fuel efficiency
corrosion resistance light weight and strength Composites also provide
a low-cost way to help keep designs looking fresh
Composites are used in
- interior parts (cockpit trimming seats instrument panels)
- exterior structure (body panels openings underbody frontrear
modules)
- engine compartment and fuelmechanical area parts (axles and
suspensions fuel and exhaust systems)
- electrical and electronic components
Lamborghinis Sesto Element carbon fiber
ldquoFat men cannot run as fast as thin men but we build most of our vehicles as though dead-weight fat increased speedhellip I cannot
imagine where the delusion that weight means strength
came fromhelliprdquo mdashHenry Ford
The mix of automotive materials is changing showing a boost for FRP in helping original
equipment manufacturers meet fuel economy and emissions challenges
(Source 2011 DuPont AutomotiveSAE survey of design engineers performed by Signet Research Inc)
Source
httpwwwtoraycomcsrhighlight2009hig_001_01html
The MonoCell tub for the McLaren MP4-12C supercar is moulded as a single
piece and weighs less than 80 kg (176 lbs)
COMPOSITES IN MARINE
TRIMARAN BOAT
AMERICA NAVYINDONESIAN NAVY
Visby Class corvette
Total length is 72 meters
The beam is 1040 meters
The displacement is 600 metric tones
fully equipped the worlds largest CRP
construction
The design of the Visby aims to minimize
the optical and infrared signature above
water acoustic and hydroa coustic
signature underwater electrical potential
and magnetic signature pressure signature
radar cross section and actively emitted
signals
A stealth corvette of the YS 2000 design
has a detection range of 13km in rough
seas and 22km in calm sea without
jamming In a jammed environment the
Visby would be detected at a range of 8km
in rough sea and 11km in calm sea
The material provides high strength and
rigidity low weight good shock resistance
low radar and magnetic signature
1996
Visby is a class of stealth corvettes for the Swedish Navy
ldquoReduced 50 of a Conventional Steelrdquo
Source
Hull Construction with composite materials for ships over 100m in length 2002
Massachusetts Institute of Technology
httpwwwnaval-technologycomprojectsvisby
YACHTS
KAL YUDISTIRAMARATHON 100 ADMIRAL YACHT
LOA 3050 MWidth 6 MFuel Tank 8000 LWater Tank 3000 LIce Box 500 LAccommodation Max 35 Personnel
2 x CATERPILLAR 3412E 1200 HPMARINE DIESEL ENGINE
PC 40 ndash KRI Krait 827Department of Indonesian Navy
LOA 40 MWidth 73 MPower 190Weapon Twin Cannon Barrels
127 mm Heavy Machine GunSpeed Knot 25 KnotDisplacement 105 tonAccommodation 23 personnel
PATROL BOAT
Rigid Inflatable BoatPATROL BOAT
Yachts
36m Luxury Yacht Moonraker
36m Luxury Yacht GoldenEye
50m Luxury Yacht Casino
Royale
45m Luxury Yacht Seashaw
Boat Parts
Barovans for Seismic Sweep
Centrifugal Liftfan House for Surface Effect
Ships
Composite Boat PropellersRTM
Deckhouses for Pilot Boats
Fairing Parts for Submarines
Flybridges for Motor yachts
Light Weight Gangway
MTB Launcher Mock-up
Pleasure Boats
12m Sailboat
12m Sail-Catamaranone-off
Canoes
Dragonfly 1000Catamaran Sailboat
Fantasy 37Sailboat
Farr 60Luxury Sailboat
EurodingyOlympic Dingy Class for
Woman
Hydrolift F23 Racing Boats
Kajacs
Najad 42Sailboat
Najad 520Sailboat
Najad 441Sailboat
Najad 391Sailboat
Nordwest 900Motorboat
Nordwest 1100Motorboat
Quatro 44Motorboat
Racemaster Competition Boats
Storebro 420
Storebro 345
Sweden Yacht 370Sailboat
Sweden Yacht 69Sailboat
Windy 41Motorboat
X-632Sailboat
X-362Sailboat
Commercial Boats
175m High Speed AmbulancePassenger Boat
19m High Speed Passenger Boat
20m High Speed Passenger Boat
364m Surface Effect Passenger Ship
45m Surface Effect Passenger Ship
120m Hull Structural Parts HSSS Catamaran Ferry
APPENDIX
Marine Vessel
1188m Fast Attack Vessel FMV 90 E
20m SAV-Surface Auxiliary Vessels
34m Personnel TransportCoast Guard Vessel
40ft Experimental SES
40m Landsort-Class Mine Hunters
54m Mine Counter Measure Vehicles SES
74m Coastal Patrol Boats
Fishing Boats
30 GT
12 GT
10 GT
5 GT
WISEWings In Surface Effect
HOVERCRAFT
Designed specifically for the tourist and transport industries the
Pioneer Mk3 hovercraft is amphibious and comfortably seats 25
passengers plus 1-crew The air-conditioned cabin allows for
maximum visibility for all aboard The Pioneer Mk3 is robust and
dynamic in its performance
Commercial hovercraft
Mk3 AirLift Hovercraft - 1215m
Power is economicaly provided by one Deutz diesel engine of
330kW (442hp) to cruise easily at 40 knots with much higher
speeds available according to the surface conditions The hull is
manufactured from fibreglassPVC foam composite sandwich
the windows are glass and the skirt is urethane coated nylon A
Military version is available with increased payload and systems
redundancy Power for the Military version comes from two Steyr
diesel engines with a total installed power of 320kW (429hp) All
transmission electrical hydraulic and air systems are duplicated
for maximum redundancy The increased performance of the
Military version comes from the reduced engine weight of the twin
Steyr installation cf the Deutz installation
Source
httpwwwnauticexpocomprodairlift-hovercraftcommercial-hovercrafts-25251-142868html
HOVERFLIGHT
BALLISTIC amp UNIT DEFENCED
Triaxis Composites Collaboration with Institute of Aeronautics and Space in the development of Missile Nose Cone
Polymer composites is the evolution of the military defence
Thin steel was the helmet material of
WWII and remained the principal material until around the 1980rsquos
The advantages of using steel
included a simple technology for manufacture of the helmets low cost and reasonably good
impact protection However these helmets were found to provide only marginal protection
against fragments
During the Vietnam War the US Army experimented with fiber-reinforced inserts in the
helmets These inserts improved ballistic protection but at the same time added weight and
reduced the air space between the head and the helmet
By the early part of the 1980rsquos the US military had developed the first all-composite
100 fiber-reinforced helmet This development resulted in even better ballistic protection
without altering the weight of the helmet Other improvements included better head coverage and
more space for ventilation
Source
Composites Armor - A difficult but huge market
by A Brent Strong Brigham Young University
MILITARY VEHICLES
HIGH SPEED TRAIN SHINKANSEN
Advanced Composites provide lightweight solutions for railway vehicles
saving as much as 50-80 of the weight compared with traditional
components
A lower overall weight translates into less stress faster acceleration and
higher speeds as well as reduced starting and stopping inertia Today
these are important criteria in global high-speed and metropolitan
railway projects
Fire smoke and toxic fumes are key safety criteria for interior
components of railway carriages Any material selected for an interior
component must meet international fire retardant standards
for Rail Interiors and Exteriors
Ceiling Panels Stairs
Seating Vestibules
Window Panels Door Pillars
Partition WallsDiffusers
Gangway and Cabinet Panels Cabin and
Desk panels
Door Pillars Lavatory Modules (standard and
Front and Rear EndsRoof Panels
Nose Cones Under Fairings
Source
httpwwwpctaerail_compositesphp
101
SKY BUS
2009
Europe is the world leader in offshore wind with
828 wind turbines and a cumulative capacity of 2056 MW spread across 38 offshore wind farms in 9
European countries
The UK and Denmark are the current leaders with a 44 and 30 share respectively In 2009
five countries built new offshore wind farms
UK (284 MW)
Demark (230 MW)
Sweden (30 MW)
Germany (30 MW)
Norway (23 MW)
2010
Asia leads the growth in global wind power which grew 358 GW in 2010 bringing
total global capacity to 1944 GW ndash up 225 from 2009
the Global Wind Energy Council (GWEC)
Asia accounted for 19 GW of new global wind power installations driven by China which installed 165
GW
ldquoChina now has 423 GW of wind powerrdquo
ldquoThis puts China firmly on a path to reach 200 GW of installed wind power by 2020 At the same
time China has become the worldrsquos largest producer of wind energy equipmentrdquo
Source
httpwwwreinforcedplasticscomview15655asia-leads-global-wind-power-growth
httpimgdeusmcomdesignnews288288605-Sandia_Sizes_up_Wind_Turbine_Blade_Design_C_largegif
WIND ENERGY
Marine Current Turbines
Source
httpwwwsiemenscompressenpressreleasepress=enpressrelease2011solar-hydroex201111005htm
httpwwwmarineturbinescom
A commercial marine current turbine consists of
two rotors which are fixed on a structure within the
sea current The twin rotors rotate with the
movement of the tidal flow and the blades pitch
through 180 degrees to optimally track tidal current
(Press picture Marine Current Turbines)
Wave Star Energys Multi-point Absorber
CFRP COLUMN REINFORCEMENT
INDUSTRIAL TANKS
107
INDUSTRIAL PIPES
PRESSURE TANKS
109
ldquoLetrsquos Make with Compositesrdquo
FIBERGLASS
PRODUK
MATERIAL DAN PRODUK FIBERGLASS
+
Resin + Additives
PERPADUAN COMPOSITES
BENANG KACA Potongan Serat Kaca CSM
CSM - CHOPPED STRAND MAT
chopped binder
Kain Fiberglass Generasi Pertama
BahanPengikat
SenyawaPada Resin
JENIS FIBERGLASS
Glass Roving Yarn Chopped Strand
ADVANTAGES DISADVANTAGES
Steel
1048707 Low cost 1048707 Corrodes easily
1048707 Ductile under ambient conditions
1048707 Has no lower fatigue limit for welded structures
1048707 Virtually isotropic 1048707 Heavy
1048707 Easily formed and fabricated 1048707 Brittle at low temperatures
1048707 Easily obtained (low relative cost) 1048707 Magnetic
1048707 Easily alloyed or heat treated for special operations
1048707 Easily repaired
1048707 Good fire resistance
1048707 Behaviour is well understood
Alumunium Alloy
1048707 Light weight 1048707 Poor fatigue properties
1048707 Corrosion resistant 1048707 Poor performance in fire
1048707 Easily formed1048707 Low melting point and softening temperature
1048707 Easily fabricated 1048707 High relative cost
1048707 Readily available 1048707 Strength and stiffness less than steel
1048707 Ductile
1048707 Non magnetic
FRP
1048707 Low magnetic properties
1048707 Low electrical conductivity (glass- reinforced plastics)
1048707 Resistance to corrosion
1048707 Resistance to rot and marine growth
1048707 Relatively high sonar transparency
1048707 Good strength to weight ratio
1048707 Good fatigue properties
1048707 Maintenance of properties at low temperatures
1048707 Availability
1048707 Can be manufactured to near net-shape
1048707 Stiffness and strength can be tailored to structural requirements
1048707 Excellent thermal insulation
1048707 Light weight
STEEL vs ALUMUNIUM vs COMPOSITES
Source
1Maritime Platforms Division Aeronautical and
Maritime Research Laboratory (Seref Aksu
Stuart Cannon Craig Gardiner and Matthew
Gudze
2 Metal Corrosion can be defined as the
destructive attack of a metal through interaction
with its environment
(httpwwwcorrosionistcomCorrosion_Fundament
alhtm)
28
Serat rarr penguat
Polimer matriks rarr pengikat
bull Sifat mekanik yang cukup baik
bull Viskositas dan temperatur pengerjaan rendah rarr mudah
dimanufaktur
bull Ketahanan korosi yang baik
bull Media perpindahan gaya rarr distribusi beban dari serat ke serat
bull Ulet rarr Melindungi serat yang getas
bull Size effect rarr Kekuatan dan kekakuan sangat tinggi
bull Aspect ratio (ld) tinggi rarr luas permukaan besar
bull Fleksibel rarr variasi teknik manufaktur
bull Serat dapat diatur sesuai dengan arah pembebanan
29
Advantages Polimer Composites
Kekuatan dan kekakuan spesifik yang tinggi FRCP vs material lain rarr kompetitif jika berat dipertimbangkan
Material Berat jenis
r (kgm3)
Kekakuan
E (GPa)
Kekuatan
tarik su
(MPa)
Kekakuan
spesifik
Er
Kekuatan
spesifik sur
Baja 7800 208 400 27 005
Aluminium 2700 70 200 259 007
Nylon 1100 25 80 23 007
Beton 2400 40 20 166 0008
Random
FRPC
1800 20 300 111 0006
Alligned FRPC
( serat)
1600 200 1500 125 094
Alligned FRCP
( serat)
1600 3 50 19 0001
Tensile Strength amp Modulus of Common Structural Materials
Densities of Common Structural Materials
Specific Tensile Strength amp Modulus of Common Structural Materials
Typical Properties of Common Structural Materials
Kesimpulan COMPOSITES = RINGAN amp KUAT
Jadi secara keseluruhan kekuatan composites
ditentukan oleh
1 Kekuatan amp Sifat Fiber
2 Kekuatan amp Sifat Resin
3 Fraksi Rasio Perbandingan Volume Fiber
dan Resin dalam Composites
4 Geometri dan Orientasi Arah Fiber dalam
Composites
PRODUKSI ANAK NEGERI
Proses Produksi Kain Fiberglass
Biji Kaca Benang Benang Kaca Kain Fiberglass
PROSES MATERIAL
Glass Beads
Glass Fiber Glass Roving YarnGlass Fabric
Proses Produksi Kain Fiberglass
Biji Kaca Benang Benang Kaca Kain Fiberglass
Glass Beads
Glass Fiber Glass Roving YarnGlass Fabric
PROSES MATERIAL
Benang Kaca Potongan Serat Kaca Chopped Strand Mat
CSM - Chopped Strand Mat
chopped binder
Produk Fiberglass Generasi Pertama
Bahan Pengikat
Senyawa Pada Resin
Glass Roving Yarn Chopped Strand
JENIS FIBERGLASS
Benang Kaca Woven Roving
WR - Woven Roving
Tenun Weaving
Produk Fiberglass Generasi Kedua
Glass Roving Yarn
JENIS FIBERGLASS
Multiaxial
MAX - Multiaxial
warp knitting
Produk Fiberglass Generasi Ketiga
Benang Kaca
Glass Roving Yarn
JENIS FIBERGLASS
MAX - Multiaxial Fabric
Fleece (optional)
Lapisan
MULTIAXIAL PROSES
Karakteristik CSM
bull Glass Content 30
bull Resin Content 70
bull Tensile Force
Chopped Strand Mat
JENIS FIBERGLASS
Karakteristik Woven Roving
bull Glass Content 45
bull Resin Content 55
Woven Roving
Resin
|
|
|
|
|
|
|
|
|
|
|
|
|
|
bull Kekuatan Tarik
JENIS FIBERGLASS
No Resin Rich Area
Karakteristik Multiaxial
bull Glass Content 60
bull Resin Content 40
Produk Fiberglass Ketiga MULTIAXIAL
JENIS FIBERGLASS
Perbedaan Woven Roving dan Multiaxial ndash Tampak Samping
JENIS FIBERGLASS
WR FRP
8 Ply WR 800
8 Ply CSM 450
Glass Weight 1 kg
Composite Weight 15kgm2
CSM FRP
22 Ply CSM 450
Glass Weight 1 kg
Composite Weight 18 kgm2
MULTIAXIAL FRP
13 Ply DB 800
Glass Weight 1 kg
Composite Weight
13 kgm2
JENIS FIBERGLASS
Multiaxial
FRP
Woven Roving
FRP
Chopped Strands Mat FRP
MULTIAXIAL
FAKTA
TEBAL BUKAN BERARTI KUAT
UNSUR MATRIX (RESIN)
TIDAK ADA KEKUATAN
ldquoMore than 50 of the glass fibers used for reinforcement is
E-glassrdquo
KarakteristikKekuatan
CSM WR MAX
Kekuatan Tarik 175 MPa 250 MPa 425 MPa
CSM 142
WR 70
KEKUATAN TARIK
Properties CSM Lamination WR Lamination MAX Lamination
Fabric Weight (kgm2) 1 1 1
Composite Weight (kgm2) 18 15 13
Resin usage (kgm2) 15 1 08
Amount of Fabric 22 Ply 16 Ply 13 Ply
Thickness 15 mm 12 mm 10 mm
Tensile Strength (Mpa) 125 1796 400
Tensile Strength (Nmmsup2) 28463 30958 4576
Processing Time High Med Low
Labour Cost High Med Low
MULTIAXIAL
Total Penggunaan Resin -51
Total Berat Kapal -40
Kekuatan Bangunan Kapal +59
Efisiensi Tenaga Kerja
Waktu Pengerjaan Lebih Cepat
KEUNGGULAN MATERIAL
Resapan Resin Lebih Baik amp Merata
Lapisan Lebih Sedikit
Meningkatkan Kekuatan Kapal
KEUNGGULAN MATERIAL
TRIAXIAL
DBL series DBT series
BIAXIAL
LT series DB series
UNIDIRECTIONAL
L series T series
QUADRIAXIAL
DBLT series
JENIS MULTIAXIAL
UNIDIRECTIONAL
DCMU 900 E ndash
KHUSUS UNTUK MEMPERKUAT BENDING KAPAL
PEMASANGAN KHUSUS PADA KEEL DAN TULANGAN
JENIS MULTIAXIAL UNTUK KAPAL
TRIAXIAL
DBL 600 ndash
APLIKASI PADA INDUSTRI PENERBANGAN
PEMASANGAN KHUSUS PADA
SAMBUNGAN BADAN DAN SAYAP
PESAWAT
JENIS MULTIAXIAL UNTUK PESAWAT
QUADRAXIAL
DBLT 800 ndash
APLIKASI PADA INDUSTRI ENERGI
DITERAPKAN UNTUK KEBUTUHAN PEMBANGKIT
LISTRIK ENERGI ANGIN
MULTIAXIAL UNTUK ENERGI
INDUSTRI KIMIA OLAHRAGA AUTOMOTIF
MULTIAXIAL UNTUK INDUSTRI LAINNYA
COMPOSITES
GUNAKAN MATERIAL FIBERGLASS
YANG SUDAH DISERTIFIKASI
BKI
FIBERGLASS UNTUK PEMBANGUNAN BAKAP
PERATURAN MENTERI PERHUBUNGAN
NOMOR PM 7 TAHUN 2013
TENTANG KEWAJIBAN KLASIFIKASI BAGI KAPAL BERBENDERA INDONESIA
PADA BADAN KLASIFIKASI
BADAN SERTIFIKASI MARITIM
Biro Klasifikasi IndonesiaDet Norske Veritas Germanischer Lloyds
PERATURAN BKI
Untuk Kapal Non-Metal
2006
PERSYARATAN MINIMUM
kekuatan material yang
harus digunakan
untuk membangun
Kapal Fiberglass
PEMBESARAN
Table 21
FIBERGLASS TRIAXIS COMPOSITES
TELAH BERSERTIFIKASI BKI
Biro Klasifikasi Indonesia
65
TEKNIK MANUFAKTUR
COMPOSITES
Wet hand lay-up
1) Peletakan
Dry Reinforcement
bull Dry reinforcement dan resin (+ katalis) ditaruh pada permukaan cetakan
2) Pemasukanpenekanan resin
bull Resin ditekan untuk meng-impregnasi serat dengan menggunakan rol
3) Pengulangan proses untuk lapisan lain
bull Beberapa lapisan dapat ditambahkan secara bertahap
4) Resin curing
bull Reaksi dimulai komponen dilepaskan setelah komponen mengeras
(fully cured)
Wet hand lay-up
Manufaktur komponen dapat dikerjakan dengan menggunakan beberapa lapis komposit
dengan memperhatikan kompatibilitas material dan tahapan curing Modifikasi proses dapat
dilakukan seperti
Vacuum bagging
setelah lay-up
Glass Roving
Bulk Resin
Catalyst
3) De-molding
2) Resin Cure
bull Curing dimulai dan komponen dilepaskan setelah pengerasan selesai
bull Serat gelas resin dan katalis dimasukkan kedalam spray gun
1) Spray-up
bull Campuran disemprotkan pada permukaan cetakan
Spray-up
69
Penyemprotan bakal komponen
Komponen
dilepaskan
dari cetakan
Full dispensing
system Chopper Roving
Atomised resin
and catalyst
Spray-up
Prepreg
1) LaminateAssembly 5) De-molding
3) Resin Melts Layup Consolidates
bull Prepreg serat yang sudah diimpregnasi oleh resin+katalis dalam kondisi padat
bull Lapisan prepreg digunting sesuai bentuk yang diinginkan kemudian diletakkan pada permukaan cetakan
sesuai bentuk komponen yang diinginkan Lay-up mudah dilakukan karena sifat ldquotackynessrdquo dari prepreg
2) Applied Vacuum Pressure and Heat
bull Tekanan dan panas diberikan resin mencair terjadi konsolidasi pada komponen
4) Resin Cures
bull Temperatur dinaikkan untuk memulai curing
Prepreg
Variasi proses Autoclave
Komponen dalam
vacuum-bag
bull Campuran resin (+katalis) dan chopped glass strands diperoleh dalam bentuk premixed compound Bulk molding
Compound (BMC) dalam bentuk adonan atau Sheet molding Compound (SMC) dalam bentuk lembaran
bull Ketika panas dan tekanan diberikan oleh cetakan compound mengalir sesuai bentuk komponen yang diinginkan
1) Placement of Charge
5) De-molding3) Squeeze to final dimensions
2) Mould Closure4) Resin Cure
bull Curing dimulai komponen dilepaskan setelah terjadi pengerasan yang cukup
Compression Molding
bull Preform atau dry reinforcement dimasukkan kedalam cetakan sesuai dengan bentuk komponen yang
diinginkan
bull Resin mengalir dengan penekanan atau pem-vakuman dan meng-impregnasi preform dan
mendorongmengeluarkan udara yang ada dalam preform
1) Preform Manufacture
2) Preform Compression
5) De-molding3) Resin Injection
4) Resin Cure
bull Curing terjadi cetakan dibuka setelah terjadi pengerasan yang mencukupi
Liquid Molding (RTM VARI VARTM)
Pultrusion
bull Dry roving or fabrics ditarik melalui bak berisi
campuran resin dan katalis
bull Campuran yang basah ditarik melalui cetakan
bull Sisa resin keluar cetakan
bull Pemanasan dilakukan untuk proses curing
bull Pendinginan dilakukan untuk mempercepat siklus
produksi
Cut-off
Cooling
Die sections
Resin bath
Fibre creel
Filament Winding
bull Dry roving ditarik melalui bak berisi campuran resin dan katalis
bull Wet roving digulungkan dalam keadaan tegang kepada mandrel
bull Kontrol mekanik dari pembawa serat mengatur orientasi peletakan serat pada
mandrel
INDUSTRI COMPOSITES
AEROSPACE
HISTORY
1950 ndash Boeing
1960 ndash F14 Tomcat
1981 ndash AV-8B Harrier
Source
Low-Cost Composite Materials and Structures for Aircraft Applications
httpwwwreinforcedplasticscom
httpwwwcentennialofflightgovessayEvolution_of_TechnologycompositesTech40htm
Automotive
Composite material is used in a number of applications in the automotive
industry due to its temperature resistance rigidity and fatigue strength
The benefits of using composites include greater fuel efficiency
corrosion resistance light weight and strength Composites also provide
a low-cost way to help keep designs looking fresh
Composites are used in
- interior parts (cockpit trimming seats instrument panels)
- exterior structure (body panels openings underbody frontrear
modules)
- engine compartment and fuelmechanical area parts (axles and
suspensions fuel and exhaust systems)
- electrical and electronic components
Lamborghinis Sesto Element carbon fiber
ldquoFat men cannot run as fast as thin men but we build most of our vehicles as though dead-weight fat increased speedhellip I cannot
imagine where the delusion that weight means strength
came fromhelliprdquo mdashHenry Ford
The mix of automotive materials is changing showing a boost for FRP in helping original
equipment manufacturers meet fuel economy and emissions challenges
(Source 2011 DuPont AutomotiveSAE survey of design engineers performed by Signet Research Inc)
Source
httpwwwtoraycomcsrhighlight2009hig_001_01html
The MonoCell tub for the McLaren MP4-12C supercar is moulded as a single
piece and weighs less than 80 kg (176 lbs)
COMPOSITES IN MARINE
TRIMARAN BOAT
AMERICA NAVYINDONESIAN NAVY
Visby Class corvette
Total length is 72 meters
The beam is 1040 meters
The displacement is 600 metric tones
fully equipped the worlds largest CRP
construction
The design of the Visby aims to minimize
the optical and infrared signature above
water acoustic and hydroa coustic
signature underwater electrical potential
and magnetic signature pressure signature
radar cross section and actively emitted
signals
A stealth corvette of the YS 2000 design
has a detection range of 13km in rough
seas and 22km in calm sea without
jamming In a jammed environment the
Visby would be detected at a range of 8km
in rough sea and 11km in calm sea
The material provides high strength and
rigidity low weight good shock resistance
low radar and magnetic signature
1996
Visby is a class of stealth corvettes for the Swedish Navy
ldquoReduced 50 of a Conventional Steelrdquo
Source
Hull Construction with composite materials for ships over 100m in length 2002
Massachusetts Institute of Technology
httpwwwnaval-technologycomprojectsvisby
YACHTS
KAL YUDISTIRAMARATHON 100 ADMIRAL YACHT
LOA 3050 MWidth 6 MFuel Tank 8000 LWater Tank 3000 LIce Box 500 LAccommodation Max 35 Personnel
2 x CATERPILLAR 3412E 1200 HPMARINE DIESEL ENGINE
PC 40 ndash KRI Krait 827Department of Indonesian Navy
LOA 40 MWidth 73 MPower 190Weapon Twin Cannon Barrels
127 mm Heavy Machine GunSpeed Knot 25 KnotDisplacement 105 tonAccommodation 23 personnel
PATROL BOAT
Rigid Inflatable BoatPATROL BOAT
Yachts
36m Luxury Yacht Moonraker
36m Luxury Yacht GoldenEye
50m Luxury Yacht Casino
Royale
45m Luxury Yacht Seashaw
Boat Parts
Barovans for Seismic Sweep
Centrifugal Liftfan House for Surface Effect
Ships
Composite Boat PropellersRTM
Deckhouses for Pilot Boats
Fairing Parts for Submarines
Flybridges for Motor yachts
Light Weight Gangway
MTB Launcher Mock-up
Pleasure Boats
12m Sailboat
12m Sail-Catamaranone-off
Canoes
Dragonfly 1000Catamaran Sailboat
Fantasy 37Sailboat
Farr 60Luxury Sailboat
EurodingyOlympic Dingy Class for
Woman
Hydrolift F23 Racing Boats
Kajacs
Najad 42Sailboat
Najad 520Sailboat
Najad 441Sailboat
Najad 391Sailboat
Nordwest 900Motorboat
Nordwest 1100Motorboat
Quatro 44Motorboat
Racemaster Competition Boats
Storebro 420
Storebro 345
Sweden Yacht 370Sailboat
Sweden Yacht 69Sailboat
Windy 41Motorboat
X-632Sailboat
X-362Sailboat
Commercial Boats
175m High Speed AmbulancePassenger Boat
19m High Speed Passenger Boat
20m High Speed Passenger Boat
364m Surface Effect Passenger Ship
45m Surface Effect Passenger Ship
120m Hull Structural Parts HSSS Catamaran Ferry
APPENDIX
Marine Vessel
1188m Fast Attack Vessel FMV 90 E
20m SAV-Surface Auxiliary Vessels
34m Personnel TransportCoast Guard Vessel
40ft Experimental SES
40m Landsort-Class Mine Hunters
54m Mine Counter Measure Vehicles SES
74m Coastal Patrol Boats
Fishing Boats
30 GT
12 GT
10 GT
5 GT
WISEWings In Surface Effect
HOVERCRAFT
Designed specifically for the tourist and transport industries the
Pioneer Mk3 hovercraft is amphibious and comfortably seats 25
passengers plus 1-crew The air-conditioned cabin allows for
maximum visibility for all aboard The Pioneer Mk3 is robust and
dynamic in its performance
Commercial hovercraft
Mk3 AirLift Hovercraft - 1215m
Power is economicaly provided by one Deutz diesel engine of
330kW (442hp) to cruise easily at 40 knots with much higher
speeds available according to the surface conditions The hull is
manufactured from fibreglassPVC foam composite sandwich
the windows are glass and the skirt is urethane coated nylon A
Military version is available with increased payload and systems
redundancy Power for the Military version comes from two Steyr
diesel engines with a total installed power of 320kW (429hp) All
transmission electrical hydraulic and air systems are duplicated
for maximum redundancy The increased performance of the
Military version comes from the reduced engine weight of the twin
Steyr installation cf the Deutz installation
Source
httpwwwnauticexpocomprodairlift-hovercraftcommercial-hovercrafts-25251-142868html
HOVERFLIGHT
BALLISTIC amp UNIT DEFENCED
Triaxis Composites Collaboration with Institute of Aeronautics and Space in the development of Missile Nose Cone
Polymer composites is the evolution of the military defence
Thin steel was the helmet material of
WWII and remained the principal material until around the 1980rsquos
The advantages of using steel
included a simple technology for manufacture of the helmets low cost and reasonably good
impact protection However these helmets were found to provide only marginal protection
against fragments
During the Vietnam War the US Army experimented with fiber-reinforced inserts in the
helmets These inserts improved ballistic protection but at the same time added weight and
reduced the air space between the head and the helmet
By the early part of the 1980rsquos the US military had developed the first all-composite
100 fiber-reinforced helmet This development resulted in even better ballistic protection
without altering the weight of the helmet Other improvements included better head coverage and
more space for ventilation
Source
Composites Armor - A difficult but huge market
by A Brent Strong Brigham Young University
MILITARY VEHICLES
HIGH SPEED TRAIN SHINKANSEN
Advanced Composites provide lightweight solutions for railway vehicles
saving as much as 50-80 of the weight compared with traditional
components
A lower overall weight translates into less stress faster acceleration and
higher speeds as well as reduced starting and stopping inertia Today
these are important criteria in global high-speed and metropolitan
railway projects
Fire smoke and toxic fumes are key safety criteria for interior
components of railway carriages Any material selected for an interior
component must meet international fire retardant standards
for Rail Interiors and Exteriors
Ceiling Panels Stairs
Seating Vestibules
Window Panels Door Pillars
Partition WallsDiffusers
Gangway and Cabinet Panels Cabin and
Desk panels
Door Pillars Lavatory Modules (standard and
Front and Rear EndsRoof Panels
Nose Cones Under Fairings
Source
httpwwwpctaerail_compositesphp
101
SKY BUS
2009
Europe is the world leader in offshore wind with
828 wind turbines and a cumulative capacity of 2056 MW spread across 38 offshore wind farms in 9
European countries
The UK and Denmark are the current leaders with a 44 and 30 share respectively In 2009
five countries built new offshore wind farms
UK (284 MW)
Demark (230 MW)
Sweden (30 MW)
Germany (30 MW)
Norway (23 MW)
2010
Asia leads the growth in global wind power which grew 358 GW in 2010 bringing
total global capacity to 1944 GW ndash up 225 from 2009
the Global Wind Energy Council (GWEC)
Asia accounted for 19 GW of new global wind power installations driven by China which installed 165
GW
ldquoChina now has 423 GW of wind powerrdquo
ldquoThis puts China firmly on a path to reach 200 GW of installed wind power by 2020 At the same
time China has become the worldrsquos largest producer of wind energy equipmentrdquo
Source
httpwwwreinforcedplasticscomview15655asia-leads-global-wind-power-growth
httpimgdeusmcomdesignnews288288605-Sandia_Sizes_up_Wind_Turbine_Blade_Design_C_largegif
WIND ENERGY
Marine Current Turbines
Source
httpwwwsiemenscompressenpressreleasepress=enpressrelease2011solar-hydroex201111005htm
httpwwwmarineturbinescom
A commercial marine current turbine consists of
two rotors which are fixed on a structure within the
sea current The twin rotors rotate with the
movement of the tidal flow and the blades pitch
through 180 degrees to optimally track tidal current
(Press picture Marine Current Turbines)
Wave Star Energys Multi-point Absorber
CFRP COLUMN REINFORCEMENT
INDUSTRIAL TANKS
107
INDUSTRIAL PIPES
PRESSURE TANKS
109
ldquoLetrsquos Make with Compositesrdquo
BENANG KACA Potongan Serat Kaca CSM
CSM - CHOPPED STRAND MAT
chopped binder
Kain Fiberglass Generasi Pertama
BahanPengikat
SenyawaPada Resin
JENIS FIBERGLASS
Glass Roving Yarn Chopped Strand
ADVANTAGES DISADVANTAGES
Steel
1048707 Low cost 1048707 Corrodes easily
1048707 Ductile under ambient conditions
1048707 Has no lower fatigue limit for welded structures
1048707 Virtually isotropic 1048707 Heavy
1048707 Easily formed and fabricated 1048707 Brittle at low temperatures
1048707 Easily obtained (low relative cost) 1048707 Magnetic
1048707 Easily alloyed or heat treated for special operations
1048707 Easily repaired
1048707 Good fire resistance
1048707 Behaviour is well understood
Alumunium Alloy
1048707 Light weight 1048707 Poor fatigue properties
1048707 Corrosion resistant 1048707 Poor performance in fire
1048707 Easily formed1048707 Low melting point and softening temperature
1048707 Easily fabricated 1048707 High relative cost
1048707 Readily available 1048707 Strength and stiffness less than steel
1048707 Ductile
1048707 Non magnetic
FRP
1048707 Low magnetic properties
1048707 Low electrical conductivity (glass- reinforced plastics)
1048707 Resistance to corrosion
1048707 Resistance to rot and marine growth
1048707 Relatively high sonar transparency
1048707 Good strength to weight ratio
1048707 Good fatigue properties
1048707 Maintenance of properties at low temperatures
1048707 Availability
1048707 Can be manufactured to near net-shape
1048707 Stiffness and strength can be tailored to structural requirements
1048707 Excellent thermal insulation
1048707 Light weight
STEEL vs ALUMUNIUM vs COMPOSITES
Source
1Maritime Platforms Division Aeronautical and
Maritime Research Laboratory (Seref Aksu
Stuart Cannon Craig Gardiner and Matthew
Gudze
2 Metal Corrosion can be defined as the
destructive attack of a metal through interaction
with its environment
(httpwwwcorrosionistcomCorrosion_Fundament
alhtm)
28
Serat rarr penguat
Polimer matriks rarr pengikat
bull Sifat mekanik yang cukup baik
bull Viskositas dan temperatur pengerjaan rendah rarr mudah
dimanufaktur
bull Ketahanan korosi yang baik
bull Media perpindahan gaya rarr distribusi beban dari serat ke serat
bull Ulet rarr Melindungi serat yang getas
bull Size effect rarr Kekuatan dan kekakuan sangat tinggi
bull Aspect ratio (ld) tinggi rarr luas permukaan besar
bull Fleksibel rarr variasi teknik manufaktur
bull Serat dapat diatur sesuai dengan arah pembebanan
29
Advantages Polimer Composites
Kekuatan dan kekakuan spesifik yang tinggi FRCP vs material lain rarr kompetitif jika berat dipertimbangkan
Material Berat jenis
r (kgm3)
Kekakuan
E (GPa)
Kekuatan
tarik su
(MPa)
Kekakuan
spesifik
Er
Kekuatan
spesifik sur
Baja 7800 208 400 27 005
Aluminium 2700 70 200 259 007
Nylon 1100 25 80 23 007
Beton 2400 40 20 166 0008
Random
FRPC
1800 20 300 111 0006
Alligned FRPC
( serat)
1600 200 1500 125 094
Alligned FRCP
( serat)
1600 3 50 19 0001
Tensile Strength amp Modulus of Common Structural Materials
Densities of Common Structural Materials
Specific Tensile Strength amp Modulus of Common Structural Materials
Typical Properties of Common Structural Materials
Kesimpulan COMPOSITES = RINGAN amp KUAT
Jadi secara keseluruhan kekuatan composites
ditentukan oleh
1 Kekuatan amp Sifat Fiber
2 Kekuatan amp Sifat Resin
3 Fraksi Rasio Perbandingan Volume Fiber
dan Resin dalam Composites
4 Geometri dan Orientasi Arah Fiber dalam
Composites
PRODUKSI ANAK NEGERI
Proses Produksi Kain Fiberglass
Biji Kaca Benang Benang Kaca Kain Fiberglass
PROSES MATERIAL
Glass Beads
Glass Fiber Glass Roving YarnGlass Fabric
Proses Produksi Kain Fiberglass
Biji Kaca Benang Benang Kaca Kain Fiberglass
Glass Beads
Glass Fiber Glass Roving YarnGlass Fabric
PROSES MATERIAL
Benang Kaca Potongan Serat Kaca Chopped Strand Mat
CSM - Chopped Strand Mat
chopped binder
Produk Fiberglass Generasi Pertama
Bahan Pengikat
Senyawa Pada Resin
Glass Roving Yarn Chopped Strand
JENIS FIBERGLASS
Benang Kaca Woven Roving
WR - Woven Roving
Tenun Weaving
Produk Fiberglass Generasi Kedua
Glass Roving Yarn
JENIS FIBERGLASS
Multiaxial
MAX - Multiaxial
warp knitting
Produk Fiberglass Generasi Ketiga
Benang Kaca
Glass Roving Yarn
JENIS FIBERGLASS
MAX - Multiaxial Fabric
Fleece (optional)
Lapisan
MULTIAXIAL PROSES
Karakteristik CSM
bull Glass Content 30
bull Resin Content 70
bull Tensile Force
Chopped Strand Mat
JENIS FIBERGLASS
Karakteristik Woven Roving
bull Glass Content 45
bull Resin Content 55
Woven Roving
Resin
|
|
|
|
|
|
|
|
|
|
|
|
|
|
bull Kekuatan Tarik
JENIS FIBERGLASS
No Resin Rich Area
Karakteristik Multiaxial
bull Glass Content 60
bull Resin Content 40
Produk Fiberglass Ketiga MULTIAXIAL
JENIS FIBERGLASS
Perbedaan Woven Roving dan Multiaxial ndash Tampak Samping
JENIS FIBERGLASS
WR FRP
8 Ply WR 800
8 Ply CSM 450
Glass Weight 1 kg
Composite Weight 15kgm2
CSM FRP
22 Ply CSM 450
Glass Weight 1 kg
Composite Weight 18 kgm2
MULTIAXIAL FRP
13 Ply DB 800
Glass Weight 1 kg
Composite Weight
13 kgm2
JENIS FIBERGLASS
Multiaxial
FRP
Woven Roving
FRP
Chopped Strands Mat FRP
MULTIAXIAL
FAKTA
TEBAL BUKAN BERARTI KUAT
UNSUR MATRIX (RESIN)
TIDAK ADA KEKUATAN
ldquoMore than 50 of the glass fibers used for reinforcement is
E-glassrdquo
KarakteristikKekuatan
CSM WR MAX
Kekuatan Tarik 175 MPa 250 MPa 425 MPa
CSM 142
WR 70
KEKUATAN TARIK
Properties CSM Lamination WR Lamination MAX Lamination
Fabric Weight (kgm2) 1 1 1
Composite Weight (kgm2) 18 15 13
Resin usage (kgm2) 15 1 08
Amount of Fabric 22 Ply 16 Ply 13 Ply
Thickness 15 mm 12 mm 10 mm
Tensile Strength (Mpa) 125 1796 400
Tensile Strength (Nmmsup2) 28463 30958 4576
Processing Time High Med Low
Labour Cost High Med Low
MULTIAXIAL
Total Penggunaan Resin -51
Total Berat Kapal -40
Kekuatan Bangunan Kapal +59
Efisiensi Tenaga Kerja
Waktu Pengerjaan Lebih Cepat
KEUNGGULAN MATERIAL
Resapan Resin Lebih Baik amp Merata
Lapisan Lebih Sedikit
Meningkatkan Kekuatan Kapal
KEUNGGULAN MATERIAL
TRIAXIAL
DBL series DBT series
BIAXIAL
LT series DB series
UNIDIRECTIONAL
L series T series
QUADRIAXIAL
DBLT series
JENIS MULTIAXIAL
UNIDIRECTIONAL
DCMU 900 E ndash
KHUSUS UNTUK MEMPERKUAT BENDING KAPAL
PEMASANGAN KHUSUS PADA KEEL DAN TULANGAN
JENIS MULTIAXIAL UNTUK KAPAL
TRIAXIAL
DBL 600 ndash
APLIKASI PADA INDUSTRI PENERBANGAN
PEMASANGAN KHUSUS PADA
SAMBUNGAN BADAN DAN SAYAP
PESAWAT
JENIS MULTIAXIAL UNTUK PESAWAT
QUADRAXIAL
DBLT 800 ndash
APLIKASI PADA INDUSTRI ENERGI
DITERAPKAN UNTUK KEBUTUHAN PEMBANGKIT
LISTRIK ENERGI ANGIN
MULTIAXIAL UNTUK ENERGI
INDUSTRI KIMIA OLAHRAGA AUTOMOTIF
MULTIAXIAL UNTUK INDUSTRI LAINNYA
COMPOSITES
GUNAKAN MATERIAL FIBERGLASS
YANG SUDAH DISERTIFIKASI
BKI
FIBERGLASS UNTUK PEMBANGUNAN BAKAP
PERATURAN MENTERI PERHUBUNGAN
NOMOR PM 7 TAHUN 2013
TENTANG KEWAJIBAN KLASIFIKASI BAGI KAPAL BERBENDERA INDONESIA
PADA BADAN KLASIFIKASI
BADAN SERTIFIKASI MARITIM
Biro Klasifikasi IndonesiaDet Norske Veritas Germanischer Lloyds
PERATURAN BKI
Untuk Kapal Non-Metal
2006
PERSYARATAN MINIMUM
kekuatan material yang
harus digunakan
untuk membangun
Kapal Fiberglass
PEMBESARAN
Table 21
FIBERGLASS TRIAXIS COMPOSITES
TELAH BERSERTIFIKASI BKI
Biro Klasifikasi Indonesia
65
TEKNIK MANUFAKTUR
COMPOSITES
Wet hand lay-up
1) Peletakan
Dry Reinforcement
bull Dry reinforcement dan resin (+ katalis) ditaruh pada permukaan cetakan
2) Pemasukanpenekanan resin
bull Resin ditekan untuk meng-impregnasi serat dengan menggunakan rol
3) Pengulangan proses untuk lapisan lain
bull Beberapa lapisan dapat ditambahkan secara bertahap
4) Resin curing
bull Reaksi dimulai komponen dilepaskan setelah komponen mengeras
(fully cured)
Wet hand lay-up
Manufaktur komponen dapat dikerjakan dengan menggunakan beberapa lapis komposit
dengan memperhatikan kompatibilitas material dan tahapan curing Modifikasi proses dapat
dilakukan seperti
Vacuum bagging
setelah lay-up
Glass Roving
Bulk Resin
Catalyst
3) De-molding
2) Resin Cure
bull Curing dimulai dan komponen dilepaskan setelah pengerasan selesai
bull Serat gelas resin dan katalis dimasukkan kedalam spray gun
1) Spray-up
bull Campuran disemprotkan pada permukaan cetakan
Spray-up
69
Penyemprotan bakal komponen
Komponen
dilepaskan
dari cetakan
Full dispensing
system Chopper Roving
Atomised resin
and catalyst
Spray-up
Prepreg
1) LaminateAssembly 5) De-molding
3) Resin Melts Layup Consolidates
bull Prepreg serat yang sudah diimpregnasi oleh resin+katalis dalam kondisi padat
bull Lapisan prepreg digunting sesuai bentuk yang diinginkan kemudian diletakkan pada permukaan cetakan
sesuai bentuk komponen yang diinginkan Lay-up mudah dilakukan karena sifat ldquotackynessrdquo dari prepreg
2) Applied Vacuum Pressure and Heat
bull Tekanan dan panas diberikan resin mencair terjadi konsolidasi pada komponen
4) Resin Cures
bull Temperatur dinaikkan untuk memulai curing
Prepreg
Variasi proses Autoclave
Komponen dalam
vacuum-bag
bull Campuran resin (+katalis) dan chopped glass strands diperoleh dalam bentuk premixed compound Bulk molding
Compound (BMC) dalam bentuk adonan atau Sheet molding Compound (SMC) dalam bentuk lembaran
bull Ketika panas dan tekanan diberikan oleh cetakan compound mengalir sesuai bentuk komponen yang diinginkan
1) Placement of Charge
5) De-molding3) Squeeze to final dimensions
2) Mould Closure4) Resin Cure
bull Curing dimulai komponen dilepaskan setelah terjadi pengerasan yang cukup
Compression Molding
bull Preform atau dry reinforcement dimasukkan kedalam cetakan sesuai dengan bentuk komponen yang
diinginkan
bull Resin mengalir dengan penekanan atau pem-vakuman dan meng-impregnasi preform dan
mendorongmengeluarkan udara yang ada dalam preform
1) Preform Manufacture
2) Preform Compression
5) De-molding3) Resin Injection
4) Resin Cure
bull Curing terjadi cetakan dibuka setelah terjadi pengerasan yang mencukupi
Liquid Molding (RTM VARI VARTM)
Pultrusion
bull Dry roving or fabrics ditarik melalui bak berisi
campuran resin dan katalis
bull Campuran yang basah ditarik melalui cetakan
bull Sisa resin keluar cetakan
bull Pemanasan dilakukan untuk proses curing
bull Pendinginan dilakukan untuk mempercepat siklus
produksi
Cut-off
Cooling
Die sections
Resin bath
Fibre creel
Filament Winding
bull Dry roving ditarik melalui bak berisi campuran resin dan katalis
bull Wet roving digulungkan dalam keadaan tegang kepada mandrel
bull Kontrol mekanik dari pembawa serat mengatur orientasi peletakan serat pada
mandrel
INDUSTRI COMPOSITES
AEROSPACE
HISTORY
1950 ndash Boeing
1960 ndash F14 Tomcat
1981 ndash AV-8B Harrier
Source
Low-Cost Composite Materials and Structures for Aircraft Applications
httpwwwreinforcedplasticscom
httpwwwcentennialofflightgovessayEvolution_of_TechnologycompositesTech40htm
Automotive
Composite material is used in a number of applications in the automotive
industry due to its temperature resistance rigidity and fatigue strength
The benefits of using composites include greater fuel efficiency
corrosion resistance light weight and strength Composites also provide
a low-cost way to help keep designs looking fresh
Composites are used in
- interior parts (cockpit trimming seats instrument panels)
- exterior structure (body panels openings underbody frontrear
modules)
- engine compartment and fuelmechanical area parts (axles and
suspensions fuel and exhaust systems)
- electrical and electronic components
Lamborghinis Sesto Element carbon fiber
ldquoFat men cannot run as fast as thin men but we build most of our vehicles as though dead-weight fat increased speedhellip I cannot
imagine where the delusion that weight means strength
came fromhelliprdquo mdashHenry Ford
The mix of automotive materials is changing showing a boost for FRP in helping original
equipment manufacturers meet fuel economy and emissions challenges
(Source 2011 DuPont AutomotiveSAE survey of design engineers performed by Signet Research Inc)
Source
httpwwwtoraycomcsrhighlight2009hig_001_01html
The MonoCell tub for the McLaren MP4-12C supercar is moulded as a single
piece and weighs less than 80 kg (176 lbs)
COMPOSITES IN MARINE
TRIMARAN BOAT
AMERICA NAVYINDONESIAN NAVY
Visby Class corvette
Total length is 72 meters
The beam is 1040 meters
The displacement is 600 metric tones
fully equipped the worlds largest CRP
construction
The design of the Visby aims to minimize
the optical and infrared signature above
water acoustic and hydroa coustic
signature underwater electrical potential
and magnetic signature pressure signature
radar cross section and actively emitted
signals
A stealth corvette of the YS 2000 design
has a detection range of 13km in rough
seas and 22km in calm sea without
jamming In a jammed environment the
Visby would be detected at a range of 8km
in rough sea and 11km in calm sea
The material provides high strength and
rigidity low weight good shock resistance
low radar and magnetic signature
1996
Visby is a class of stealth corvettes for the Swedish Navy
ldquoReduced 50 of a Conventional Steelrdquo
Source
Hull Construction with composite materials for ships over 100m in length 2002
Massachusetts Institute of Technology
httpwwwnaval-technologycomprojectsvisby
YACHTS
KAL YUDISTIRAMARATHON 100 ADMIRAL YACHT
LOA 3050 MWidth 6 MFuel Tank 8000 LWater Tank 3000 LIce Box 500 LAccommodation Max 35 Personnel
2 x CATERPILLAR 3412E 1200 HPMARINE DIESEL ENGINE
PC 40 ndash KRI Krait 827Department of Indonesian Navy
LOA 40 MWidth 73 MPower 190Weapon Twin Cannon Barrels
127 mm Heavy Machine GunSpeed Knot 25 KnotDisplacement 105 tonAccommodation 23 personnel
PATROL BOAT
Rigid Inflatable BoatPATROL BOAT
Yachts
36m Luxury Yacht Moonraker
36m Luxury Yacht GoldenEye
50m Luxury Yacht Casino
Royale
45m Luxury Yacht Seashaw
Boat Parts
Barovans for Seismic Sweep
Centrifugal Liftfan House for Surface Effect
Ships
Composite Boat PropellersRTM
Deckhouses for Pilot Boats
Fairing Parts for Submarines
Flybridges for Motor yachts
Light Weight Gangway
MTB Launcher Mock-up
Pleasure Boats
12m Sailboat
12m Sail-Catamaranone-off
Canoes
Dragonfly 1000Catamaran Sailboat
Fantasy 37Sailboat
Farr 60Luxury Sailboat
EurodingyOlympic Dingy Class for
Woman
Hydrolift F23 Racing Boats
Kajacs
Najad 42Sailboat
Najad 520Sailboat
Najad 441Sailboat
Najad 391Sailboat
Nordwest 900Motorboat
Nordwest 1100Motorboat
Quatro 44Motorboat
Racemaster Competition Boats
Storebro 420
Storebro 345
Sweden Yacht 370Sailboat
Sweden Yacht 69Sailboat
Windy 41Motorboat
X-632Sailboat
X-362Sailboat
Commercial Boats
175m High Speed AmbulancePassenger Boat
19m High Speed Passenger Boat
20m High Speed Passenger Boat
364m Surface Effect Passenger Ship
45m Surface Effect Passenger Ship
120m Hull Structural Parts HSSS Catamaran Ferry
APPENDIX
Marine Vessel
1188m Fast Attack Vessel FMV 90 E
20m SAV-Surface Auxiliary Vessels
34m Personnel TransportCoast Guard Vessel
40ft Experimental SES
40m Landsort-Class Mine Hunters
54m Mine Counter Measure Vehicles SES
74m Coastal Patrol Boats
Fishing Boats
30 GT
12 GT
10 GT
5 GT
WISEWings In Surface Effect
HOVERCRAFT
Designed specifically for the tourist and transport industries the
Pioneer Mk3 hovercraft is amphibious and comfortably seats 25
passengers plus 1-crew The air-conditioned cabin allows for
maximum visibility for all aboard The Pioneer Mk3 is robust and
dynamic in its performance
Commercial hovercraft
Mk3 AirLift Hovercraft - 1215m
Power is economicaly provided by one Deutz diesel engine of
330kW (442hp) to cruise easily at 40 knots with much higher
speeds available according to the surface conditions The hull is
manufactured from fibreglassPVC foam composite sandwich
the windows are glass and the skirt is urethane coated nylon A
Military version is available with increased payload and systems
redundancy Power for the Military version comes from two Steyr
diesel engines with a total installed power of 320kW (429hp) All
transmission electrical hydraulic and air systems are duplicated
for maximum redundancy The increased performance of the
Military version comes from the reduced engine weight of the twin
Steyr installation cf the Deutz installation
Source
httpwwwnauticexpocomprodairlift-hovercraftcommercial-hovercrafts-25251-142868html
HOVERFLIGHT
BALLISTIC amp UNIT DEFENCED
Triaxis Composites Collaboration with Institute of Aeronautics and Space in the development of Missile Nose Cone
Polymer composites is the evolution of the military defence
Thin steel was the helmet material of
WWII and remained the principal material until around the 1980rsquos
The advantages of using steel
included a simple technology for manufacture of the helmets low cost and reasonably good
impact protection However these helmets were found to provide only marginal protection
against fragments
During the Vietnam War the US Army experimented with fiber-reinforced inserts in the
helmets These inserts improved ballistic protection but at the same time added weight and
reduced the air space between the head and the helmet
By the early part of the 1980rsquos the US military had developed the first all-composite
100 fiber-reinforced helmet This development resulted in even better ballistic protection
without altering the weight of the helmet Other improvements included better head coverage and
more space for ventilation
Source
Composites Armor - A difficult but huge market
by A Brent Strong Brigham Young University
MILITARY VEHICLES
HIGH SPEED TRAIN SHINKANSEN
Advanced Composites provide lightweight solutions for railway vehicles
saving as much as 50-80 of the weight compared with traditional
components
A lower overall weight translates into less stress faster acceleration and
higher speeds as well as reduced starting and stopping inertia Today
these are important criteria in global high-speed and metropolitan
railway projects
Fire smoke and toxic fumes are key safety criteria for interior
components of railway carriages Any material selected for an interior
component must meet international fire retardant standards
for Rail Interiors and Exteriors
Ceiling Panels Stairs
Seating Vestibules
Window Panels Door Pillars
Partition WallsDiffusers
Gangway and Cabinet Panels Cabin and
Desk panels
Door Pillars Lavatory Modules (standard and
Front and Rear EndsRoof Panels
Nose Cones Under Fairings
Source
httpwwwpctaerail_compositesphp
101
SKY BUS
2009
Europe is the world leader in offshore wind with
828 wind turbines and a cumulative capacity of 2056 MW spread across 38 offshore wind farms in 9
European countries
The UK and Denmark are the current leaders with a 44 and 30 share respectively In 2009
five countries built new offshore wind farms
UK (284 MW)
Demark (230 MW)
Sweden (30 MW)
Germany (30 MW)
Norway (23 MW)
2010
Asia leads the growth in global wind power which grew 358 GW in 2010 bringing
total global capacity to 1944 GW ndash up 225 from 2009
the Global Wind Energy Council (GWEC)
Asia accounted for 19 GW of new global wind power installations driven by China which installed 165
GW
ldquoChina now has 423 GW of wind powerrdquo
ldquoThis puts China firmly on a path to reach 200 GW of installed wind power by 2020 At the same
time China has become the worldrsquos largest producer of wind energy equipmentrdquo
Source
httpwwwreinforcedplasticscomview15655asia-leads-global-wind-power-growth
httpimgdeusmcomdesignnews288288605-Sandia_Sizes_up_Wind_Turbine_Blade_Design_C_largegif
WIND ENERGY
Marine Current Turbines
Source
httpwwwsiemenscompressenpressreleasepress=enpressrelease2011solar-hydroex201111005htm
httpwwwmarineturbinescom
A commercial marine current turbine consists of
two rotors which are fixed on a structure within the
sea current The twin rotors rotate with the
movement of the tidal flow and the blades pitch
through 180 degrees to optimally track tidal current
(Press picture Marine Current Turbines)
Wave Star Energys Multi-point Absorber
CFRP COLUMN REINFORCEMENT
INDUSTRIAL TANKS
107
INDUSTRIAL PIPES
PRESSURE TANKS
109
ldquoLetrsquos Make with Compositesrdquo
ADVANTAGES DISADVANTAGES
Steel
1048707 Low cost 1048707 Corrodes easily
1048707 Ductile under ambient conditions
1048707 Has no lower fatigue limit for welded structures
1048707 Virtually isotropic 1048707 Heavy
1048707 Easily formed and fabricated 1048707 Brittle at low temperatures
1048707 Easily obtained (low relative cost) 1048707 Magnetic
1048707 Easily alloyed or heat treated for special operations
1048707 Easily repaired
1048707 Good fire resistance
1048707 Behaviour is well understood
Alumunium Alloy
1048707 Light weight 1048707 Poor fatigue properties
1048707 Corrosion resistant 1048707 Poor performance in fire
1048707 Easily formed1048707 Low melting point and softening temperature
1048707 Easily fabricated 1048707 High relative cost
1048707 Readily available 1048707 Strength and stiffness less than steel
1048707 Ductile
1048707 Non magnetic
FRP
1048707 Low magnetic properties
1048707 Low electrical conductivity (glass- reinforced plastics)
1048707 Resistance to corrosion
1048707 Resistance to rot and marine growth
1048707 Relatively high sonar transparency
1048707 Good strength to weight ratio
1048707 Good fatigue properties
1048707 Maintenance of properties at low temperatures
1048707 Availability
1048707 Can be manufactured to near net-shape
1048707 Stiffness and strength can be tailored to structural requirements
1048707 Excellent thermal insulation
1048707 Light weight
STEEL vs ALUMUNIUM vs COMPOSITES
Source
1Maritime Platforms Division Aeronautical and
Maritime Research Laboratory (Seref Aksu
Stuart Cannon Craig Gardiner and Matthew
Gudze
2 Metal Corrosion can be defined as the
destructive attack of a metal through interaction
with its environment
(httpwwwcorrosionistcomCorrosion_Fundament
alhtm)
28
Serat rarr penguat
Polimer matriks rarr pengikat
bull Sifat mekanik yang cukup baik
bull Viskositas dan temperatur pengerjaan rendah rarr mudah
dimanufaktur
bull Ketahanan korosi yang baik
bull Media perpindahan gaya rarr distribusi beban dari serat ke serat
bull Ulet rarr Melindungi serat yang getas
bull Size effect rarr Kekuatan dan kekakuan sangat tinggi
bull Aspect ratio (ld) tinggi rarr luas permukaan besar
bull Fleksibel rarr variasi teknik manufaktur
bull Serat dapat diatur sesuai dengan arah pembebanan
29
Advantages Polimer Composites
Kekuatan dan kekakuan spesifik yang tinggi FRCP vs material lain rarr kompetitif jika berat dipertimbangkan
Material Berat jenis
r (kgm3)
Kekakuan
E (GPa)
Kekuatan
tarik su
(MPa)
Kekakuan
spesifik
Er
Kekuatan
spesifik sur
Baja 7800 208 400 27 005
Aluminium 2700 70 200 259 007
Nylon 1100 25 80 23 007
Beton 2400 40 20 166 0008
Random
FRPC
1800 20 300 111 0006
Alligned FRPC
( serat)
1600 200 1500 125 094
Alligned FRCP
( serat)
1600 3 50 19 0001
Tensile Strength amp Modulus of Common Structural Materials
Densities of Common Structural Materials
Specific Tensile Strength amp Modulus of Common Structural Materials
Typical Properties of Common Structural Materials
Kesimpulan COMPOSITES = RINGAN amp KUAT
Jadi secara keseluruhan kekuatan composites
ditentukan oleh
1 Kekuatan amp Sifat Fiber
2 Kekuatan amp Sifat Resin
3 Fraksi Rasio Perbandingan Volume Fiber
dan Resin dalam Composites
4 Geometri dan Orientasi Arah Fiber dalam
Composites
PRODUKSI ANAK NEGERI
Proses Produksi Kain Fiberglass
Biji Kaca Benang Benang Kaca Kain Fiberglass
PROSES MATERIAL
Glass Beads
Glass Fiber Glass Roving YarnGlass Fabric
Proses Produksi Kain Fiberglass
Biji Kaca Benang Benang Kaca Kain Fiberglass
Glass Beads
Glass Fiber Glass Roving YarnGlass Fabric
PROSES MATERIAL
Benang Kaca Potongan Serat Kaca Chopped Strand Mat
CSM - Chopped Strand Mat
chopped binder
Produk Fiberglass Generasi Pertama
Bahan Pengikat
Senyawa Pada Resin
Glass Roving Yarn Chopped Strand
JENIS FIBERGLASS
Benang Kaca Woven Roving
WR - Woven Roving
Tenun Weaving
Produk Fiberglass Generasi Kedua
Glass Roving Yarn
JENIS FIBERGLASS
Multiaxial
MAX - Multiaxial
warp knitting
Produk Fiberglass Generasi Ketiga
Benang Kaca
Glass Roving Yarn
JENIS FIBERGLASS
MAX - Multiaxial Fabric
Fleece (optional)
Lapisan
MULTIAXIAL PROSES
Karakteristik CSM
bull Glass Content 30
bull Resin Content 70
bull Tensile Force
Chopped Strand Mat
JENIS FIBERGLASS
Karakteristik Woven Roving
bull Glass Content 45
bull Resin Content 55
Woven Roving
Resin
|
|
|
|
|
|
|
|
|
|
|
|
|
|
bull Kekuatan Tarik
JENIS FIBERGLASS
No Resin Rich Area
Karakteristik Multiaxial
bull Glass Content 60
bull Resin Content 40
Produk Fiberglass Ketiga MULTIAXIAL
JENIS FIBERGLASS
Perbedaan Woven Roving dan Multiaxial ndash Tampak Samping
JENIS FIBERGLASS
WR FRP
8 Ply WR 800
8 Ply CSM 450
Glass Weight 1 kg
Composite Weight 15kgm2
CSM FRP
22 Ply CSM 450
Glass Weight 1 kg
Composite Weight 18 kgm2
MULTIAXIAL FRP
13 Ply DB 800
Glass Weight 1 kg
Composite Weight
13 kgm2
JENIS FIBERGLASS
Multiaxial
FRP
Woven Roving
FRP
Chopped Strands Mat FRP
MULTIAXIAL
FAKTA
TEBAL BUKAN BERARTI KUAT
UNSUR MATRIX (RESIN)
TIDAK ADA KEKUATAN
ldquoMore than 50 of the glass fibers used for reinforcement is
E-glassrdquo
KarakteristikKekuatan
CSM WR MAX
Kekuatan Tarik 175 MPa 250 MPa 425 MPa
CSM 142
WR 70
KEKUATAN TARIK
Properties CSM Lamination WR Lamination MAX Lamination
Fabric Weight (kgm2) 1 1 1
Composite Weight (kgm2) 18 15 13
Resin usage (kgm2) 15 1 08
Amount of Fabric 22 Ply 16 Ply 13 Ply
Thickness 15 mm 12 mm 10 mm
Tensile Strength (Mpa) 125 1796 400
Tensile Strength (Nmmsup2) 28463 30958 4576
Processing Time High Med Low
Labour Cost High Med Low
MULTIAXIAL
Total Penggunaan Resin -51
Total Berat Kapal -40
Kekuatan Bangunan Kapal +59
Efisiensi Tenaga Kerja
Waktu Pengerjaan Lebih Cepat
KEUNGGULAN MATERIAL
Resapan Resin Lebih Baik amp Merata
Lapisan Lebih Sedikit
Meningkatkan Kekuatan Kapal
KEUNGGULAN MATERIAL
TRIAXIAL
DBL series DBT series
BIAXIAL
LT series DB series
UNIDIRECTIONAL
L series T series
QUADRIAXIAL
DBLT series
JENIS MULTIAXIAL
UNIDIRECTIONAL
DCMU 900 E ndash
KHUSUS UNTUK MEMPERKUAT BENDING KAPAL
PEMASANGAN KHUSUS PADA KEEL DAN TULANGAN
JENIS MULTIAXIAL UNTUK KAPAL
TRIAXIAL
DBL 600 ndash
APLIKASI PADA INDUSTRI PENERBANGAN
PEMASANGAN KHUSUS PADA
SAMBUNGAN BADAN DAN SAYAP
PESAWAT
JENIS MULTIAXIAL UNTUK PESAWAT
QUADRAXIAL
DBLT 800 ndash
APLIKASI PADA INDUSTRI ENERGI
DITERAPKAN UNTUK KEBUTUHAN PEMBANGKIT
LISTRIK ENERGI ANGIN
MULTIAXIAL UNTUK ENERGI
INDUSTRI KIMIA OLAHRAGA AUTOMOTIF
MULTIAXIAL UNTUK INDUSTRI LAINNYA
COMPOSITES
GUNAKAN MATERIAL FIBERGLASS
YANG SUDAH DISERTIFIKASI
BKI
FIBERGLASS UNTUK PEMBANGUNAN BAKAP
PERATURAN MENTERI PERHUBUNGAN
NOMOR PM 7 TAHUN 2013
TENTANG KEWAJIBAN KLASIFIKASI BAGI KAPAL BERBENDERA INDONESIA
PADA BADAN KLASIFIKASI
BADAN SERTIFIKASI MARITIM
Biro Klasifikasi IndonesiaDet Norske Veritas Germanischer Lloyds
PERATURAN BKI
Untuk Kapal Non-Metal
2006
PERSYARATAN MINIMUM
kekuatan material yang
harus digunakan
untuk membangun
Kapal Fiberglass
PEMBESARAN
Table 21
FIBERGLASS TRIAXIS COMPOSITES
TELAH BERSERTIFIKASI BKI
Biro Klasifikasi Indonesia
65
TEKNIK MANUFAKTUR
COMPOSITES
Wet hand lay-up
1) Peletakan
Dry Reinforcement
bull Dry reinforcement dan resin (+ katalis) ditaruh pada permukaan cetakan
2) Pemasukanpenekanan resin
bull Resin ditekan untuk meng-impregnasi serat dengan menggunakan rol
3) Pengulangan proses untuk lapisan lain
bull Beberapa lapisan dapat ditambahkan secara bertahap
4) Resin curing
bull Reaksi dimulai komponen dilepaskan setelah komponen mengeras
(fully cured)
Wet hand lay-up
Manufaktur komponen dapat dikerjakan dengan menggunakan beberapa lapis komposit
dengan memperhatikan kompatibilitas material dan tahapan curing Modifikasi proses dapat
dilakukan seperti
Vacuum bagging
setelah lay-up
Glass Roving
Bulk Resin
Catalyst
3) De-molding
2) Resin Cure
bull Curing dimulai dan komponen dilepaskan setelah pengerasan selesai
bull Serat gelas resin dan katalis dimasukkan kedalam spray gun
1) Spray-up
bull Campuran disemprotkan pada permukaan cetakan
Spray-up
69
Penyemprotan bakal komponen
Komponen
dilepaskan
dari cetakan
Full dispensing
system Chopper Roving
Atomised resin
and catalyst
Spray-up
Prepreg
1) LaminateAssembly 5) De-molding
3) Resin Melts Layup Consolidates
bull Prepreg serat yang sudah diimpregnasi oleh resin+katalis dalam kondisi padat
bull Lapisan prepreg digunting sesuai bentuk yang diinginkan kemudian diletakkan pada permukaan cetakan
sesuai bentuk komponen yang diinginkan Lay-up mudah dilakukan karena sifat ldquotackynessrdquo dari prepreg
2) Applied Vacuum Pressure and Heat
bull Tekanan dan panas diberikan resin mencair terjadi konsolidasi pada komponen
4) Resin Cures
bull Temperatur dinaikkan untuk memulai curing
Prepreg
Variasi proses Autoclave
Komponen dalam
vacuum-bag
bull Campuran resin (+katalis) dan chopped glass strands diperoleh dalam bentuk premixed compound Bulk molding
Compound (BMC) dalam bentuk adonan atau Sheet molding Compound (SMC) dalam bentuk lembaran
bull Ketika panas dan tekanan diberikan oleh cetakan compound mengalir sesuai bentuk komponen yang diinginkan
1) Placement of Charge
5) De-molding3) Squeeze to final dimensions
2) Mould Closure4) Resin Cure
bull Curing dimulai komponen dilepaskan setelah terjadi pengerasan yang cukup
Compression Molding
bull Preform atau dry reinforcement dimasukkan kedalam cetakan sesuai dengan bentuk komponen yang
diinginkan
bull Resin mengalir dengan penekanan atau pem-vakuman dan meng-impregnasi preform dan
mendorongmengeluarkan udara yang ada dalam preform
1) Preform Manufacture
2) Preform Compression
5) De-molding3) Resin Injection
4) Resin Cure
bull Curing terjadi cetakan dibuka setelah terjadi pengerasan yang mencukupi
Liquid Molding (RTM VARI VARTM)
Pultrusion
bull Dry roving or fabrics ditarik melalui bak berisi
campuran resin dan katalis
bull Campuran yang basah ditarik melalui cetakan
bull Sisa resin keluar cetakan
bull Pemanasan dilakukan untuk proses curing
bull Pendinginan dilakukan untuk mempercepat siklus
produksi
Cut-off
Cooling
Die sections
Resin bath
Fibre creel
Filament Winding
bull Dry roving ditarik melalui bak berisi campuran resin dan katalis
bull Wet roving digulungkan dalam keadaan tegang kepada mandrel
bull Kontrol mekanik dari pembawa serat mengatur orientasi peletakan serat pada
mandrel
INDUSTRI COMPOSITES
AEROSPACE
HISTORY
1950 ndash Boeing
1960 ndash F14 Tomcat
1981 ndash AV-8B Harrier
Source
Low-Cost Composite Materials and Structures for Aircraft Applications
httpwwwreinforcedplasticscom
httpwwwcentennialofflightgovessayEvolution_of_TechnologycompositesTech40htm
Automotive
Composite material is used in a number of applications in the automotive
industry due to its temperature resistance rigidity and fatigue strength
The benefits of using composites include greater fuel efficiency
corrosion resistance light weight and strength Composites also provide
a low-cost way to help keep designs looking fresh
Composites are used in
- interior parts (cockpit trimming seats instrument panels)
- exterior structure (body panels openings underbody frontrear
modules)
- engine compartment and fuelmechanical area parts (axles and
suspensions fuel and exhaust systems)
- electrical and electronic components
Lamborghinis Sesto Element carbon fiber
ldquoFat men cannot run as fast as thin men but we build most of our vehicles as though dead-weight fat increased speedhellip I cannot
imagine where the delusion that weight means strength
came fromhelliprdquo mdashHenry Ford
The mix of automotive materials is changing showing a boost for FRP in helping original
equipment manufacturers meet fuel economy and emissions challenges
(Source 2011 DuPont AutomotiveSAE survey of design engineers performed by Signet Research Inc)
Source
httpwwwtoraycomcsrhighlight2009hig_001_01html
The MonoCell tub for the McLaren MP4-12C supercar is moulded as a single
piece and weighs less than 80 kg (176 lbs)
COMPOSITES IN MARINE
TRIMARAN BOAT
AMERICA NAVYINDONESIAN NAVY
Visby Class corvette
Total length is 72 meters
The beam is 1040 meters
The displacement is 600 metric tones
fully equipped the worlds largest CRP
construction
The design of the Visby aims to minimize
the optical and infrared signature above
water acoustic and hydroa coustic
signature underwater electrical potential
and magnetic signature pressure signature
radar cross section and actively emitted
signals
A stealth corvette of the YS 2000 design
has a detection range of 13km in rough
seas and 22km in calm sea without
jamming In a jammed environment the
Visby would be detected at a range of 8km
in rough sea and 11km in calm sea
The material provides high strength and
rigidity low weight good shock resistance
low radar and magnetic signature
1996
Visby is a class of stealth corvettes for the Swedish Navy
ldquoReduced 50 of a Conventional Steelrdquo
Source
Hull Construction with composite materials for ships over 100m in length 2002
Massachusetts Institute of Technology
httpwwwnaval-technologycomprojectsvisby
YACHTS
KAL YUDISTIRAMARATHON 100 ADMIRAL YACHT
LOA 3050 MWidth 6 MFuel Tank 8000 LWater Tank 3000 LIce Box 500 LAccommodation Max 35 Personnel
2 x CATERPILLAR 3412E 1200 HPMARINE DIESEL ENGINE
PC 40 ndash KRI Krait 827Department of Indonesian Navy
LOA 40 MWidth 73 MPower 190Weapon Twin Cannon Barrels
127 mm Heavy Machine GunSpeed Knot 25 KnotDisplacement 105 tonAccommodation 23 personnel
PATROL BOAT
Rigid Inflatable BoatPATROL BOAT
Yachts
36m Luxury Yacht Moonraker
36m Luxury Yacht GoldenEye
50m Luxury Yacht Casino
Royale
45m Luxury Yacht Seashaw
Boat Parts
Barovans for Seismic Sweep
Centrifugal Liftfan House for Surface Effect
Ships
Composite Boat PropellersRTM
Deckhouses for Pilot Boats
Fairing Parts for Submarines
Flybridges for Motor yachts
Light Weight Gangway
MTB Launcher Mock-up
Pleasure Boats
12m Sailboat
12m Sail-Catamaranone-off
Canoes
Dragonfly 1000Catamaran Sailboat
Fantasy 37Sailboat
Farr 60Luxury Sailboat
EurodingyOlympic Dingy Class for
Woman
Hydrolift F23 Racing Boats
Kajacs
Najad 42Sailboat
Najad 520Sailboat
Najad 441Sailboat
Najad 391Sailboat
Nordwest 900Motorboat
Nordwest 1100Motorboat
Quatro 44Motorboat
Racemaster Competition Boats
Storebro 420
Storebro 345
Sweden Yacht 370Sailboat
Sweden Yacht 69Sailboat
Windy 41Motorboat
X-632Sailboat
X-362Sailboat
Commercial Boats
175m High Speed AmbulancePassenger Boat
19m High Speed Passenger Boat
20m High Speed Passenger Boat
364m Surface Effect Passenger Ship
45m Surface Effect Passenger Ship
120m Hull Structural Parts HSSS Catamaran Ferry
APPENDIX
Marine Vessel
1188m Fast Attack Vessel FMV 90 E
20m SAV-Surface Auxiliary Vessels
34m Personnel TransportCoast Guard Vessel
40ft Experimental SES
40m Landsort-Class Mine Hunters
54m Mine Counter Measure Vehicles SES
74m Coastal Patrol Boats
Fishing Boats
30 GT
12 GT
10 GT
5 GT
WISEWings In Surface Effect
HOVERCRAFT
Designed specifically for the tourist and transport industries the
Pioneer Mk3 hovercraft is amphibious and comfortably seats 25
passengers plus 1-crew The air-conditioned cabin allows for
maximum visibility for all aboard The Pioneer Mk3 is robust and
dynamic in its performance
Commercial hovercraft
Mk3 AirLift Hovercraft - 1215m
Power is economicaly provided by one Deutz diesel engine of
330kW (442hp) to cruise easily at 40 knots with much higher
speeds available according to the surface conditions The hull is
manufactured from fibreglassPVC foam composite sandwich
the windows are glass and the skirt is urethane coated nylon A
Military version is available with increased payload and systems
redundancy Power for the Military version comes from two Steyr
diesel engines with a total installed power of 320kW (429hp) All
transmission electrical hydraulic and air systems are duplicated
for maximum redundancy The increased performance of the
Military version comes from the reduced engine weight of the twin
Steyr installation cf the Deutz installation
Source
httpwwwnauticexpocomprodairlift-hovercraftcommercial-hovercrafts-25251-142868html
HOVERFLIGHT
BALLISTIC amp UNIT DEFENCED
Triaxis Composites Collaboration with Institute of Aeronautics and Space in the development of Missile Nose Cone
Polymer composites is the evolution of the military defence
Thin steel was the helmet material of
WWII and remained the principal material until around the 1980rsquos
The advantages of using steel
included a simple technology for manufacture of the helmets low cost and reasonably good
impact protection However these helmets were found to provide only marginal protection
against fragments
During the Vietnam War the US Army experimented with fiber-reinforced inserts in the
helmets These inserts improved ballistic protection but at the same time added weight and
reduced the air space between the head and the helmet
By the early part of the 1980rsquos the US military had developed the first all-composite
100 fiber-reinforced helmet This development resulted in even better ballistic protection
without altering the weight of the helmet Other improvements included better head coverage and
more space for ventilation
Source
Composites Armor - A difficult but huge market
by A Brent Strong Brigham Young University
MILITARY VEHICLES
HIGH SPEED TRAIN SHINKANSEN
Advanced Composites provide lightweight solutions for railway vehicles
saving as much as 50-80 of the weight compared with traditional
components
A lower overall weight translates into less stress faster acceleration and
higher speeds as well as reduced starting and stopping inertia Today
these are important criteria in global high-speed and metropolitan
railway projects
Fire smoke and toxic fumes are key safety criteria for interior
components of railway carriages Any material selected for an interior
component must meet international fire retardant standards
for Rail Interiors and Exteriors
Ceiling Panels Stairs
Seating Vestibules
Window Panels Door Pillars
Partition WallsDiffusers
Gangway and Cabinet Panels Cabin and
Desk panels
Door Pillars Lavatory Modules (standard and
Front and Rear EndsRoof Panels
Nose Cones Under Fairings
Source
httpwwwpctaerail_compositesphp
101
SKY BUS
2009
Europe is the world leader in offshore wind with
828 wind turbines and a cumulative capacity of 2056 MW spread across 38 offshore wind farms in 9
European countries
The UK and Denmark are the current leaders with a 44 and 30 share respectively In 2009
five countries built new offshore wind farms
UK (284 MW)
Demark (230 MW)
Sweden (30 MW)
Germany (30 MW)
Norway (23 MW)
2010
Asia leads the growth in global wind power which grew 358 GW in 2010 bringing
total global capacity to 1944 GW ndash up 225 from 2009
the Global Wind Energy Council (GWEC)
Asia accounted for 19 GW of new global wind power installations driven by China which installed 165
GW
ldquoChina now has 423 GW of wind powerrdquo
ldquoThis puts China firmly on a path to reach 200 GW of installed wind power by 2020 At the same
time China has become the worldrsquos largest producer of wind energy equipmentrdquo
Source
httpwwwreinforcedplasticscomview15655asia-leads-global-wind-power-growth
httpimgdeusmcomdesignnews288288605-Sandia_Sizes_up_Wind_Turbine_Blade_Design_C_largegif
WIND ENERGY
Marine Current Turbines
Source
httpwwwsiemenscompressenpressreleasepress=enpressrelease2011solar-hydroex201111005htm
httpwwwmarineturbinescom
A commercial marine current turbine consists of
two rotors which are fixed on a structure within the
sea current The twin rotors rotate with the
movement of the tidal flow and the blades pitch
through 180 degrees to optimally track tidal current
(Press picture Marine Current Turbines)
Wave Star Energys Multi-point Absorber
CFRP COLUMN REINFORCEMENT
INDUSTRIAL TANKS
107
INDUSTRIAL PIPES
PRESSURE TANKS
109
ldquoLetrsquos Make with Compositesrdquo
28
Serat rarr penguat
Polimer matriks rarr pengikat
bull Sifat mekanik yang cukup baik
bull Viskositas dan temperatur pengerjaan rendah rarr mudah
dimanufaktur
bull Ketahanan korosi yang baik
bull Media perpindahan gaya rarr distribusi beban dari serat ke serat
bull Ulet rarr Melindungi serat yang getas
bull Size effect rarr Kekuatan dan kekakuan sangat tinggi
bull Aspect ratio (ld) tinggi rarr luas permukaan besar
bull Fleksibel rarr variasi teknik manufaktur
bull Serat dapat diatur sesuai dengan arah pembebanan
29
Advantages Polimer Composites
Kekuatan dan kekakuan spesifik yang tinggi FRCP vs material lain rarr kompetitif jika berat dipertimbangkan
Material Berat jenis
r (kgm3)
Kekakuan
E (GPa)
Kekuatan
tarik su
(MPa)
Kekakuan
spesifik
Er
Kekuatan
spesifik sur
Baja 7800 208 400 27 005
Aluminium 2700 70 200 259 007
Nylon 1100 25 80 23 007
Beton 2400 40 20 166 0008
Random
FRPC
1800 20 300 111 0006
Alligned FRPC
( serat)
1600 200 1500 125 094
Alligned FRCP
( serat)
1600 3 50 19 0001
Tensile Strength amp Modulus of Common Structural Materials
Densities of Common Structural Materials
Specific Tensile Strength amp Modulus of Common Structural Materials
Typical Properties of Common Structural Materials
Kesimpulan COMPOSITES = RINGAN amp KUAT
Jadi secara keseluruhan kekuatan composites
ditentukan oleh
1 Kekuatan amp Sifat Fiber
2 Kekuatan amp Sifat Resin
3 Fraksi Rasio Perbandingan Volume Fiber
dan Resin dalam Composites
4 Geometri dan Orientasi Arah Fiber dalam
Composites
PRODUKSI ANAK NEGERI
Proses Produksi Kain Fiberglass
Biji Kaca Benang Benang Kaca Kain Fiberglass
PROSES MATERIAL
Glass Beads
Glass Fiber Glass Roving YarnGlass Fabric
Proses Produksi Kain Fiberglass
Biji Kaca Benang Benang Kaca Kain Fiberglass
Glass Beads
Glass Fiber Glass Roving YarnGlass Fabric
PROSES MATERIAL
Benang Kaca Potongan Serat Kaca Chopped Strand Mat
CSM - Chopped Strand Mat
chopped binder
Produk Fiberglass Generasi Pertama
Bahan Pengikat
Senyawa Pada Resin
Glass Roving Yarn Chopped Strand
JENIS FIBERGLASS
Benang Kaca Woven Roving
WR - Woven Roving
Tenun Weaving
Produk Fiberglass Generasi Kedua
Glass Roving Yarn
JENIS FIBERGLASS
Multiaxial
MAX - Multiaxial
warp knitting
Produk Fiberglass Generasi Ketiga
Benang Kaca
Glass Roving Yarn
JENIS FIBERGLASS
MAX - Multiaxial Fabric
Fleece (optional)
Lapisan
MULTIAXIAL PROSES
Karakteristik CSM
bull Glass Content 30
bull Resin Content 70
bull Tensile Force
Chopped Strand Mat
JENIS FIBERGLASS
Karakteristik Woven Roving
bull Glass Content 45
bull Resin Content 55
Woven Roving
Resin
|
|
|
|
|
|
|
|
|
|
|
|
|
|
bull Kekuatan Tarik
JENIS FIBERGLASS
No Resin Rich Area
Karakteristik Multiaxial
bull Glass Content 60
bull Resin Content 40
Produk Fiberglass Ketiga MULTIAXIAL
JENIS FIBERGLASS
Perbedaan Woven Roving dan Multiaxial ndash Tampak Samping
JENIS FIBERGLASS
WR FRP
8 Ply WR 800
8 Ply CSM 450
Glass Weight 1 kg
Composite Weight 15kgm2
CSM FRP
22 Ply CSM 450
Glass Weight 1 kg
Composite Weight 18 kgm2
MULTIAXIAL FRP
13 Ply DB 800
Glass Weight 1 kg
Composite Weight
13 kgm2
JENIS FIBERGLASS
Multiaxial
FRP
Woven Roving
FRP
Chopped Strands Mat FRP
MULTIAXIAL
FAKTA
TEBAL BUKAN BERARTI KUAT
UNSUR MATRIX (RESIN)
TIDAK ADA KEKUATAN
ldquoMore than 50 of the glass fibers used for reinforcement is
E-glassrdquo
KarakteristikKekuatan
CSM WR MAX
Kekuatan Tarik 175 MPa 250 MPa 425 MPa
CSM 142
WR 70
KEKUATAN TARIK
Properties CSM Lamination WR Lamination MAX Lamination
Fabric Weight (kgm2) 1 1 1
Composite Weight (kgm2) 18 15 13
Resin usage (kgm2) 15 1 08
Amount of Fabric 22 Ply 16 Ply 13 Ply
Thickness 15 mm 12 mm 10 mm
Tensile Strength (Mpa) 125 1796 400
Tensile Strength (Nmmsup2) 28463 30958 4576
Processing Time High Med Low
Labour Cost High Med Low
MULTIAXIAL
Total Penggunaan Resin -51
Total Berat Kapal -40
Kekuatan Bangunan Kapal +59
Efisiensi Tenaga Kerja
Waktu Pengerjaan Lebih Cepat
KEUNGGULAN MATERIAL
Resapan Resin Lebih Baik amp Merata
Lapisan Lebih Sedikit
Meningkatkan Kekuatan Kapal
KEUNGGULAN MATERIAL
TRIAXIAL
DBL series DBT series
BIAXIAL
LT series DB series
UNIDIRECTIONAL
L series T series
QUADRIAXIAL
DBLT series
JENIS MULTIAXIAL
UNIDIRECTIONAL
DCMU 900 E ndash
KHUSUS UNTUK MEMPERKUAT BENDING KAPAL
PEMASANGAN KHUSUS PADA KEEL DAN TULANGAN
JENIS MULTIAXIAL UNTUK KAPAL
TRIAXIAL
DBL 600 ndash
APLIKASI PADA INDUSTRI PENERBANGAN
PEMASANGAN KHUSUS PADA
SAMBUNGAN BADAN DAN SAYAP
PESAWAT
JENIS MULTIAXIAL UNTUK PESAWAT
QUADRAXIAL
DBLT 800 ndash
APLIKASI PADA INDUSTRI ENERGI
DITERAPKAN UNTUK KEBUTUHAN PEMBANGKIT
LISTRIK ENERGI ANGIN
MULTIAXIAL UNTUK ENERGI
INDUSTRI KIMIA OLAHRAGA AUTOMOTIF
MULTIAXIAL UNTUK INDUSTRI LAINNYA
COMPOSITES
GUNAKAN MATERIAL FIBERGLASS
YANG SUDAH DISERTIFIKASI
BKI
FIBERGLASS UNTUK PEMBANGUNAN BAKAP
PERATURAN MENTERI PERHUBUNGAN
NOMOR PM 7 TAHUN 2013
TENTANG KEWAJIBAN KLASIFIKASI BAGI KAPAL BERBENDERA INDONESIA
PADA BADAN KLASIFIKASI
BADAN SERTIFIKASI MARITIM
Biro Klasifikasi IndonesiaDet Norske Veritas Germanischer Lloyds
PERATURAN BKI
Untuk Kapal Non-Metal
2006
PERSYARATAN MINIMUM
kekuatan material yang
harus digunakan
untuk membangun
Kapal Fiberglass
PEMBESARAN
Table 21
FIBERGLASS TRIAXIS COMPOSITES
TELAH BERSERTIFIKASI BKI
Biro Klasifikasi Indonesia
65
TEKNIK MANUFAKTUR
COMPOSITES
Wet hand lay-up
1) Peletakan
Dry Reinforcement
bull Dry reinforcement dan resin (+ katalis) ditaruh pada permukaan cetakan
2) Pemasukanpenekanan resin
bull Resin ditekan untuk meng-impregnasi serat dengan menggunakan rol
3) Pengulangan proses untuk lapisan lain
bull Beberapa lapisan dapat ditambahkan secara bertahap
4) Resin curing
bull Reaksi dimulai komponen dilepaskan setelah komponen mengeras
(fully cured)
Wet hand lay-up
Manufaktur komponen dapat dikerjakan dengan menggunakan beberapa lapis komposit
dengan memperhatikan kompatibilitas material dan tahapan curing Modifikasi proses dapat
dilakukan seperti
Vacuum bagging
setelah lay-up
Glass Roving
Bulk Resin
Catalyst
3) De-molding
2) Resin Cure
bull Curing dimulai dan komponen dilepaskan setelah pengerasan selesai
bull Serat gelas resin dan katalis dimasukkan kedalam spray gun
1) Spray-up
bull Campuran disemprotkan pada permukaan cetakan
Spray-up
69
Penyemprotan bakal komponen
Komponen
dilepaskan
dari cetakan
Full dispensing
system Chopper Roving
Atomised resin
and catalyst
Spray-up
Prepreg
1) LaminateAssembly 5) De-molding
3) Resin Melts Layup Consolidates
bull Prepreg serat yang sudah diimpregnasi oleh resin+katalis dalam kondisi padat
bull Lapisan prepreg digunting sesuai bentuk yang diinginkan kemudian diletakkan pada permukaan cetakan
sesuai bentuk komponen yang diinginkan Lay-up mudah dilakukan karena sifat ldquotackynessrdquo dari prepreg
2) Applied Vacuum Pressure and Heat
bull Tekanan dan panas diberikan resin mencair terjadi konsolidasi pada komponen
4) Resin Cures
bull Temperatur dinaikkan untuk memulai curing
Prepreg
Variasi proses Autoclave
Komponen dalam
vacuum-bag
bull Campuran resin (+katalis) dan chopped glass strands diperoleh dalam bentuk premixed compound Bulk molding
Compound (BMC) dalam bentuk adonan atau Sheet molding Compound (SMC) dalam bentuk lembaran
bull Ketika panas dan tekanan diberikan oleh cetakan compound mengalir sesuai bentuk komponen yang diinginkan
1) Placement of Charge
5) De-molding3) Squeeze to final dimensions
2) Mould Closure4) Resin Cure
bull Curing dimulai komponen dilepaskan setelah terjadi pengerasan yang cukup
Compression Molding
bull Preform atau dry reinforcement dimasukkan kedalam cetakan sesuai dengan bentuk komponen yang
diinginkan
bull Resin mengalir dengan penekanan atau pem-vakuman dan meng-impregnasi preform dan
mendorongmengeluarkan udara yang ada dalam preform
1) Preform Manufacture
2) Preform Compression
5) De-molding3) Resin Injection
4) Resin Cure
bull Curing terjadi cetakan dibuka setelah terjadi pengerasan yang mencukupi
Liquid Molding (RTM VARI VARTM)
Pultrusion
bull Dry roving or fabrics ditarik melalui bak berisi
campuran resin dan katalis
bull Campuran yang basah ditarik melalui cetakan
bull Sisa resin keluar cetakan
bull Pemanasan dilakukan untuk proses curing
bull Pendinginan dilakukan untuk mempercepat siklus
produksi
Cut-off
Cooling
Die sections
Resin bath
Fibre creel
Filament Winding
bull Dry roving ditarik melalui bak berisi campuran resin dan katalis
bull Wet roving digulungkan dalam keadaan tegang kepada mandrel
bull Kontrol mekanik dari pembawa serat mengatur orientasi peletakan serat pada
mandrel
INDUSTRI COMPOSITES
AEROSPACE
HISTORY
1950 ndash Boeing
1960 ndash F14 Tomcat
1981 ndash AV-8B Harrier
Source
Low-Cost Composite Materials and Structures for Aircraft Applications
httpwwwreinforcedplasticscom
httpwwwcentennialofflightgovessayEvolution_of_TechnologycompositesTech40htm
Automotive
Composite material is used in a number of applications in the automotive
industry due to its temperature resistance rigidity and fatigue strength
The benefits of using composites include greater fuel efficiency
corrosion resistance light weight and strength Composites also provide
a low-cost way to help keep designs looking fresh
Composites are used in
- interior parts (cockpit trimming seats instrument panels)
- exterior structure (body panels openings underbody frontrear
modules)
- engine compartment and fuelmechanical area parts (axles and
suspensions fuel and exhaust systems)
- electrical and electronic components
Lamborghinis Sesto Element carbon fiber
ldquoFat men cannot run as fast as thin men but we build most of our vehicles as though dead-weight fat increased speedhellip I cannot
imagine where the delusion that weight means strength
came fromhelliprdquo mdashHenry Ford
The mix of automotive materials is changing showing a boost for FRP in helping original
equipment manufacturers meet fuel economy and emissions challenges
(Source 2011 DuPont AutomotiveSAE survey of design engineers performed by Signet Research Inc)
Source
httpwwwtoraycomcsrhighlight2009hig_001_01html
The MonoCell tub for the McLaren MP4-12C supercar is moulded as a single
piece and weighs less than 80 kg (176 lbs)
COMPOSITES IN MARINE
TRIMARAN BOAT
AMERICA NAVYINDONESIAN NAVY
Visby Class corvette
Total length is 72 meters
The beam is 1040 meters
The displacement is 600 metric tones
fully equipped the worlds largest CRP
construction
The design of the Visby aims to minimize
the optical and infrared signature above
water acoustic and hydroa coustic
signature underwater electrical potential
and magnetic signature pressure signature
radar cross section and actively emitted
signals
A stealth corvette of the YS 2000 design
has a detection range of 13km in rough
seas and 22km in calm sea without
jamming In a jammed environment the
Visby would be detected at a range of 8km
in rough sea and 11km in calm sea
The material provides high strength and
rigidity low weight good shock resistance
low radar and magnetic signature
1996
Visby is a class of stealth corvettes for the Swedish Navy
ldquoReduced 50 of a Conventional Steelrdquo
Source
Hull Construction with composite materials for ships over 100m in length 2002
Massachusetts Institute of Technology
httpwwwnaval-technologycomprojectsvisby
YACHTS
KAL YUDISTIRAMARATHON 100 ADMIRAL YACHT
LOA 3050 MWidth 6 MFuel Tank 8000 LWater Tank 3000 LIce Box 500 LAccommodation Max 35 Personnel
2 x CATERPILLAR 3412E 1200 HPMARINE DIESEL ENGINE
PC 40 ndash KRI Krait 827Department of Indonesian Navy
LOA 40 MWidth 73 MPower 190Weapon Twin Cannon Barrels
127 mm Heavy Machine GunSpeed Knot 25 KnotDisplacement 105 tonAccommodation 23 personnel
PATROL BOAT
Rigid Inflatable BoatPATROL BOAT
Yachts
36m Luxury Yacht Moonraker
36m Luxury Yacht GoldenEye
50m Luxury Yacht Casino
Royale
45m Luxury Yacht Seashaw
Boat Parts
Barovans for Seismic Sweep
Centrifugal Liftfan House for Surface Effect
Ships
Composite Boat PropellersRTM
Deckhouses for Pilot Boats
Fairing Parts for Submarines
Flybridges for Motor yachts
Light Weight Gangway
MTB Launcher Mock-up
Pleasure Boats
12m Sailboat
12m Sail-Catamaranone-off
Canoes
Dragonfly 1000Catamaran Sailboat
Fantasy 37Sailboat
Farr 60Luxury Sailboat
EurodingyOlympic Dingy Class for
Woman
Hydrolift F23 Racing Boats
Kajacs
Najad 42Sailboat
Najad 520Sailboat
Najad 441Sailboat
Najad 391Sailboat
Nordwest 900Motorboat
Nordwest 1100Motorboat
Quatro 44Motorboat
Racemaster Competition Boats
Storebro 420
Storebro 345
Sweden Yacht 370Sailboat
Sweden Yacht 69Sailboat
Windy 41Motorboat
X-632Sailboat
X-362Sailboat
Commercial Boats
175m High Speed AmbulancePassenger Boat
19m High Speed Passenger Boat
20m High Speed Passenger Boat
364m Surface Effect Passenger Ship
45m Surface Effect Passenger Ship
120m Hull Structural Parts HSSS Catamaran Ferry
APPENDIX
Marine Vessel
1188m Fast Attack Vessel FMV 90 E
20m SAV-Surface Auxiliary Vessels
34m Personnel TransportCoast Guard Vessel
40ft Experimental SES
40m Landsort-Class Mine Hunters
54m Mine Counter Measure Vehicles SES
74m Coastal Patrol Boats
Fishing Boats
30 GT
12 GT
10 GT
5 GT
WISEWings In Surface Effect
HOVERCRAFT
Designed specifically for the tourist and transport industries the
Pioneer Mk3 hovercraft is amphibious and comfortably seats 25
passengers plus 1-crew The air-conditioned cabin allows for
maximum visibility for all aboard The Pioneer Mk3 is robust and
dynamic in its performance
Commercial hovercraft
Mk3 AirLift Hovercraft - 1215m
Power is economicaly provided by one Deutz diesel engine of
330kW (442hp) to cruise easily at 40 knots with much higher
speeds available according to the surface conditions The hull is
manufactured from fibreglassPVC foam composite sandwich
the windows are glass and the skirt is urethane coated nylon A
Military version is available with increased payload and systems
redundancy Power for the Military version comes from two Steyr
diesel engines with a total installed power of 320kW (429hp) All
transmission electrical hydraulic and air systems are duplicated
for maximum redundancy The increased performance of the
Military version comes from the reduced engine weight of the twin
Steyr installation cf the Deutz installation
Source
httpwwwnauticexpocomprodairlift-hovercraftcommercial-hovercrafts-25251-142868html
HOVERFLIGHT
BALLISTIC amp UNIT DEFENCED
Triaxis Composites Collaboration with Institute of Aeronautics and Space in the development of Missile Nose Cone
Polymer composites is the evolution of the military defence
Thin steel was the helmet material of
WWII and remained the principal material until around the 1980rsquos
The advantages of using steel
included a simple technology for manufacture of the helmets low cost and reasonably good
impact protection However these helmets were found to provide only marginal protection
against fragments
During the Vietnam War the US Army experimented with fiber-reinforced inserts in the
helmets These inserts improved ballistic protection but at the same time added weight and
reduced the air space between the head and the helmet
By the early part of the 1980rsquos the US military had developed the first all-composite
100 fiber-reinforced helmet This development resulted in even better ballistic protection
without altering the weight of the helmet Other improvements included better head coverage and
more space for ventilation
Source
Composites Armor - A difficult but huge market
by A Brent Strong Brigham Young University
MILITARY VEHICLES
HIGH SPEED TRAIN SHINKANSEN
Advanced Composites provide lightweight solutions for railway vehicles
saving as much as 50-80 of the weight compared with traditional
components
A lower overall weight translates into less stress faster acceleration and
higher speeds as well as reduced starting and stopping inertia Today
these are important criteria in global high-speed and metropolitan
railway projects
Fire smoke and toxic fumes are key safety criteria for interior
components of railway carriages Any material selected for an interior
component must meet international fire retardant standards
for Rail Interiors and Exteriors
Ceiling Panels Stairs
Seating Vestibules
Window Panels Door Pillars
Partition WallsDiffusers
Gangway and Cabinet Panels Cabin and
Desk panels
Door Pillars Lavatory Modules (standard and
Front and Rear EndsRoof Panels
Nose Cones Under Fairings
Source
httpwwwpctaerail_compositesphp
101
SKY BUS
2009
Europe is the world leader in offshore wind with
828 wind turbines and a cumulative capacity of 2056 MW spread across 38 offshore wind farms in 9
European countries
The UK and Denmark are the current leaders with a 44 and 30 share respectively In 2009
five countries built new offshore wind farms
UK (284 MW)
Demark (230 MW)
Sweden (30 MW)
Germany (30 MW)
Norway (23 MW)
2010
Asia leads the growth in global wind power which grew 358 GW in 2010 bringing
total global capacity to 1944 GW ndash up 225 from 2009
the Global Wind Energy Council (GWEC)
Asia accounted for 19 GW of new global wind power installations driven by China which installed 165
GW
ldquoChina now has 423 GW of wind powerrdquo
ldquoThis puts China firmly on a path to reach 200 GW of installed wind power by 2020 At the same
time China has become the worldrsquos largest producer of wind energy equipmentrdquo
Source
httpwwwreinforcedplasticscomview15655asia-leads-global-wind-power-growth
httpimgdeusmcomdesignnews288288605-Sandia_Sizes_up_Wind_Turbine_Blade_Design_C_largegif
WIND ENERGY
Marine Current Turbines
Source
httpwwwsiemenscompressenpressreleasepress=enpressrelease2011solar-hydroex201111005htm
httpwwwmarineturbinescom
A commercial marine current turbine consists of
two rotors which are fixed on a structure within the
sea current The twin rotors rotate with the
movement of the tidal flow and the blades pitch
through 180 degrees to optimally track tidal current
(Press picture Marine Current Turbines)
Wave Star Energys Multi-point Absorber
CFRP COLUMN REINFORCEMENT
INDUSTRIAL TANKS
107
INDUSTRIAL PIPES
PRESSURE TANKS
109
ldquoLetrsquos Make with Compositesrdquo
29
Advantages Polimer Composites
Kekuatan dan kekakuan spesifik yang tinggi FRCP vs material lain rarr kompetitif jika berat dipertimbangkan
Material Berat jenis
r (kgm3)
Kekakuan
E (GPa)
Kekuatan
tarik su
(MPa)
Kekakuan
spesifik
Er
Kekuatan
spesifik sur
Baja 7800 208 400 27 005
Aluminium 2700 70 200 259 007
Nylon 1100 25 80 23 007
Beton 2400 40 20 166 0008
Random
FRPC
1800 20 300 111 0006
Alligned FRPC
( serat)
1600 200 1500 125 094
Alligned FRCP
( serat)
1600 3 50 19 0001
Tensile Strength amp Modulus of Common Structural Materials
Densities of Common Structural Materials
Specific Tensile Strength amp Modulus of Common Structural Materials
Typical Properties of Common Structural Materials
Kesimpulan COMPOSITES = RINGAN amp KUAT
Jadi secara keseluruhan kekuatan composites
ditentukan oleh
1 Kekuatan amp Sifat Fiber
2 Kekuatan amp Sifat Resin
3 Fraksi Rasio Perbandingan Volume Fiber
dan Resin dalam Composites
4 Geometri dan Orientasi Arah Fiber dalam
Composites
PRODUKSI ANAK NEGERI
Proses Produksi Kain Fiberglass
Biji Kaca Benang Benang Kaca Kain Fiberglass
PROSES MATERIAL
Glass Beads
Glass Fiber Glass Roving YarnGlass Fabric
Proses Produksi Kain Fiberglass
Biji Kaca Benang Benang Kaca Kain Fiberglass
Glass Beads
Glass Fiber Glass Roving YarnGlass Fabric
PROSES MATERIAL
Benang Kaca Potongan Serat Kaca Chopped Strand Mat
CSM - Chopped Strand Mat
chopped binder
Produk Fiberglass Generasi Pertama
Bahan Pengikat
Senyawa Pada Resin
Glass Roving Yarn Chopped Strand
JENIS FIBERGLASS
Benang Kaca Woven Roving
WR - Woven Roving
Tenun Weaving
Produk Fiberglass Generasi Kedua
Glass Roving Yarn
JENIS FIBERGLASS
Multiaxial
MAX - Multiaxial
warp knitting
Produk Fiberglass Generasi Ketiga
Benang Kaca
Glass Roving Yarn
JENIS FIBERGLASS
MAX - Multiaxial Fabric
Fleece (optional)
Lapisan
MULTIAXIAL PROSES
Karakteristik CSM
bull Glass Content 30
bull Resin Content 70
bull Tensile Force
Chopped Strand Mat
JENIS FIBERGLASS
Karakteristik Woven Roving
bull Glass Content 45
bull Resin Content 55
Woven Roving
Resin
|
|
|
|
|
|
|
|
|
|
|
|
|
|
bull Kekuatan Tarik
JENIS FIBERGLASS
No Resin Rich Area
Karakteristik Multiaxial
bull Glass Content 60
bull Resin Content 40
Produk Fiberglass Ketiga MULTIAXIAL
JENIS FIBERGLASS
Perbedaan Woven Roving dan Multiaxial ndash Tampak Samping
JENIS FIBERGLASS
WR FRP
8 Ply WR 800
8 Ply CSM 450
Glass Weight 1 kg
Composite Weight 15kgm2
CSM FRP
22 Ply CSM 450
Glass Weight 1 kg
Composite Weight 18 kgm2
MULTIAXIAL FRP
13 Ply DB 800
Glass Weight 1 kg
Composite Weight
13 kgm2
JENIS FIBERGLASS
Multiaxial
FRP
Woven Roving
FRP
Chopped Strands Mat FRP
MULTIAXIAL
FAKTA
TEBAL BUKAN BERARTI KUAT
UNSUR MATRIX (RESIN)
TIDAK ADA KEKUATAN
ldquoMore than 50 of the glass fibers used for reinforcement is
E-glassrdquo
KarakteristikKekuatan
CSM WR MAX
Kekuatan Tarik 175 MPa 250 MPa 425 MPa
CSM 142
WR 70
KEKUATAN TARIK
Properties CSM Lamination WR Lamination MAX Lamination
Fabric Weight (kgm2) 1 1 1
Composite Weight (kgm2) 18 15 13
Resin usage (kgm2) 15 1 08
Amount of Fabric 22 Ply 16 Ply 13 Ply
Thickness 15 mm 12 mm 10 mm
Tensile Strength (Mpa) 125 1796 400
Tensile Strength (Nmmsup2) 28463 30958 4576
Processing Time High Med Low
Labour Cost High Med Low
MULTIAXIAL
Total Penggunaan Resin -51
Total Berat Kapal -40
Kekuatan Bangunan Kapal +59
Efisiensi Tenaga Kerja
Waktu Pengerjaan Lebih Cepat
KEUNGGULAN MATERIAL
Resapan Resin Lebih Baik amp Merata
Lapisan Lebih Sedikit
Meningkatkan Kekuatan Kapal
KEUNGGULAN MATERIAL
TRIAXIAL
DBL series DBT series
BIAXIAL
LT series DB series
UNIDIRECTIONAL
L series T series
QUADRIAXIAL
DBLT series
JENIS MULTIAXIAL
UNIDIRECTIONAL
DCMU 900 E ndash
KHUSUS UNTUK MEMPERKUAT BENDING KAPAL
PEMASANGAN KHUSUS PADA KEEL DAN TULANGAN
JENIS MULTIAXIAL UNTUK KAPAL
TRIAXIAL
DBL 600 ndash
APLIKASI PADA INDUSTRI PENERBANGAN
PEMASANGAN KHUSUS PADA
SAMBUNGAN BADAN DAN SAYAP
PESAWAT
JENIS MULTIAXIAL UNTUK PESAWAT
QUADRAXIAL
DBLT 800 ndash
APLIKASI PADA INDUSTRI ENERGI
DITERAPKAN UNTUK KEBUTUHAN PEMBANGKIT
LISTRIK ENERGI ANGIN
MULTIAXIAL UNTUK ENERGI
INDUSTRI KIMIA OLAHRAGA AUTOMOTIF
MULTIAXIAL UNTUK INDUSTRI LAINNYA
COMPOSITES
GUNAKAN MATERIAL FIBERGLASS
YANG SUDAH DISERTIFIKASI
BKI
FIBERGLASS UNTUK PEMBANGUNAN BAKAP
PERATURAN MENTERI PERHUBUNGAN
NOMOR PM 7 TAHUN 2013
TENTANG KEWAJIBAN KLASIFIKASI BAGI KAPAL BERBENDERA INDONESIA
PADA BADAN KLASIFIKASI
BADAN SERTIFIKASI MARITIM
Biro Klasifikasi IndonesiaDet Norske Veritas Germanischer Lloyds
PERATURAN BKI
Untuk Kapal Non-Metal
2006
PERSYARATAN MINIMUM
kekuatan material yang
harus digunakan
untuk membangun
Kapal Fiberglass
PEMBESARAN
Table 21
FIBERGLASS TRIAXIS COMPOSITES
TELAH BERSERTIFIKASI BKI
Biro Klasifikasi Indonesia
65
TEKNIK MANUFAKTUR
COMPOSITES
Wet hand lay-up
1) Peletakan
Dry Reinforcement
bull Dry reinforcement dan resin (+ katalis) ditaruh pada permukaan cetakan
2) Pemasukanpenekanan resin
bull Resin ditekan untuk meng-impregnasi serat dengan menggunakan rol
3) Pengulangan proses untuk lapisan lain
bull Beberapa lapisan dapat ditambahkan secara bertahap
4) Resin curing
bull Reaksi dimulai komponen dilepaskan setelah komponen mengeras
(fully cured)
Wet hand lay-up
Manufaktur komponen dapat dikerjakan dengan menggunakan beberapa lapis komposit
dengan memperhatikan kompatibilitas material dan tahapan curing Modifikasi proses dapat
dilakukan seperti
Vacuum bagging
setelah lay-up
Glass Roving
Bulk Resin
Catalyst
3) De-molding
2) Resin Cure
bull Curing dimulai dan komponen dilepaskan setelah pengerasan selesai
bull Serat gelas resin dan katalis dimasukkan kedalam spray gun
1) Spray-up
bull Campuran disemprotkan pada permukaan cetakan
Spray-up
69
Penyemprotan bakal komponen
Komponen
dilepaskan
dari cetakan
Full dispensing
system Chopper Roving
Atomised resin
and catalyst
Spray-up
Prepreg
1) LaminateAssembly 5) De-molding
3) Resin Melts Layup Consolidates
bull Prepreg serat yang sudah diimpregnasi oleh resin+katalis dalam kondisi padat
bull Lapisan prepreg digunting sesuai bentuk yang diinginkan kemudian diletakkan pada permukaan cetakan
sesuai bentuk komponen yang diinginkan Lay-up mudah dilakukan karena sifat ldquotackynessrdquo dari prepreg
2) Applied Vacuum Pressure and Heat
bull Tekanan dan panas diberikan resin mencair terjadi konsolidasi pada komponen
4) Resin Cures
bull Temperatur dinaikkan untuk memulai curing
Prepreg
Variasi proses Autoclave
Komponen dalam
vacuum-bag
bull Campuran resin (+katalis) dan chopped glass strands diperoleh dalam bentuk premixed compound Bulk molding
Compound (BMC) dalam bentuk adonan atau Sheet molding Compound (SMC) dalam bentuk lembaran
bull Ketika panas dan tekanan diberikan oleh cetakan compound mengalir sesuai bentuk komponen yang diinginkan
1) Placement of Charge
5) De-molding3) Squeeze to final dimensions
2) Mould Closure4) Resin Cure
bull Curing dimulai komponen dilepaskan setelah terjadi pengerasan yang cukup
Compression Molding
bull Preform atau dry reinforcement dimasukkan kedalam cetakan sesuai dengan bentuk komponen yang
diinginkan
bull Resin mengalir dengan penekanan atau pem-vakuman dan meng-impregnasi preform dan
mendorongmengeluarkan udara yang ada dalam preform
1) Preform Manufacture
2) Preform Compression
5) De-molding3) Resin Injection
4) Resin Cure
bull Curing terjadi cetakan dibuka setelah terjadi pengerasan yang mencukupi
Liquid Molding (RTM VARI VARTM)
Pultrusion
bull Dry roving or fabrics ditarik melalui bak berisi
campuran resin dan katalis
bull Campuran yang basah ditarik melalui cetakan
bull Sisa resin keluar cetakan
bull Pemanasan dilakukan untuk proses curing
bull Pendinginan dilakukan untuk mempercepat siklus
produksi
Cut-off
Cooling
Die sections
Resin bath
Fibre creel
Filament Winding
bull Dry roving ditarik melalui bak berisi campuran resin dan katalis
bull Wet roving digulungkan dalam keadaan tegang kepada mandrel
bull Kontrol mekanik dari pembawa serat mengatur orientasi peletakan serat pada
mandrel
INDUSTRI COMPOSITES
AEROSPACE
HISTORY
1950 ndash Boeing
1960 ndash F14 Tomcat
1981 ndash AV-8B Harrier
Source
Low-Cost Composite Materials and Structures for Aircraft Applications
httpwwwreinforcedplasticscom
httpwwwcentennialofflightgovessayEvolution_of_TechnologycompositesTech40htm
Automotive
Composite material is used in a number of applications in the automotive
industry due to its temperature resistance rigidity and fatigue strength
The benefits of using composites include greater fuel efficiency
corrosion resistance light weight and strength Composites also provide
a low-cost way to help keep designs looking fresh
Composites are used in
- interior parts (cockpit trimming seats instrument panels)
- exterior structure (body panels openings underbody frontrear
modules)
- engine compartment and fuelmechanical area parts (axles and
suspensions fuel and exhaust systems)
- electrical and electronic components
Lamborghinis Sesto Element carbon fiber
ldquoFat men cannot run as fast as thin men but we build most of our vehicles as though dead-weight fat increased speedhellip I cannot
imagine where the delusion that weight means strength
came fromhelliprdquo mdashHenry Ford
The mix of automotive materials is changing showing a boost for FRP in helping original
equipment manufacturers meet fuel economy and emissions challenges
(Source 2011 DuPont AutomotiveSAE survey of design engineers performed by Signet Research Inc)
Source
httpwwwtoraycomcsrhighlight2009hig_001_01html
The MonoCell tub for the McLaren MP4-12C supercar is moulded as a single
piece and weighs less than 80 kg (176 lbs)
COMPOSITES IN MARINE
TRIMARAN BOAT
AMERICA NAVYINDONESIAN NAVY
Visby Class corvette
Total length is 72 meters
The beam is 1040 meters
The displacement is 600 metric tones
fully equipped the worlds largest CRP
construction
The design of the Visby aims to minimize
the optical and infrared signature above
water acoustic and hydroa coustic
signature underwater electrical potential
and magnetic signature pressure signature
radar cross section and actively emitted
signals
A stealth corvette of the YS 2000 design
has a detection range of 13km in rough
seas and 22km in calm sea without
jamming In a jammed environment the
Visby would be detected at a range of 8km
in rough sea and 11km in calm sea
The material provides high strength and
rigidity low weight good shock resistance
low radar and magnetic signature
1996
Visby is a class of stealth corvettes for the Swedish Navy
ldquoReduced 50 of a Conventional Steelrdquo
Source
Hull Construction with composite materials for ships over 100m in length 2002
Massachusetts Institute of Technology
httpwwwnaval-technologycomprojectsvisby
YACHTS
KAL YUDISTIRAMARATHON 100 ADMIRAL YACHT
LOA 3050 MWidth 6 MFuel Tank 8000 LWater Tank 3000 LIce Box 500 LAccommodation Max 35 Personnel
2 x CATERPILLAR 3412E 1200 HPMARINE DIESEL ENGINE
PC 40 ndash KRI Krait 827Department of Indonesian Navy
LOA 40 MWidth 73 MPower 190Weapon Twin Cannon Barrels
127 mm Heavy Machine GunSpeed Knot 25 KnotDisplacement 105 tonAccommodation 23 personnel
PATROL BOAT
Rigid Inflatable BoatPATROL BOAT
Yachts
36m Luxury Yacht Moonraker
36m Luxury Yacht GoldenEye
50m Luxury Yacht Casino
Royale
45m Luxury Yacht Seashaw
Boat Parts
Barovans for Seismic Sweep
Centrifugal Liftfan House for Surface Effect
Ships
Composite Boat PropellersRTM
Deckhouses for Pilot Boats
Fairing Parts for Submarines
Flybridges for Motor yachts
Light Weight Gangway
MTB Launcher Mock-up
Pleasure Boats
12m Sailboat
12m Sail-Catamaranone-off
Canoes
Dragonfly 1000Catamaran Sailboat
Fantasy 37Sailboat
Farr 60Luxury Sailboat
EurodingyOlympic Dingy Class for
Woman
Hydrolift F23 Racing Boats
Kajacs
Najad 42Sailboat
Najad 520Sailboat
Najad 441Sailboat
Najad 391Sailboat
Nordwest 900Motorboat
Nordwest 1100Motorboat
Quatro 44Motorboat
Racemaster Competition Boats
Storebro 420
Storebro 345
Sweden Yacht 370Sailboat
Sweden Yacht 69Sailboat
Windy 41Motorboat
X-632Sailboat
X-362Sailboat
Commercial Boats
175m High Speed AmbulancePassenger Boat
19m High Speed Passenger Boat
20m High Speed Passenger Boat
364m Surface Effect Passenger Ship
45m Surface Effect Passenger Ship
120m Hull Structural Parts HSSS Catamaran Ferry
APPENDIX
Marine Vessel
1188m Fast Attack Vessel FMV 90 E
20m SAV-Surface Auxiliary Vessels
34m Personnel TransportCoast Guard Vessel
40ft Experimental SES
40m Landsort-Class Mine Hunters
54m Mine Counter Measure Vehicles SES
74m Coastal Patrol Boats
Fishing Boats
30 GT
12 GT
10 GT
5 GT
WISEWings In Surface Effect
HOVERCRAFT
Designed specifically for the tourist and transport industries the
Pioneer Mk3 hovercraft is amphibious and comfortably seats 25
passengers plus 1-crew The air-conditioned cabin allows for
maximum visibility for all aboard The Pioneer Mk3 is robust and
dynamic in its performance
Commercial hovercraft
Mk3 AirLift Hovercraft - 1215m
Power is economicaly provided by one Deutz diesel engine of
330kW (442hp) to cruise easily at 40 knots with much higher
speeds available according to the surface conditions The hull is
manufactured from fibreglassPVC foam composite sandwich
the windows are glass and the skirt is urethane coated nylon A
Military version is available with increased payload and systems
redundancy Power for the Military version comes from two Steyr
diesel engines with a total installed power of 320kW (429hp) All
transmission electrical hydraulic and air systems are duplicated
for maximum redundancy The increased performance of the
Military version comes from the reduced engine weight of the twin
Steyr installation cf the Deutz installation
Source
httpwwwnauticexpocomprodairlift-hovercraftcommercial-hovercrafts-25251-142868html
HOVERFLIGHT
BALLISTIC amp UNIT DEFENCED
Triaxis Composites Collaboration with Institute of Aeronautics and Space in the development of Missile Nose Cone
Polymer composites is the evolution of the military defence
Thin steel was the helmet material of
WWII and remained the principal material until around the 1980rsquos
The advantages of using steel
included a simple technology for manufacture of the helmets low cost and reasonably good
impact protection However these helmets were found to provide only marginal protection
against fragments
During the Vietnam War the US Army experimented with fiber-reinforced inserts in the
helmets These inserts improved ballistic protection but at the same time added weight and
reduced the air space between the head and the helmet
By the early part of the 1980rsquos the US military had developed the first all-composite
100 fiber-reinforced helmet This development resulted in even better ballistic protection
without altering the weight of the helmet Other improvements included better head coverage and
more space for ventilation
Source
Composites Armor - A difficult but huge market
by A Brent Strong Brigham Young University
MILITARY VEHICLES
HIGH SPEED TRAIN SHINKANSEN
Advanced Composites provide lightweight solutions for railway vehicles
saving as much as 50-80 of the weight compared with traditional
components
A lower overall weight translates into less stress faster acceleration and
higher speeds as well as reduced starting and stopping inertia Today
these are important criteria in global high-speed and metropolitan
railway projects
Fire smoke and toxic fumes are key safety criteria for interior
components of railway carriages Any material selected for an interior
component must meet international fire retardant standards
for Rail Interiors and Exteriors
Ceiling Panels Stairs
Seating Vestibules
Window Panels Door Pillars
Partition WallsDiffusers
Gangway and Cabinet Panels Cabin and
Desk panels
Door Pillars Lavatory Modules (standard and
Front and Rear EndsRoof Panels
Nose Cones Under Fairings
Source
httpwwwpctaerail_compositesphp
101
SKY BUS
2009
Europe is the world leader in offshore wind with
828 wind turbines and a cumulative capacity of 2056 MW spread across 38 offshore wind farms in 9
European countries
The UK and Denmark are the current leaders with a 44 and 30 share respectively In 2009
five countries built new offshore wind farms
UK (284 MW)
Demark (230 MW)
Sweden (30 MW)
Germany (30 MW)
Norway (23 MW)
2010
Asia leads the growth in global wind power which grew 358 GW in 2010 bringing
total global capacity to 1944 GW ndash up 225 from 2009
the Global Wind Energy Council (GWEC)
Asia accounted for 19 GW of new global wind power installations driven by China which installed 165
GW
ldquoChina now has 423 GW of wind powerrdquo
ldquoThis puts China firmly on a path to reach 200 GW of installed wind power by 2020 At the same
time China has become the worldrsquos largest producer of wind energy equipmentrdquo
Source
httpwwwreinforcedplasticscomview15655asia-leads-global-wind-power-growth
httpimgdeusmcomdesignnews288288605-Sandia_Sizes_up_Wind_Turbine_Blade_Design_C_largegif
WIND ENERGY
Marine Current Turbines
Source
httpwwwsiemenscompressenpressreleasepress=enpressrelease2011solar-hydroex201111005htm
httpwwwmarineturbinescom
A commercial marine current turbine consists of
two rotors which are fixed on a structure within the
sea current The twin rotors rotate with the
movement of the tidal flow and the blades pitch
through 180 degrees to optimally track tidal current
(Press picture Marine Current Turbines)
Wave Star Energys Multi-point Absorber
CFRP COLUMN REINFORCEMENT
INDUSTRIAL TANKS
107
INDUSTRIAL PIPES
PRESSURE TANKS
109
ldquoLetrsquos Make with Compositesrdquo
Tensile Strength amp Modulus of Common Structural Materials
Densities of Common Structural Materials
Specific Tensile Strength amp Modulus of Common Structural Materials
Typical Properties of Common Structural Materials
Kesimpulan COMPOSITES = RINGAN amp KUAT
Jadi secara keseluruhan kekuatan composites
ditentukan oleh
1 Kekuatan amp Sifat Fiber
2 Kekuatan amp Sifat Resin
3 Fraksi Rasio Perbandingan Volume Fiber
dan Resin dalam Composites
4 Geometri dan Orientasi Arah Fiber dalam
Composites
PRODUKSI ANAK NEGERI
Proses Produksi Kain Fiberglass
Biji Kaca Benang Benang Kaca Kain Fiberglass
PROSES MATERIAL
Glass Beads
Glass Fiber Glass Roving YarnGlass Fabric
Proses Produksi Kain Fiberglass
Biji Kaca Benang Benang Kaca Kain Fiberglass
Glass Beads
Glass Fiber Glass Roving YarnGlass Fabric
PROSES MATERIAL
Benang Kaca Potongan Serat Kaca Chopped Strand Mat
CSM - Chopped Strand Mat
chopped binder
Produk Fiberglass Generasi Pertama
Bahan Pengikat
Senyawa Pada Resin
Glass Roving Yarn Chopped Strand
JENIS FIBERGLASS
Benang Kaca Woven Roving
WR - Woven Roving
Tenun Weaving
Produk Fiberglass Generasi Kedua
Glass Roving Yarn
JENIS FIBERGLASS
Multiaxial
MAX - Multiaxial
warp knitting
Produk Fiberglass Generasi Ketiga
Benang Kaca
Glass Roving Yarn
JENIS FIBERGLASS
MAX - Multiaxial Fabric
Fleece (optional)
Lapisan
MULTIAXIAL PROSES
Karakteristik CSM
bull Glass Content 30
bull Resin Content 70
bull Tensile Force
Chopped Strand Mat
JENIS FIBERGLASS
Karakteristik Woven Roving
bull Glass Content 45
bull Resin Content 55
Woven Roving
Resin
|
|
|
|
|
|
|
|
|
|
|
|
|
|
bull Kekuatan Tarik
JENIS FIBERGLASS
No Resin Rich Area
Karakteristik Multiaxial
bull Glass Content 60
bull Resin Content 40
Produk Fiberglass Ketiga MULTIAXIAL
JENIS FIBERGLASS
Perbedaan Woven Roving dan Multiaxial ndash Tampak Samping
JENIS FIBERGLASS
WR FRP
8 Ply WR 800
8 Ply CSM 450
Glass Weight 1 kg
Composite Weight 15kgm2
CSM FRP
22 Ply CSM 450
Glass Weight 1 kg
Composite Weight 18 kgm2
MULTIAXIAL FRP
13 Ply DB 800
Glass Weight 1 kg
Composite Weight
13 kgm2
JENIS FIBERGLASS
Multiaxial
FRP
Woven Roving
FRP
Chopped Strands Mat FRP
MULTIAXIAL
FAKTA
TEBAL BUKAN BERARTI KUAT
UNSUR MATRIX (RESIN)
TIDAK ADA KEKUATAN
ldquoMore than 50 of the glass fibers used for reinforcement is
E-glassrdquo
KarakteristikKekuatan
CSM WR MAX
Kekuatan Tarik 175 MPa 250 MPa 425 MPa
CSM 142
WR 70
KEKUATAN TARIK
Properties CSM Lamination WR Lamination MAX Lamination
Fabric Weight (kgm2) 1 1 1
Composite Weight (kgm2) 18 15 13
Resin usage (kgm2) 15 1 08
Amount of Fabric 22 Ply 16 Ply 13 Ply
Thickness 15 mm 12 mm 10 mm
Tensile Strength (Mpa) 125 1796 400
Tensile Strength (Nmmsup2) 28463 30958 4576
Processing Time High Med Low
Labour Cost High Med Low
MULTIAXIAL
Total Penggunaan Resin -51
Total Berat Kapal -40
Kekuatan Bangunan Kapal +59
Efisiensi Tenaga Kerja
Waktu Pengerjaan Lebih Cepat
KEUNGGULAN MATERIAL
Resapan Resin Lebih Baik amp Merata
Lapisan Lebih Sedikit
Meningkatkan Kekuatan Kapal
KEUNGGULAN MATERIAL
TRIAXIAL
DBL series DBT series
BIAXIAL
LT series DB series
UNIDIRECTIONAL
L series T series
QUADRIAXIAL
DBLT series
JENIS MULTIAXIAL
UNIDIRECTIONAL
DCMU 900 E ndash
KHUSUS UNTUK MEMPERKUAT BENDING KAPAL
PEMASANGAN KHUSUS PADA KEEL DAN TULANGAN
JENIS MULTIAXIAL UNTUK KAPAL
TRIAXIAL
DBL 600 ndash
APLIKASI PADA INDUSTRI PENERBANGAN
PEMASANGAN KHUSUS PADA
SAMBUNGAN BADAN DAN SAYAP
PESAWAT
JENIS MULTIAXIAL UNTUK PESAWAT
QUADRAXIAL
DBLT 800 ndash
APLIKASI PADA INDUSTRI ENERGI
DITERAPKAN UNTUK KEBUTUHAN PEMBANGKIT
LISTRIK ENERGI ANGIN
MULTIAXIAL UNTUK ENERGI
INDUSTRI KIMIA OLAHRAGA AUTOMOTIF
MULTIAXIAL UNTUK INDUSTRI LAINNYA
COMPOSITES
GUNAKAN MATERIAL FIBERGLASS
YANG SUDAH DISERTIFIKASI
BKI
FIBERGLASS UNTUK PEMBANGUNAN BAKAP
PERATURAN MENTERI PERHUBUNGAN
NOMOR PM 7 TAHUN 2013
TENTANG KEWAJIBAN KLASIFIKASI BAGI KAPAL BERBENDERA INDONESIA
PADA BADAN KLASIFIKASI
BADAN SERTIFIKASI MARITIM
Biro Klasifikasi IndonesiaDet Norske Veritas Germanischer Lloyds
PERATURAN BKI
Untuk Kapal Non-Metal
2006
PERSYARATAN MINIMUM
kekuatan material yang
harus digunakan
untuk membangun
Kapal Fiberglass
PEMBESARAN
Table 21
FIBERGLASS TRIAXIS COMPOSITES
TELAH BERSERTIFIKASI BKI
Biro Klasifikasi Indonesia
65
TEKNIK MANUFAKTUR
COMPOSITES
Wet hand lay-up
1) Peletakan
Dry Reinforcement
bull Dry reinforcement dan resin (+ katalis) ditaruh pada permukaan cetakan
2) Pemasukanpenekanan resin
bull Resin ditekan untuk meng-impregnasi serat dengan menggunakan rol
3) Pengulangan proses untuk lapisan lain
bull Beberapa lapisan dapat ditambahkan secara bertahap
4) Resin curing
bull Reaksi dimulai komponen dilepaskan setelah komponen mengeras
(fully cured)
Wet hand lay-up
Manufaktur komponen dapat dikerjakan dengan menggunakan beberapa lapis komposit
dengan memperhatikan kompatibilitas material dan tahapan curing Modifikasi proses dapat
dilakukan seperti
Vacuum bagging
setelah lay-up
Glass Roving
Bulk Resin
Catalyst
3) De-molding
2) Resin Cure
bull Curing dimulai dan komponen dilepaskan setelah pengerasan selesai
bull Serat gelas resin dan katalis dimasukkan kedalam spray gun
1) Spray-up
bull Campuran disemprotkan pada permukaan cetakan
Spray-up
69
Penyemprotan bakal komponen
Komponen
dilepaskan
dari cetakan
Full dispensing
system Chopper Roving
Atomised resin
and catalyst
Spray-up
Prepreg
1) LaminateAssembly 5) De-molding
3) Resin Melts Layup Consolidates
bull Prepreg serat yang sudah diimpregnasi oleh resin+katalis dalam kondisi padat
bull Lapisan prepreg digunting sesuai bentuk yang diinginkan kemudian diletakkan pada permukaan cetakan
sesuai bentuk komponen yang diinginkan Lay-up mudah dilakukan karena sifat ldquotackynessrdquo dari prepreg
2) Applied Vacuum Pressure and Heat
bull Tekanan dan panas diberikan resin mencair terjadi konsolidasi pada komponen
4) Resin Cures
bull Temperatur dinaikkan untuk memulai curing
Prepreg
Variasi proses Autoclave
Komponen dalam
vacuum-bag
bull Campuran resin (+katalis) dan chopped glass strands diperoleh dalam bentuk premixed compound Bulk molding
Compound (BMC) dalam bentuk adonan atau Sheet molding Compound (SMC) dalam bentuk lembaran
bull Ketika panas dan tekanan diberikan oleh cetakan compound mengalir sesuai bentuk komponen yang diinginkan
1) Placement of Charge
5) De-molding3) Squeeze to final dimensions
2) Mould Closure4) Resin Cure
bull Curing dimulai komponen dilepaskan setelah terjadi pengerasan yang cukup
Compression Molding
bull Preform atau dry reinforcement dimasukkan kedalam cetakan sesuai dengan bentuk komponen yang
diinginkan
bull Resin mengalir dengan penekanan atau pem-vakuman dan meng-impregnasi preform dan
mendorongmengeluarkan udara yang ada dalam preform
1) Preform Manufacture
2) Preform Compression
5) De-molding3) Resin Injection
4) Resin Cure
bull Curing terjadi cetakan dibuka setelah terjadi pengerasan yang mencukupi
Liquid Molding (RTM VARI VARTM)
Pultrusion
bull Dry roving or fabrics ditarik melalui bak berisi
campuran resin dan katalis
bull Campuran yang basah ditarik melalui cetakan
bull Sisa resin keluar cetakan
bull Pemanasan dilakukan untuk proses curing
bull Pendinginan dilakukan untuk mempercepat siklus
produksi
Cut-off
Cooling
Die sections
Resin bath
Fibre creel
Filament Winding
bull Dry roving ditarik melalui bak berisi campuran resin dan katalis
bull Wet roving digulungkan dalam keadaan tegang kepada mandrel
bull Kontrol mekanik dari pembawa serat mengatur orientasi peletakan serat pada
mandrel
INDUSTRI COMPOSITES
AEROSPACE
HISTORY
1950 ndash Boeing
1960 ndash F14 Tomcat
1981 ndash AV-8B Harrier
Source
Low-Cost Composite Materials and Structures for Aircraft Applications
httpwwwreinforcedplasticscom
httpwwwcentennialofflightgovessayEvolution_of_TechnologycompositesTech40htm
Automotive
Composite material is used in a number of applications in the automotive
industry due to its temperature resistance rigidity and fatigue strength
The benefits of using composites include greater fuel efficiency
corrosion resistance light weight and strength Composites also provide
a low-cost way to help keep designs looking fresh
Composites are used in
- interior parts (cockpit trimming seats instrument panels)
- exterior structure (body panels openings underbody frontrear
modules)
- engine compartment and fuelmechanical area parts (axles and
suspensions fuel and exhaust systems)
- electrical and electronic components
Lamborghinis Sesto Element carbon fiber
ldquoFat men cannot run as fast as thin men but we build most of our vehicles as though dead-weight fat increased speedhellip I cannot
imagine where the delusion that weight means strength
came fromhelliprdquo mdashHenry Ford
The mix of automotive materials is changing showing a boost for FRP in helping original
equipment manufacturers meet fuel economy and emissions challenges
(Source 2011 DuPont AutomotiveSAE survey of design engineers performed by Signet Research Inc)
Source
httpwwwtoraycomcsrhighlight2009hig_001_01html
The MonoCell tub for the McLaren MP4-12C supercar is moulded as a single
piece and weighs less than 80 kg (176 lbs)
COMPOSITES IN MARINE
TRIMARAN BOAT
AMERICA NAVYINDONESIAN NAVY
Visby Class corvette
Total length is 72 meters
The beam is 1040 meters
The displacement is 600 metric tones
fully equipped the worlds largest CRP
construction
The design of the Visby aims to minimize
the optical and infrared signature above
water acoustic and hydroa coustic
signature underwater electrical potential
and magnetic signature pressure signature
radar cross section and actively emitted
signals
A stealth corvette of the YS 2000 design
has a detection range of 13km in rough
seas and 22km in calm sea without
jamming In a jammed environment the
Visby would be detected at a range of 8km
in rough sea and 11km in calm sea
The material provides high strength and
rigidity low weight good shock resistance
low radar and magnetic signature
1996
Visby is a class of stealth corvettes for the Swedish Navy
ldquoReduced 50 of a Conventional Steelrdquo
Source
Hull Construction with composite materials for ships over 100m in length 2002
Massachusetts Institute of Technology
httpwwwnaval-technologycomprojectsvisby
YACHTS
KAL YUDISTIRAMARATHON 100 ADMIRAL YACHT
LOA 3050 MWidth 6 MFuel Tank 8000 LWater Tank 3000 LIce Box 500 LAccommodation Max 35 Personnel
2 x CATERPILLAR 3412E 1200 HPMARINE DIESEL ENGINE
PC 40 ndash KRI Krait 827Department of Indonesian Navy
LOA 40 MWidth 73 MPower 190Weapon Twin Cannon Barrels
127 mm Heavy Machine GunSpeed Knot 25 KnotDisplacement 105 tonAccommodation 23 personnel
PATROL BOAT
Rigid Inflatable BoatPATROL BOAT
Yachts
36m Luxury Yacht Moonraker
36m Luxury Yacht GoldenEye
50m Luxury Yacht Casino
Royale
45m Luxury Yacht Seashaw
Boat Parts
Barovans for Seismic Sweep
Centrifugal Liftfan House for Surface Effect
Ships
Composite Boat PropellersRTM
Deckhouses for Pilot Boats
Fairing Parts for Submarines
Flybridges for Motor yachts
Light Weight Gangway
MTB Launcher Mock-up
Pleasure Boats
12m Sailboat
12m Sail-Catamaranone-off
Canoes
Dragonfly 1000Catamaran Sailboat
Fantasy 37Sailboat
Farr 60Luxury Sailboat
EurodingyOlympic Dingy Class for
Woman
Hydrolift F23 Racing Boats
Kajacs
Najad 42Sailboat
Najad 520Sailboat
Najad 441Sailboat
Najad 391Sailboat
Nordwest 900Motorboat
Nordwest 1100Motorboat
Quatro 44Motorboat
Racemaster Competition Boats
Storebro 420
Storebro 345
Sweden Yacht 370Sailboat
Sweden Yacht 69Sailboat
Windy 41Motorboat
X-632Sailboat
X-362Sailboat
Commercial Boats
175m High Speed AmbulancePassenger Boat
19m High Speed Passenger Boat
20m High Speed Passenger Boat
364m Surface Effect Passenger Ship
45m Surface Effect Passenger Ship
120m Hull Structural Parts HSSS Catamaran Ferry
APPENDIX
Marine Vessel
1188m Fast Attack Vessel FMV 90 E
20m SAV-Surface Auxiliary Vessels
34m Personnel TransportCoast Guard Vessel
40ft Experimental SES
40m Landsort-Class Mine Hunters
54m Mine Counter Measure Vehicles SES
74m Coastal Patrol Boats
Fishing Boats
30 GT
12 GT
10 GT
5 GT
WISEWings In Surface Effect
HOVERCRAFT
Designed specifically for the tourist and transport industries the
Pioneer Mk3 hovercraft is amphibious and comfortably seats 25
passengers plus 1-crew The air-conditioned cabin allows for
maximum visibility for all aboard The Pioneer Mk3 is robust and
dynamic in its performance
Commercial hovercraft
Mk3 AirLift Hovercraft - 1215m
Power is economicaly provided by one Deutz diesel engine of
330kW (442hp) to cruise easily at 40 knots with much higher
speeds available according to the surface conditions The hull is
manufactured from fibreglassPVC foam composite sandwich
the windows are glass and the skirt is urethane coated nylon A
Military version is available with increased payload and systems
redundancy Power for the Military version comes from two Steyr
diesel engines with a total installed power of 320kW (429hp) All
transmission electrical hydraulic and air systems are duplicated
for maximum redundancy The increased performance of the
Military version comes from the reduced engine weight of the twin
Steyr installation cf the Deutz installation
Source
httpwwwnauticexpocomprodairlift-hovercraftcommercial-hovercrafts-25251-142868html
HOVERFLIGHT
BALLISTIC amp UNIT DEFENCED
Triaxis Composites Collaboration with Institute of Aeronautics and Space in the development of Missile Nose Cone
Polymer composites is the evolution of the military defence
Thin steel was the helmet material of
WWII and remained the principal material until around the 1980rsquos
The advantages of using steel
included a simple technology for manufacture of the helmets low cost and reasonably good
impact protection However these helmets were found to provide only marginal protection
against fragments
During the Vietnam War the US Army experimented with fiber-reinforced inserts in the
helmets These inserts improved ballistic protection but at the same time added weight and
reduced the air space between the head and the helmet
By the early part of the 1980rsquos the US military had developed the first all-composite
100 fiber-reinforced helmet This development resulted in even better ballistic protection
without altering the weight of the helmet Other improvements included better head coverage and
more space for ventilation
Source
Composites Armor - A difficult but huge market
by A Brent Strong Brigham Young University
MILITARY VEHICLES
HIGH SPEED TRAIN SHINKANSEN
Advanced Composites provide lightweight solutions for railway vehicles
saving as much as 50-80 of the weight compared with traditional
components
A lower overall weight translates into less stress faster acceleration and
higher speeds as well as reduced starting and stopping inertia Today
these are important criteria in global high-speed and metropolitan
railway projects
Fire smoke and toxic fumes are key safety criteria for interior
components of railway carriages Any material selected for an interior
component must meet international fire retardant standards
for Rail Interiors and Exteriors
Ceiling Panels Stairs
Seating Vestibules
Window Panels Door Pillars
Partition WallsDiffusers
Gangway and Cabinet Panels Cabin and
Desk panels
Door Pillars Lavatory Modules (standard and
Front and Rear EndsRoof Panels
Nose Cones Under Fairings
Source
httpwwwpctaerail_compositesphp
101
SKY BUS
2009
Europe is the world leader in offshore wind with
828 wind turbines and a cumulative capacity of 2056 MW spread across 38 offshore wind farms in 9
European countries
The UK and Denmark are the current leaders with a 44 and 30 share respectively In 2009
five countries built new offshore wind farms
UK (284 MW)
Demark (230 MW)
Sweden (30 MW)
Germany (30 MW)
Norway (23 MW)
2010
Asia leads the growth in global wind power which grew 358 GW in 2010 bringing
total global capacity to 1944 GW ndash up 225 from 2009
the Global Wind Energy Council (GWEC)
Asia accounted for 19 GW of new global wind power installations driven by China which installed 165
GW
ldquoChina now has 423 GW of wind powerrdquo
ldquoThis puts China firmly on a path to reach 200 GW of installed wind power by 2020 At the same
time China has become the worldrsquos largest producer of wind energy equipmentrdquo
Source
httpwwwreinforcedplasticscomview15655asia-leads-global-wind-power-growth
httpimgdeusmcomdesignnews288288605-Sandia_Sizes_up_Wind_Turbine_Blade_Design_C_largegif
WIND ENERGY
Marine Current Turbines
Source
httpwwwsiemenscompressenpressreleasepress=enpressrelease2011solar-hydroex201111005htm
httpwwwmarineturbinescom
A commercial marine current turbine consists of
two rotors which are fixed on a structure within the
sea current The twin rotors rotate with the
movement of the tidal flow and the blades pitch
through 180 degrees to optimally track tidal current
(Press picture Marine Current Turbines)
Wave Star Energys Multi-point Absorber
CFRP COLUMN REINFORCEMENT
INDUSTRIAL TANKS
107
INDUSTRIAL PIPES
PRESSURE TANKS
109
ldquoLetrsquos Make with Compositesrdquo
Densities of Common Structural Materials
Specific Tensile Strength amp Modulus of Common Structural Materials
Typical Properties of Common Structural Materials
Kesimpulan COMPOSITES = RINGAN amp KUAT
Jadi secara keseluruhan kekuatan composites
ditentukan oleh
1 Kekuatan amp Sifat Fiber
2 Kekuatan amp Sifat Resin
3 Fraksi Rasio Perbandingan Volume Fiber
dan Resin dalam Composites
4 Geometri dan Orientasi Arah Fiber dalam
Composites
PRODUKSI ANAK NEGERI
Proses Produksi Kain Fiberglass
Biji Kaca Benang Benang Kaca Kain Fiberglass
PROSES MATERIAL
Glass Beads
Glass Fiber Glass Roving YarnGlass Fabric
Proses Produksi Kain Fiberglass
Biji Kaca Benang Benang Kaca Kain Fiberglass
Glass Beads
Glass Fiber Glass Roving YarnGlass Fabric
PROSES MATERIAL
Benang Kaca Potongan Serat Kaca Chopped Strand Mat
CSM - Chopped Strand Mat
chopped binder
Produk Fiberglass Generasi Pertama
Bahan Pengikat
Senyawa Pada Resin
Glass Roving Yarn Chopped Strand
JENIS FIBERGLASS
Benang Kaca Woven Roving
WR - Woven Roving
Tenun Weaving
Produk Fiberglass Generasi Kedua
Glass Roving Yarn
JENIS FIBERGLASS
Multiaxial
MAX - Multiaxial
warp knitting
Produk Fiberglass Generasi Ketiga
Benang Kaca
Glass Roving Yarn
JENIS FIBERGLASS
MAX - Multiaxial Fabric
Fleece (optional)
Lapisan
MULTIAXIAL PROSES
Karakteristik CSM
bull Glass Content 30
bull Resin Content 70
bull Tensile Force
Chopped Strand Mat
JENIS FIBERGLASS
Karakteristik Woven Roving
bull Glass Content 45
bull Resin Content 55
Woven Roving
Resin
|
|
|
|
|
|
|
|
|
|
|
|
|
|
bull Kekuatan Tarik
JENIS FIBERGLASS
No Resin Rich Area
Karakteristik Multiaxial
bull Glass Content 60
bull Resin Content 40
Produk Fiberglass Ketiga MULTIAXIAL
JENIS FIBERGLASS
Perbedaan Woven Roving dan Multiaxial ndash Tampak Samping
JENIS FIBERGLASS
WR FRP
8 Ply WR 800
8 Ply CSM 450
Glass Weight 1 kg
Composite Weight 15kgm2
CSM FRP
22 Ply CSM 450
Glass Weight 1 kg
Composite Weight 18 kgm2
MULTIAXIAL FRP
13 Ply DB 800
Glass Weight 1 kg
Composite Weight
13 kgm2
JENIS FIBERGLASS
Multiaxial
FRP
Woven Roving
FRP
Chopped Strands Mat FRP
MULTIAXIAL
FAKTA
TEBAL BUKAN BERARTI KUAT
UNSUR MATRIX (RESIN)
TIDAK ADA KEKUATAN
ldquoMore than 50 of the glass fibers used for reinforcement is
E-glassrdquo
KarakteristikKekuatan
CSM WR MAX
Kekuatan Tarik 175 MPa 250 MPa 425 MPa
CSM 142
WR 70
KEKUATAN TARIK
Properties CSM Lamination WR Lamination MAX Lamination
Fabric Weight (kgm2) 1 1 1
Composite Weight (kgm2) 18 15 13
Resin usage (kgm2) 15 1 08
Amount of Fabric 22 Ply 16 Ply 13 Ply
Thickness 15 mm 12 mm 10 mm
Tensile Strength (Mpa) 125 1796 400
Tensile Strength (Nmmsup2) 28463 30958 4576
Processing Time High Med Low
Labour Cost High Med Low
MULTIAXIAL
Total Penggunaan Resin -51
Total Berat Kapal -40
Kekuatan Bangunan Kapal +59
Efisiensi Tenaga Kerja
Waktu Pengerjaan Lebih Cepat
KEUNGGULAN MATERIAL
Resapan Resin Lebih Baik amp Merata
Lapisan Lebih Sedikit
Meningkatkan Kekuatan Kapal
KEUNGGULAN MATERIAL
TRIAXIAL
DBL series DBT series
BIAXIAL
LT series DB series
UNIDIRECTIONAL
L series T series
QUADRIAXIAL
DBLT series
JENIS MULTIAXIAL
UNIDIRECTIONAL
DCMU 900 E ndash
KHUSUS UNTUK MEMPERKUAT BENDING KAPAL
PEMASANGAN KHUSUS PADA KEEL DAN TULANGAN
JENIS MULTIAXIAL UNTUK KAPAL
TRIAXIAL
DBL 600 ndash
APLIKASI PADA INDUSTRI PENERBANGAN
PEMASANGAN KHUSUS PADA
SAMBUNGAN BADAN DAN SAYAP
PESAWAT
JENIS MULTIAXIAL UNTUK PESAWAT
QUADRAXIAL
DBLT 800 ndash
APLIKASI PADA INDUSTRI ENERGI
DITERAPKAN UNTUK KEBUTUHAN PEMBANGKIT
LISTRIK ENERGI ANGIN
MULTIAXIAL UNTUK ENERGI
INDUSTRI KIMIA OLAHRAGA AUTOMOTIF
MULTIAXIAL UNTUK INDUSTRI LAINNYA
COMPOSITES
GUNAKAN MATERIAL FIBERGLASS
YANG SUDAH DISERTIFIKASI
BKI
FIBERGLASS UNTUK PEMBANGUNAN BAKAP
PERATURAN MENTERI PERHUBUNGAN
NOMOR PM 7 TAHUN 2013
TENTANG KEWAJIBAN KLASIFIKASI BAGI KAPAL BERBENDERA INDONESIA
PADA BADAN KLASIFIKASI
BADAN SERTIFIKASI MARITIM
Biro Klasifikasi IndonesiaDet Norske Veritas Germanischer Lloyds
PERATURAN BKI
Untuk Kapal Non-Metal
2006
PERSYARATAN MINIMUM
kekuatan material yang
harus digunakan
untuk membangun
Kapal Fiberglass
PEMBESARAN
Table 21
FIBERGLASS TRIAXIS COMPOSITES
TELAH BERSERTIFIKASI BKI
Biro Klasifikasi Indonesia
65
TEKNIK MANUFAKTUR
COMPOSITES
Wet hand lay-up
1) Peletakan
Dry Reinforcement
bull Dry reinforcement dan resin (+ katalis) ditaruh pada permukaan cetakan
2) Pemasukanpenekanan resin
bull Resin ditekan untuk meng-impregnasi serat dengan menggunakan rol
3) Pengulangan proses untuk lapisan lain
bull Beberapa lapisan dapat ditambahkan secara bertahap
4) Resin curing
bull Reaksi dimulai komponen dilepaskan setelah komponen mengeras
(fully cured)
Wet hand lay-up
Manufaktur komponen dapat dikerjakan dengan menggunakan beberapa lapis komposit
dengan memperhatikan kompatibilitas material dan tahapan curing Modifikasi proses dapat
dilakukan seperti
Vacuum bagging
setelah lay-up
Glass Roving
Bulk Resin
Catalyst
3) De-molding
2) Resin Cure
bull Curing dimulai dan komponen dilepaskan setelah pengerasan selesai
bull Serat gelas resin dan katalis dimasukkan kedalam spray gun
1) Spray-up
bull Campuran disemprotkan pada permukaan cetakan
Spray-up
69
Penyemprotan bakal komponen
Komponen
dilepaskan
dari cetakan
Full dispensing
system Chopper Roving
Atomised resin
and catalyst
Spray-up
Prepreg
1) LaminateAssembly 5) De-molding
3) Resin Melts Layup Consolidates
bull Prepreg serat yang sudah diimpregnasi oleh resin+katalis dalam kondisi padat
bull Lapisan prepreg digunting sesuai bentuk yang diinginkan kemudian diletakkan pada permukaan cetakan
sesuai bentuk komponen yang diinginkan Lay-up mudah dilakukan karena sifat ldquotackynessrdquo dari prepreg
2) Applied Vacuum Pressure and Heat
bull Tekanan dan panas diberikan resin mencair terjadi konsolidasi pada komponen
4) Resin Cures
bull Temperatur dinaikkan untuk memulai curing
Prepreg
Variasi proses Autoclave
Komponen dalam
vacuum-bag
bull Campuran resin (+katalis) dan chopped glass strands diperoleh dalam bentuk premixed compound Bulk molding
Compound (BMC) dalam bentuk adonan atau Sheet molding Compound (SMC) dalam bentuk lembaran
bull Ketika panas dan tekanan diberikan oleh cetakan compound mengalir sesuai bentuk komponen yang diinginkan
1) Placement of Charge
5) De-molding3) Squeeze to final dimensions
2) Mould Closure4) Resin Cure
bull Curing dimulai komponen dilepaskan setelah terjadi pengerasan yang cukup
Compression Molding
bull Preform atau dry reinforcement dimasukkan kedalam cetakan sesuai dengan bentuk komponen yang
diinginkan
bull Resin mengalir dengan penekanan atau pem-vakuman dan meng-impregnasi preform dan
mendorongmengeluarkan udara yang ada dalam preform
1) Preform Manufacture
2) Preform Compression
5) De-molding3) Resin Injection
4) Resin Cure
bull Curing terjadi cetakan dibuka setelah terjadi pengerasan yang mencukupi
Liquid Molding (RTM VARI VARTM)
Pultrusion
bull Dry roving or fabrics ditarik melalui bak berisi
campuran resin dan katalis
bull Campuran yang basah ditarik melalui cetakan
bull Sisa resin keluar cetakan
bull Pemanasan dilakukan untuk proses curing
bull Pendinginan dilakukan untuk mempercepat siklus
produksi
Cut-off
Cooling
Die sections
Resin bath
Fibre creel
Filament Winding
bull Dry roving ditarik melalui bak berisi campuran resin dan katalis
bull Wet roving digulungkan dalam keadaan tegang kepada mandrel
bull Kontrol mekanik dari pembawa serat mengatur orientasi peletakan serat pada
mandrel
INDUSTRI COMPOSITES
AEROSPACE
HISTORY
1950 ndash Boeing
1960 ndash F14 Tomcat
1981 ndash AV-8B Harrier
Source
Low-Cost Composite Materials and Structures for Aircraft Applications
httpwwwreinforcedplasticscom
httpwwwcentennialofflightgovessayEvolution_of_TechnologycompositesTech40htm
Automotive
Composite material is used in a number of applications in the automotive
industry due to its temperature resistance rigidity and fatigue strength
The benefits of using composites include greater fuel efficiency
corrosion resistance light weight and strength Composites also provide
a low-cost way to help keep designs looking fresh
Composites are used in
- interior parts (cockpit trimming seats instrument panels)
- exterior structure (body panels openings underbody frontrear
modules)
- engine compartment and fuelmechanical area parts (axles and
suspensions fuel and exhaust systems)
- electrical and electronic components
Lamborghinis Sesto Element carbon fiber
ldquoFat men cannot run as fast as thin men but we build most of our vehicles as though dead-weight fat increased speedhellip I cannot
imagine where the delusion that weight means strength
came fromhelliprdquo mdashHenry Ford
The mix of automotive materials is changing showing a boost for FRP in helping original
equipment manufacturers meet fuel economy and emissions challenges
(Source 2011 DuPont AutomotiveSAE survey of design engineers performed by Signet Research Inc)
Source
httpwwwtoraycomcsrhighlight2009hig_001_01html
The MonoCell tub for the McLaren MP4-12C supercar is moulded as a single
piece and weighs less than 80 kg (176 lbs)
COMPOSITES IN MARINE
TRIMARAN BOAT
AMERICA NAVYINDONESIAN NAVY
Visby Class corvette
Total length is 72 meters
The beam is 1040 meters
The displacement is 600 metric tones
fully equipped the worlds largest CRP
construction
The design of the Visby aims to minimize
the optical and infrared signature above
water acoustic and hydroa coustic
signature underwater electrical potential
and magnetic signature pressure signature
radar cross section and actively emitted
signals
A stealth corvette of the YS 2000 design
has a detection range of 13km in rough
seas and 22km in calm sea without
jamming In a jammed environment the
Visby would be detected at a range of 8km
in rough sea and 11km in calm sea
The material provides high strength and
rigidity low weight good shock resistance
low radar and magnetic signature
1996
Visby is a class of stealth corvettes for the Swedish Navy
ldquoReduced 50 of a Conventional Steelrdquo
Source
Hull Construction with composite materials for ships over 100m in length 2002
Massachusetts Institute of Technology
httpwwwnaval-technologycomprojectsvisby
YACHTS
KAL YUDISTIRAMARATHON 100 ADMIRAL YACHT
LOA 3050 MWidth 6 MFuel Tank 8000 LWater Tank 3000 LIce Box 500 LAccommodation Max 35 Personnel
2 x CATERPILLAR 3412E 1200 HPMARINE DIESEL ENGINE
PC 40 ndash KRI Krait 827Department of Indonesian Navy
LOA 40 MWidth 73 MPower 190Weapon Twin Cannon Barrels
127 mm Heavy Machine GunSpeed Knot 25 KnotDisplacement 105 tonAccommodation 23 personnel
PATROL BOAT
Rigid Inflatable BoatPATROL BOAT
Yachts
36m Luxury Yacht Moonraker
36m Luxury Yacht GoldenEye
50m Luxury Yacht Casino
Royale
45m Luxury Yacht Seashaw
Boat Parts
Barovans for Seismic Sweep
Centrifugal Liftfan House for Surface Effect
Ships
Composite Boat PropellersRTM
Deckhouses for Pilot Boats
Fairing Parts for Submarines
Flybridges for Motor yachts
Light Weight Gangway
MTB Launcher Mock-up
Pleasure Boats
12m Sailboat
12m Sail-Catamaranone-off
Canoes
Dragonfly 1000Catamaran Sailboat
Fantasy 37Sailboat
Farr 60Luxury Sailboat
EurodingyOlympic Dingy Class for
Woman
Hydrolift F23 Racing Boats
Kajacs
Najad 42Sailboat
Najad 520Sailboat
Najad 441Sailboat
Najad 391Sailboat
Nordwest 900Motorboat
Nordwest 1100Motorboat
Quatro 44Motorboat
Racemaster Competition Boats
Storebro 420
Storebro 345
Sweden Yacht 370Sailboat
Sweden Yacht 69Sailboat
Windy 41Motorboat
X-632Sailboat
X-362Sailboat
Commercial Boats
175m High Speed AmbulancePassenger Boat
19m High Speed Passenger Boat
20m High Speed Passenger Boat
364m Surface Effect Passenger Ship
45m Surface Effect Passenger Ship
120m Hull Structural Parts HSSS Catamaran Ferry
APPENDIX
Marine Vessel
1188m Fast Attack Vessel FMV 90 E
20m SAV-Surface Auxiliary Vessels
34m Personnel TransportCoast Guard Vessel
40ft Experimental SES
40m Landsort-Class Mine Hunters
54m Mine Counter Measure Vehicles SES
74m Coastal Patrol Boats
Fishing Boats
30 GT
12 GT
10 GT
5 GT
WISEWings In Surface Effect
HOVERCRAFT
Designed specifically for the tourist and transport industries the
Pioneer Mk3 hovercraft is amphibious and comfortably seats 25
passengers plus 1-crew The air-conditioned cabin allows for
maximum visibility for all aboard The Pioneer Mk3 is robust and
dynamic in its performance
Commercial hovercraft
Mk3 AirLift Hovercraft - 1215m
Power is economicaly provided by one Deutz diesel engine of
330kW (442hp) to cruise easily at 40 knots with much higher
speeds available according to the surface conditions The hull is
manufactured from fibreglassPVC foam composite sandwich
the windows are glass and the skirt is urethane coated nylon A
Military version is available with increased payload and systems
redundancy Power for the Military version comes from two Steyr
diesel engines with a total installed power of 320kW (429hp) All
transmission electrical hydraulic and air systems are duplicated
for maximum redundancy The increased performance of the
Military version comes from the reduced engine weight of the twin
Steyr installation cf the Deutz installation
Source
httpwwwnauticexpocomprodairlift-hovercraftcommercial-hovercrafts-25251-142868html
HOVERFLIGHT
BALLISTIC amp UNIT DEFENCED
Triaxis Composites Collaboration with Institute of Aeronautics and Space in the development of Missile Nose Cone
Polymer composites is the evolution of the military defence
Thin steel was the helmet material of
WWII and remained the principal material until around the 1980rsquos
The advantages of using steel
included a simple technology for manufacture of the helmets low cost and reasonably good
impact protection However these helmets were found to provide only marginal protection
against fragments
During the Vietnam War the US Army experimented with fiber-reinforced inserts in the
helmets These inserts improved ballistic protection but at the same time added weight and
reduced the air space between the head and the helmet
By the early part of the 1980rsquos the US military had developed the first all-composite
100 fiber-reinforced helmet This development resulted in even better ballistic protection
without altering the weight of the helmet Other improvements included better head coverage and
more space for ventilation
Source
Composites Armor - A difficult but huge market
by A Brent Strong Brigham Young University
MILITARY VEHICLES
HIGH SPEED TRAIN SHINKANSEN
Advanced Composites provide lightweight solutions for railway vehicles
saving as much as 50-80 of the weight compared with traditional
components
A lower overall weight translates into less stress faster acceleration and
higher speeds as well as reduced starting and stopping inertia Today
these are important criteria in global high-speed and metropolitan
railway projects
Fire smoke and toxic fumes are key safety criteria for interior
components of railway carriages Any material selected for an interior
component must meet international fire retardant standards
for Rail Interiors and Exteriors
Ceiling Panels Stairs
Seating Vestibules
Window Panels Door Pillars
Partition WallsDiffusers
Gangway and Cabinet Panels Cabin and
Desk panels
Door Pillars Lavatory Modules (standard and
Front and Rear EndsRoof Panels
Nose Cones Under Fairings
Source
httpwwwpctaerail_compositesphp
101
SKY BUS
2009
Europe is the world leader in offshore wind with
828 wind turbines and a cumulative capacity of 2056 MW spread across 38 offshore wind farms in 9
European countries
The UK and Denmark are the current leaders with a 44 and 30 share respectively In 2009
five countries built new offshore wind farms
UK (284 MW)
Demark (230 MW)
Sweden (30 MW)
Germany (30 MW)
Norway (23 MW)
2010
Asia leads the growth in global wind power which grew 358 GW in 2010 bringing
total global capacity to 1944 GW ndash up 225 from 2009
the Global Wind Energy Council (GWEC)
Asia accounted for 19 GW of new global wind power installations driven by China which installed 165
GW
ldquoChina now has 423 GW of wind powerrdquo
ldquoThis puts China firmly on a path to reach 200 GW of installed wind power by 2020 At the same
time China has become the worldrsquos largest producer of wind energy equipmentrdquo
Source
httpwwwreinforcedplasticscomview15655asia-leads-global-wind-power-growth
httpimgdeusmcomdesignnews288288605-Sandia_Sizes_up_Wind_Turbine_Blade_Design_C_largegif
WIND ENERGY
Marine Current Turbines
Source
httpwwwsiemenscompressenpressreleasepress=enpressrelease2011solar-hydroex201111005htm
httpwwwmarineturbinescom
A commercial marine current turbine consists of
two rotors which are fixed on a structure within the
sea current The twin rotors rotate with the
movement of the tidal flow and the blades pitch
through 180 degrees to optimally track tidal current
(Press picture Marine Current Turbines)
Wave Star Energys Multi-point Absorber
CFRP COLUMN REINFORCEMENT
INDUSTRIAL TANKS
107
INDUSTRIAL PIPES
PRESSURE TANKS
109
ldquoLetrsquos Make with Compositesrdquo
Specific Tensile Strength amp Modulus of Common Structural Materials
Typical Properties of Common Structural Materials
Kesimpulan COMPOSITES = RINGAN amp KUAT
Jadi secara keseluruhan kekuatan composites
ditentukan oleh
1 Kekuatan amp Sifat Fiber
2 Kekuatan amp Sifat Resin
3 Fraksi Rasio Perbandingan Volume Fiber
dan Resin dalam Composites
4 Geometri dan Orientasi Arah Fiber dalam
Composites
PRODUKSI ANAK NEGERI
Proses Produksi Kain Fiberglass
Biji Kaca Benang Benang Kaca Kain Fiberglass
PROSES MATERIAL
Glass Beads
Glass Fiber Glass Roving YarnGlass Fabric
Proses Produksi Kain Fiberglass
Biji Kaca Benang Benang Kaca Kain Fiberglass
Glass Beads
Glass Fiber Glass Roving YarnGlass Fabric
PROSES MATERIAL
Benang Kaca Potongan Serat Kaca Chopped Strand Mat
CSM - Chopped Strand Mat
chopped binder
Produk Fiberglass Generasi Pertama
Bahan Pengikat
Senyawa Pada Resin
Glass Roving Yarn Chopped Strand
JENIS FIBERGLASS
Benang Kaca Woven Roving
WR - Woven Roving
Tenun Weaving
Produk Fiberglass Generasi Kedua
Glass Roving Yarn
JENIS FIBERGLASS
Multiaxial
MAX - Multiaxial
warp knitting
Produk Fiberglass Generasi Ketiga
Benang Kaca
Glass Roving Yarn
JENIS FIBERGLASS
MAX - Multiaxial Fabric
Fleece (optional)
Lapisan
MULTIAXIAL PROSES
Karakteristik CSM
bull Glass Content 30
bull Resin Content 70
bull Tensile Force
Chopped Strand Mat
JENIS FIBERGLASS
Karakteristik Woven Roving
bull Glass Content 45
bull Resin Content 55
Woven Roving
Resin
|
|
|
|
|
|
|
|
|
|
|
|
|
|
bull Kekuatan Tarik
JENIS FIBERGLASS
No Resin Rich Area
Karakteristik Multiaxial
bull Glass Content 60
bull Resin Content 40
Produk Fiberglass Ketiga MULTIAXIAL
JENIS FIBERGLASS
Perbedaan Woven Roving dan Multiaxial ndash Tampak Samping
JENIS FIBERGLASS
WR FRP
8 Ply WR 800
8 Ply CSM 450
Glass Weight 1 kg
Composite Weight 15kgm2
CSM FRP
22 Ply CSM 450
Glass Weight 1 kg
Composite Weight 18 kgm2
MULTIAXIAL FRP
13 Ply DB 800
Glass Weight 1 kg
Composite Weight
13 kgm2
JENIS FIBERGLASS
Multiaxial
FRP
Woven Roving
FRP
Chopped Strands Mat FRP
MULTIAXIAL
FAKTA
TEBAL BUKAN BERARTI KUAT
UNSUR MATRIX (RESIN)
TIDAK ADA KEKUATAN
ldquoMore than 50 of the glass fibers used for reinforcement is
E-glassrdquo
KarakteristikKekuatan
CSM WR MAX
Kekuatan Tarik 175 MPa 250 MPa 425 MPa
CSM 142
WR 70
KEKUATAN TARIK
Properties CSM Lamination WR Lamination MAX Lamination
Fabric Weight (kgm2) 1 1 1
Composite Weight (kgm2) 18 15 13
Resin usage (kgm2) 15 1 08
Amount of Fabric 22 Ply 16 Ply 13 Ply
Thickness 15 mm 12 mm 10 mm
Tensile Strength (Mpa) 125 1796 400
Tensile Strength (Nmmsup2) 28463 30958 4576
Processing Time High Med Low
Labour Cost High Med Low
MULTIAXIAL
Total Penggunaan Resin -51
Total Berat Kapal -40
Kekuatan Bangunan Kapal +59
Efisiensi Tenaga Kerja
Waktu Pengerjaan Lebih Cepat
KEUNGGULAN MATERIAL
Resapan Resin Lebih Baik amp Merata
Lapisan Lebih Sedikit
Meningkatkan Kekuatan Kapal
KEUNGGULAN MATERIAL
TRIAXIAL
DBL series DBT series
BIAXIAL
LT series DB series
UNIDIRECTIONAL
L series T series
QUADRIAXIAL
DBLT series
JENIS MULTIAXIAL
UNIDIRECTIONAL
DCMU 900 E ndash
KHUSUS UNTUK MEMPERKUAT BENDING KAPAL
PEMASANGAN KHUSUS PADA KEEL DAN TULANGAN
JENIS MULTIAXIAL UNTUK KAPAL
TRIAXIAL
DBL 600 ndash
APLIKASI PADA INDUSTRI PENERBANGAN
PEMASANGAN KHUSUS PADA
SAMBUNGAN BADAN DAN SAYAP
PESAWAT
JENIS MULTIAXIAL UNTUK PESAWAT
QUADRAXIAL
DBLT 800 ndash
APLIKASI PADA INDUSTRI ENERGI
DITERAPKAN UNTUK KEBUTUHAN PEMBANGKIT
LISTRIK ENERGI ANGIN
MULTIAXIAL UNTUK ENERGI
INDUSTRI KIMIA OLAHRAGA AUTOMOTIF
MULTIAXIAL UNTUK INDUSTRI LAINNYA
COMPOSITES
GUNAKAN MATERIAL FIBERGLASS
YANG SUDAH DISERTIFIKASI
BKI
FIBERGLASS UNTUK PEMBANGUNAN BAKAP
PERATURAN MENTERI PERHUBUNGAN
NOMOR PM 7 TAHUN 2013
TENTANG KEWAJIBAN KLASIFIKASI BAGI KAPAL BERBENDERA INDONESIA
PADA BADAN KLASIFIKASI
BADAN SERTIFIKASI MARITIM
Biro Klasifikasi IndonesiaDet Norske Veritas Germanischer Lloyds
PERATURAN BKI
Untuk Kapal Non-Metal
2006
PERSYARATAN MINIMUM
kekuatan material yang
harus digunakan
untuk membangun
Kapal Fiberglass
PEMBESARAN
Table 21
FIBERGLASS TRIAXIS COMPOSITES
TELAH BERSERTIFIKASI BKI
Biro Klasifikasi Indonesia
65
TEKNIK MANUFAKTUR
COMPOSITES
Wet hand lay-up
1) Peletakan
Dry Reinforcement
bull Dry reinforcement dan resin (+ katalis) ditaruh pada permukaan cetakan
2) Pemasukanpenekanan resin
bull Resin ditekan untuk meng-impregnasi serat dengan menggunakan rol
3) Pengulangan proses untuk lapisan lain
bull Beberapa lapisan dapat ditambahkan secara bertahap
4) Resin curing
bull Reaksi dimulai komponen dilepaskan setelah komponen mengeras
(fully cured)
Wet hand lay-up
Manufaktur komponen dapat dikerjakan dengan menggunakan beberapa lapis komposit
dengan memperhatikan kompatibilitas material dan tahapan curing Modifikasi proses dapat
dilakukan seperti
Vacuum bagging
setelah lay-up
Glass Roving
Bulk Resin
Catalyst
3) De-molding
2) Resin Cure
bull Curing dimulai dan komponen dilepaskan setelah pengerasan selesai
bull Serat gelas resin dan katalis dimasukkan kedalam spray gun
1) Spray-up
bull Campuran disemprotkan pada permukaan cetakan
Spray-up
69
Penyemprotan bakal komponen
Komponen
dilepaskan
dari cetakan
Full dispensing
system Chopper Roving
Atomised resin
and catalyst
Spray-up
Prepreg
1) LaminateAssembly 5) De-molding
3) Resin Melts Layup Consolidates
bull Prepreg serat yang sudah diimpregnasi oleh resin+katalis dalam kondisi padat
bull Lapisan prepreg digunting sesuai bentuk yang diinginkan kemudian diletakkan pada permukaan cetakan
sesuai bentuk komponen yang diinginkan Lay-up mudah dilakukan karena sifat ldquotackynessrdquo dari prepreg
2) Applied Vacuum Pressure and Heat
bull Tekanan dan panas diberikan resin mencair terjadi konsolidasi pada komponen
4) Resin Cures
bull Temperatur dinaikkan untuk memulai curing
Prepreg
Variasi proses Autoclave
Komponen dalam
vacuum-bag
bull Campuran resin (+katalis) dan chopped glass strands diperoleh dalam bentuk premixed compound Bulk molding
Compound (BMC) dalam bentuk adonan atau Sheet molding Compound (SMC) dalam bentuk lembaran
bull Ketika panas dan tekanan diberikan oleh cetakan compound mengalir sesuai bentuk komponen yang diinginkan
1) Placement of Charge
5) De-molding3) Squeeze to final dimensions
2) Mould Closure4) Resin Cure
bull Curing dimulai komponen dilepaskan setelah terjadi pengerasan yang cukup
Compression Molding
bull Preform atau dry reinforcement dimasukkan kedalam cetakan sesuai dengan bentuk komponen yang
diinginkan
bull Resin mengalir dengan penekanan atau pem-vakuman dan meng-impregnasi preform dan
mendorongmengeluarkan udara yang ada dalam preform
1) Preform Manufacture
2) Preform Compression
5) De-molding3) Resin Injection
4) Resin Cure
bull Curing terjadi cetakan dibuka setelah terjadi pengerasan yang mencukupi
Liquid Molding (RTM VARI VARTM)
Pultrusion
bull Dry roving or fabrics ditarik melalui bak berisi
campuran resin dan katalis
bull Campuran yang basah ditarik melalui cetakan
bull Sisa resin keluar cetakan
bull Pemanasan dilakukan untuk proses curing
bull Pendinginan dilakukan untuk mempercepat siklus
produksi
Cut-off
Cooling
Die sections
Resin bath
Fibre creel
Filament Winding
bull Dry roving ditarik melalui bak berisi campuran resin dan katalis
bull Wet roving digulungkan dalam keadaan tegang kepada mandrel
bull Kontrol mekanik dari pembawa serat mengatur orientasi peletakan serat pada
mandrel
INDUSTRI COMPOSITES
AEROSPACE
HISTORY
1950 ndash Boeing
1960 ndash F14 Tomcat
1981 ndash AV-8B Harrier
Source
Low-Cost Composite Materials and Structures for Aircraft Applications
httpwwwreinforcedplasticscom
httpwwwcentennialofflightgovessayEvolution_of_TechnologycompositesTech40htm
Automotive
Composite material is used in a number of applications in the automotive
industry due to its temperature resistance rigidity and fatigue strength
The benefits of using composites include greater fuel efficiency
corrosion resistance light weight and strength Composites also provide
a low-cost way to help keep designs looking fresh
Composites are used in
- interior parts (cockpit trimming seats instrument panels)
- exterior structure (body panels openings underbody frontrear
modules)
- engine compartment and fuelmechanical area parts (axles and
suspensions fuel and exhaust systems)
- electrical and electronic components
Lamborghinis Sesto Element carbon fiber
ldquoFat men cannot run as fast as thin men but we build most of our vehicles as though dead-weight fat increased speedhellip I cannot
imagine where the delusion that weight means strength
came fromhelliprdquo mdashHenry Ford
The mix of automotive materials is changing showing a boost for FRP in helping original
equipment manufacturers meet fuel economy and emissions challenges
(Source 2011 DuPont AutomotiveSAE survey of design engineers performed by Signet Research Inc)
Source
httpwwwtoraycomcsrhighlight2009hig_001_01html
The MonoCell tub for the McLaren MP4-12C supercar is moulded as a single
piece and weighs less than 80 kg (176 lbs)
COMPOSITES IN MARINE
TRIMARAN BOAT
AMERICA NAVYINDONESIAN NAVY
Visby Class corvette
Total length is 72 meters
The beam is 1040 meters
The displacement is 600 metric tones
fully equipped the worlds largest CRP
construction
The design of the Visby aims to minimize
the optical and infrared signature above
water acoustic and hydroa coustic
signature underwater electrical potential
and magnetic signature pressure signature
radar cross section and actively emitted
signals
A stealth corvette of the YS 2000 design
has a detection range of 13km in rough
seas and 22km in calm sea without
jamming In a jammed environment the
Visby would be detected at a range of 8km
in rough sea and 11km in calm sea
The material provides high strength and
rigidity low weight good shock resistance
low radar and magnetic signature
1996
Visby is a class of stealth corvettes for the Swedish Navy
ldquoReduced 50 of a Conventional Steelrdquo
Source
Hull Construction with composite materials for ships over 100m in length 2002
Massachusetts Institute of Technology
httpwwwnaval-technologycomprojectsvisby
YACHTS
KAL YUDISTIRAMARATHON 100 ADMIRAL YACHT
LOA 3050 MWidth 6 MFuel Tank 8000 LWater Tank 3000 LIce Box 500 LAccommodation Max 35 Personnel
2 x CATERPILLAR 3412E 1200 HPMARINE DIESEL ENGINE
PC 40 ndash KRI Krait 827Department of Indonesian Navy
LOA 40 MWidth 73 MPower 190Weapon Twin Cannon Barrels
127 mm Heavy Machine GunSpeed Knot 25 KnotDisplacement 105 tonAccommodation 23 personnel
PATROL BOAT
Rigid Inflatable BoatPATROL BOAT
Yachts
36m Luxury Yacht Moonraker
36m Luxury Yacht GoldenEye
50m Luxury Yacht Casino
Royale
45m Luxury Yacht Seashaw
Boat Parts
Barovans for Seismic Sweep
Centrifugal Liftfan House for Surface Effect
Ships
Composite Boat PropellersRTM
Deckhouses for Pilot Boats
Fairing Parts for Submarines
Flybridges for Motor yachts
Light Weight Gangway
MTB Launcher Mock-up
Pleasure Boats
12m Sailboat
12m Sail-Catamaranone-off
Canoes
Dragonfly 1000Catamaran Sailboat
Fantasy 37Sailboat
Farr 60Luxury Sailboat
EurodingyOlympic Dingy Class for
Woman
Hydrolift F23 Racing Boats
Kajacs
Najad 42Sailboat
Najad 520Sailboat
Najad 441Sailboat
Najad 391Sailboat
Nordwest 900Motorboat
Nordwest 1100Motorboat
Quatro 44Motorboat
Racemaster Competition Boats
Storebro 420
Storebro 345
Sweden Yacht 370Sailboat
Sweden Yacht 69Sailboat
Windy 41Motorboat
X-632Sailboat
X-362Sailboat
Commercial Boats
175m High Speed AmbulancePassenger Boat
19m High Speed Passenger Boat
20m High Speed Passenger Boat
364m Surface Effect Passenger Ship
45m Surface Effect Passenger Ship
120m Hull Structural Parts HSSS Catamaran Ferry
APPENDIX
Marine Vessel
1188m Fast Attack Vessel FMV 90 E
20m SAV-Surface Auxiliary Vessels
34m Personnel TransportCoast Guard Vessel
40ft Experimental SES
40m Landsort-Class Mine Hunters
54m Mine Counter Measure Vehicles SES
74m Coastal Patrol Boats
Fishing Boats
30 GT
12 GT
10 GT
5 GT
WISEWings In Surface Effect
HOVERCRAFT
Designed specifically for the tourist and transport industries the
Pioneer Mk3 hovercraft is amphibious and comfortably seats 25
passengers plus 1-crew The air-conditioned cabin allows for
maximum visibility for all aboard The Pioneer Mk3 is robust and
dynamic in its performance
Commercial hovercraft
Mk3 AirLift Hovercraft - 1215m
Power is economicaly provided by one Deutz diesel engine of
330kW (442hp) to cruise easily at 40 knots with much higher
speeds available according to the surface conditions The hull is
manufactured from fibreglassPVC foam composite sandwich
the windows are glass and the skirt is urethane coated nylon A
Military version is available with increased payload and systems
redundancy Power for the Military version comes from two Steyr
diesel engines with a total installed power of 320kW (429hp) All
transmission electrical hydraulic and air systems are duplicated
for maximum redundancy The increased performance of the
Military version comes from the reduced engine weight of the twin
Steyr installation cf the Deutz installation
Source
httpwwwnauticexpocomprodairlift-hovercraftcommercial-hovercrafts-25251-142868html
HOVERFLIGHT
BALLISTIC amp UNIT DEFENCED
Triaxis Composites Collaboration with Institute of Aeronautics and Space in the development of Missile Nose Cone
Polymer composites is the evolution of the military defence
Thin steel was the helmet material of
WWII and remained the principal material until around the 1980rsquos
The advantages of using steel
included a simple technology for manufacture of the helmets low cost and reasonably good
impact protection However these helmets were found to provide only marginal protection
against fragments
During the Vietnam War the US Army experimented with fiber-reinforced inserts in the
helmets These inserts improved ballistic protection but at the same time added weight and
reduced the air space between the head and the helmet
By the early part of the 1980rsquos the US military had developed the first all-composite
100 fiber-reinforced helmet This development resulted in even better ballistic protection
without altering the weight of the helmet Other improvements included better head coverage and
more space for ventilation
Source
Composites Armor - A difficult but huge market
by A Brent Strong Brigham Young University
MILITARY VEHICLES
HIGH SPEED TRAIN SHINKANSEN
Advanced Composites provide lightweight solutions for railway vehicles
saving as much as 50-80 of the weight compared with traditional
components
A lower overall weight translates into less stress faster acceleration and
higher speeds as well as reduced starting and stopping inertia Today
these are important criteria in global high-speed and metropolitan
railway projects
Fire smoke and toxic fumes are key safety criteria for interior
components of railway carriages Any material selected for an interior
component must meet international fire retardant standards
for Rail Interiors and Exteriors
Ceiling Panels Stairs
Seating Vestibules
Window Panels Door Pillars
Partition WallsDiffusers
Gangway and Cabinet Panels Cabin and
Desk panels
Door Pillars Lavatory Modules (standard and
Front and Rear EndsRoof Panels
Nose Cones Under Fairings
Source
httpwwwpctaerail_compositesphp
101
SKY BUS
2009
Europe is the world leader in offshore wind with
828 wind turbines and a cumulative capacity of 2056 MW spread across 38 offshore wind farms in 9
European countries
The UK and Denmark are the current leaders with a 44 and 30 share respectively In 2009
five countries built new offshore wind farms
UK (284 MW)
Demark (230 MW)
Sweden (30 MW)
Germany (30 MW)
Norway (23 MW)
2010
Asia leads the growth in global wind power which grew 358 GW in 2010 bringing
total global capacity to 1944 GW ndash up 225 from 2009
the Global Wind Energy Council (GWEC)
Asia accounted for 19 GW of new global wind power installations driven by China which installed 165
GW
ldquoChina now has 423 GW of wind powerrdquo
ldquoThis puts China firmly on a path to reach 200 GW of installed wind power by 2020 At the same
time China has become the worldrsquos largest producer of wind energy equipmentrdquo
Source
httpwwwreinforcedplasticscomview15655asia-leads-global-wind-power-growth
httpimgdeusmcomdesignnews288288605-Sandia_Sizes_up_Wind_Turbine_Blade_Design_C_largegif
WIND ENERGY
Marine Current Turbines
Source
httpwwwsiemenscompressenpressreleasepress=enpressrelease2011solar-hydroex201111005htm
httpwwwmarineturbinescom
A commercial marine current turbine consists of
two rotors which are fixed on a structure within the
sea current The twin rotors rotate with the
movement of the tidal flow and the blades pitch
through 180 degrees to optimally track tidal current
(Press picture Marine Current Turbines)
Wave Star Energys Multi-point Absorber
CFRP COLUMN REINFORCEMENT
INDUSTRIAL TANKS
107
INDUSTRIAL PIPES
PRESSURE TANKS
109
ldquoLetrsquos Make with Compositesrdquo
Typical Properties of Common Structural Materials
Kesimpulan COMPOSITES = RINGAN amp KUAT
Jadi secara keseluruhan kekuatan composites
ditentukan oleh
1 Kekuatan amp Sifat Fiber
2 Kekuatan amp Sifat Resin
3 Fraksi Rasio Perbandingan Volume Fiber
dan Resin dalam Composites
4 Geometri dan Orientasi Arah Fiber dalam
Composites
PRODUKSI ANAK NEGERI
Proses Produksi Kain Fiberglass
Biji Kaca Benang Benang Kaca Kain Fiberglass
PROSES MATERIAL
Glass Beads
Glass Fiber Glass Roving YarnGlass Fabric
Proses Produksi Kain Fiberglass
Biji Kaca Benang Benang Kaca Kain Fiberglass
Glass Beads
Glass Fiber Glass Roving YarnGlass Fabric
PROSES MATERIAL
Benang Kaca Potongan Serat Kaca Chopped Strand Mat
CSM - Chopped Strand Mat
chopped binder
Produk Fiberglass Generasi Pertama
Bahan Pengikat
Senyawa Pada Resin
Glass Roving Yarn Chopped Strand
JENIS FIBERGLASS
Benang Kaca Woven Roving
WR - Woven Roving
Tenun Weaving
Produk Fiberglass Generasi Kedua
Glass Roving Yarn
JENIS FIBERGLASS
Multiaxial
MAX - Multiaxial
warp knitting
Produk Fiberglass Generasi Ketiga
Benang Kaca
Glass Roving Yarn
JENIS FIBERGLASS
MAX - Multiaxial Fabric
Fleece (optional)
Lapisan
MULTIAXIAL PROSES
Karakteristik CSM
bull Glass Content 30
bull Resin Content 70
bull Tensile Force
Chopped Strand Mat
JENIS FIBERGLASS
Karakteristik Woven Roving
bull Glass Content 45
bull Resin Content 55
Woven Roving
Resin
|
|
|
|
|
|
|
|
|
|
|
|
|
|
bull Kekuatan Tarik
JENIS FIBERGLASS
No Resin Rich Area
Karakteristik Multiaxial
bull Glass Content 60
bull Resin Content 40
Produk Fiberglass Ketiga MULTIAXIAL
JENIS FIBERGLASS
Perbedaan Woven Roving dan Multiaxial ndash Tampak Samping
JENIS FIBERGLASS
WR FRP
8 Ply WR 800
8 Ply CSM 450
Glass Weight 1 kg
Composite Weight 15kgm2
CSM FRP
22 Ply CSM 450
Glass Weight 1 kg
Composite Weight 18 kgm2
MULTIAXIAL FRP
13 Ply DB 800
Glass Weight 1 kg
Composite Weight
13 kgm2
JENIS FIBERGLASS
Multiaxial
FRP
Woven Roving
FRP
Chopped Strands Mat FRP
MULTIAXIAL
FAKTA
TEBAL BUKAN BERARTI KUAT
UNSUR MATRIX (RESIN)
TIDAK ADA KEKUATAN
ldquoMore than 50 of the glass fibers used for reinforcement is
E-glassrdquo
KarakteristikKekuatan
CSM WR MAX
Kekuatan Tarik 175 MPa 250 MPa 425 MPa
CSM 142
WR 70
KEKUATAN TARIK
Properties CSM Lamination WR Lamination MAX Lamination
Fabric Weight (kgm2) 1 1 1
Composite Weight (kgm2) 18 15 13
Resin usage (kgm2) 15 1 08
Amount of Fabric 22 Ply 16 Ply 13 Ply
Thickness 15 mm 12 mm 10 mm
Tensile Strength (Mpa) 125 1796 400
Tensile Strength (Nmmsup2) 28463 30958 4576
Processing Time High Med Low
Labour Cost High Med Low
MULTIAXIAL
Total Penggunaan Resin -51
Total Berat Kapal -40
Kekuatan Bangunan Kapal +59
Efisiensi Tenaga Kerja
Waktu Pengerjaan Lebih Cepat
KEUNGGULAN MATERIAL
Resapan Resin Lebih Baik amp Merata
Lapisan Lebih Sedikit
Meningkatkan Kekuatan Kapal
KEUNGGULAN MATERIAL
TRIAXIAL
DBL series DBT series
BIAXIAL
LT series DB series
UNIDIRECTIONAL
L series T series
QUADRIAXIAL
DBLT series
JENIS MULTIAXIAL
UNIDIRECTIONAL
DCMU 900 E ndash
KHUSUS UNTUK MEMPERKUAT BENDING KAPAL
PEMASANGAN KHUSUS PADA KEEL DAN TULANGAN
JENIS MULTIAXIAL UNTUK KAPAL
TRIAXIAL
DBL 600 ndash
APLIKASI PADA INDUSTRI PENERBANGAN
PEMASANGAN KHUSUS PADA
SAMBUNGAN BADAN DAN SAYAP
PESAWAT
JENIS MULTIAXIAL UNTUK PESAWAT
QUADRAXIAL
DBLT 800 ndash
APLIKASI PADA INDUSTRI ENERGI
DITERAPKAN UNTUK KEBUTUHAN PEMBANGKIT
LISTRIK ENERGI ANGIN
MULTIAXIAL UNTUK ENERGI
INDUSTRI KIMIA OLAHRAGA AUTOMOTIF
MULTIAXIAL UNTUK INDUSTRI LAINNYA
COMPOSITES
GUNAKAN MATERIAL FIBERGLASS
YANG SUDAH DISERTIFIKASI
BKI
FIBERGLASS UNTUK PEMBANGUNAN BAKAP
PERATURAN MENTERI PERHUBUNGAN
NOMOR PM 7 TAHUN 2013
TENTANG KEWAJIBAN KLASIFIKASI BAGI KAPAL BERBENDERA INDONESIA
PADA BADAN KLASIFIKASI
BADAN SERTIFIKASI MARITIM
Biro Klasifikasi IndonesiaDet Norske Veritas Germanischer Lloyds
PERATURAN BKI
Untuk Kapal Non-Metal
2006
PERSYARATAN MINIMUM
kekuatan material yang
harus digunakan
untuk membangun
Kapal Fiberglass
PEMBESARAN
Table 21
FIBERGLASS TRIAXIS COMPOSITES
TELAH BERSERTIFIKASI BKI
Biro Klasifikasi Indonesia
65
TEKNIK MANUFAKTUR
COMPOSITES
Wet hand lay-up
1) Peletakan
Dry Reinforcement
bull Dry reinforcement dan resin (+ katalis) ditaruh pada permukaan cetakan
2) Pemasukanpenekanan resin
bull Resin ditekan untuk meng-impregnasi serat dengan menggunakan rol
3) Pengulangan proses untuk lapisan lain
bull Beberapa lapisan dapat ditambahkan secara bertahap
4) Resin curing
bull Reaksi dimulai komponen dilepaskan setelah komponen mengeras
(fully cured)
Wet hand lay-up
Manufaktur komponen dapat dikerjakan dengan menggunakan beberapa lapis komposit
dengan memperhatikan kompatibilitas material dan tahapan curing Modifikasi proses dapat
dilakukan seperti
Vacuum bagging
setelah lay-up
Glass Roving
Bulk Resin
Catalyst
3) De-molding
2) Resin Cure
bull Curing dimulai dan komponen dilepaskan setelah pengerasan selesai
bull Serat gelas resin dan katalis dimasukkan kedalam spray gun
1) Spray-up
bull Campuran disemprotkan pada permukaan cetakan
Spray-up
69
Penyemprotan bakal komponen
Komponen
dilepaskan
dari cetakan
Full dispensing
system Chopper Roving
Atomised resin
and catalyst
Spray-up
Prepreg
1) LaminateAssembly 5) De-molding
3) Resin Melts Layup Consolidates
bull Prepreg serat yang sudah diimpregnasi oleh resin+katalis dalam kondisi padat
bull Lapisan prepreg digunting sesuai bentuk yang diinginkan kemudian diletakkan pada permukaan cetakan
sesuai bentuk komponen yang diinginkan Lay-up mudah dilakukan karena sifat ldquotackynessrdquo dari prepreg
2) Applied Vacuum Pressure and Heat
bull Tekanan dan panas diberikan resin mencair terjadi konsolidasi pada komponen
4) Resin Cures
bull Temperatur dinaikkan untuk memulai curing
Prepreg
Variasi proses Autoclave
Komponen dalam
vacuum-bag
bull Campuran resin (+katalis) dan chopped glass strands diperoleh dalam bentuk premixed compound Bulk molding
Compound (BMC) dalam bentuk adonan atau Sheet molding Compound (SMC) dalam bentuk lembaran
bull Ketika panas dan tekanan diberikan oleh cetakan compound mengalir sesuai bentuk komponen yang diinginkan
1) Placement of Charge
5) De-molding3) Squeeze to final dimensions
2) Mould Closure4) Resin Cure
bull Curing dimulai komponen dilepaskan setelah terjadi pengerasan yang cukup
Compression Molding
bull Preform atau dry reinforcement dimasukkan kedalam cetakan sesuai dengan bentuk komponen yang
diinginkan
bull Resin mengalir dengan penekanan atau pem-vakuman dan meng-impregnasi preform dan
mendorongmengeluarkan udara yang ada dalam preform
1) Preform Manufacture
2) Preform Compression
5) De-molding3) Resin Injection
4) Resin Cure
bull Curing terjadi cetakan dibuka setelah terjadi pengerasan yang mencukupi
Liquid Molding (RTM VARI VARTM)
Pultrusion
bull Dry roving or fabrics ditarik melalui bak berisi
campuran resin dan katalis
bull Campuran yang basah ditarik melalui cetakan
bull Sisa resin keluar cetakan
bull Pemanasan dilakukan untuk proses curing
bull Pendinginan dilakukan untuk mempercepat siklus
produksi
Cut-off
Cooling
Die sections
Resin bath
Fibre creel
Filament Winding
bull Dry roving ditarik melalui bak berisi campuran resin dan katalis
bull Wet roving digulungkan dalam keadaan tegang kepada mandrel
bull Kontrol mekanik dari pembawa serat mengatur orientasi peletakan serat pada
mandrel
INDUSTRI COMPOSITES
AEROSPACE
HISTORY
1950 ndash Boeing
1960 ndash F14 Tomcat
1981 ndash AV-8B Harrier
Source
Low-Cost Composite Materials and Structures for Aircraft Applications
httpwwwreinforcedplasticscom
httpwwwcentennialofflightgovessayEvolution_of_TechnologycompositesTech40htm
Automotive
Composite material is used in a number of applications in the automotive
industry due to its temperature resistance rigidity and fatigue strength
The benefits of using composites include greater fuel efficiency
corrosion resistance light weight and strength Composites also provide
a low-cost way to help keep designs looking fresh
Composites are used in
- interior parts (cockpit trimming seats instrument panels)
- exterior structure (body panels openings underbody frontrear
modules)
- engine compartment and fuelmechanical area parts (axles and
suspensions fuel and exhaust systems)
- electrical and electronic components
Lamborghinis Sesto Element carbon fiber
ldquoFat men cannot run as fast as thin men but we build most of our vehicles as though dead-weight fat increased speedhellip I cannot
imagine where the delusion that weight means strength
came fromhelliprdquo mdashHenry Ford
The mix of automotive materials is changing showing a boost for FRP in helping original
equipment manufacturers meet fuel economy and emissions challenges
(Source 2011 DuPont AutomotiveSAE survey of design engineers performed by Signet Research Inc)
Source
httpwwwtoraycomcsrhighlight2009hig_001_01html
The MonoCell tub for the McLaren MP4-12C supercar is moulded as a single
piece and weighs less than 80 kg (176 lbs)
COMPOSITES IN MARINE
TRIMARAN BOAT
AMERICA NAVYINDONESIAN NAVY
Visby Class corvette
Total length is 72 meters
The beam is 1040 meters
The displacement is 600 metric tones
fully equipped the worlds largest CRP
construction
The design of the Visby aims to minimize
the optical and infrared signature above
water acoustic and hydroa coustic
signature underwater electrical potential
and magnetic signature pressure signature
radar cross section and actively emitted
signals
A stealth corvette of the YS 2000 design
has a detection range of 13km in rough
seas and 22km in calm sea without
jamming In a jammed environment the
Visby would be detected at a range of 8km
in rough sea and 11km in calm sea
The material provides high strength and
rigidity low weight good shock resistance
low radar and magnetic signature
1996
Visby is a class of stealth corvettes for the Swedish Navy
ldquoReduced 50 of a Conventional Steelrdquo
Source
Hull Construction with composite materials for ships over 100m in length 2002
Massachusetts Institute of Technology
httpwwwnaval-technologycomprojectsvisby
YACHTS
KAL YUDISTIRAMARATHON 100 ADMIRAL YACHT
LOA 3050 MWidth 6 MFuel Tank 8000 LWater Tank 3000 LIce Box 500 LAccommodation Max 35 Personnel
2 x CATERPILLAR 3412E 1200 HPMARINE DIESEL ENGINE
PC 40 ndash KRI Krait 827Department of Indonesian Navy
LOA 40 MWidth 73 MPower 190Weapon Twin Cannon Barrels
127 mm Heavy Machine GunSpeed Knot 25 KnotDisplacement 105 tonAccommodation 23 personnel
PATROL BOAT
Rigid Inflatable BoatPATROL BOAT
Yachts
36m Luxury Yacht Moonraker
36m Luxury Yacht GoldenEye
50m Luxury Yacht Casino
Royale
45m Luxury Yacht Seashaw
Boat Parts
Barovans for Seismic Sweep
Centrifugal Liftfan House for Surface Effect
Ships
Composite Boat PropellersRTM
Deckhouses for Pilot Boats
Fairing Parts for Submarines
Flybridges for Motor yachts
Light Weight Gangway
MTB Launcher Mock-up
Pleasure Boats
12m Sailboat
12m Sail-Catamaranone-off
Canoes
Dragonfly 1000Catamaran Sailboat
Fantasy 37Sailboat
Farr 60Luxury Sailboat
EurodingyOlympic Dingy Class for
Woman
Hydrolift F23 Racing Boats
Kajacs
Najad 42Sailboat
Najad 520Sailboat
Najad 441Sailboat
Najad 391Sailboat
Nordwest 900Motorboat
Nordwest 1100Motorboat
Quatro 44Motorboat
Racemaster Competition Boats
Storebro 420
Storebro 345
Sweden Yacht 370Sailboat
Sweden Yacht 69Sailboat
Windy 41Motorboat
X-632Sailboat
X-362Sailboat
Commercial Boats
175m High Speed AmbulancePassenger Boat
19m High Speed Passenger Boat
20m High Speed Passenger Boat
364m Surface Effect Passenger Ship
45m Surface Effect Passenger Ship
120m Hull Structural Parts HSSS Catamaran Ferry
APPENDIX
Marine Vessel
1188m Fast Attack Vessel FMV 90 E
20m SAV-Surface Auxiliary Vessels
34m Personnel TransportCoast Guard Vessel
40ft Experimental SES
40m Landsort-Class Mine Hunters
54m Mine Counter Measure Vehicles SES
74m Coastal Patrol Boats
Fishing Boats
30 GT
12 GT
10 GT
5 GT
WISEWings In Surface Effect
HOVERCRAFT
Designed specifically for the tourist and transport industries the
Pioneer Mk3 hovercraft is amphibious and comfortably seats 25
passengers plus 1-crew The air-conditioned cabin allows for
maximum visibility for all aboard The Pioneer Mk3 is robust and
dynamic in its performance
Commercial hovercraft
Mk3 AirLift Hovercraft - 1215m
Power is economicaly provided by one Deutz diesel engine of
330kW (442hp) to cruise easily at 40 knots with much higher
speeds available according to the surface conditions The hull is
manufactured from fibreglassPVC foam composite sandwich
the windows are glass and the skirt is urethane coated nylon A
Military version is available with increased payload and systems
redundancy Power for the Military version comes from two Steyr
diesel engines with a total installed power of 320kW (429hp) All
transmission electrical hydraulic and air systems are duplicated
for maximum redundancy The increased performance of the
Military version comes from the reduced engine weight of the twin
Steyr installation cf the Deutz installation
Source
httpwwwnauticexpocomprodairlift-hovercraftcommercial-hovercrafts-25251-142868html
HOVERFLIGHT
BALLISTIC amp UNIT DEFENCED
Triaxis Composites Collaboration with Institute of Aeronautics and Space in the development of Missile Nose Cone
Polymer composites is the evolution of the military defence
Thin steel was the helmet material of
WWII and remained the principal material until around the 1980rsquos
The advantages of using steel
included a simple technology for manufacture of the helmets low cost and reasonably good
impact protection However these helmets were found to provide only marginal protection
against fragments
During the Vietnam War the US Army experimented with fiber-reinforced inserts in the
helmets These inserts improved ballistic protection but at the same time added weight and
reduced the air space between the head and the helmet
By the early part of the 1980rsquos the US military had developed the first all-composite
100 fiber-reinforced helmet This development resulted in even better ballistic protection
without altering the weight of the helmet Other improvements included better head coverage and
more space for ventilation
Source
Composites Armor - A difficult but huge market
by A Brent Strong Brigham Young University
MILITARY VEHICLES
HIGH SPEED TRAIN SHINKANSEN
Advanced Composites provide lightweight solutions for railway vehicles
saving as much as 50-80 of the weight compared with traditional
components
A lower overall weight translates into less stress faster acceleration and
higher speeds as well as reduced starting and stopping inertia Today
these are important criteria in global high-speed and metropolitan
railway projects
Fire smoke and toxic fumes are key safety criteria for interior
components of railway carriages Any material selected for an interior
component must meet international fire retardant standards
for Rail Interiors and Exteriors
Ceiling Panels Stairs
Seating Vestibules
Window Panels Door Pillars
Partition WallsDiffusers
Gangway and Cabinet Panels Cabin and
Desk panels
Door Pillars Lavatory Modules (standard and
Front and Rear EndsRoof Panels
Nose Cones Under Fairings
Source
httpwwwpctaerail_compositesphp
101
SKY BUS
2009
Europe is the world leader in offshore wind with
828 wind turbines and a cumulative capacity of 2056 MW spread across 38 offshore wind farms in 9
European countries
The UK and Denmark are the current leaders with a 44 and 30 share respectively In 2009
five countries built new offshore wind farms
UK (284 MW)
Demark (230 MW)
Sweden (30 MW)
Germany (30 MW)
Norway (23 MW)
2010
Asia leads the growth in global wind power which grew 358 GW in 2010 bringing
total global capacity to 1944 GW ndash up 225 from 2009
the Global Wind Energy Council (GWEC)
Asia accounted for 19 GW of new global wind power installations driven by China which installed 165
GW
ldquoChina now has 423 GW of wind powerrdquo
ldquoThis puts China firmly on a path to reach 200 GW of installed wind power by 2020 At the same
time China has become the worldrsquos largest producer of wind energy equipmentrdquo
Source
httpwwwreinforcedplasticscomview15655asia-leads-global-wind-power-growth
httpimgdeusmcomdesignnews288288605-Sandia_Sizes_up_Wind_Turbine_Blade_Design_C_largegif
WIND ENERGY
Marine Current Turbines
Source
httpwwwsiemenscompressenpressreleasepress=enpressrelease2011solar-hydroex201111005htm
httpwwwmarineturbinescom
A commercial marine current turbine consists of
two rotors which are fixed on a structure within the
sea current The twin rotors rotate with the
movement of the tidal flow and the blades pitch
through 180 degrees to optimally track tidal current
(Press picture Marine Current Turbines)
Wave Star Energys Multi-point Absorber
CFRP COLUMN REINFORCEMENT
INDUSTRIAL TANKS
107
INDUSTRIAL PIPES
PRESSURE TANKS
109
ldquoLetrsquos Make with Compositesrdquo
Kesimpulan COMPOSITES = RINGAN amp KUAT
Jadi secara keseluruhan kekuatan composites
ditentukan oleh
1 Kekuatan amp Sifat Fiber
2 Kekuatan amp Sifat Resin
3 Fraksi Rasio Perbandingan Volume Fiber
dan Resin dalam Composites
4 Geometri dan Orientasi Arah Fiber dalam
Composites
PRODUKSI ANAK NEGERI
Proses Produksi Kain Fiberglass
Biji Kaca Benang Benang Kaca Kain Fiberglass
PROSES MATERIAL
Glass Beads
Glass Fiber Glass Roving YarnGlass Fabric
Proses Produksi Kain Fiberglass
Biji Kaca Benang Benang Kaca Kain Fiberglass
Glass Beads
Glass Fiber Glass Roving YarnGlass Fabric
PROSES MATERIAL
Benang Kaca Potongan Serat Kaca Chopped Strand Mat
CSM - Chopped Strand Mat
chopped binder
Produk Fiberglass Generasi Pertama
Bahan Pengikat
Senyawa Pada Resin
Glass Roving Yarn Chopped Strand
JENIS FIBERGLASS
Benang Kaca Woven Roving
WR - Woven Roving
Tenun Weaving
Produk Fiberglass Generasi Kedua
Glass Roving Yarn
JENIS FIBERGLASS
Multiaxial
MAX - Multiaxial
warp knitting
Produk Fiberglass Generasi Ketiga
Benang Kaca
Glass Roving Yarn
JENIS FIBERGLASS
MAX - Multiaxial Fabric
Fleece (optional)
Lapisan
MULTIAXIAL PROSES
Karakteristik CSM
bull Glass Content 30
bull Resin Content 70
bull Tensile Force
Chopped Strand Mat
JENIS FIBERGLASS
Karakteristik Woven Roving
bull Glass Content 45
bull Resin Content 55
Woven Roving
Resin
|
|
|
|
|
|
|
|
|
|
|
|
|
|
bull Kekuatan Tarik
JENIS FIBERGLASS
No Resin Rich Area
Karakteristik Multiaxial
bull Glass Content 60
bull Resin Content 40
Produk Fiberglass Ketiga MULTIAXIAL
JENIS FIBERGLASS
Perbedaan Woven Roving dan Multiaxial ndash Tampak Samping
JENIS FIBERGLASS
WR FRP
8 Ply WR 800
8 Ply CSM 450
Glass Weight 1 kg
Composite Weight 15kgm2
CSM FRP
22 Ply CSM 450
Glass Weight 1 kg
Composite Weight 18 kgm2
MULTIAXIAL FRP
13 Ply DB 800
Glass Weight 1 kg
Composite Weight
13 kgm2
JENIS FIBERGLASS
Multiaxial
FRP
Woven Roving
FRP
Chopped Strands Mat FRP
MULTIAXIAL
FAKTA
TEBAL BUKAN BERARTI KUAT
UNSUR MATRIX (RESIN)
TIDAK ADA KEKUATAN
ldquoMore than 50 of the glass fibers used for reinforcement is
E-glassrdquo
KarakteristikKekuatan
CSM WR MAX
Kekuatan Tarik 175 MPa 250 MPa 425 MPa
CSM 142
WR 70
KEKUATAN TARIK
Properties CSM Lamination WR Lamination MAX Lamination
Fabric Weight (kgm2) 1 1 1
Composite Weight (kgm2) 18 15 13
Resin usage (kgm2) 15 1 08
Amount of Fabric 22 Ply 16 Ply 13 Ply
Thickness 15 mm 12 mm 10 mm
Tensile Strength (Mpa) 125 1796 400
Tensile Strength (Nmmsup2) 28463 30958 4576
Processing Time High Med Low
Labour Cost High Med Low
MULTIAXIAL
Total Penggunaan Resin -51
Total Berat Kapal -40
Kekuatan Bangunan Kapal +59
Efisiensi Tenaga Kerja
Waktu Pengerjaan Lebih Cepat
KEUNGGULAN MATERIAL
Resapan Resin Lebih Baik amp Merata
Lapisan Lebih Sedikit
Meningkatkan Kekuatan Kapal
KEUNGGULAN MATERIAL
TRIAXIAL
DBL series DBT series
BIAXIAL
LT series DB series
UNIDIRECTIONAL
L series T series
QUADRIAXIAL
DBLT series
JENIS MULTIAXIAL
UNIDIRECTIONAL
DCMU 900 E ndash
KHUSUS UNTUK MEMPERKUAT BENDING KAPAL
PEMASANGAN KHUSUS PADA KEEL DAN TULANGAN
JENIS MULTIAXIAL UNTUK KAPAL
TRIAXIAL
DBL 600 ndash
APLIKASI PADA INDUSTRI PENERBANGAN
PEMASANGAN KHUSUS PADA
SAMBUNGAN BADAN DAN SAYAP
PESAWAT
JENIS MULTIAXIAL UNTUK PESAWAT
QUADRAXIAL
DBLT 800 ndash
APLIKASI PADA INDUSTRI ENERGI
DITERAPKAN UNTUK KEBUTUHAN PEMBANGKIT
LISTRIK ENERGI ANGIN
MULTIAXIAL UNTUK ENERGI
INDUSTRI KIMIA OLAHRAGA AUTOMOTIF
MULTIAXIAL UNTUK INDUSTRI LAINNYA
COMPOSITES
GUNAKAN MATERIAL FIBERGLASS
YANG SUDAH DISERTIFIKASI
BKI
FIBERGLASS UNTUK PEMBANGUNAN BAKAP
PERATURAN MENTERI PERHUBUNGAN
NOMOR PM 7 TAHUN 2013
TENTANG KEWAJIBAN KLASIFIKASI BAGI KAPAL BERBENDERA INDONESIA
PADA BADAN KLASIFIKASI
BADAN SERTIFIKASI MARITIM
Biro Klasifikasi IndonesiaDet Norske Veritas Germanischer Lloyds
PERATURAN BKI
Untuk Kapal Non-Metal
2006
PERSYARATAN MINIMUM
kekuatan material yang
harus digunakan
untuk membangun
Kapal Fiberglass
PEMBESARAN
Table 21
FIBERGLASS TRIAXIS COMPOSITES
TELAH BERSERTIFIKASI BKI
Biro Klasifikasi Indonesia
65
TEKNIK MANUFAKTUR
COMPOSITES
Wet hand lay-up
1) Peletakan
Dry Reinforcement
bull Dry reinforcement dan resin (+ katalis) ditaruh pada permukaan cetakan
2) Pemasukanpenekanan resin
bull Resin ditekan untuk meng-impregnasi serat dengan menggunakan rol
3) Pengulangan proses untuk lapisan lain
bull Beberapa lapisan dapat ditambahkan secara bertahap
4) Resin curing
bull Reaksi dimulai komponen dilepaskan setelah komponen mengeras
(fully cured)
Wet hand lay-up
Manufaktur komponen dapat dikerjakan dengan menggunakan beberapa lapis komposit
dengan memperhatikan kompatibilitas material dan tahapan curing Modifikasi proses dapat
dilakukan seperti
Vacuum bagging
setelah lay-up
Glass Roving
Bulk Resin
Catalyst
3) De-molding
2) Resin Cure
bull Curing dimulai dan komponen dilepaskan setelah pengerasan selesai
bull Serat gelas resin dan katalis dimasukkan kedalam spray gun
1) Spray-up
bull Campuran disemprotkan pada permukaan cetakan
Spray-up
69
Penyemprotan bakal komponen
Komponen
dilepaskan
dari cetakan
Full dispensing
system Chopper Roving
Atomised resin
and catalyst
Spray-up
Prepreg
1) LaminateAssembly 5) De-molding
3) Resin Melts Layup Consolidates
bull Prepreg serat yang sudah diimpregnasi oleh resin+katalis dalam kondisi padat
bull Lapisan prepreg digunting sesuai bentuk yang diinginkan kemudian diletakkan pada permukaan cetakan
sesuai bentuk komponen yang diinginkan Lay-up mudah dilakukan karena sifat ldquotackynessrdquo dari prepreg
2) Applied Vacuum Pressure and Heat
bull Tekanan dan panas diberikan resin mencair terjadi konsolidasi pada komponen
4) Resin Cures
bull Temperatur dinaikkan untuk memulai curing
Prepreg
Variasi proses Autoclave
Komponen dalam
vacuum-bag
bull Campuran resin (+katalis) dan chopped glass strands diperoleh dalam bentuk premixed compound Bulk molding
Compound (BMC) dalam bentuk adonan atau Sheet molding Compound (SMC) dalam bentuk lembaran
bull Ketika panas dan tekanan diberikan oleh cetakan compound mengalir sesuai bentuk komponen yang diinginkan
1) Placement of Charge
5) De-molding3) Squeeze to final dimensions
2) Mould Closure4) Resin Cure
bull Curing dimulai komponen dilepaskan setelah terjadi pengerasan yang cukup
Compression Molding
bull Preform atau dry reinforcement dimasukkan kedalam cetakan sesuai dengan bentuk komponen yang
diinginkan
bull Resin mengalir dengan penekanan atau pem-vakuman dan meng-impregnasi preform dan
mendorongmengeluarkan udara yang ada dalam preform
1) Preform Manufacture
2) Preform Compression
5) De-molding3) Resin Injection
4) Resin Cure
bull Curing terjadi cetakan dibuka setelah terjadi pengerasan yang mencukupi
Liquid Molding (RTM VARI VARTM)
Pultrusion
bull Dry roving or fabrics ditarik melalui bak berisi
campuran resin dan katalis
bull Campuran yang basah ditarik melalui cetakan
bull Sisa resin keluar cetakan
bull Pemanasan dilakukan untuk proses curing
bull Pendinginan dilakukan untuk mempercepat siklus
produksi
Cut-off
Cooling
Die sections
Resin bath
Fibre creel
Filament Winding
bull Dry roving ditarik melalui bak berisi campuran resin dan katalis
bull Wet roving digulungkan dalam keadaan tegang kepada mandrel
bull Kontrol mekanik dari pembawa serat mengatur orientasi peletakan serat pada
mandrel
INDUSTRI COMPOSITES
AEROSPACE
HISTORY
1950 ndash Boeing
1960 ndash F14 Tomcat
1981 ndash AV-8B Harrier
Source
Low-Cost Composite Materials and Structures for Aircraft Applications
httpwwwreinforcedplasticscom
httpwwwcentennialofflightgovessayEvolution_of_TechnologycompositesTech40htm
Automotive
Composite material is used in a number of applications in the automotive
industry due to its temperature resistance rigidity and fatigue strength
The benefits of using composites include greater fuel efficiency
corrosion resistance light weight and strength Composites also provide
a low-cost way to help keep designs looking fresh
Composites are used in
- interior parts (cockpit trimming seats instrument panels)
- exterior structure (body panels openings underbody frontrear
modules)
- engine compartment and fuelmechanical area parts (axles and
suspensions fuel and exhaust systems)
- electrical and electronic components
Lamborghinis Sesto Element carbon fiber
ldquoFat men cannot run as fast as thin men but we build most of our vehicles as though dead-weight fat increased speedhellip I cannot
imagine where the delusion that weight means strength
came fromhelliprdquo mdashHenry Ford
The mix of automotive materials is changing showing a boost for FRP in helping original
equipment manufacturers meet fuel economy and emissions challenges
(Source 2011 DuPont AutomotiveSAE survey of design engineers performed by Signet Research Inc)
Source
httpwwwtoraycomcsrhighlight2009hig_001_01html
The MonoCell tub for the McLaren MP4-12C supercar is moulded as a single
piece and weighs less than 80 kg (176 lbs)
COMPOSITES IN MARINE
TRIMARAN BOAT
AMERICA NAVYINDONESIAN NAVY
Visby Class corvette
Total length is 72 meters
The beam is 1040 meters
The displacement is 600 metric tones
fully equipped the worlds largest CRP
construction
The design of the Visby aims to minimize
the optical and infrared signature above
water acoustic and hydroa coustic
signature underwater electrical potential
and magnetic signature pressure signature
radar cross section and actively emitted
signals
A stealth corvette of the YS 2000 design
has a detection range of 13km in rough
seas and 22km in calm sea without
jamming In a jammed environment the
Visby would be detected at a range of 8km
in rough sea and 11km in calm sea
The material provides high strength and
rigidity low weight good shock resistance
low radar and magnetic signature
1996
Visby is a class of stealth corvettes for the Swedish Navy
ldquoReduced 50 of a Conventional Steelrdquo
Source
Hull Construction with composite materials for ships over 100m in length 2002
Massachusetts Institute of Technology
httpwwwnaval-technologycomprojectsvisby
YACHTS
KAL YUDISTIRAMARATHON 100 ADMIRAL YACHT
LOA 3050 MWidth 6 MFuel Tank 8000 LWater Tank 3000 LIce Box 500 LAccommodation Max 35 Personnel
2 x CATERPILLAR 3412E 1200 HPMARINE DIESEL ENGINE
PC 40 ndash KRI Krait 827Department of Indonesian Navy
LOA 40 MWidth 73 MPower 190Weapon Twin Cannon Barrels
127 mm Heavy Machine GunSpeed Knot 25 KnotDisplacement 105 tonAccommodation 23 personnel
PATROL BOAT
Rigid Inflatable BoatPATROL BOAT
Yachts
36m Luxury Yacht Moonraker
36m Luxury Yacht GoldenEye
50m Luxury Yacht Casino
Royale
45m Luxury Yacht Seashaw
Boat Parts
Barovans for Seismic Sweep
Centrifugal Liftfan House for Surface Effect
Ships
Composite Boat PropellersRTM
Deckhouses for Pilot Boats
Fairing Parts for Submarines
Flybridges for Motor yachts
Light Weight Gangway
MTB Launcher Mock-up
Pleasure Boats
12m Sailboat
12m Sail-Catamaranone-off
Canoes
Dragonfly 1000Catamaran Sailboat
Fantasy 37Sailboat
Farr 60Luxury Sailboat
EurodingyOlympic Dingy Class for
Woman
Hydrolift F23 Racing Boats
Kajacs
Najad 42Sailboat
Najad 520Sailboat
Najad 441Sailboat
Najad 391Sailboat
Nordwest 900Motorboat
Nordwest 1100Motorboat
Quatro 44Motorboat
Racemaster Competition Boats
Storebro 420
Storebro 345
Sweden Yacht 370Sailboat
Sweden Yacht 69Sailboat
Windy 41Motorboat
X-632Sailboat
X-362Sailboat
Commercial Boats
175m High Speed AmbulancePassenger Boat
19m High Speed Passenger Boat
20m High Speed Passenger Boat
364m Surface Effect Passenger Ship
45m Surface Effect Passenger Ship
120m Hull Structural Parts HSSS Catamaran Ferry
APPENDIX
Marine Vessel
1188m Fast Attack Vessel FMV 90 E
20m SAV-Surface Auxiliary Vessels
34m Personnel TransportCoast Guard Vessel
40ft Experimental SES
40m Landsort-Class Mine Hunters
54m Mine Counter Measure Vehicles SES
74m Coastal Patrol Boats
Fishing Boats
30 GT
12 GT
10 GT
5 GT
WISEWings In Surface Effect
HOVERCRAFT
Designed specifically for the tourist and transport industries the
Pioneer Mk3 hovercraft is amphibious and comfortably seats 25
passengers plus 1-crew The air-conditioned cabin allows for
maximum visibility for all aboard The Pioneer Mk3 is robust and
dynamic in its performance
Commercial hovercraft
Mk3 AirLift Hovercraft - 1215m
Power is economicaly provided by one Deutz diesel engine of
330kW (442hp) to cruise easily at 40 knots with much higher
speeds available according to the surface conditions The hull is
manufactured from fibreglassPVC foam composite sandwich
the windows are glass and the skirt is urethane coated nylon A
Military version is available with increased payload and systems
redundancy Power for the Military version comes from two Steyr
diesel engines with a total installed power of 320kW (429hp) All
transmission electrical hydraulic and air systems are duplicated
for maximum redundancy The increased performance of the
Military version comes from the reduced engine weight of the twin
Steyr installation cf the Deutz installation
Source
httpwwwnauticexpocomprodairlift-hovercraftcommercial-hovercrafts-25251-142868html
HOVERFLIGHT
BALLISTIC amp UNIT DEFENCED
Triaxis Composites Collaboration with Institute of Aeronautics and Space in the development of Missile Nose Cone
Polymer composites is the evolution of the military defence
Thin steel was the helmet material of
WWII and remained the principal material until around the 1980rsquos
The advantages of using steel
included a simple technology for manufacture of the helmets low cost and reasonably good
impact protection However these helmets were found to provide only marginal protection
against fragments
During the Vietnam War the US Army experimented with fiber-reinforced inserts in the
helmets These inserts improved ballistic protection but at the same time added weight and
reduced the air space between the head and the helmet
By the early part of the 1980rsquos the US military had developed the first all-composite
100 fiber-reinforced helmet This development resulted in even better ballistic protection
without altering the weight of the helmet Other improvements included better head coverage and
more space for ventilation
Source
Composites Armor - A difficult but huge market
by A Brent Strong Brigham Young University
MILITARY VEHICLES
HIGH SPEED TRAIN SHINKANSEN
Advanced Composites provide lightweight solutions for railway vehicles
saving as much as 50-80 of the weight compared with traditional
components
A lower overall weight translates into less stress faster acceleration and
higher speeds as well as reduced starting and stopping inertia Today
these are important criteria in global high-speed and metropolitan
railway projects
Fire smoke and toxic fumes are key safety criteria for interior
components of railway carriages Any material selected for an interior
component must meet international fire retardant standards
for Rail Interiors and Exteriors
Ceiling Panels Stairs
Seating Vestibules
Window Panels Door Pillars
Partition WallsDiffusers
Gangway and Cabinet Panels Cabin and
Desk panels
Door Pillars Lavatory Modules (standard and
Front and Rear EndsRoof Panels
Nose Cones Under Fairings
Source
httpwwwpctaerail_compositesphp
101
SKY BUS
2009
Europe is the world leader in offshore wind with
828 wind turbines and a cumulative capacity of 2056 MW spread across 38 offshore wind farms in 9
European countries
The UK and Denmark are the current leaders with a 44 and 30 share respectively In 2009
five countries built new offshore wind farms
UK (284 MW)
Demark (230 MW)
Sweden (30 MW)
Germany (30 MW)
Norway (23 MW)
2010
Asia leads the growth in global wind power which grew 358 GW in 2010 bringing
total global capacity to 1944 GW ndash up 225 from 2009
the Global Wind Energy Council (GWEC)
Asia accounted for 19 GW of new global wind power installations driven by China which installed 165
GW
ldquoChina now has 423 GW of wind powerrdquo
ldquoThis puts China firmly on a path to reach 200 GW of installed wind power by 2020 At the same
time China has become the worldrsquos largest producer of wind energy equipmentrdquo
Source
httpwwwreinforcedplasticscomview15655asia-leads-global-wind-power-growth
httpimgdeusmcomdesignnews288288605-Sandia_Sizes_up_Wind_Turbine_Blade_Design_C_largegif
WIND ENERGY
Marine Current Turbines
Source
httpwwwsiemenscompressenpressreleasepress=enpressrelease2011solar-hydroex201111005htm
httpwwwmarineturbinescom
A commercial marine current turbine consists of
two rotors which are fixed on a structure within the
sea current The twin rotors rotate with the
movement of the tidal flow and the blades pitch
through 180 degrees to optimally track tidal current
(Press picture Marine Current Turbines)
Wave Star Energys Multi-point Absorber
CFRP COLUMN REINFORCEMENT
INDUSTRIAL TANKS
107
INDUSTRIAL PIPES
PRESSURE TANKS
109
ldquoLetrsquos Make with Compositesrdquo
PRODUKSI ANAK NEGERI
Proses Produksi Kain Fiberglass
Biji Kaca Benang Benang Kaca Kain Fiberglass
PROSES MATERIAL
Glass Beads
Glass Fiber Glass Roving YarnGlass Fabric
Proses Produksi Kain Fiberglass
Biji Kaca Benang Benang Kaca Kain Fiberglass
Glass Beads
Glass Fiber Glass Roving YarnGlass Fabric
PROSES MATERIAL
Benang Kaca Potongan Serat Kaca Chopped Strand Mat
CSM - Chopped Strand Mat
chopped binder
Produk Fiberglass Generasi Pertama
Bahan Pengikat
Senyawa Pada Resin
Glass Roving Yarn Chopped Strand
JENIS FIBERGLASS
Benang Kaca Woven Roving
WR - Woven Roving
Tenun Weaving
Produk Fiberglass Generasi Kedua
Glass Roving Yarn
JENIS FIBERGLASS
Multiaxial
MAX - Multiaxial
warp knitting
Produk Fiberglass Generasi Ketiga
Benang Kaca
Glass Roving Yarn
JENIS FIBERGLASS
MAX - Multiaxial Fabric
Fleece (optional)
Lapisan
MULTIAXIAL PROSES
Karakteristik CSM
bull Glass Content 30
bull Resin Content 70
bull Tensile Force
Chopped Strand Mat
JENIS FIBERGLASS
Karakteristik Woven Roving
bull Glass Content 45
bull Resin Content 55
Woven Roving
Resin
|
|
|
|
|
|
|
|
|
|
|
|
|
|
bull Kekuatan Tarik
JENIS FIBERGLASS
No Resin Rich Area
Karakteristik Multiaxial
bull Glass Content 60
bull Resin Content 40
Produk Fiberglass Ketiga MULTIAXIAL
JENIS FIBERGLASS
Perbedaan Woven Roving dan Multiaxial ndash Tampak Samping
JENIS FIBERGLASS
WR FRP
8 Ply WR 800
8 Ply CSM 450
Glass Weight 1 kg
Composite Weight 15kgm2
CSM FRP
22 Ply CSM 450
Glass Weight 1 kg
Composite Weight 18 kgm2
MULTIAXIAL FRP
13 Ply DB 800
Glass Weight 1 kg
Composite Weight
13 kgm2
JENIS FIBERGLASS
Multiaxial
FRP
Woven Roving
FRP
Chopped Strands Mat FRP
MULTIAXIAL
FAKTA
TEBAL BUKAN BERARTI KUAT
UNSUR MATRIX (RESIN)
TIDAK ADA KEKUATAN
ldquoMore than 50 of the glass fibers used for reinforcement is
E-glassrdquo
KarakteristikKekuatan
CSM WR MAX
Kekuatan Tarik 175 MPa 250 MPa 425 MPa
CSM 142
WR 70
KEKUATAN TARIK
Properties CSM Lamination WR Lamination MAX Lamination
Fabric Weight (kgm2) 1 1 1
Composite Weight (kgm2) 18 15 13
Resin usage (kgm2) 15 1 08
Amount of Fabric 22 Ply 16 Ply 13 Ply
Thickness 15 mm 12 mm 10 mm
Tensile Strength (Mpa) 125 1796 400
Tensile Strength (Nmmsup2) 28463 30958 4576
Processing Time High Med Low
Labour Cost High Med Low
MULTIAXIAL
Total Penggunaan Resin -51
Total Berat Kapal -40
Kekuatan Bangunan Kapal +59
Efisiensi Tenaga Kerja
Waktu Pengerjaan Lebih Cepat
KEUNGGULAN MATERIAL
Resapan Resin Lebih Baik amp Merata
Lapisan Lebih Sedikit
Meningkatkan Kekuatan Kapal
KEUNGGULAN MATERIAL
TRIAXIAL
DBL series DBT series
BIAXIAL
LT series DB series
UNIDIRECTIONAL
L series T series
QUADRIAXIAL
DBLT series
JENIS MULTIAXIAL
UNIDIRECTIONAL
DCMU 900 E ndash
KHUSUS UNTUK MEMPERKUAT BENDING KAPAL
PEMASANGAN KHUSUS PADA KEEL DAN TULANGAN
JENIS MULTIAXIAL UNTUK KAPAL
TRIAXIAL
DBL 600 ndash
APLIKASI PADA INDUSTRI PENERBANGAN
PEMASANGAN KHUSUS PADA
SAMBUNGAN BADAN DAN SAYAP
PESAWAT
JENIS MULTIAXIAL UNTUK PESAWAT
QUADRAXIAL
DBLT 800 ndash
APLIKASI PADA INDUSTRI ENERGI
DITERAPKAN UNTUK KEBUTUHAN PEMBANGKIT
LISTRIK ENERGI ANGIN
MULTIAXIAL UNTUK ENERGI
INDUSTRI KIMIA OLAHRAGA AUTOMOTIF
MULTIAXIAL UNTUK INDUSTRI LAINNYA
COMPOSITES
GUNAKAN MATERIAL FIBERGLASS
YANG SUDAH DISERTIFIKASI
BKI
FIBERGLASS UNTUK PEMBANGUNAN BAKAP
PERATURAN MENTERI PERHUBUNGAN
NOMOR PM 7 TAHUN 2013
TENTANG KEWAJIBAN KLASIFIKASI BAGI KAPAL BERBENDERA INDONESIA
PADA BADAN KLASIFIKASI
BADAN SERTIFIKASI MARITIM
Biro Klasifikasi IndonesiaDet Norske Veritas Germanischer Lloyds
PERATURAN BKI
Untuk Kapal Non-Metal
2006
PERSYARATAN MINIMUM
kekuatan material yang
harus digunakan
untuk membangun
Kapal Fiberglass
PEMBESARAN
Table 21
FIBERGLASS TRIAXIS COMPOSITES
TELAH BERSERTIFIKASI BKI
Biro Klasifikasi Indonesia
65
TEKNIK MANUFAKTUR
COMPOSITES
Wet hand lay-up
1) Peletakan
Dry Reinforcement
bull Dry reinforcement dan resin (+ katalis) ditaruh pada permukaan cetakan
2) Pemasukanpenekanan resin
bull Resin ditekan untuk meng-impregnasi serat dengan menggunakan rol
3) Pengulangan proses untuk lapisan lain
bull Beberapa lapisan dapat ditambahkan secara bertahap
4) Resin curing
bull Reaksi dimulai komponen dilepaskan setelah komponen mengeras
(fully cured)
Wet hand lay-up
Manufaktur komponen dapat dikerjakan dengan menggunakan beberapa lapis komposit
dengan memperhatikan kompatibilitas material dan tahapan curing Modifikasi proses dapat
dilakukan seperti
Vacuum bagging
setelah lay-up
Glass Roving
Bulk Resin
Catalyst
3) De-molding
2) Resin Cure
bull Curing dimulai dan komponen dilepaskan setelah pengerasan selesai
bull Serat gelas resin dan katalis dimasukkan kedalam spray gun
1) Spray-up
bull Campuran disemprotkan pada permukaan cetakan
Spray-up
69
Penyemprotan bakal komponen
Komponen
dilepaskan
dari cetakan
Full dispensing
system Chopper Roving
Atomised resin
and catalyst
Spray-up
Prepreg
1) LaminateAssembly 5) De-molding
3) Resin Melts Layup Consolidates
bull Prepreg serat yang sudah diimpregnasi oleh resin+katalis dalam kondisi padat
bull Lapisan prepreg digunting sesuai bentuk yang diinginkan kemudian diletakkan pada permukaan cetakan
sesuai bentuk komponen yang diinginkan Lay-up mudah dilakukan karena sifat ldquotackynessrdquo dari prepreg
2) Applied Vacuum Pressure and Heat
bull Tekanan dan panas diberikan resin mencair terjadi konsolidasi pada komponen
4) Resin Cures
bull Temperatur dinaikkan untuk memulai curing
Prepreg
Variasi proses Autoclave
Komponen dalam
vacuum-bag
bull Campuran resin (+katalis) dan chopped glass strands diperoleh dalam bentuk premixed compound Bulk molding
Compound (BMC) dalam bentuk adonan atau Sheet molding Compound (SMC) dalam bentuk lembaran
bull Ketika panas dan tekanan diberikan oleh cetakan compound mengalir sesuai bentuk komponen yang diinginkan
1) Placement of Charge
5) De-molding3) Squeeze to final dimensions
2) Mould Closure4) Resin Cure
bull Curing dimulai komponen dilepaskan setelah terjadi pengerasan yang cukup
Compression Molding
bull Preform atau dry reinforcement dimasukkan kedalam cetakan sesuai dengan bentuk komponen yang
diinginkan
bull Resin mengalir dengan penekanan atau pem-vakuman dan meng-impregnasi preform dan
mendorongmengeluarkan udara yang ada dalam preform
1) Preform Manufacture
2) Preform Compression
5) De-molding3) Resin Injection
4) Resin Cure
bull Curing terjadi cetakan dibuka setelah terjadi pengerasan yang mencukupi
Liquid Molding (RTM VARI VARTM)
Pultrusion
bull Dry roving or fabrics ditarik melalui bak berisi
campuran resin dan katalis
bull Campuran yang basah ditarik melalui cetakan
bull Sisa resin keluar cetakan
bull Pemanasan dilakukan untuk proses curing
bull Pendinginan dilakukan untuk mempercepat siklus
produksi
Cut-off
Cooling
Die sections
Resin bath
Fibre creel
Filament Winding
bull Dry roving ditarik melalui bak berisi campuran resin dan katalis
bull Wet roving digulungkan dalam keadaan tegang kepada mandrel
bull Kontrol mekanik dari pembawa serat mengatur orientasi peletakan serat pada
mandrel
INDUSTRI COMPOSITES
AEROSPACE
HISTORY
1950 ndash Boeing
1960 ndash F14 Tomcat
1981 ndash AV-8B Harrier
Source
Low-Cost Composite Materials and Structures for Aircraft Applications
httpwwwreinforcedplasticscom
httpwwwcentennialofflightgovessayEvolution_of_TechnologycompositesTech40htm
Automotive
Composite material is used in a number of applications in the automotive
industry due to its temperature resistance rigidity and fatigue strength
The benefits of using composites include greater fuel efficiency
corrosion resistance light weight and strength Composites also provide
a low-cost way to help keep designs looking fresh
Composites are used in
- interior parts (cockpit trimming seats instrument panels)
- exterior structure (body panels openings underbody frontrear
modules)
- engine compartment and fuelmechanical area parts (axles and
suspensions fuel and exhaust systems)
- electrical and electronic components
Lamborghinis Sesto Element carbon fiber
ldquoFat men cannot run as fast as thin men but we build most of our vehicles as though dead-weight fat increased speedhellip I cannot
imagine where the delusion that weight means strength
came fromhelliprdquo mdashHenry Ford
The mix of automotive materials is changing showing a boost for FRP in helping original
equipment manufacturers meet fuel economy and emissions challenges
(Source 2011 DuPont AutomotiveSAE survey of design engineers performed by Signet Research Inc)
Source
httpwwwtoraycomcsrhighlight2009hig_001_01html
The MonoCell tub for the McLaren MP4-12C supercar is moulded as a single
piece and weighs less than 80 kg (176 lbs)
COMPOSITES IN MARINE
TRIMARAN BOAT
AMERICA NAVYINDONESIAN NAVY
Visby Class corvette
Total length is 72 meters
The beam is 1040 meters
The displacement is 600 metric tones
fully equipped the worlds largest CRP
construction
The design of the Visby aims to minimize
the optical and infrared signature above
water acoustic and hydroa coustic
signature underwater electrical potential
and magnetic signature pressure signature
radar cross section and actively emitted
signals
A stealth corvette of the YS 2000 design
has a detection range of 13km in rough
seas and 22km in calm sea without
jamming In a jammed environment the
Visby would be detected at a range of 8km
in rough sea and 11km in calm sea
The material provides high strength and
rigidity low weight good shock resistance
low radar and magnetic signature
1996
Visby is a class of stealth corvettes for the Swedish Navy
ldquoReduced 50 of a Conventional Steelrdquo
Source
Hull Construction with composite materials for ships over 100m in length 2002
Massachusetts Institute of Technology
httpwwwnaval-technologycomprojectsvisby
YACHTS
KAL YUDISTIRAMARATHON 100 ADMIRAL YACHT
LOA 3050 MWidth 6 MFuel Tank 8000 LWater Tank 3000 LIce Box 500 LAccommodation Max 35 Personnel
2 x CATERPILLAR 3412E 1200 HPMARINE DIESEL ENGINE
PC 40 ndash KRI Krait 827Department of Indonesian Navy
LOA 40 MWidth 73 MPower 190Weapon Twin Cannon Barrels
127 mm Heavy Machine GunSpeed Knot 25 KnotDisplacement 105 tonAccommodation 23 personnel
PATROL BOAT
Rigid Inflatable BoatPATROL BOAT
Yachts
36m Luxury Yacht Moonraker
36m Luxury Yacht GoldenEye
50m Luxury Yacht Casino
Royale
45m Luxury Yacht Seashaw
Boat Parts
Barovans for Seismic Sweep
Centrifugal Liftfan House for Surface Effect
Ships
Composite Boat PropellersRTM
Deckhouses for Pilot Boats
Fairing Parts for Submarines
Flybridges for Motor yachts
Light Weight Gangway
MTB Launcher Mock-up
Pleasure Boats
12m Sailboat
12m Sail-Catamaranone-off
Canoes
Dragonfly 1000Catamaran Sailboat
Fantasy 37Sailboat
Farr 60Luxury Sailboat
EurodingyOlympic Dingy Class for
Woman
Hydrolift F23 Racing Boats
Kajacs
Najad 42Sailboat
Najad 520Sailboat
Najad 441Sailboat
Najad 391Sailboat
Nordwest 900Motorboat
Nordwest 1100Motorboat
Quatro 44Motorboat
Racemaster Competition Boats
Storebro 420
Storebro 345
Sweden Yacht 370Sailboat
Sweden Yacht 69Sailboat
Windy 41Motorboat
X-632Sailboat
X-362Sailboat
Commercial Boats
175m High Speed AmbulancePassenger Boat
19m High Speed Passenger Boat
20m High Speed Passenger Boat
364m Surface Effect Passenger Ship
45m Surface Effect Passenger Ship
120m Hull Structural Parts HSSS Catamaran Ferry
APPENDIX
Marine Vessel
1188m Fast Attack Vessel FMV 90 E
20m SAV-Surface Auxiliary Vessels
34m Personnel TransportCoast Guard Vessel
40ft Experimental SES
40m Landsort-Class Mine Hunters
54m Mine Counter Measure Vehicles SES
74m Coastal Patrol Boats
Fishing Boats
30 GT
12 GT
10 GT
5 GT
WISEWings In Surface Effect
HOVERCRAFT
Designed specifically for the tourist and transport industries the
Pioneer Mk3 hovercraft is amphibious and comfortably seats 25
passengers plus 1-crew The air-conditioned cabin allows for
maximum visibility for all aboard The Pioneer Mk3 is robust and
dynamic in its performance
Commercial hovercraft
Mk3 AirLift Hovercraft - 1215m
Power is economicaly provided by one Deutz diesel engine of
330kW (442hp) to cruise easily at 40 knots with much higher
speeds available according to the surface conditions The hull is
manufactured from fibreglassPVC foam composite sandwich
the windows are glass and the skirt is urethane coated nylon A
Military version is available with increased payload and systems
redundancy Power for the Military version comes from two Steyr
diesel engines with a total installed power of 320kW (429hp) All
transmission electrical hydraulic and air systems are duplicated
for maximum redundancy The increased performance of the
Military version comes from the reduced engine weight of the twin
Steyr installation cf the Deutz installation
Source
httpwwwnauticexpocomprodairlift-hovercraftcommercial-hovercrafts-25251-142868html
HOVERFLIGHT
BALLISTIC amp UNIT DEFENCED
Triaxis Composites Collaboration with Institute of Aeronautics and Space in the development of Missile Nose Cone
Polymer composites is the evolution of the military defence
Thin steel was the helmet material of
WWII and remained the principal material until around the 1980rsquos
The advantages of using steel
included a simple technology for manufacture of the helmets low cost and reasonably good
impact protection However these helmets were found to provide only marginal protection
against fragments
During the Vietnam War the US Army experimented with fiber-reinforced inserts in the
helmets These inserts improved ballistic protection but at the same time added weight and
reduced the air space between the head and the helmet
By the early part of the 1980rsquos the US military had developed the first all-composite
100 fiber-reinforced helmet This development resulted in even better ballistic protection
without altering the weight of the helmet Other improvements included better head coverage and
more space for ventilation
Source
Composites Armor - A difficult but huge market
by A Brent Strong Brigham Young University
MILITARY VEHICLES
HIGH SPEED TRAIN SHINKANSEN
Advanced Composites provide lightweight solutions for railway vehicles
saving as much as 50-80 of the weight compared with traditional
components
A lower overall weight translates into less stress faster acceleration and
higher speeds as well as reduced starting and stopping inertia Today
these are important criteria in global high-speed and metropolitan
railway projects
Fire smoke and toxic fumes are key safety criteria for interior
components of railway carriages Any material selected for an interior
component must meet international fire retardant standards
for Rail Interiors and Exteriors
Ceiling Panels Stairs
Seating Vestibules
Window Panels Door Pillars
Partition WallsDiffusers
Gangway and Cabinet Panels Cabin and
Desk panels
Door Pillars Lavatory Modules (standard and
Front and Rear EndsRoof Panels
Nose Cones Under Fairings
Source
httpwwwpctaerail_compositesphp
101
SKY BUS
2009
Europe is the world leader in offshore wind with
828 wind turbines and a cumulative capacity of 2056 MW spread across 38 offshore wind farms in 9
European countries
The UK and Denmark are the current leaders with a 44 and 30 share respectively In 2009
five countries built new offshore wind farms
UK (284 MW)
Demark (230 MW)
Sweden (30 MW)
Germany (30 MW)
Norway (23 MW)
2010
Asia leads the growth in global wind power which grew 358 GW in 2010 bringing
total global capacity to 1944 GW ndash up 225 from 2009
the Global Wind Energy Council (GWEC)
Asia accounted for 19 GW of new global wind power installations driven by China which installed 165
GW
ldquoChina now has 423 GW of wind powerrdquo
ldquoThis puts China firmly on a path to reach 200 GW of installed wind power by 2020 At the same
time China has become the worldrsquos largest producer of wind energy equipmentrdquo
Source
httpwwwreinforcedplasticscomview15655asia-leads-global-wind-power-growth
httpimgdeusmcomdesignnews288288605-Sandia_Sizes_up_Wind_Turbine_Blade_Design_C_largegif
WIND ENERGY
Marine Current Turbines
Source
httpwwwsiemenscompressenpressreleasepress=enpressrelease2011solar-hydroex201111005htm
httpwwwmarineturbinescom
A commercial marine current turbine consists of
two rotors which are fixed on a structure within the
sea current The twin rotors rotate with the
movement of the tidal flow and the blades pitch
through 180 degrees to optimally track tidal current
(Press picture Marine Current Turbines)
Wave Star Energys Multi-point Absorber
CFRP COLUMN REINFORCEMENT
INDUSTRIAL TANKS
107
INDUSTRIAL PIPES
PRESSURE TANKS
109
ldquoLetrsquos Make with Compositesrdquo
Proses Produksi Kain Fiberglass
Biji Kaca Benang Benang Kaca Kain Fiberglass
PROSES MATERIAL
Glass Beads
Glass Fiber Glass Roving YarnGlass Fabric
Proses Produksi Kain Fiberglass
Biji Kaca Benang Benang Kaca Kain Fiberglass
Glass Beads
Glass Fiber Glass Roving YarnGlass Fabric
PROSES MATERIAL
Benang Kaca Potongan Serat Kaca Chopped Strand Mat
CSM - Chopped Strand Mat
chopped binder
Produk Fiberglass Generasi Pertama
Bahan Pengikat
Senyawa Pada Resin
Glass Roving Yarn Chopped Strand
JENIS FIBERGLASS
Benang Kaca Woven Roving
WR - Woven Roving
Tenun Weaving
Produk Fiberglass Generasi Kedua
Glass Roving Yarn
JENIS FIBERGLASS
Multiaxial
MAX - Multiaxial
warp knitting
Produk Fiberglass Generasi Ketiga
Benang Kaca
Glass Roving Yarn
JENIS FIBERGLASS
MAX - Multiaxial Fabric
Fleece (optional)
Lapisan
MULTIAXIAL PROSES
Karakteristik CSM
bull Glass Content 30
bull Resin Content 70
bull Tensile Force
Chopped Strand Mat
JENIS FIBERGLASS
Karakteristik Woven Roving
bull Glass Content 45
bull Resin Content 55
Woven Roving
Resin
|
|
|
|
|
|
|
|
|
|
|
|
|
|
bull Kekuatan Tarik
JENIS FIBERGLASS
No Resin Rich Area
Karakteristik Multiaxial
bull Glass Content 60
bull Resin Content 40
Produk Fiberglass Ketiga MULTIAXIAL
JENIS FIBERGLASS
Perbedaan Woven Roving dan Multiaxial ndash Tampak Samping
JENIS FIBERGLASS
WR FRP
8 Ply WR 800
8 Ply CSM 450
Glass Weight 1 kg
Composite Weight 15kgm2
CSM FRP
22 Ply CSM 450
Glass Weight 1 kg
Composite Weight 18 kgm2
MULTIAXIAL FRP
13 Ply DB 800
Glass Weight 1 kg
Composite Weight
13 kgm2
JENIS FIBERGLASS
Multiaxial
FRP
Woven Roving
FRP
Chopped Strands Mat FRP
MULTIAXIAL
FAKTA
TEBAL BUKAN BERARTI KUAT
UNSUR MATRIX (RESIN)
TIDAK ADA KEKUATAN
ldquoMore than 50 of the glass fibers used for reinforcement is
E-glassrdquo
KarakteristikKekuatan
CSM WR MAX
Kekuatan Tarik 175 MPa 250 MPa 425 MPa
CSM 142
WR 70
KEKUATAN TARIK
Properties CSM Lamination WR Lamination MAX Lamination
Fabric Weight (kgm2) 1 1 1
Composite Weight (kgm2) 18 15 13
Resin usage (kgm2) 15 1 08
Amount of Fabric 22 Ply 16 Ply 13 Ply
Thickness 15 mm 12 mm 10 mm
Tensile Strength (Mpa) 125 1796 400
Tensile Strength (Nmmsup2) 28463 30958 4576
Processing Time High Med Low
Labour Cost High Med Low
MULTIAXIAL
Total Penggunaan Resin -51
Total Berat Kapal -40
Kekuatan Bangunan Kapal +59
Efisiensi Tenaga Kerja
Waktu Pengerjaan Lebih Cepat
KEUNGGULAN MATERIAL
Resapan Resin Lebih Baik amp Merata
Lapisan Lebih Sedikit
Meningkatkan Kekuatan Kapal
KEUNGGULAN MATERIAL
TRIAXIAL
DBL series DBT series
BIAXIAL
LT series DB series
UNIDIRECTIONAL
L series T series
QUADRIAXIAL
DBLT series
JENIS MULTIAXIAL
UNIDIRECTIONAL
DCMU 900 E ndash
KHUSUS UNTUK MEMPERKUAT BENDING KAPAL
PEMASANGAN KHUSUS PADA KEEL DAN TULANGAN
JENIS MULTIAXIAL UNTUK KAPAL
TRIAXIAL
DBL 600 ndash
APLIKASI PADA INDUSTRI PENERBANGAN
PEMASANGAN KHUSUS PADA
SAMBUNGAN BADAN DAN SAYAP
PESAWAT
JENIS MULTIAXIAL UNTUK PESAWAT
QUADRAXIAL
DBLT 800 ndash
APLIKASI PADA INDUSTRI ENERGI
DITERAPKAN UNTUK KEBUTUHAN PEMBANGKIT
LISTRIK ENERGI ANGIN
MULTIAXIAL UNTUK ENERGI
INDUSTRI KIMIA OLAHRAGA AUTOMOTIF
MULTIAXIAL UNTUK INDUSTRI LAINNYA
COMPOSITES
GUNAKAN MATERIAL FIBERGLASS
YANG SUDAH DISERTIFIKASI
BKI
FIBERGLASS UNTUK PEMBANGUNAN BAKAP
PERATURAN MENTERI PERHUBUNGAN
NOMOR PM 7 TAHUN 2013
TENTANG KEWAJIBAN KLASIFIKASI BAGI KAPAL BERBENDERA INDONESIA
PADA BADAN KLASIFIKASI
BADAN SERTIFIKASI MARITIM
Biro Klasifikasi IndonesiaDet Norske Veritas Germanischer Lloyds
PERATURAN BKI
Untuk Kapal Non-Metal
2006
PERSYARATAN MINIMUM
kekuatan material yang
harus digunakan
untuk membangun
Kapal Fiberglass
PEMBESARAN
Table 21
FIBERGLASS TRIAXIS COMPOSITES
TELAH BERSERTIFIKASI BKI
Biro Klasifikasi Indonesia
65
TEKNIK MANUFAKTUR
COMPOSITES
Wet hand lay-up
1) Peletakan
Dry Reinforcement
bull Dry reinforcement dan resin (+ katalis) ditaruh pada permukaan cetakan
2) Pemasukanpenekanan resin
bull Resin ditekan untuk meng-impregnasi serat dengan menggunakan rol
3) Pengulangan proses untuk lapisan lain
bull Beberapa lapisan dapat ditambahkan secara bertahap
4) Resin curing
bull Reaksi dimulai komponen dilepaskan setelah komponen mengeras
(fully cured)
Wet hand lay-up
Manufaktur komponen dapat dikerjakan dengan menggunakan beberapa lapis komposit
dengan memperhatikan kompatibilitas material dan tahapan curing Modifikasi proses dapat
dilakukan seperti
Vacuum bagging
setelah lay-up
Glass Roving
Bulk Resin
Catalyst
3) De-molding
2) Resin Cure
bull Curing dimulai dan komponen dilepaskan setelah pengerasan selesai
bull Serat gelas resin dan katalis dimasukkan kedalam spray gun
1) Spray-up
bull Campuran disemprotkan pada permukaan cetakan
Spray-up
69
Penyemprotan bakal komponen
Komponen
dilepaskan
dari cetakan
Full dispensing
system Chopper Roving
Atomised resin
and catalyst
Spray-up
Prepreg
1) LaminateAssembly 5) De-molding
3) Resin Melts Layup Consolidates
bull Prepreg serat yang sudah diimpregnasi oleh resin+katalis dalam kondisi padat
bull Lapisan prepreg digunting sesuai bentuk yang diinginkan kemudian diletakkan pada permukaan cetakan
sesuai bentuk komponen yang diinginkan Lay-up mudah dilakukan karena sifat ldquotackynessrdquo dari prepreg
2) Applied Vacuum Pressure and Heat
bull Tekanan dan panas diberikan resin mencair terjadi konsolidasi pada komponen
4) Resin Cures
bull Temperatur dinaikkan untuk memulai curing
Prepreg
Variasi proses Autoclave
Komponen dalam
vacuum-bag
bull Campuran resin (+katalis) dan chopped glass strands diperoleh dalam bentuk premixed compound Bulk molding
Compound (BMC) dalam bentuk adonan atau Sheet molding Compound (SMC) dalam bentuk lembaran
bull Ketika panas dan tekanan diberikan oleh cetakan compound mengalir sesuai bentuk komponen yang diinginkan
1) Placement of Charge
5) De-molding3) Squeeze to final dimensions
2) Mould Closure4) Resin Cure
bull Curing dimulai komponen dilepaskan setelah terjadi pengerasan yang cukup
Compression Molding
bull Preform atau dry reinforcement dimasukkan kedalam cetakan sesuai dengan bentuk komponen yang
diinginkan
bull Resin mengalir dengan penekanan atau pem-vakuman dan meng-impregnasi preform dan
mendorongmengeluarkan udara yang ada dalam preform
1) Preform Manufacture
2) Preform Compression
5) De-molding3) Resin Injection
4) Resin Cure
bull Curing terjadi cetakan dibuka setelah terjadi pengerasan yang mencukupi
Liquid Molding (RTM VARI VARTM)
Pultrusion
bull Dry roving or fabrics ditarik melalui bak berisi
campuran resin dan katalis
bull Campuran yang basah ditarik melalui cetakan
bull Sisa resin keluar cetakan
bull Pemanasan dilakukan untuk proses curing
bull Pendinginan dilakukan untuk mempercepat siklus
produksi
Cut-off
Cooling
Die sections
Resin bath
Fibre creel
Filament Winding
bull Dry roving ditarik melalui bak berisi campuran resin dan katalis
bull Wet roving digulungkan dalam keadaan tegang kepada mandrel
bull Kontrol mekanik dari pembawa serat mengatur orientasi peletakan serat pada
mandrel
INDUSTRI COMPOSITES
AEROSPACE
HISTORY
1950 ndash Boeing
1960 ndash F14 Tomcat
1981 ndash AV-8B Harrier
Source
Low-Cost Composite Materials and Structures for Aircraft Applications
httpwwwreinforcedplasticscom
httpwwwcentennialofflightgovessayEvolution_of_TechnologycompositesTech40htm
Automotive
Composite material is used in a number of applications in the automotive
industry due to its temperature resistance rigidity and fatigue strength
The benefits of using composites include greater fuel efficiency
corrosion resistance light weight and strength Composites also provide
a low-cost way to help keep designs looking fresh
Composites are used in
- interior parts (cockpit trimming seats instrument panels)
- exterior structure (body panels openings underbody frontrear
modules)
- engine compartment and fuelmechanical area parts (axles and
suspensions fuel and exhaust systems)
- electrical and electronic components
Lamborghinis Sesto Element carbon fiber
ldquoFat men cannot run as fast as thin men but we build most of our vehicles as though dead-weight fat increased speedhellip I cannot
imagine where the delusion that weight means strength
came fromhelliprdquo mdashHenry Ford
The mix of automotive materials is changing showing a boost for FRP in helping original
equipment manufacturers meet fuel economy and emissions challenges
(Source 2011 DuPont AutomotiveSAE survey of design engineers performed by Signet Research Inc)
Source
httpwwwtoraycomcsrhighlight2009hig_001_01html
The MonoCell tub for the McLaren MP4-12C supercar is moulded as a single
piece and weighs less than 80 kg (176 lbs)
COMPOSITES IN MARINE
TRIMARAN BOAT
AMERICA NAVYINDONESIAN NAVY
Visby Class corvette
Total length is 72 meters
The beam is 1040 meters
The displacement is 600 metric tones
fully equipped the worlds largest CRP
construction
The design of the Visby aims to minimize
the optical and infrared signature above
water acoustic and hydroa coustic
signature underwater electrical potential
and magnetic signature pressure signature
radar cross section and actively emitted
signals
A stealth corvette of the YS 2000 design
has a detection range of 13km in rough
seas and 22km in calm sea without
jamming In a jammed environment the
Visby would be detected at a range of 8km
in rough sea and 11km in calm sea
The material provides high strength and
rigidity low weight good shock resistance
low radar and magnetic signature
1996
Visby is a class of stealth corvettes for the Swedish Navy
ldquoReduced 50 of a Conventional Steelrdquo
Source
Hull Construction with composite materials for ships over 100m in length 2002
Massachusetts Institute of Technology
httpwwwnaval-technologycomprojectsvisby
YACHTS
KAL YUDISTIRAMARATHON 100 ADMIRAL YACHT
LOA 3050 MWidth 6 MFuel Tank 8000 LWater Tank 3000 LIce Box 500 LAccommodation Max 35 Personnel
2 x CATERPILLAR 3412E 1200 HPMARINE DIESEL ENGINE
PC 40 ndash KRI Krait 827Department of Indonesian Navy
LOA 40 MWidth 73 MPower 190Weapon Twin Cannon Barrels
127 mm Heavy Machine GunSpeed Knot 25 KnotDisplacement 105 tonAccommodation 23 personnel
PATROL BOAT
Rigid Inflatable BoatPATROL BOAT
Yachts
36m Luxury Yacht Moonraker
36m Luxury Yacht GoldenEye
50m Luxury Yacht Casino
Royale
45m Luxury Yacht Seashaw
Boat Parts
Barovans for Seismic Sweep
Centrifugal Liftfan House for Surface Effect
Ships
Composite Boat PropellersRTM
Deckhouses for Pilot Boats
Fairing Parts for Submarines
Flybridges for Motor yachts
Light Weight Gangway
MTB Launcher Mock-up
Pleasure Boats
12m Sailboat
12m Sail-Catamaranone-off
Canoes
Dragonfly 1000Catamaran Sailboat
Fantasy 37Sailboat
Farr 60Luxury Sailboat
EurodingyOlympic Dingy Class for
Woman
Hydrolift F23 Racing Boats
Kajacs
Najad 42Sailboat
Najad 520Sailboat
Najad 441Sailboat
Najad 391Sailboat
Nordwest 900Motorboat
Nordwest 1100Motorboat
Quatro 44Motorboat
Racemaster Competition Boats
Storebro 420
Storebro 345
Sweden Yacht 370Sailboat
Sweden Yacht 69Sailboat
Windy 41Motorboat
X-632Sailboat
X-362Sailboat
Commercial Boats
175m High Speed AmbulancePassenger Boat
19m High Speed Passenger Boat
20m High Speed Passenger Boat
364m Surface Effect Passenger Ship
45m Surface Effect Passenger Ship
120m Hull Structural Parts HSSS Catamaran Ferry
APPENDIX
Marine Vessel
1188m Fast Attack Vessel FMV 90 E
20m SAV-Surface Auxiliary Vessels
34m Personnel TransportCoast Guard Vessel
40ft Experimental SES
40m Landsort-Class Mine Hunters
54m Mine Counter Measure Vehicles SES
74m Coastal Patrol Boats
Fishing Boats
30 GT
12 GT
10 GT
5 GT
WISEWings In Surface Effect
HOVERCRAFT
Designed specifically for the tourist and transport industries the
Pioneer Mk3 hovercraft is amphibious and comfortably seats 25
passengers plus 1-crew The air-conditioned cabin allows for
maximum visibility for all aboard The Pioneer Mk3 is robust and
dynamic in its performance
Commercial hovercraft
Mk3 AirLift Hovercraft - 1215m
Power is economicaly provided by one Deutz diesel engine of
330kW (442hp) to cruise easily at 40 knots with much higher
speeds available according to the surface conditions The hull is
manufactured from fibreglassPVC foam composite sandwich
the windows are glass and the skirt is urethane coated nylon A
Military version is available with increased payload and systems
redundancy Power for the Military version comes from two Steyr
diesel engines with a total installed power of 320kW (429hp) All
transmission electrical hydraulic and air systems are duplicated
for maximum redundancy The increased performance of the
Military version comes from the reduced engine weight of the twin
Steyr installation cf the Deutz installation
Source
httpwwwnauticexpocomprodairlift-hovercraftcommercial-hovercrafts-25251-142868html
HOVERFLIGHT
BALLISTIC amp UNIT DEFENCED
Triaxis Composites Collaboration with Institute of Aeronautics and Space in the development of Missile Nose Cone
Polymer composites is the evolution of the military defence
Thin steel was the helmet material of
WWII and remained the principal material until around the 1980rsquos
The advantages of using steel
included a simple technology for manufacture of the helmets low cost and reasonably good
impact protection However these helmets were found to provide only marginal protection
against fragments
During the Vietnam War the US Army experimented with fiber-reinforced inserts in the
helmets These inserts improved ballistic protection but at the same time added weight and
reduced the air space between the head and the helmet
By the early part of the 1980rsquos the US military had developed the first all-composite
100 fiber-reinforced helmet This development resulted in even better ballistic protection
without altering the weight of the helmet Other improvements included better head coverage and
more space for ventilation
Source
Composites Armor - A difficult but huge market
by A Brent Strong Brigham Young University
MILITARY VEHICLES
HIGH SPEED TRAIN SHINKANSEN
Advanced Composites provide lightweight solutions for railway vehicles
saving as much as 50-80 of the weight compared with traditional
components
A lower overall weight translates into less stress faster acceleration and
higher speeds as well as reduced starting and stopping inertia Today
these are important criteria in global high-speed and metropolitan
railway projects
Fire smoke and toxic fumes are key safety criteria for interior
components of railway carriages Any material selected for an interior
component must meet international fire retardant standards
for Rail Interiors and Exteriors
Ceiling Panels Stairs
Seating Vestibules
Window Panels Door Pillars
Partition WallsDiffusers
Gangway and Cabinet Panels Cabin and
Desk panels
Door Pillars Lavatory Modules (standard and
Front and Rear EndsRoof Panels
Nose Cones Under Fairings
Source
httpwwwpctaerail_compositesphp
101
SKY BUS
2009
Europe is the world leader in offshore wind with
828 wind turbines and a cumulative capacity of 2056 MW spread across 38 offshore wind farms in 9
European countries
The UK and Denmark are the current leaders with a 44 and 30 share respectively In 2009
five countries built new offshore wind farms
UK (284 MW)
Demark (230 MW)
Sweden (30 MW)
Germany (30 MW)
Norway (23 MW)
2010
Asia leads the growth in global wind power which grew 358 GW in 2010 bringing
total global capacity to 1944 GW ndash up 225 from 2009
the Global Wind Energy Council (GWEC)
Asia accounted for 19 GW of new global wind power installations driven by China which installed 165
GW
ldquoChina now has 423 GW of wind powerrdquo
ldquoThis puts China firmly on a path to reach 200 GW of installed wind power by 2020 At the same
time China has become the worldrsquos largest producer of wind energy equipmentrdquo
Source
httpwwwreinforcedplasticscomview15655asia-leads-global-wind-power-growth
httpimgdeusmcomdesignnews288288605-Sandia_Sizes_up_Wind_Turbine_Blade_Design_C_largegif
WIND ENERGY
Marine Current Turbines
Source
httpwwwsiemenscompressenpressreleasepress=enpressrelease2011solar-hydroex201111005htm
httpwwwmarineturbinescom
A commercial marine current turbine consists of
two rotors which are fixed on a structure within the
sea current The twin rotors rotate with the
movement of the tidal flow and the blades pitch
through 180 degrees to optimally track tidal current
(Press picture Marine Current Turbines)
Wave Star Energys Multi-point Absorber
CFRP COLUMN REINFORCEMENT
INDUSTRIAL TANKS
107
INDUSTRIAL PIPES
PRESSURE TANKS
109
ldquoLetrsquos Make with Compositesrdquo
Proses Produksi Kain Fiberglass
Biji Kaca Benang Benang Kaca Kain Fiberglass
Glass Beads
Glass Fiber Glass Roving YarnGlass Fabric
PROSES MATERIAL
Benang Kaca Potongan Serat Kaca Chopped Strand Mat
CSM - Chopped Strand Mat
chopped binder
Produk Fiberglass Generasi Pertama
Bahan Pengikat
Senyawa Pada Resin
Glass Roving Yarn Chopped Strand
JENIS FIBERGLASS
Benang Kaca Woven Roving
WR - Woven Roving
Tenun Weaving
Produk Fiberglass Generasi Kedua
Glass Roving Yarn
JENIS FIBERGLASS
Multiaxial
MAX - Multiaxial
warp knitting
Produk Fiberglass Generasi Ketiga
Benang Kaca
Glass Roving Yarn
JENIS FIBERGLASS
MAX - Multiaxial Fabric
Fleece (optional)
Lapisan
MULTIAXIAL PROSES
Karakteristik CSM
bull Glass Content 30
bull Resin Content 70
bull Tensile Force
Chopped Strand Mat
JENIS FIBERGLASS
Karakteristik Woven Roving
bull Glass Content 45
bull Resin Content 55
Woven Roving
Resin
|
|
|
|
|
|
|
|
|
|
|
|
|
|
bull Kekuatan Tarik
JENIS FIBERGLASS
No Resin Rich Area
Karakteristik Multiaxial
bull Glass Content 60
bull Resin Content 40
Produk Fiberglass Ketiga MULTIAXIAL
JENIS FIBERGLASS
Perbedaan Woven Roving dan Multiaxial ndash Tampak Samping
JENIS FIBERGLASS
WR FRP
8 Ply WR 800
8 Ply CSM 450
Glass Weight 1 kg
Composite Weight 15kgm2
CSM FRP
22 Ply CSM 450
Glass Weight 1 kg
Composite Weight 18 kgm2
MULTIAXIAL FRP
13 Ply DB 800
Glass Weight 1 kg
Composite Weight
13 kgm2
JENIS FIBERGLASS
Multiaxial
FRP
Woven Roving
FRP
Chopped Strands Mat FRP
MULTIAXIAL
FAKTA
TEBAL BUKAN BERARTI KUAT
UNSUR MATRIX (RESIN)
TIDAK ADA KEKUATAN
ldquoMore than 50 of the glass fibers used for reinforcement is
E-glassrdquo
KarakteristikKekuatan
CSM WR MAX
Kekuatan Tarik 175 MPa 250 MPa 425 MPa
CSM 142
WR 70
KEKUATAN TARIK
Properties CSM Lamination WR Lamination MAX Lamination
Fabric Weight (kgm2) 1 1 1
Composite Weight (kgm2) 18 15 13
Resin usage (kgm2) 15 1 08
Amount of Fabric 22 Ply 16 Ply 13 Ply
Thickness 15 mm 12 mm 10 mm
Tensile Strength (Mpa) 125 1796 400
Tensile Strength (Nmmsup2) 28463 30958 4576
Processing Time High Med Low
Labour Cost High Med Low
MULTIAXIAL
Total Penggunaan Resin -51
Total Berat Kapal -40
Kekuatan Bangunan Kapal +59
Efisiensi Tenaga Kerja
Waktu Pengerjaan Lebih Cepat
KEUNGGULAN MATERIAL
Resapan Resin Lebih Baik amp Merata
Lapisan Lebih Sedikit
Meningkatkan Kekuatan Kapal
KEUNGGULAN MATERIAL
TRIAXIAL
DBL series DBT series
BIAXIAL
LT series DB series
UNIDIRECTIONAL
L series T series
QUADRIAXIAL
DBLT series
JENIS MULTIAXIAL
UNIDIRECTIONAL
DCMU 900 E ndash
KHUSUS UNTUK MEMPERKUAT BENDING KAPAL
PEMASANGAN KHUSUS PADA KEEL DAN TULANGAN
JENIS MULTIAXIAL UNTUK KAPAL
TRIAXIAL
DBL 600 ndash
APLIKASI PADA INDUSTRI PENERBANGAN
PEMASANGAN KHUSUS PADA
SAMBUNGAN BADAN DAN SAYAP
PESAWAT
JENIS MULTIAXIAL UNTUK PESAWAT
QUADRAXIAL
DBLT 800 ndash
APLIKASI PADA INDUSTRI ENERGI
DITERAPKAN UNTUK KEBUTUHAN PEMBANGKIT
LISTRIK ENERGI ANGIN
MULTIAXIAL UNTUK ENERGI
INDUSTRI KIMIA OLAHRAGA AUTOMOTIF
MULTIAXIAL UNTUK INDUSTRI LAINNYA
COMPOSITES
GUNAKAN MATERIAL FIBERGLASS
YANG SUDAH DISERTIFIKASI
BKI
FIBERGLASS UNTUK PEMBANGUNAN BAKAP
PERATURAN MENTERI PERHUBUNGAN
NOMOR PM 7 TAHUN 2013
TENTANG KEWAJIBAN KLASIFIKASI BAGI KAPAL BERBENDERA INDONESIA
PADA BADAN KLASIFIKASI
BADAN SERTIFIKASI MARITIM
Biro Klasifikasi IndonesiaDet Norske Veritas Germanischer Lloyds
PERATURAN BKI
Untuk Kapal Non-Metal
2006
PERSYARATAN MINIMUM
kekuatan material yang
harus digunakan
untuk membangun
Kapal Fiberglass
PEMBESARAN
Table 21
FIBERGLASS TRIAXIS COMPOSITES
TELAH BERSERTIFIKASI BKI
Biro Klasifikasi Indonesia
65
TEKNIK MANUFAKTUR
COMPOSITES
Wet hand lay-up
1) Peletakan
Dry Reinforcement
bull Dry reinforcement dan resin (+ katalis) ditaruh pada permukaan cetakan
2) Pemasukanpenekanan resin
bull Resin ditekan untuk meng-impregnasi serat dengan menggunakan rol
3) Pengulangan proses untuk lapisan lain
bull Beberapa lapisan dapat ditambahkan secara bertahap
4) Resin curing
bull Reaksi dimulai komponen dilepaskan setelah komponen mengeras
(fully cured)
Wet hand lay-up
Manufaktur komponen dapat dikerjakan dengan menggunakan beberapa lapis komposit
dengan memperhatikan kompatibilitas material dan tahapan curing Modifikasi proses dapat
dilakukan seperti
Vacuum bagging
setelah lay-up
Glass Roving
Bulk Resin
Catalyst
3) De-molding
2) Resin Cure
bull Curing dimulai dan komponen dilepaskan setelah pengerasan selesai
bull Serat gelas resin dan katalis dimasukkan kedalam spray gun
1) Spray-up
bull Campuran disemprotkan pada permukaan cetakan
Spray-up
69
Penyemprotan bakal komponen
Komponen
dilepaskan
dari cetakan
Full dispensing
system Chopper Roving
Atomised resin
and catalyst
Spray-up
Prepreg
1) LaminateAssembly 5) De-molding
3) Resin Melts Layup Consolidates
bull Prepreg serat yang sudah diimpregnasi oleh resin+katalis dalam kondisi padat
bull Lapisan prepreg digunting sesuai bentuk yang diinginkan kemudian diletakkan pada permukaan cetakan
sesuai bentuk komponen yang diinginkan Lay-up mudah dilakukan karena sifat ldquotackynessrdquo dari prepreg
2) Applied Vacuum Pressure and Heat
bull Tekanan dan panas diberikan resin mencair terjadi konsolidasi pada komponen
4) Resin Cures
bull Temperatur dinaikkan untuk memulai curing
Prepreg
Variasi proses Autoclave
Komponen dalam
vacuum-bag
bull Campuran resin (+katalis) dan chopped glass strands diperoleh dalam bentuk premixed compound Bulk molding
Compound (BMC) dalam bentuk adonan atau Sheet molding Compound (SMC) dalam bentuk lembaran
bull Ketika panas dan tekanan diberikan oleh cetakan compound mengalir sesuai bentuk komponen yang diinginkan
1) Placement of Charge
5) De-molding3) Squeeze to final dimensions
2) Mould Closure4) Resin Cure
bull Curing dimulai komponen dilepaskan setelah terjadi pengerasan yang cukup
Compression Molding
bull Preform atau dry reinforcement dimasukkan kedalam cetakan sesuai dengan bentuk komponen yang
diinginkan
bull Resin mengalir dengan penekanan atau pem-vakuman dan meng-impregnasi preform dan
mendorongmengeluarkan udara yang ada dalam preform
1) Preform Manufacture
2) Preform Compression
5) De-molding3) Resin Injection
4) Resin Cure
bull Curing terjadi cetakan dibuka setelah terjadi pengerasan yang mencukupi
Liquid Molding (RTM VARI VARTM)
Pultrusion
bull Dry roving or fabrics ditarik melalui bak berisi
campuran resin dan katalis
bull Campuran yang basah ditarik melalui cetakan
bull Sisa resin keluar cetakan
bull Pemanasan dilakukan untuk proses curing
bull Pendinginan dilakukan untuk mempercepat siklus
produksi
Cut-off
Cooling
Die sections
Resin bath
Fibre creel
Filament Winding
bull Dry roving ditarik melalui bak berisi campuran resin dan katalis
bull Wet roving digulungkan dalam keadaan tegang kepada mandrel
bull Kontrol mekanik dari pembawa serat mengatur orientasi peletakan serat pada
mandrel
INDUSTRI COMPOSITES
AEROSPACE
HISTORY
1950 ndash Boeing
1960 ndash F14 Tomcat
1981 ndash AV-8B Harrier
Source
Low-Cost Composite Materials and Structures for Aircraft Applications
httpwwwreinforcedplasticscom
httpwwwcentennialofflightgovessayEvolution_of_TechnologycompositesTech40htm
Automotive
Composite material is used in a number of applications in the automotive
industry due to its temperature resistance rigidity and fatigue strength
The benefits of using composites include greater fuel efficiency
corrosion resistance light weight and strength Composites also provide
a low-cost way to help keep designs looking fresh
Composites are used in
- interior parts (cockpit trimming seats instrument panels)
- exterior structure (body panels openings underbody frontrear
modules)
- engine compartment and fuelmechanical area parts (axles and
suspensions fuel and exhaust systems)
- electrical and electronic components
Lamborghinis Sesto Element carbon fiber
ldquoFat men cannot run as fast as thin men but we build most of our vehicles as though dead-weight fat increased speedhellip I cannot
imagine where the delusion that weight means strength
came fromhelliprdquo mdashHenry Ford
The mix of automotive materials is changing showing a boost for FRP in helping original
equipment manufacturers meet fuel economy and emissions challenges
(Source 2011 DuPont AutomotiveSAE survey of design engineers performed by Signet Research Inc)
Source
httpwwwtoraycomcsrhighlight2009hig_001_01html
The MonoCell tub for the McLaren MP4-12C supercar is moulded as a single
piece and weighs less than 80 kg (176 lbs)
COMPOSITES IN MARINE
TRIMARAN BOAT
AMERICA NAVYINDONESIAN NAVY
Visby Class corvette
Total length is 72 meters
The beam is 1040 meters
The displacement is 600 metric tones
fully equipped the worlds largest CRP
construction
The design of the Visby aims to minimize
the optical and infrared signature above
water acoustic and hydroa coustic
signature underwater electrical potential
and magnetic signature pressure signature
radar cross section and actively emitted
signals
A stealth corvette of the YS 2000 design
has a detection range of 13km in rough
seas and 22km in calm sea without
jamming In a jammed environment the
Visby would be detected at a range of 8km
in rough sea and 11km in calm sea
The material provides high strength and
rigidity low weight good shock resistance
low radar and magnetic signature
1996
Visby is a class of stealth corvettes for the Swedish Navy
ldquoReduced 50 of a Conventional Steelrdquo
Source
Hull Construction with composite materials for ships over 100m in length 2002
Massachusetts Institute of Technology
httpwwwnaval-technologycomprojectsvisby
YACHTS
KAL YUDISTIRAMARATHON 100 ADMIRAL YACHT
LOA 3050 MWidth 6 MFuel Tank 8000 LWater Tank 3000 LIce Box 500 LAccommodation Max 35 Personnel
2 x CATERPILLAR 3412E 1200 HPMARINE DIESEL ENGINE
PC 40 ndash KRI Krait 827Department of Indonesian Navy
LOA 40 MWidth 73 MPower 190Weapon Twin Cannon Barrels
127 mm Heavy Machine GunSpeed Knot 25 KnotDisplacement 105 tonAccommodation 23 personnel
PATROL BOAT
Rigid Inflatable BoatPATROL BOAT
Yachts
36m Luxury Yacht Moonraker
36m Luxury Yacht GoldenEye
50m Luxury Yacht Casino
Royale
45m Luxury Yacht Seashaw
Boat Parts
Barovans for Seismic Sweep
Centrifugal Liftfan House for Surface Effect
Ships
Composite Boat PropellersRTM
Deckhouses for Pilot Boats
Fairing Parts for Submarines
Flybridges for Motor yachts
Light Weight Gangway
MTB Launcher Mock-up
Pleasure Boats
12m Sailboat
12m Sail-Catamaranone-off
Canoes
Dragonfly 1000Catamaran Sailboat
Fantasy 37Sailboat
Farr 60Luxury Sailboat
EurodingyOlympic Dingy Class for
Woman
Hydrolift F23 Racing Boats
Kajacs
Najad 42Sailboat
Najad 520Sailboat
Najad 441Sailboat
Najad 391Sailboat
Nordwest 900Motorboat
Nordwest 1100Motorboat
Quatro 44Motorboat
Racemaster Competition Boats
Storebro 420
Storebro 345
Sweden Yacht 370Sailboat
Sweden Yacht 69Sailboat
Windy 41Motorboat
X-632Sailboat
X-362Sailboat
Commercial Boats
175m High Speed AmbulancePassenger Boat
19m High Speed Passenger Boat
20m High Speed Passenger Boat
364m Surface Effect Passenger Ship
45m Surface Effect Passenger Ship
120m Hull Structural Parts HSSS Catamaran Ferry
APPENDIX
Marine Vessel
1188m Fast Attack Vessel FMV 90 E
20m SAV-Surface Auxiliary Vessels
34m Personnel TransportCoast Guard Vessel
40ft Experimental SES
40m Landsort-Class Mine Hunters
54m Mine Counter Measure Vehicles SES
74m Coastal Patrol Boats
Fishing Boats
30 GT
12 GT
10 GT
5 GT
WISEWings In Surface Effect
HOVERCRAFT
Designed specifically for the tourist and transport industries the
Pioneer Mk3 hovercraft is amphibious and comfortably seats 25
passengers plus 1-crew The air-conditioned cabin allows for
maximum visibility for all aboard The Pioneer Mk3 is robust and
dynamic in its performance
Commercial hovercraft
Mk3 AirLift Hovercraft - 1215m
Power is economicaly provided by one Deutz diesel engine of
330kW (442hp) to cruise easily at 40 knots with much higher
speeds available according to the surface conditions The hull is
manufactured from fibreglassPVC foam composite sandwich
the windows are glass and the skirt is urethane coated nylon A
Military version is available with increased payload and systems
redundancy Power for the Military version comes from two Steyr
diesel engines with a total installed power of 320kW (429hp) All
transmission electrical hydraulic and air systems are duplicated
for maximum redundancy The increased performance of the
Military version comes from the reduced engine weight of the twin
Steyr installation cf the Deutz installation
Source
httpwwwnauticexpocomprodairlift-hovercraftcommercial-hovercrafts-25251-142868html
HOVERFLIGHT
BALLISTIC amp UNIT DEFENCED
Triaxis Composites Collaboration with Institute of Aeronautics and Space in the development of Missile Nose Cone
Polymer composites is the evolution of the military defence
Thin steel was the helmet material of
WWII and remained the principal material until around the 1980rsquos
The advantages of using steel
included a simple technology for manufacture of the helmets low cost and reasonably good
impact protection However these helmets were found to provide only marginal protection
against fragments
During the Vietnam War the US Army experimented with fiber-reinforced inserts in the
helmets These inserts improved ballistic protection but at the same time added weight and
reduced the air space between the head and the helmet
By the early part of the 1980rsquos the US military had developed the first all-composite
100 fiber-reinforced helmet This development resulted in even better ballistic protection
without altering the weight of the helmet Other improvements included better head coverage and
more space for ventilation
Source
Composites Armor - A difficult but huge market
by A Brent Strong Brigham Young University
MILITARY VEHICLES
HIGH SPEED TRAIN SHINKANSEN
Advanced Composites provide lightweight solutions for railway vehicles
saving as much as 50-80 of the weight compared with traditional
components
A lower overall weight translates into less stress faster acceleration and
higher speeds as well as reduced starting and stopping inertia Today
these are important criteria in global high-speed and metropolitan
railway projects
Fire smoke and toxic fumes are key safety criteria for interior
components of railway carriages Any material selected for an interior
component must meet international fire retardant standards
for Rail Interiors and Exteriors
Ceiling Panels Stairs
Seating Vestibules
Window Panels Door Pillars
Partition WallsDiffusers
Gangway and Cabinet Panels Cabin and
Desk panels
Door Pillars Lavatory Modules (standard and
Front and Rear EndsRoof Panels
Nose Cones Under Fairings
Source
httpwwwpctaerail_compositesphp
101
SKY BUS
2009
Europe is the world leader in offshore wind with
828 wind turbines and a cumulative capacity of 2056 MW spread across 38 offshore wind farms in 9
European countries
The UK and Denmark are the current leaders with a 44 and 30 share respectively In 2009
five countries built new offshore wind farms
UK (284 MW)
Demark (230 MW)
Sweden (30 MW)
Germany (30 MW)
Norway (23 MW)
2010
Asia leads the growth in global wind power which grew 358 GW in 2010 bringing
total global capacity to 1944 GW ndash up 225 from 2009
the Global Wind Energy Council (GWEC)
Asia accounted for 19 GW of new global wind power installations driven by China which installed 165
GW
ldquoChina now has 423 GW of wind powerrdquo
ldquoThis puts China firmly on a path to reach 200 GW of installed wind power by 2020 At the same
time China has become the worldrsquos largest producer of wind energy equipmentrdquo
Source
httpwwwreinforcedplasticscomview15655asia-leads-global-wind-power-growth
httpimgdeusmcomdesignnews288288605-Sandia_Sizes_up_Wind_Turbine_Blade_Design_C_largegif
WIND ENERGY
Marine Current Turbines
Source
httpwwwsiemenscompressenpressreleasepress=enpressrelease2011solar-hydroex201111005htm
httpwwwmarineturbinescom
A commercial marine current turbine consists of
two rotors which are fixed on a structure within the
sea current The twin rotors rotate with the
movement of the tidal flow and the blades pitch
through 180 degrees to optimally track tidal current
(Press picture Marine Current Turbines)
Wave Star Energys Multi-point Absorber
CFRP COLUMN REINFORCEMENT
INDUSTRIAL TANKS
107
INDUSTRIAL PIPES
PRESSURE TANKS
109
ldquoLetrsquos Make with Compositesrdquo
Benang Kaca Potongan Serat Kaca Chopped Strand Mat
CSM - Chopped Strand Mat
chopped binder
Produk Fiberglass Generasi Pertama
Bahan Pengikat
Senyawa Pada Resin
Glass Roving Yarn Chopped Strand
JENIS FIBERGLASS
Benang Kaca Woven Roving
WR - Woven Roving
Tenun Weaving
Produk Fiberglass Generasi Kedua
Glass Roving Yarn
JENIS FIBERGLASS
Multiaxial
MAX - Multiaxial
warp knitting
Produk Fiberglass Generasi Ketiga
Benang Kaca
Glass Roving Yarn
JENIS FIBERGLASS
MAX - Multiaxial Fabric
Fleece (optional)
Lapisan
MULTIAXIAL PROSES
Karakteristik CSM
bull Glass Content 30
bull Resin Content 70
bull Tensile Force
Chopped Strand Mat
JENIS FIBERGLASS
Karakteristik Woven Roving
bull Glass Content 45
bull Resin Content 55
Woven Roving
Resin
|
|
|
|
|
|
|
|
|
|
|
|
|
|
bull Kekuatan Tarik
JENIS FIBERGLASS
No Resin Rich Area
Karakteristik Multiaxial
bull Glass Content 60
bull Resin Content 40
Produk Fiberglass Ketiga MULTIAXIAL
JENIS FIBERGLASS
Perbedaan Woven Roving dan Multiaxial ndash Tampak Samping
JENIS FIBERGLASS
WR FRP
8 Ply WR 800
8 Ply CSM 450
Glass Weight 1 kg
Composite Weight 15kgm2
CSM FRP
22 Ply CSM 450
Glass Weight 1 kg
Composite Weight 18 kgm2
MULTIAXIAL FRP
13 Ply DB 800
Glass Weight 1 kg
Composite Weight
13 kgm2
JENIS FIBERGLASS
Multiaxial
FRP
Woven Roving
FRP
Chopped Strands Mat FRP
MULTIAXIAL
FAKTA
TEBAL BUKAN BERARTI KUAT
UNSUR MATRIX (RESIN)
TIDAK ADA KEKUATAN
ldquoMore than 50 of the glass fibers used for reinforcement is
E-glassrdquo
KarakteristikKekuatan
CSM WR MAX
Kekuatan Tarik 175 MPa 250 MPa 425 MPa
CSM 142
WR 70
KEKUATAN TARIK
Properties CSM Lamination WR Lamination MAX Lamination
Fabric Weight (kgm2) 1 1 1
Composite Weight (kgm2) 18 15 13
Resin usage (kgm2) 15 1 08
Amount of Fabric 22 Ply 16 Ply 13 Ply
Thickness 15 mm 12 mm 10 mm
Tensile Strength (Mpa) 125 1796 400
Tensile Strength (Nmmsup2) 28463 30958 4576
Processing Time High Med Low
Labour Cost High Med Low
MULTIAXIAL
Total Penggunaan Resin -51
Total Berat Kapal -40
Kekuatan Bangunan Kapal +59
Efisiensi Tenaga Kerja
Waktu Pengerjaan Lebih Cepat
KEUNGGULAN MATERIAL
Resapan Resin Lebih Baik amp Merata
Lapisan Lebih Sedikit
Meningkatkan Kekuatan Kapal
KEUNGGULAN MATERIAL
TRIAXIAL
DBL series DBT series
BIAXIAL
LT series DB series
UNIDIRECTIONAL
L series T series
QUADRIAXIAL
DBLT series
JENIS MULTIAXIAL
UNIDIRECTIONAL
DCMU 900 E ndash
KHUSUS UNTUK MEMPERKUAT BENDING KAPAL
PEMASANGAN KHUSUS PADA KEEL DAN TULANGAN
JENIS MULTIAXIAL UNTUK KAPAL
TRIAXIAL
DBL 600 ndash
APLIKASI PADA INDUSTRI PENERBANGAN
PEMASANGAN KHUSUS PADA
SAMBUNGAN BADAN DAN SAYAP
PESAWAT
JENIS MULTIAXIAL UNTUK PESAWAT
QUADRAXIAL
DBLT 800 ndash
APLIKASI PADA INDUSTRI ENERGI
DITERAPKAN UNTUK KEBUTUHAN PEMBANGKIT
LISTRIK ENERGI ANGIN
MULTIAXIAL UNTUK ENERGI
INDUSTRI KIMIA OLAHRAGA AUTOMOTIF
MULTIAXIAL UNTUK INDUSTRI LAINNYA
COMPOSITES
GUNAKAN MATERIAL FIBERGLASS
YANG SUDAH DISERTIFIKASI
BKI
FIBERGLASS UNTUK PEMBANGUNAN BAKAP
PERATURAN MENTERI PERHUBUNGAN
NOMOR PM 7 TAHUN 2013
TENTANG KEWAJIBAN KLASIFIKASI BAGI KAPAL BERBENDERA INDONESIA
PADA BADAN KLASIFIKASI
BADAN SERTIFIKASI MARITIM
Biro Klasifikasi IndonesiaDet Norske Veritas Germanischer Lloyds
PERATURAN BKI
Untuk Kapal Non-Metal
2006
PERSYARATAN MINIMUM
kekuatan material yang
harus digunakan
untuk membangun
Kapal Fiberglass
PEMBESARAN
Table 21
FIBERGLASS TRIAXIS COMPOSITES
TELAH BERSERTIFIKASI BKI
Biro Klasifikasi Indonesia
65
TEKNIK MANUFAKTUR
COMPOSITES
Wet hand lay-up
1) Peletakan
Dry Reinforcement
bull Dry reinforcement dan resin (+ katalis) ditaruh pada permukaan cetakan
2) Pemasukanpenekanan resin
bull Resin ditekan untuk meng-impregnasi serat dengan menggunakan rol
3) Pengulangan proses untuk lapisan lain
bull Beberapa lapisan dapat ditambahkan secara bertahap
4) Resin curing
bull Reaksi dimulai komponen dilepaskan setelah komponen mengeras
(fully cured)
Wet hand lay-up
Manufaktur komponen dapat dikerjakan dengan menggunakan beberapa lapis komposit
dengan memperhatikan kompatibilitas material dan tahapan curing Modifikasi proses dapat
dilakukan seperti
Vacuum bagging
setelah lay-up
Glass Roving
Bulk Resin
Catalyst
3) De-molding
2) Resin Cure
bull Curing dimulai dan komponen dilepaskan setelah pengerasan selesai
bull Serat gelas resin dan katalis dimasukkan kedalam spray gun
1) Spray-up
bull Campuran disemprotkan pada permukaan cetakan
Spray-up
69
Penyemprotan bakal komponen
Komponen
dilepaskan
dari cetakan
Full dispensing
system Chopper Roving
Atomised resin
and catalyst
Spray-up
Prepreg
1) LaminateAssembly 5) De-molding
3) Resin Melts Layup Consolidates
bull Prepreg serat yang sudah diimpregnasi oleh resin+katalis dalam kondisi padat
bull Lapisan prepreg digunting sesuai bentuk yang diinginkan kemudian diletakkan pada permukaan cetakan
sesuai bentuk komponen yang diinginkan Lay-up mudah dilakukan karena sifat ldquotackynessrdquo dari prepreg
2) Applied Vacuum Pressure and Heat
bull Tekanan dan panas diberikan resin mencair terjadi konsolidasi pada komponen
4) Resin Cures
bull Temperatur dinaikkan untuk memulai curing
Prepreg
Variasi proses Autoclave
Komponen dalam
vacuum-bag
bull Campuran resin (+katalis) dan chopped glass strands diperoleh dalam bentuk premixed compound Bulk molding
Compound (BMC) dalam bentuk adonan atau Sheet molding Compound (SMC) dalam bentuk lembaran
bull Ketika panas dan tekanan diberikan oleh cetakan compound mengalir sesuai bentuk komponen yang diinginkan
1) Placement of Charge
5) De-molding3) Squeeze to final dimensions
2) Mould Closure4) Resin Cure
bull Curing dimulai komponen dilepaskan setelah terjadi pengerasan yang cukup
Compression Molding
bull Preform atau dry reinforcement dimasukkan kedalam cetakan sesuai dengan bentuk komponen yang
diinginkan
bull Resin mengalir dengan penekanan atau pem-vakuman dan meng-impregnasi preform dan
mendorongmengeluarkan udara yang ada dalam preform
1) Preform Manufacture
2) Preform Compression
5) De-molding3) Resin Injection
4) Resin Cure
bull Curing terjadi cetakan dibuka setelah terjadi pengerasan yang mencukupi
Liquid Molding (RTM VARI VARTM)
Pultrusion
bull Dry roving or fabrics ditarik melalui bak berisi
campuran resin dan katalis
bull Campuran yang basah ditarik melalui cetakan
bull Sisa resin keluar cetakan
bull Pemanasan dilakukan untuk proses curing
bull Pendinginan dilakukan untuk mempercepat siklus
produksi
Cut-off
Cooling
Die sections
Resin bath
Fibre creel
Filament Winding
bull Dry roving ditarik melalui bak berisi campuran resin dan katalis
bull Wet roving digulungkan dalam keadaan tegang kepada mandrel
bull Kontrol mekanik dari pembawa serat mengatur orientasi peletakan serat pada
mandrel
INDUSTRI COMPOSITES
AEROSPACE
HISTORY
1950 ndash Boeing
1960 ndash F14 Tomcat
1981 ndash AV-8B Harrier
Source
Low-Cost Composite Materials and Structures for Aircraft Applications
httpwwwreinforcedplasticscom
httpwwwcentennialofflightgovessayEvolution_of_TechnologycompositesTech40htm
Automotive
Composite material is used in a number of applications in the automotive
industry due to its temperature resistance rigidity and fatigue strength
The benefits of using composites include greater fuel efficiency
corrosion resistance light weight and strength Composites also provide
a low-cost way to help keep designs looking fresh
Composites are used in
- interior parts (cockpit trimming seats instrument panels)
- exterior structure (body panels openings underbody frontrear
modules)
- engine compartment and fuelmechanical area parts (axles and
suspensions fuel and exhaust systems)
- electrical and electronic components
Lamborghinis Sesto Element carbon fiber
ldquoFat men cannot run as fast as thin men but we build most of our vehicles as though dead-weight fat increased speedhellip I cannot
imagine where the delusion that weight means strength
came fromhelliprdquo mdashHenry Ford
The mix of automotive materials is changing showing a boost for FRP in helping original
equipment manufacturers meet fuel economy and emissions challenges
(Source 2011 DuPont AutomotiveSAE survey of design engineers performed by Signet Research Inc)
Source
httpwwwtoraycomcsrhighlight2009hig_001_01html
The MonoCell tub for the McLaren MP4-12C supercar is moulded as a single
piece and weighs less than 80 kg (176 lbs)
COMPOSITES IN MARINE
TRIMARAN BOAT
AMERICA NAVYINDONESIAN NAVY
Visby Class corvette
Total length is 72 meters
The beam is 1040 meters
The displacement is 600 metric tones
fully equipped the worlds largest CRP
construction
The design of the Visby aims to minimize
the optical and infrared signature above
water acoustic and hydroa coustic
signature underwater electrical potential
and magnetic signature pressure signature
radar cross section and actively emitted
signals
A stealth corvette of the YS 2000 design
has a detection range of 13km in rough
seas and 22km in calm sea without
jamming In a jammed environment the
Visby would be detected at a range of 8km
in rough sea and 11km in calm sea
The material provides high strength and
rigidity low weight good shock resistance
low radar and magnetic signature
1996
Visby is a class of stealth corvettes for the Swedish Navy
ldquoReduced 50 of a Conventional Steelrdquo
Source
Hull Construction with composite materials for ships over 100m in length 2002
Massachusetts Institute of Technology
httpwwwnaval-technologycomprojectsvisby
YACHTS
KAL YUDISTIRAMARATHON 100 ADMIRAL YACHT
LOA 3050 MWidth 6 MFuel Tank 8000 LWater Tank 3000 LIce Box 500 LAccommodation Max 35 Personnel
2 x CATERPILLAR 3412E 1200 HPMARINE DIESEL ENGINE
PC 40 ndash KRI Krait 827Department of Indonesian Navy
LOA 40 MWidth 73 MPower 190Weapon Twin Cannon Barrels
127 mm Heavy Machine GunSpeed Knot 25 KnotDisplacement 105 tonAccommodation 23 personnel
PATROL BOAT
Rigid Inflatable BoatPATROL BOAT
Yachts
36m Luxury Yacht Moonraker
36m Luxury Yacht GoldenEye
50m Luxury Yacht Casino
Royale
45m Luxury Yacht Seashaw
Boat Parts
Barovans for Seismic Sweep
Centrifugal Liftfan House for Surface Effect
Ships
Composite Boat PropellersRTM
Deckhouses for Pilot Boats
Fairing Parts for Submarines
Flybridges for Motor yachts
Light Weight Gangway
MTB Launcher Mock-up
Pleasure Boats
12m Sailboat
12m Sail-Catamaranone-off
Canoes
Dragonfly 1000Catamaran Sailboat
Fantasy 37Sailboat
Farr 60Luxury Sailboat
EurodingyOlympic Dingy Class for
Woman
Hydrolift F23 Racing Boats
Kajacs
Najad 42Sailboat
Najad 520Sailboat
Najad 441Sailboat
Najad 391Sailboat
Nordwest 900Motorboat
Nordwest 1100Motorboat
Quatro 44Motorboat
Racemaster Competition Boats
Storebro 420
Storebro 345
Sweden Yacht 370Sailboat
Sweden Yacht 69Sailboat
Windy 41Motorboat
X-632Sailboat
X-362Sailboat
Commercial Boats
175m High Speed AmbulancePassenger Boat
19m High Speed Passenger Boat
20m High Speed Passenger Boat
364m Surface Effect Passenger Ship
45m Surface Effect Passenger Ship
120m Hull Structural Parts HSSS Catamaran Ferry
APPENDIX
Marine Vessel
1188m Fast Attack Vessel FMV 90 E
20m SAV-Surface Auxiliary Vessels
34m Personnel TransportCoast Guard Vessel
40ft Experimental SES
40m Landsort-Class Mine Hunters
54m Mine Counter Measure Vehicles SES
74m Coastal Patrol Boats
Fishing Boats
30 GT
12 GT
10 GT
5 GT
WISEWings In Surface Effect
HOVERCRAFT
Designed specifically for the tourist and transport industries the
Pioneer Mk3 hovercraft is amphibious and comfortably seats 25
passengers plus 1-crew The air-conditioned cabin allows for
maximum visibility for all aboard The Pioneer Mk3 is robust and
dynamic in its performance
Commercial hovercraft
Mk3 AirLift Hovercraft - 1215m
Power is economicaly provided by one Deutz diesel engine of
330kW (442hp) to cruise easily at 40 knots with much higher
speeds available according to the surface conditions The hull is
manufactured from fibreglassPVC foam composite sandwich
the windows are glass and the skirt is urethane coated nylon A
Military version is available with increased payload and systems
redundancy Power for the Military version comes from two Steyr
diesel engines with a total installed power of 320kW (429hp) All
transmission electrical hydraulic and air systems are duplicated
for maximum redundancy The increased performance of the
Military version comes from the reduced engine weight of the twin
Steyr installation cf the Deutz installation
Source
httpwwwnauticexpocomprodairlift-hovercraftcommercial-hovercrafts-25251-142868html
HOVERFLIGHT
BALLISTIC amp UNIT DEFENCED
Triaxis Composites Collaboration with Institute of Aeronautics and Space in the development of Missile Nose Cone
Polymer composites is the evolution of the military defence
Thin steel was the helmet material of
WWII and remained the principal material until around the 1980rsquos
The advantages of using steel
included a simple technology for manufacture of the helmets low cost and reasonably good
impact protection However these helmets were found to provide only marginal protection
against fragments
During the Vietnam War the US Army experimented with fiber-reinforced inserts in the
helmets These inserts improved ballistic protection but at the same time added weight and
reduced the air space between the head and the helmet
By the early part of the 1980rsquos the US military had developed the first all-composite
100 fiber-reinforced helmet This development resulted in even better ballistic protection
without altering the weight of the helmet Other improvements included better head coverage and
more space for ventilation
Source
Composites Armor - A difficult but huge market
by A Brent Strong Brigham Young University
MILITARY VEHICLES
HIGH SPEED TRAIN SHINKANSEN
Advanced Composites provide lightweight solutions for railway vehicles
saving as much as 50-80 of the weight compared with traditional
components
A lower overall weight translates into less stress faster acceleration and
higher speeds as well as reduced starting and stopping inertia Today
these are important criteria in global high-speed and metropolitan
railway projects
Fire smoke and toxic fumes are key safety criteria for interior
components of railway carriages Any material selected for an interior
component must meet international fire retardant standards
for Rail Interiors and Exteriors
Ceiling Panels Stairs
Seating Vestibules
Window Panels Door Pillars
Partition WallsDiffusers
Gangway and Cabinet Panels Cabin and
Desk panels
Door Pillars Lavatory Modules (standard and
Front and Rear EndsRoof Panels
Nose Cones Under Fairings
Source
httpwwwpctaerail_compositesphp
101
SKY BUS
2009
Europe is the world leader in offshore wind with
828 wind turbines and a cumulative capacity of 2056 MW spread across 38 offshore wind farms in 9
European countries
The UK and Denmark are the current leaders with a 44 and 30 share respectively In 2009
five countries built new offshore wind farms
UK (284 MW)
Demark (230 MW)
Sweden (30 MW)
Germany (30 MW)
Norway (23 MW)
2010
Asia leads the growth in global wind power which grew 358 GW in 2010 bringing
total global capacity to 1944 GW ndash up 225 from 2009
the Global Wind Energy Council (GWEC)
Asia accounted for 19 GW of new global wind power installations driven by China which installed 165
GW
ldquoChina now has 423 GW of wind powerrdquo
ldquoThis puts China firmly on a path to reach 200 GW of installed wind power by 2020 At the same
time China has become the worldrsquos largest producer of wind energy equipmentrdquo
Source
httpwwwreinforcedplasticscomview15655asia-leads-global-wind-power-growth
httpimgdeusmcomdesignnews288288605-Sandia_Sizes_up_Wind_Turbine_Blade_Design_C_largegif
WIND ENERGY
Marine Current Turbines
Source
httpwwwsiemenscompressenpressreleasepress=enpressrelease2011solar-hydroex201111005htm
httpwwwmarineturbinescom
A commercial marine current turbine consists of
two rotors which are fixed on a structure within the
sea current The twin rotors rotate with the
movement of the tidal flow and the blades pitch
through 180 degrees to optimally track tidal current
(Press picture Marine Current Turbines)
Wave Star Energys Multi-point Absorber
CFRP COLUMN REINFORCEMENT
INDUSTRIAL TANKS
107
INDUSTRIAL PIPES
PRESSURE TANKS
109
ldquoLetrsquos Make with Compositesrdquo
Benang Kaca Woven Roving
WR - Woven Roving
Tenun Weaving
Produk Fiberglass Generasi Kedua
Glass Roving Yarn
JENIS FIBERGLASS
Multiaxial
MAX - Multiaxial
warp knitting
Produk Fiberglass Generasi Ketiga
Benang Kaca
Glass Roving Yarn
JENIS FIBERGLASS
MAX - Multiaxial Fabric
Fleece (optional)
Lapisan
MULTIAXIAL PROSES
Karakteristik CSM
bull Glass Content 30
bull Resin Content 70
bull Tensile Force
Chopped Strand Mat
JENIS FIBERGLASS
Karakteristik Woven Roving
bull Glass Content 45
bull Resin Content 55
Woven Roving
Resin
|
|
|
|
|
|
|
|
|
|
|
|
|
|
bull Kekuatan Tarik
JENIS FIBERGLASS
No Resin Rich Area
Karakteristik Multiaxial
bull Glass Content 60
bull Resin Content 40
Produk Fiberglass Ketiga MULTIAXIAL
JENIS FIBERGLASS
Perbedaan Woven Roving dan Multiaxial ndash Tampak Samping
JENIS FIBERGLASS
WR FRP
8 Ply WR 800
8 Ply CSM 450
Glass Weight 1 kg
Composite Weight 15kgm2
CSM FRP
22 Ply CSM 450
Glass Weight 1 kg
Composite Weight 18 kgm2
MULTIAXIAL FRP
13 Ply DB 800
Glass Weight 1 kg
Composite Weight
13 kgm2
JENIS FIBERGLASS
Multiaxial
FRP
Woven Roving
FRP
Chopped Strands Mat FRP
MULTIAXIAL
FAKTA
TEBAL BUKAN BERARTI KUAT
UNSUR MATRIX (RESIN)
TIDAK ADA KEKUATAN
ldquoMore than 50 of the glass fibers used for reinforcement is
E-glassrdquo
KarakteristikKekuatan
CSM WR MAX
Kekuatan Tarik 175 MPa 250 MPa 425 MPa
CSM 142
WR 70
KEKUATAN TARIK
Properties CSM Lamination WR Lamination MAX Lamination
Fabric Weight (kgm2) 1 1 1
Composite Weight (kgm2) 18 15 13
Resin usage (kgm2) 15 1 08
Amount of Fabric 22 Ply 16 Ply 13 Ply
Thickness 15 mm 12 mm 10 mm
Tensile Strength (Mpa) 125 1796 400
Tensile Strength (Nmmsup2) 28463 30958 4576
Processing Time High Med Low
Labour Cost High Med Low
MULTIAXIAL
Total Penggunaan Resin -51
Total Berat Kapal -40
Kekuatan Bangunan Kapal +59
Efisiensi Tenaga Kerja
Waktu Pengerjaan Lebih Cepat
KEUNGGULAN MATERIAL
Resapan Resin Lebih Baik amp Merata
Lapisan Lebih Sedikit
Meningkatkan Kekuatan Kapal
KEUNGGULAN MATERIAL
TRIAXIAL
DBL series DBT series
BIAXIAL
LT series DB series
UNIDIRECTIONAL
L series T series
QUADRIAXIAL
DBLT series
JENIS MULTIAXIAL
UNIDIRECTIONAL
DCMU 900 E ndash
KHUSUS UNTUK MEMPERKUAT BENDING KAPAL
PEMASANGAN KHUSUS PADA KEEL DAN TULANGAN
JENIS MULTIAXIAL UNTUK KAPAL
TRIAXIAL
DBL 600 ndash
APLIKASI PADA INDUSTRI PENERBANGAN
PEMASANGAN KHUSUS PADA
SAMBUNGAN BADAN DAN SAYAP
PESAWAT
JENIS MULTIAXIAL UNTUK PESAWAT
QUADRAXIAL
DBLT 800 ndash
APLIKASI PADA INDUSTRI ENERGI
DITERAPKAN UNTUK KEBUTUHAN PEMBANGKIT
LISTRIK ENERGI ANGIN
MULTIAXIAL UNTUK ENERGI
INDUSTRI KIMIA OLAHRAGA AUTOMOTIF
MULTIAXIAL UNTUK INDUSTRI LAINNYA
COMPOSITES
GUNAKAN MATERIAL FIBERGLASS
YANG SUDAH DISERTIFIKASI
BKI
FIBERGLASS UNTUK PEMBANGUNAN BAKAP
PERATURAN MENTERI PERHUBUNGAN
NOMOR PM 7 TAHUN 2013
TENTANG KEWAJIBAN KLASIFIKASI BAGI KAPAL BERBENDERA INDONESIA
PADA BADAN KLASIFIKASI
BADAN SERTIFIKASI MARITIM
Biro Klasifikasi IndonesiaDet Norske Veritas Germanischer Lloyds
PERATURAN BKI
Untuk Kapal Non-Metal
2006
PERSYARATAN MINIMUM
kekuatan material yang
harus digunakan
untuk membangun
Kapal Fiberglass
PEMBESARAN
Table 21
FIBERGLASS TRIAXIS COMPOSITES
TELAH BERSERTIFIKASI BKI
Biro Klasifikasi Indonesia
65
TEKNIK MANUFAKTUR
COMPOSITES
Wet hand lay-up
1) Peletakan
Dry Reinforcement
bull Dry reinforcement dan resin (+ katalis) ditaruh pada permukaan cetakan
2) Pemasukanpenekanan resin
bull Resin ditekan untuk meng-impregnasi serat dengan menggunakan rol
3) Pengulangan proses untuk lapisan lain
bull Beberapa lapisan dapat ditambahkan secara bertahap
4) Resin curing
bull Reaksi dimulai komponen dilepaskan setelah komponen mengeras
(fully cured)
Wet hand lay-up
Manufaktur komponen dapat dikerjakan dengan menggunakan beberapa lapis komposit
dengan memperhatikan kompatibilitas material dan tahapan curing Modifikasi proses dapat
dilakukan seperti
Vacuum bagging
setelah lay-up
Glass Roving
Bulk Resin
Catalyst
3) De-molding
2) Resin Cure
bull Curing dimulai dan komponen dilepaskan setelah pengerasan selesai
bull Serat gelas resin dan katalis dimasukkan kedalam spray gun
1) Spray-up
bull Campuran disemprotkan pada permukaan cetakan
Spray-up
69
Penyemprotan bakal komponen
Komponen
dilepaskan
dari cetakan
Full dispensing
system Chopper Roving
Atomised resin
and catalyst
Spray-up
Prepreg
1) LaminateAssembly 5) De-molding
3) Resin Melts Layup Consolidates
bull Prepreg serat yang sudah diimpregnasi oleh resin+katalis dalam kondisi padat
bull Lapisan prepreg digunting sesuai bentuk yang diinginkan kemudian diletakkan pada permukaan cetakan
sesuai bentuk komponen yang diinginkan Lay-up mudah dilakukan karena sifat ldquotackynessrdquo dari prepreg
2) Applied Vacuum Pressure and Heat
bull Tekanan dan panas diberikan resin mencair terjadi konsolidasi pada komponen
4) Resin Cures
bull Temperatur dinaikkan untuk memulai curing
Prepreg
Variasi proses Autoclave
Komponen dalam
vacuum-bag
bull Campuran resin (+katalis) dan chopped glass strands diperoleh dalam bentuk premixed compound Bulk molding
Compound (BMC) dalam bentuk adonan atau Sheet molding Compound (SMC) dalam bentuk lembaran
bull Ketika panas dan tekanan diberikan oleh cetakan compound mengalir sesuai bentuk komponen yang diinginkan
1) Placement of Charge
5) De-molding3) Squeeze to final dimensions
2) Mould Closure4) Resin Cure
bull Curing dimulai komponen dilepaskan setelah terjadi pengerasan yang cukup
Compression Molding
bull Preform atau dry reinforcement dimasukkan kedalam cetakan sesuai dengan bentuk komponen yang
diinginkan
bull Resin mengalir dengan penekanan atau pem-vakuman dan meng-impregnasi preform dan
mendorongmengeluarkan udara yang ada dalam preform
1) Preform Manufacture
2) Preform Compression
5) De-molding3) Resin Injection
4) Resin Cure
bull Curing terjadi cetakan dibuka setelah terjadi pengerasan yang mencukupi
Liquid Molding (RTM VARI VARTM)
Pultrusion
bull Dry roving or fabrics ditarik melalui bak berisi
campuran resin dan katalis
bull Campuran yang basah ditarik melalui cetakan
bull Sisa resin keluar cetakan
bull Pemanasan dilakukan untuk proses curing
bull Pendinginan dilakukan untuk mempercepat siklus
produksi
Cut-off
Cooling
Die sections
Resin bath
Fibre creel
Filament Winding
bull Dry roving ditarik melalui bak berisi campuran resin dan katalis
bull Wet roving digulungkan dalam keadaan tegang kepada mandrel
bull Kontrol mekanik dari pembawa serat mengatur orientasi peletakan serat pada
mandrel
INDUSTRI COMPOSITES
AEROSPACE
HISTORY
1950 ndash Boeing
1960 ndash F14 Tomcat
1981 ndash AV-8B Harrier
Source
Low-Cost Composite Materials and Structures for Aircraft Applications
httpwwwreinforcedplasticscom
httpwwwcentennialofflightgovessayEvolution_of_TechnologycompositesTech40htm
Automotive
Composite material is used in a number of applications in the automotive
industry due to its temperature resistance rigidity and fatigue strength
The benefits of using composites include greater fuel efficiency
corrosion resistance light weight and strength Composites also provide
a low-cost way to help keep designs looking fresh
Composites are used in
- interior parts (cockpit trimming seats instrument panels)
- exterior structure (body panels openings underbody frontrear
modules)
- engine compartment and fuelmechanical area parts (axles and
suspensions fuel and exhaust systems)
- electrical and electronic components
Lamborghinis Sesto Element carbon fiber
ldquoFat men cannot run as fast as thin men but we build most of our vehicles as though dead-weight fat increased speedhellip I cannot
imagine where the delusion that weight means strength
came fromhelliprdquo mdashHenry Ford
The mix of automotive materials is changing showing a boost for FRP in helping original
equipment manufacturers meet fuel economy and emissions challenges
(Source 2011 DuPont AutomotiveSAE survey of design engineers performed by Signet Research Inc)
Source
httpwwwtoraycomcsrhighlight2009hig_001_01html
The MonoCell tub for the McLaren MP4-12C supercar is moulded as a single
piece and weighs less than 80 kg (176 lbs)
COMPOSITES IN MARINE
TRIMARAN BOAT
AMERICA NAVYINDONESIAN NAVY
Visby Class corvette
Total length is 72 meters
The beam is 1040 meters
The displacement is 600 metric tones
fully equipped the worlds largest CRP
construction
The design of the Visby aims to minimize
the optical and infrared signature above
water acoustic and hydroa coustic
signature underwater electrical potential
and magnetic signature pressure signature
radar cross section and actively emitted
signals
A stealth corvette of the YS 2000 design
has a detection range of 13km in rough
seas and 22km in calm sea without
jamming In a jammed environment the
Visby would be detected at a range of 8km
in rough sea and 11km in calm sea
The material provides high strength and
rigidity low weight good shock resistance
low radar and magnetic signature
1996
Visby is a class of stealth corvettes for the Swedish Navy
ldquoReduced 50 of a Conventional Steelrdquo
Source
Hull Construction with composite materials for ships over 100m in length 2002
Massachusetts Institute of Technology
httpwwwnaval-technologycomprojectsvisby
YACHTS
KAL YUDISTIRAMARATHON 100 ADMIRAL YACHT
LOA 3050 MWidth 6 MFuel Tank 8000 LWater Tank 3000 LIce Box 500 LAccommodation Max 35 Personnel
2 x CATERPILLAR 3412E 1200 HPMARINE DIESEL ENGINE
PC 40 ndash KRI Krait 827Department of Indonesian Navy
LOA 40 MWidth 73 MPower 190Weapon Twin Cannon Barrels
127 mm Heavy Machine GunSpeed Knot 25 KnotDisplacement 105 tonAccommodation 23 personnel
PATROL BOAT
Rigid Inflatable BoatPATROL BOAT
Yachts
36m Luxury Yacht Moonraker
36m Luxury Yacht GoldenEye
50m Luxury Yacht Casino
Royale
45m Luxury Yacht Seashaw
Boat Parts
Barovans for Seismic Sweep
Centrifugal Liftfan House for Surface Effect
Ships
Composite Boat PropellersRTM
Deckhouses for Pilot Boats
Fairing Parts for Submarines
Flybridges for Motor yachts
Light Weight Gangway
MTB Launcher Mock-up
Pleasure Boats
12m Sailboat
12m Sail-Catamaranone-off
Canoes
Dragonfly 1000Catamaran Sailboat
Fantasy 37Sailboat
Farr 60Luxury Sailboat
EurodingyOlympic Dingy Class for
Woman
Hydrolift F23 Racing Boats
Kajacs
Najad 42Sailboat
Najad 520Sailboat
Najad 441Sailboat
Najad 391Sailboat
Nordwest 900Motorboat
Nordwest 1100Motorboat
Quatro 44Motorboat
Racemaster Competition Boats
Storebro 420
Storebro 345
Sweden Yacht 370Sailboat
Sweden Yacht 69Sailboat
Windy 41Motorboat
X-632Sailboat
X-362Sailboat
Commercial Boats
175m High Speed AmbulancePassenger Boat
19m High Speed Passenger Boat
20m High Speed Passenger Boat
364m Surface Effect Passenger Ship
45m Surface Effect Passenger Ship
120m Hull Structural Parts HSSS Catamaran Ferry
APPENDIX
Marine Vessel
1188m Fast Attack Vessel FMV 90 E
20m SAV-Surface Auxiliary Vessels
34m Personnel TransportCoast Guard Vessel
40ft Experimental SES
40m Landsort-Class Mine Hunters
54m Mine Counter Measure Vehicles SES
74m Coastal Patrol Boats
Fishing Boats
30 GT
12 GT
10 GT
5 GT
WISEWings In Surface Effect
HOVERCRAFT
Designed specifically for the tourist and transport industries the
Pioneer Mk3 hovercraft is amphibious and comfortably seats 25
passengers plus 1-crew The air-conditioned cabin allows for
maximum visibility for all aboard The Pioneer Mk3 is robust and
dynamic in its performance
Commercial hovercraft
Mk3 AirLift Hovercraft - 1215m
Power is economicaly provided by one Deutz diesel engine of
330kW (442hp) to cruise easily at 40 knots with much higher
speeds available according to the surface conditions The hull is
manufactured from fibreglassPVC foam composite sandwich
the windows are glass and the skirt is urethane coated nylon A
Military version is available with increased payload and systems
redundancy Power for the Military version comes from two Steyr
diesel engines with a total installed power of 320kW (429hp) All
transmission electrical hydraulic and air systems are duplicated
for maximum redundancy The increased performance of the
Military version comes from the reduced engine weight of the twin
Steyr installation cf the Deutz installation
Source
httpwwwnauticexpocomprodairlift-hovercraftcommercial-hovercrafts-25251-142868html
HOVERFLIGHT
BALLISTIC amp UNIT DEFENCED
Triaxis Composites Collaboration with Institute of Aeronautics and Space in the development of Missile Nose Cone
Polymer composites is the evolution of the military defence
Thin steel was the helmet material of
WWII and remained the principal material until around the 1980rsquos
The advantages of using steel
included a simple technology for manufacture of the helmets low cost and reasonably good
impact protection However these helmets were found to provide only marginal protection
against fragments
During the Vietnam War the US Army experimented with fiber-reinforced inserts in the
helmets These inserts improved ballistic protection but at the same time added weight and
reduced the air space between the head and the helmet
By the early part of the 1980rsquos the US military had developed the first all-composite
100 fiber-reinforced helmet This development resulted in even better ballistic protection
without altering the weight of the helmet Other improvements included better head coverage and
more space for ventilation
Source
Composites Armor - A difficult but huge market
by A Brent Strong Brigham Young University
MILITARY VEHICLES
HIGH SPEED TRAIN SHINKANSEN
Advanced Composites provide lightweight solutions for railway vehicles
saving as much as 50-80 of the weight compared with traditional
components
A lower overall weight translates into less stress faster acceleration and
higher speeds as well as reduced starting and stopping inertia Today
these are important criteria in global high-speed and metropolitan
railway projects
Fire smoke and toxic fumes are key safety criteria for interior
components of railway carriages Any material selected for an interior
component must meet international fire retardant standards
for Rail Interiors and Exteriors
Ceiling Panels Stairs
Seating Vestibules
Window Panels Door Pillars
Partition WallsDiffusers
Gangway and Cabinet Panels Cabin and
Desk panels
Door Pillars Lavatory Modules (standard and
Front and Rear EndsRoof Panels
Nose Cones Under Fairings
Source
httpwwwpctaerail_compositesphp
101
SKY BUS
2009
Europe is the world leader in offshore wind with
828 wind turbines and a cumulative capacity of 2056 MW spread across 38 offshore wind farms in 9
European countries
The UK and Denmark are the current leaders with a 44 and 30 share respectively In 2009
five countries built new offshore wind farms
UK (284 MW)
Demark (230 MW)
Sweden (30 MW)
Germany (30 MW)
Norway (23 MW)
2010
Asia leads the growth in global wind power which grew 358 GW in 2010 bringing
total global capacity to 1944 GW ndash up 225 from 2009
the Global Wind Energy Council (GWEC)
Asia accounted for 19 GW of new global wind power installations driven by China which installed 165
GW
ldquoChina now has 423 GW of wind powerrdquo
ldquoThis puts China firmly on a path to reach 200 GW of installed wind power by 2020 At the same
time China has become the worldrsquos largest producer of wind energy equipmentrdquo
Source
httpwwwreinforcedplasticscomview15655asia-leads-global-wind-power-growth
httpimgdeusmcomdesignnews288288605-Sandia_Sizes_up_Wind_Turbine_Blade_Design_C_largegif
WIND ENERGY
Marine Current Turbines
Source
httpwwwsiemenscompressenpressreleasepress=enpressrelease2011solar-hydroex201111005htm
httpwwwmarineturbinescom
A commercial marine current turbine consists of
two rotors which are fixed on a structure within the
sea current The twin rotors rotate with the
movement of the tidal flow and the blades pitch
through 180 degrees to optimally track tidal current
(Press picture Marine Current Turbines)
Wave Star Energys Multi-point Absorber
CFRP COLUMN REINFORCEMENT
INDUSTRIAL TANKS
107
INDUSTRIAL PIPES
PRESSURE TANKS
109
ldquoLetrsquos Make with Compositesrdquo
Multiaxial
MAX - Multiaxial
warp knitting
Produk Fiberglass Generasi Ketiga
Benang Kaca
Glass Roving Yarn
JENIS FIBERGLASS
MAX - Multiaxial Fabric
Fleece (optional)
Lapisan
MULTIAXIAL PROSES
Karakteristik CSM
bull Glass Content 30
bull Resin Content 70
bull Tensile Force
Chopped Strand Mat
JENIS FIBERGLASS
Karakteristik Woven Roving
bull Glass Content 45
bull Resin Content 55
Woven Roving
Resin
|
|
|
|
|
|
|
|
|
|
|
|
|
|
bull Kekuatan Tarik
JENIS FIBERGLASS
No Resin Rich Area
Karakteristik Multiaxial
bull Glass Content 60
bull Resin Content 40
Produk Fiberglass Ketiga MULTIAXIAL
JENIS FIBERGLASS
Perbedaan Woven Roving dan Multiaxial ndash Tampak Samping
JENIS FIBERGLASS
WR FRP
8 Ply WR 800
8 Ply CSM 450
Glass Weight 1 kg
Composite Weight 15kgm2
CSM FRP
22 Ply CSM 450
Glass Weight 1 kg
Composite Weight 18 kgm2
MULTIAXIAL FRP
13 Ply DB 800
Glass Weight 1 kg
Composite Weight
13 kgm2
JENIS FIBERGLASS
Multiaxial
FRP
Woven Roving
FRP
Chopped Strands Mat FRP
MULTIAXIAL
FAKTA
TEBAL BUKAN BERARTI KUAT
UNSUR MATRIX (RESIN)
TIDAK ADA KEKUATAN
ldquoMore than 50 of the glass fibers used for reinforcement is
E-glassrdquo
KarakteristikKekuatan
CSM WR MAX
Kekuatan Tarik 175 MPa 250 MPa 425 MPa
CSM 142
WR 70
KEKUATAN TARIK
Properties CSM Lamination WR Lamination MAX Lamination
Fabric Weight (kgm2) 1 1 1
Composite Weight (kgm2) 18 15 13
Resin usage (kgm2) 15 1 08
Amount of Fabric 22 Ply 16 Ply 13 Ply
Thickness 15 mm 12 mm 10 mm
Tensile Strength (Mpa) 125 1796 400
Tensile Strength (Nmmsup2) 28463 30958 4576
Processing Time High Med Low
Labour Cost High Med Low
MULTIAXIAL
Total Penggunaan Resin -51
Total Berat Kapal -40
Kekuatan Bangunan Kapal +59
Efisiensi Tenaga Kerja
Waktu Pengerjaan Lebih Cepat
KEUNGGULAN MATERIAL
Resapan Resin Lebih Baik amp Merata
Lapisan Lebih Sedikit
Meningkatkan Kekuatan Kapal
KEUNGGULAN MATERIAL
TRIAXIAL
DBL series DBT series
BIAXIAL
LT series DB series
UNIDIRECTIONAL
L series T series
QUADRIAXIAL
DBLT series
JENIS MULTIAXIAL
UNIDIRECTIONAL
DCMU 900 E ndash
KHUSUS UNTUK MEMPERKUAT BENDING KAPAL
PEMASANGAN KHUSUS PADA KEEL DAN TULANGAN
JENIS MULTIAXIAL UNTUK KAPAL
TRIAXIAL
DBL 600 ndash
APLIKASI PADA INDUSTRI PENERBANGAN
PEMASANGAN KHUSUS PADA
SAMBUNGAN BADAN DAN SAYAP
PESAWAT
JENIS MULTIAXIAL UNTUK PESAWAT
QUADRAXIAL
DBLT 800 ndash
APLIKASI PADA INDUSTRI ENERGI
DITERAPKAN UNTUK KEBUTUHAN PEMBANGKIT
LISTRIK ENERGI ANGIN
MULTIAXIAL UNTUK ENERGI
INDUSTRI KIMIA OLAHRAGA AUTOMOTIF
MULTIAXIAL UNTUK INDUSTRI LAINNYA
COMPOSITES
GUNAKAN MATERIAL FIBERGLASS
YANG SUDAH DISERTIFIKASI
BKI
FIBERGLASS UNTUK PEMBANGUNAN BAKAP
PERATURAN MENTERI PERHUBUNGAN
NOMOR PM 7 TAHUN 2013
TENTANG KEWAJIBAN KLASIFIKASI BAGI KAPAL BERBENDERA INDONESIA
PADA BADAN KLASIFIKASI
BADAN SERTIFIKASI MARITIM
Biro Klasifikasi IndonesiaDet Norske Veritas Germanischer Lloyds
PERATURAN BKI
Untuk Kapal Non-Metal
2006
PERSYARATAN MINIMUM
kekuatan material yang
harus digunakan
untuk membangun
Kapal Fiberglass
PEMBESARAN
Table 21
FIBERGLASS TRIAXIS COMPOSITES
TELAH BERSERTIFIKASI BKI
Biro Klasifikasi Indonesia
65
TEKNIK MANUFAKTUR
COMPOSITES
Wet hand lay-up
1) Peletakan
Dry Reinforcement
bull Dry reinforcement dan resin (+ katalis) ditaruh pada permukaan cetakan
2) Pemasukanpenekanan resin
bull Resin ditekan untuk meng-impregnasi serat dengan menggunakan rol
3) Pengulangan proses untuk lapisan lain
bull Beberapa lapisan dapat ditambahkan secara bertahap
4) Resin curing
bull Reaksi dimulai komponen dilepaskan setelah komponen mengeras
(fully cured)
Wet hand lay-up
Manufaktur komponen dapat dikerjakan dengan menggunakan beberapa lapis komposit
dengan memperhatikan kompatibilitas material dan tahapan curing Modifikasi proses dapat
dilakukan seperti
Vacuum bagging
setelah lay-up
Glass Roving
Bulk Resin
Catalyst
3) De-molding
2) Resin Cure
bull Curing dimulai dan komponen dilepaskan setelah pengerasan selesai
bull Serat gelas resin dan katalis dimasukkan kedalam spray gun
1) Spray-up
bull Campuran disemprotkan pada permukaan cetakan
Spray-up
69
Penyemprotan bakal komponen
Komponen
dilepaskan
dari cetakan
Full dispensing
system Chopper Roving
Atomised resin
and catalyst
Spray-up
Prepreg
1) LaminateAssembly 5) De-molding
3) Resin Melts Layup Consolidates
bull Prepreg serat yang sudah diimpregnasi oleh resin+katalis dalam kondisi padat
bull Lapisan prepreg digunting sesuai bentuk yang diinginkan kemudian diletakkan pada permukaan cetakan
sesuai bentuk komponen yang diinginkan Lay-up mudah dilakukan karena sifat ldquotackynessrdquo dari prepreg
2) Applied Vacuum Pressure and Heat
bull Tekanan dan panas diberikan resin mencair terjadi konsolidasi pada komponen
4) Resin Cures
bull Temperatur dinaikkan untuk memulai curing
Prepreg
Variasi proses Autoclave
Komponen dalam
vacuum-bag
bull Campuran resin (+katalis) dan chopped glass strands diperoleh dalam bentuk premixed compound Bulk molding
Compound (BMC) dalam bentuk adonan atau Sheet molding Compound (SMC) dalam bentuk lembaran
bull Ketika panas dan tekanan diberikan oleh cetakan compound mengalir sesuai bentuk komponen yang diinginkan
1) Placement of Charge
5) De-molding3) Squeeze to final dimensions
2) Mould Closure4) Resin Cure
bull Curing dimulai komponen dilepaskan setelah terjadi pengerasan yang cukup
Compression Molding
bull Preform atau dry reinforcement dimasukkan kedalam cetakan sesuai dengan bentuk komponen yang
diinginkan
bull Resin mengalir dengan penekanan atau pem-vakuman dan meng-impregnasi preform dan
mendorongmengeluarkan udara yang ada dalam preform
1) Preform Manufacture
2) Preform Compression
5) De-molding3) Resin Injection
4) Resin Cure
bull Curing terjadi cetakan dibuka setelah terjadi pengerasan yang mencukupi
Liquid Molding (RTM VARI VARTM)
Pultrusion
bull Dry roving or fabrics ditarik melalui bak berisi
campuran resin dan katalis
bull Campuran yang basah ditarik melalui cetakan
bull Sisa resin keluar cetakan
bull Pemanasan dilakukan untuk proses curing
bull Pendinginan dilakukan untuk mempercepat siklus
produksi
Cut-off
Cooling
Die sections
Resin bath
Fibre creel
Filament Winding
bull Dry roving ditarik melalui bak berisi campuran resin dan katalis
bull Wet roving digulungkan dalam keadaan tegang kepada mandrel
bull Kontrol mekanik dari pembawa serat mengatur orientasi peletakan serat pada
mandrel
INDUSTRI COMPOSITES
AEROSPACE
HISTORY
1950 ndash Boeing
1960 ndash F14 Tomcat
1981 ndash AV-8B Harrier
Source
Low-Cost Composite Materials and Structures for Aircraft Applications
httpwwwreinforcedplasticscom
httpwwwcentennialofflightgovessayEvolution_of_TechnologycompositesTech40htm
Automotive
Composite material is used in a number of applications in the automotive
industry due to its temperature resistance rigidity and fatigue strength
The benefits of using composites include greater fuel efficiency
corrosion resistance light weight and strength Composites also provide
a low-cost way to help keep designs looking fresh
Composites are used in
- interior parts (cockpit trimming seats instrument panels)
- exterior structure (body panels openings underbody frontrear
modules)
- engine compartment and fuelmechanical area parts (axles and
suspensions fuel and exhaust systems)
- electrical and electronic components
Lamborghinis Sesto Element carbon fiber
ldquoFat men cannot run as fast as thin men but we build most of our vehicles as though dead-weight fat increased speedhellip I cannot
imagine where the delusion that weight means strength
came fromhelliprdquo mdashHenry Ford
The mix of automotive materials is changing showing a boost for FRP in helping original
equipment manufacturers meet fuel economy and emissions challenges
(Source 2011 DuPont AutomotiveSAE survey of design engineers performed by Signet Research Inc)
Source
httpwwwtoraycomcsrhighlight2009hig_001_01html
The MonoCell tub for the McLaren MP4-12C supercar is moulded as a single
piece and weighs less than 80 kg (176 lbs)
COMPOSITES IN MARINE
TRIMARAN BOAT
AMERICA NAVYINDONESIAN NAVY
Visby Class corvette
Total length is 72 meters
The beam is 1040 meters
The displacement is 600 metric tones
fully equipped the worlds largest CRP
construction
The design of the Visby aims to minimize
the optical and infrared signature above
water acoustic and hydroa coustic
signature underwater electrical potential
and magnetic signature pressure signature
radar cross section and actively emitted
signals
A stealth corvette of the YS 2000 design
has a detection range of 13km in rough
seas and 22km in calm sea without
jamming In a jammed environment the
Visby would be detected at a range of 8km
in rough sea and 11km in calm sea
The material provides high strength and
rigidity low weight good shock resistance
low radar and magnetic signature
1996
Visby is a class of stealth corvettes for the Swedish Navy
ldquoReduced 50 of a Conventional Steelrdquo
Source
Hull Construction with composite materials for ships over 100m in length 2002
Massachusetts Institute of Technology
httpwwwnaval-technologycomprojectsvisby
YACHTS
KAL YUDISTIRAMARATHON 100 ADMIRAL YACHT
LOA 3050 MWidth 6 MFuel Tank 8000 LWater Tank 3000 LIce Box 500 LAccommodation Max 35 Personnel
2 x CATERPILLAR 3412E 1200 HPMARINE DIESEL ENGINE
PC 40 ndash KRI Krait 827Department of Indonesian Navy
LOA 40 MWidth 73 MPower 190Weapon Twin Cannon Barrels
127 mm Heavy Machine GunSpeed Knot 25 KnotDisplacement 105 tonAccommodation 23 personnel
PATROL BOAT
Rigid Inflatable BoatPATROL BOAT
Yachts
36m Luxury Yacht Moonraker
36m Luxury Yacht GoldenEye
50m Luxury Yacht Casino
Royale
45m Luxury Yacht Seashaw
Boat Parts
Barovans for Seismic Sweep
Centrifugal Liftfan House for Surface Effect
Ships
Composite Boat PropellersRTM
Deckhouses for Pilot Boats
Fairing Parts for Submarines
Flybridges for Motor yachts
Light Weight Gangway
MTB Launcher Mock-up
Pleasure Boats
12m Sailboat
12m Sail-Catamaranone-off
Canoes
Dragonfly 1000Catamaran Sailboat
Fantasy 37Sailboat
Farr 60Luxury Sailboat
EurodingyOlympic Dingy Class for
Woman
Hydrolift F23 Racing Boats
Kajacs
Najad 42Sailboat
Najad 520Sailboat
Najad 441Sailboat
Najad 391Sailboat
Nordwest 900Motorboat
Nordwest 1100Motorboat
Quatro 44Motorboat
Racemaster Competition Boats
Storebro 420
Storebro 345
Sweden Yacht 370Sailboat
Sweden Yacht 69Sailboat
Windy 41Motorboat
X-632Sailboat
X-362Sailboat
Commercial Boats
175m High Speed AmbulancePassenger Boat
19m High Speed Passenger Boat
20m High Speed Passenger Boat
364m Surface Effect Passenger Ship
45m Surface Effect Passenger Ship
120m Hull Structural Parts HSSS Catamaran Ferry
APPENDIX
Marine Vessel
1188m Fast Attack Vessel FMV 90 E
20m SAV-Surface Auxiliary Vessels
34m Personnel TransportCoast Guard Vessel
40ft Experimental SES
40m Landsort-Class Mine Hunters
54m Mine Counter Measure Vehicles SES
74m Coastal Patrol Boats
Fishing Boats
30 GT
12 GT
10 GT
5 GT
WISEWings In Surface Effect
HOVERCRAFT
Designed specifically for the tourist and transport industries the
Pioneer Mk3 hovercraft is amphibious and comfortably seats 25
passengers plus 1-crew The air-conditioned cabin allows for
maximum visibility for all aboard The Pioneer Mk3 is robust and
dynamic in its performance
Commercial hovercraft
Mk3 AirLift Hovercraft - 1215m
Power is economicaly provided by one Deutz diesel engine of
330kW (442hp) to cruise easily at 40 knots with much higher
speeds available according to the surface conditions The hull is
manufactured from fibreglassPVC foam composite sandwich
the windows are glass and the skirt is urethane coated nylon A
Military version is available with increased payload and systems
redundancy Power for the Military version comes from two Steyr
diesel engines with a total installed power of 320kW (429hp) All
transmission electrical hydraulic and air systems are duplicated
for maximum redundancy The increased performance of the
Military version comes from the reduced engine weight of the twin
Steyr installation cf the Deutz installation
Source
httpwwwnauticexpocomprodairlift-hovercraftcommercial-hovercrafts-25251-142868html
HOVERFLIGHT
BALLISTIC amp UNIT DEFENCED
Triaxis Composites Collaboration with Institute of Aeronautics and Space in the development of Missile Nose Cone
Polymer composites is the evolution of the military defence
Thin steel was the helmet material of
WWII and remained the principal material until around the 1980rsquos
The advantages of using steel
included a simple technology for manufacture of the helmets low cost and reasonably good
impact protection However these helmets were found to provide only marginal protection
against fragments
During the Vietnam War the US Army experimented with fiber-reinforced inserts in the
helmets These inserts improved ballistic protection but at the same time added weight and
reduced the air space between the head and the helmet
By the early part of the 1980rsquos the US military had developed the first all-composite
100 fiber-reinforced helmet This development resulted in even better ballistic protection
without altering the weight of the helmet Other improvements included better head coverage and
more space for ventilation
Source
Composites Armor - A difficult but huge market
by A Brent Strong Brigham Young University
MILITARY VEHICLES
HIGH SPEED TRAIN SHINKANSEN
Advanced Composites provide lightweight solutions for railway vehicles
saving as much as 50-80 of the weight compared with traditional
components
A lower overall weight translates into less stress faster acceleration and
higher speeds as well as reduced starting and stopping inertia Today
these are important criteria in global high-speed and metropolitan
railway projects
Fire smoke and toxic fumes are key safety criteria for interior
components of railway carriages Any material selected for an interior
component must meet international fire retardant standards
for Rail Interiors and Exteriors
Ceiling Panels Stairs
Seating Vestibules
Window Panels Door Pillars
Partition WallsDiffusers
Gangway and Cabinet Panels Cabin and
Desk panels
Door Pillars Lavatory Modules (standard and
Front and Rear EndsRoof Panels
Nose Cones Under Fairings
Source
httpwwwpctaerail_compositesphp
101
SKY BUS
2009
Europe is the world leader in offshore wind with
828 wind turbines and a cumulative capacity of 2056 MW spread across 38 offshore wind farms in 9
European countries
The UK and Denmark are the current leaders with a 44 and 30 share respectively In 2009
five countries built new offshore wind farms
UK (284 MW)
Demark (230 MW)
Sweden (30 MW)
Germany (30 MW)
Norway (23 MW)
2010
Asia leads the growth in global wind power which grew 358 GW in 2010 bringing
total global capacity to 1944 GW ndash up 225 from 2009
the Global Wind Energy Council (GWEC)
Asia accounted for 19 GW of new global wind power installations driven by China which installed 165
GW
ldquoChina now has 423 GW of wind powerrdquo
ldquoThis puts China firmly on a path to reach 200 GW of installed wind power by 2020 At the same
time China has become the worldrsquos largest producer of wind energy equipmentrdquo
Source
httpwwwreinforcedplasticscomview15655asia-leads-global-wind-power-growth
httpimgdeusmcomdesignnews288288605-Sandia_Sizes_up_Wind_Turbine_Blade_Design_C_largegif
WIND ENERGY
Marine Current Turbines
Source
httpwwwsiemenscompressenpressreleasepress=enpressrelease2011solar-hydroex201111005htm
httpwwwmarineturbinescom
A commercial marine current turbine consists of
two rotors which are fixed on a structure within the
sea current The twin rotors rotate with the
movement of the tidal flow and the blades pitch
through 180 degrees to optimally track tidal current
(Press picture Marine Current Turbines)
Wave Star Energys Multi-point Absorber
CFRP COLUMN REINFORCEMENT
INDUSTRIAL TANKS
107
INDUSTRIAL PIPES
PRESSURE TANKS
109
ldquoLetrsquos Make with Compositesrdquo
MAX - Multiaxial Fabric
Fleece (optional)
Lapisan
MULTIAXIAL PROSES
Karakteristik CSM
bull Glass Content 30
bull Resin Content 70
bull Tensile Force
Chopped Strand Mat
JENIS FIBERGLASS
Karakteristik Woven Roving
bull Glass Content 45
bull Resin Content 55
Woven Roving
Resin
|
|
|
|
|
|
|
|
|
|
|
|
|
|
bull Kekuatan Tarik
JENIS FIBERGLASS
No Resin Rich Area
Karakteristik Multiaxial
bull Glass Content 60
bull Resin Content 40
Produk Fiberglass Ketiga MULTIAXIAL
JENIS FIBERGLASS
Perbedaan Woven Roving dan Multiaxial ndash Tampak Samping
JENIS FIBERGLASS
WR FRP
8 Ply WR 800
8 Ply CSM 450
Glass Weight 1 kg
Composite Weight 15kgm2
CSM FRP
22 Ply CSM 450
Glass Weight 1 kg
Composite Weight 18 kgm2
MULTIAXIAL FRP
13 Ply DB 800
Glass Weight 1 kg
Composite Weight
13 kgm2
JENIS FIBERGLASS
Multiaxial
FRP
Woven Roving
FRP
Chopped Strands Mat FRP
MULTIAXIAL
FAKTA
TEBAL BUKAN BERARTI KUAT
UNSUR MATRIX (RESIN)
TIDAK ADA KEKUATAN
ldquoMore than 50 of the glass fibers used for reinforcement is
E-glassrdquo
KarakteristikKekuatan
CSM WR MAX
Kekuatan Tarik 175 MPa 250 MPa 425 MPa
CSM 142
WR 70
KEKUATAN TARIK
Properties CSM Lamination WR Lamination MAX Lamination
Fabric Weight (kgm2) 1 1 1
Composite Weight (kgm2) 18 15 13
Resin usage (kgm2) 15 1 08
Amount of Fabric 22 Ply 16 Ply 13 Ply
Thickness 15 mm 12 mm 10 mm
Tensile Strength (Mpa) 125 1796 400
Tensile Strength (Nmmsup2) 28463 30958 4576
Processing Time High Med Low
Labour Cost High Med Low
MULTIAXIAL
Total Penggunaan Resin -51
Total Berat Kapal -40
Kekuatan Bangunan Kapal +59
Efisiensi Tenaga Kerja
Waktu Pengerjaan Lebih Cepat
KEUNGGULAN MATERIAL
Resapan Resin Lebih Baik amp Merata
Lapisan Lebih Sedikit
Meningkatkan Kekuatan Kapal
KEUNGGULAN MATERIAL
TRIAXIAL
DBL series DBT series
BIAXIAL
LT series DB series
UNIDIRECTIONAL
L series T series
QUADRIAXIAL
DBLT series
JENIS MULTIAXIAL
UNIDIRECTIONAL
DCMU 900 E ndash
KHUSUS UNTUK MEMPERKUAT BENDING KAPAL
PEMASANGAN KHUSUS PADA KEEL DAN TULANGAN
JENIS MULTIAXIAL UNTUK KAPAL
TRIAXIAL
DBL 600 ndash
APLIKASI PADA INDUSTRI PENERBANGAN
PEMASANGAN KHUSUS PADA
SAMBUNGAN BADAN DAN SAYAP
PESAWAT
JENIS MULTIAXIAL UNTUK PESAWAT
QUADRAXIAL
DBLT 800 ndash
APLIKASI PADA INDUSTRI ENERGI
DITERAPKAN UNTUK KEBUTUHAN PEMBANGKIT
LISTRIK ENERGI ANGIN
MULTIAXIAL UNTUK ENERGI
INDUSTRI KIMIA OLAHRAGA AUTOMOTIF
MULTIAXIAL UNTUK INDUSTRI LAINNYA
COMPOSITES
GUNAKAN MATERIAL FIBERGLASS
YANG SUDAH DISERTIFIKASI
BKI
FIBERGLASS UNTUK PEMBANGUNAN BAKAP
PERATURAN MENTERI PERHUBUNGAN
NOMOR PM 7 TAHUN 2013
TENTANG KEWAJIBAN KLASIFIKASI BAGI KAPAL BERBENDERA INDONESIA
PADA BADAN KLASIFIKASI
BADAN SERTIFIKASI MARITIM
Biro Klasifikasi IndonesiaDet Norske Veritas Germanischer Lloyds
PERATURAN BKI
Untuk Kapal Non-Metal
2006
PERSYARATAN MINIMUM
kekuatan material yang
harus digunakan
untuk membangun
Kapal Fiberglass
PEMBESARAN
Table 21
FIBERGLASS TRIAXIS COMPOSITES
TELAH BERSERTIFIKASI BKI
Biro Klasifikasi Indonesia
65
TEKNIK MANUFAKTUR
COMPOSITES
Wet hand lay-up
1) Peletakan
Dry Reinforcement
bull Dry reinforcement dan resin (+ katalis) ditaruh pada permukaan cetakan
2) Pemasukanpenekanan resin
bull Resin ditekan untuk meng-impregnasi serat dengan menggunakan rol
3) Pengulangan proses untuk lapisan lain
bull Beberapa lapisan dapat ditambahkan secara bertahap
4) Resin curing
bull Reaksi dimulai komponen dilepaskan setelah komponen mengeras
(fully cured)
Wet hand lay-up
Manufaktur komponen dapat dikerjakan dengan menggunakan beberapa lapis komposit
dengan memperhatikan kompatibilitas material dan tahapan curing Modifikasi proses dapat
dilakukan seperti
Vacuum bagging
setelah lay-up
Glass Roving
Bulk Resin
Catalyst
3) De-molding
2) Resin Cure
bull Curing dimulai dan komponen dilepaskan setelah pengerasan selesai
bull Serat gelas resin dan katalis dimasukkan kedalam spray gun
1) Spray-up
bull Campuran disemprotkan pada permukaan cetakan
Spray-up
69
Penyemprotan bakal komponen
Komponen
dilepaskan
dari cetakan
Full dispensing
system Chopper Roving
Atomised resin
and catalyst
Spray-up
Prepreg
1) LaminateAssembly 5) De-molding
3) Resin Melts Layup Consolidates
bull Prepreg serat yang sudah diimpregnasi oleh resin+katalis dalam kondisi padat
bull Lapisan prepreg digunting sesuai bentuk yang diinginkan kemudian diletakkan pada permukaan cetakan
sesuai bentuk komponen yang diinginkan Lay-up mudah dilakukan karena sifat ldquotackynessrdquo dari prepreg
2) Applied Vacuum Pressure and Heat
bull Tekanan dan panas diberikan resin mencair terjadi konsolidasi pada komponen
4) Resin Cures
bull Temperatur dinaikkan untuk memulai curing
Prepreg
Variasi proses Autoclave
Komponen dalam
vacuum-bag
bull Campuran resin (+katalis) dan chopped glass strands diperoleh dalam bentuk premixed compound Bulk molding
Compound (BMC) dalam bentuk adonan atau Sheet molding Compound (SMC) dalam bentuk lembaran
bull Ketika panas dan tekanan diberikan oleh cetakan compound mengalir sesuai bentuk komponen yang diinginkan
1) Placement of Charge
5) De-molding3) Squeeze to final dimensions
2) Mould Closure4) Resin Cure
bull Curing dimulai komponen dilepaskan setelah terjadi pengerasan yang cukup
Compression Molding
bull Preform atau dry reinforcement dimasukkan kedalam cetakan sesuai dengan bentuk komponen yang
diinginkan
bull Resin mengalir dengan penekanan atau pem-vakuman dan meng-impregnasi preform dan
mendorongmengeluarkan udara yang ada dalam preform
1) Preform Manufacture
2) Preform Compression
5) De-molding3) Resin Injection
4) Resin Cure
bull Curing terjadi cetakan dibuka setelah terjadi pengerasan yang mencukupi
Liquid Molding (RTM VARI VARTM)
Pultrusion
bull Dry roving or fabrics ditarik melalui bak berisi
campuran resin dan katalis
bull Campuran yang basah ditarik melalui cetakan
bull Sisa resin keluar cetakan
bull Pemanasan dilakukan untuk proses curing
bull Pendinginan dilakukan untuk mempercepat siklus
produksi
Cut-off
Cooling
Die sections
Resin bath
Fibre creel
Filament Winding
bull Dry roving ditarik melalui bak berisi campuran resin dan katalis
bull Wet roving digulungkan dalam keadaan tegang kepada mandrel
bull Kontrol mekanik dari pembawa serat mengatur orientasi peletakan serat pada
mandrel
INDUSTRI COMPOSITES
AEROSPACE
HISTORY
1950 ndash Boeing
1960 ndash F14 Tomcat
1981 ndash AV-8B Harrier
Source
Low-Cost Composite Materials and Structures for Aircraft Applications
httpwwwreinforcedplasticscom
httpwwwcentennialofflightgovessayEvolution_of_TechnologycompositesTech40htm
Automotive
Composite material is used in a number of applications in the automotive
industry due to its temperature resistance rigidity and fatigue strength
The benefits of using composites include greater fuel efficiency
corrosion resistance light weight and strength Composites also provide
a low-cost way to help keep designs looking fresh
Composites are used in
- interior parts (cockpit trimming seats instrument panels)
- exterior structure (body panels openings underbody frontrear
modules)
- engine compartment and fuelmechanical area parts (axles and
suspensions fuel and exhaust systems)
- electrical and electronic components
Lamborghinis Sesto Element carbon fiber
ldquoFat men cannot run as fast as thin men but we build most of our vehicles as though dead-weight fat increased speedhellip I cannot
imagine where the delusion that weight means strength
came fromhelliprdquo mdashHenry Ford
The mix of automotive materials is changing showing a boost for FRP in helping original
equipment manufacturers meet fuel economy and emissions challenges
(Source 2011 DuPont AutomotiveSAE survey of design engineers performed by Signet Research Inc)
Source
httpwwwtoraycomcsrhighlight2009hig_001_01html
The MonoCell tub for the McLaren MP4-12C supercar is moulded as a single
piece and weighs less than 80 kg (176 lbs)
COMPOSITES IN MARINE
TRIMARAN BOAT
AMERICA NAVYINDONESIAN NAVY
Visby Class corvette
Total length is 72 meters
The beam is 1040 meters
The displacement is 600 metric tones
fully equipped the worlds largest CRP
construction
The design of the Visby aims to minimize
the optical and infrared signature above
water acoustic and hydroa coustic
signature underwater electrical potential
and magnetic signature pressure signature
radar cross section and actively emitted
signals
A stealth corvette of the YS 2000 design
has a detection range of 13km in rough
seas and 22km in calm sea without
jamming In a jammed environment the
Visby would be detected at a range of 8km
in rough sea and 11km in calm sea
The material provides high strength and
rigidity low weight good shock resistance
low radar and magnetic signature
1996
Visby is a class of stealth corvettes for the Swedish Navy
ldquoReduced 50 of a Conventional Steelrdquo
Source
Hull Construction with composite materials for ships over 100m in length 2002
Massachusetts Institute of Technology
httpwwwnaval-technologycomprojectsvisby
YACHTS
KAL YUDISTIRAMARATHON 100 ADMIRAL YACHT
LOA 3050 MWidth 6 MFuel Tank 8000 LWater Tank 3000 LIce Box 500 LAccommodation Max 35 Personnel
2 x CATERPILLAR 3412E 1200 HPMARINE DIESEL ENGINE
PC 40 ndash KRI Krait 827Department of Indonesian Navy
LOA 40 MWidth 73 MPower 190Weapon Twin Cannon Barrels
127 mm Heavy Machine GunSpeed Knot 25 KnotDisplacement 105 tonAccommodation 23 personnel
PATROL BOAT
Rigid Inflatable BoatPATROL BOAT
Yachts
36m Luxury Yacht Moonraker
36m Luxury Yacht GoldenEye
50m Luxury Yacht Casino
Royale
45m Luxury Yacht Seashaw
Boat Parts
Barovans for Seismic Sweep
Centrifugal Liftfan House for Surface Effect
Ships
Composite Boat PropellersRTM
Deckhouses for Pilot Boats
Fairing Parts for Submarines
Flybridges for Motor yachts
Light Weight Gangway
MTB Launcher Mock-up
Pleasure Boats
12m Sailboat
12m Sail-Catamaranone-off
Canoes
Dragonfly 1000Catamaran Sailboat
Fantasy 37Sailboat
Farr 60Luxury Sailboat
EurodingyOlympic Dingy Class for
Woman
Hydrolift F23 Racing Boats
Kajacs
Najad 42Sailboat
Najad 520Sailboat
Najad 441Sailboat
Najad 391Sailboat
Nordwest 900Motorboat
Nordwest 1100Motorboat
Quatro 44Motorboat
Racemaster Competition Boats
Storebro 420
Storebro 345
Sweden Yacht 370Sailboat
Sweden Yacht 69Sailboat
Windy 41Motorboat
X-632Sailboat
X-362Sailboat
Commercial Boats
175m High Speed AmbulancePassenger Boat
19m High Speed Passenger Boat
20m High Speed Passenger Boat
364m Surface Effect Passenger Ship
45m Surface Effect Passenger Ship
120m Hull Structural Parts HSSS Catamaran Ferry
APPENDIX
Marine Vessel
1188m Fast Attack Vessel FMV 90 E
20m SAV-Surface Auxiliary Vessels
34m Personnel TransportCoast Guard Vessel
40ft Experimental SES
40m Landsort-Class Mine Hunters
54m Mine Counter Measure Vehicles SES
74m Coastal Patrol Boats
Fishing Boats
30 GT
12 GT
10 GT
5 GT
WISEWings In Surface Effect
HOVERCRAFT
Designed specifically for the tourist and transport industries the
Pioneer Mk3 hovercraft is amphibious and comfortably seats 25
passengers plus 1-crew The air-conditioned cabin allows for
maximum visibility for all aboard The Pioneer Mk3 is robust and
dynamic in its performance
Commercial hovercraft
Mk3 AirLift Hovercraft - 1215m
Power is economicaly provided by one Deutz diesel engine of
330kW (442hp) to cruise easily at 40 knots with much higher
speeds available according to the surface conditions The hull is
manufactured from fibreglassPVC foam composite sandwich
the windows are glass and the skirt is urethane coated nylon A
Military version is available with increased payload and systems
redundancy Power for the Military version comes from two Steyr
diesel engines with a total installed power of 320kW (429hp) All
transmission electrical hydraulic and air systems are duplicated
for maximum redundancy The increased performance of the
Military version comes from the reduced engine weight of the twin
Steyr installation cf the Deutz installation
Source
httpwwwnauticexpocomprodairlift-hovercraftcommercial-hovercrafts-25251-142868html
HOVERFLIGHT
BALLISTIC amp UNIT DEFENCED
Triaxis Composites Collaboration with Institute of Aeronautics and Space in the development of Missile Nose Cone
Polymer composites is the evolution of the military defence
Thin steel was the helmet material of
WWII and remained the principal material until around the 1980rsquos
The advantages of using steel
included a simple technology for manufacture of the helmets low cost and reasonably good
impact protection However these helmets were found to provide only marginal protection
against fragments
During the Vietnam War the US Army experimented with fiber-reinforced inserts in the
helmets These inserts improved ballistic protection but at the same time added weight and
reduced the air space between the head and the helmet
By the early part of the 1980rsquos the US military had developed the first all-composite
100 fiber-reinforced helmet This development resulted in even better ballistic protection
without altering the weight of the helmet Other improvements included better head coverage and
more space for ventilation
Source
Composites Armor - A difficult but huge market
by A Brent Strong Brigham Young University
MILITARY VEHICLES
HIGH SPEED TRAIN SHINKANSEN
Advanced Composites provide lightweight solutions for railway vehicles
saving as much as 50-80 of the weight compared with traditional
components
A lower overall weight translates into less stress faster acceleration and
higher speeds as well as reduced starting and stopping inertia Today
these are important criteria in global high-speed and metropolitan
railway projects
Fire smoke and toxic fumes are key safety criteria for interior
components of railway carriages Any material selected for an interior
component must meet international fire retardant standards
for Rail Interiors and Exteriors
Ceiling Panels Stairs
Seating Vestibules
Window Panels Door Pillars
Partition WallsDiffusers
Gangway and Cabinet Panels Cabin and
Desk panels
Door Pillars Lavatory Modules (standard and
Front and Rear EndsRoof Panels
Nose Cones Under Fairings
Source
httpwwwpctaerail_compositesphp
101
SKY BUS
2009
Europe is the world leader in offshore wind with
828 wind turbines and a cumulative capacity of 2056 MW spread across 38 offshore wind farms in 9
European countries
The UK and Denmark are the current leaders with a 44 and 30 share respectively In 2009
five countries built new offshore wind farms
UK (284 MW)
Demark (230 MW)
Sweden (30 MW)
Germany (30 MW)
Norway (23 MW)
2010
Asia leads the growth in global wind power which grew 358 GW in 2010 bringing
total global capacity to 1944 GW ndash up 225 from 2009
the Global Wind Energy Council (GWEC)
Asia accounted for 19 GW of new global wind power installations driven by China which installed 165
GW
ldquoChina now has 423 GW of wind powerrdquo
ldquoThis puts China firmly on a path to reach 200 GW of installed wind power by 2020 At the same
time China has become the worldrsquos largest producer of wind energy equipmentrdquo
Source
httpwwwreinforcedplasticscomview15655asia-leads-global-wind-power-growth
httpimgdeusmcomdesignnews288288605-Sandia_Sizes_up_Wind_Turbine_Blade_Design_C_largegif
WIND ENERGY
Marine Current Turbines
Source
httpwwwsiemenscompressenpressreleasepress=enpressrelease2011solar-hydroex201111005htm
httpwwwmarineturbinescom
A commercial marine current turbine consists of
two rotors which are fixed on a structure within the
sea current The twin rotors rotate with the
movement of the tidal flow and the blades pitch
through 180 degrees to optimally track tidal current
(Press picture Marine Current Turbines)
Wave Star Energys Multi-point Absorber
CFRP COLUMN REINFORCEMENT
INDUSTRIAL TANKS
107
INDUSTRIAL PIPES
PRESSURE TANKS
109
ldquoLetrsquos Make with Compositesrdquo
Karakteristik CSM
bull Glass Content 30
bull Resin Content 70
bull Tensile Force
Chopped Strand Mat
JENIS FIBERGLASS
Karakteristik Woven Roving
bull Glass Content 45
bull Resin Content 55
Woven Roving
Resin
|
|
|
|
|
|
|
|
|
|
|
|
|
|
bull Kekuatan Tarik
JENIS FIBERGLASS
No Resin Rich Area
Karakteristik Multiaxial
bull Glass Content 60
bull Resin Content 40
Produk Fiberglass Ketiga MULTIAXIAL
JENIS FIBERGLASS
Perbedaan Woven Roving dan Multiaxial ndash Tampak Samping
JENIS FIBERGLASS
WR FRP
8 Ply WR 800
8 Ply CSM 450
Glass Weight 1 kg
Composite Weight 15kgm2
CSM FRP
22 Ply CSM 450
Glass Weight 1 kg
Composite Weight 18 kgm2
MULTIAXIAL FRP
13 Ply DB 800
Glass Weight 1 kg
Composite Weight
13 kgm2
JENIS FIBERGLASS
Multiaxial
FRP
Woven Roving
FRP
Chopped Strands Mat FRP
MULTIAXIAL
FAKTA
TEBAL BUKAN BERARTI KUAT
UNSUR MATRIX (RESIN)
TIDAK ADA KEKUATAN
ldquoMore than 50 of the glass fibers used for reinforcement is
E-glassrdquo
KarakteristikKekuatan
CSM WR MAX
Kekuatan Tarik 175 MPa 250 MPa 425 MPa
CSM 142
WR 70
KEKUATAN TARIK
Properties CSM Lamination WR Lamination MAX Lamination
Fabric Weight (kgm2) 1 1 1
Composite Weight (kgm2) 18 15 13
Resin usage (kgm2) 15 1 08
Amount of Fabric 22 Ply 16 Ply 13 Ply
Thickness 15 mm 12 mm 10 mm
Tensile Strength (Mpa) 125 1796 400
Tensile Strength (Nmmsup2) 28463 30958 4576
Processing Time High Med Low
Labour Cost High Med Low
MULTIAXIAL
Total Penggunaan Resin -51
Total Berat Kapal -40
Kekuatan Bangunan Kapal +59
Efisiensi Tenaga Kerja
Waktu Pengerjaan Lebih Cepat
KEUNGGULAN MATERIAL
Resapan Resin Lebih Baik amp Merata
Lapisan Lebih Sedikit
Meningkatkan Kekuatan Kapal
KEUNGGULAN MATERIAL
TRIAXIAL
DBL series DBT series
BIAXIAL
LT series DB series
UNIDIRECTIONAL
L series T series
QUADRIAXIAL
DBLT series
JENIS MULTIAXIAL
UNIDIRECTIONAL
DCMU 900 E ndash
KHUSUS UNTUK MEMPERKUAT BENDING KAPAL
PEMASANGAN KHUSUS PADA KEEL DAN TULANGAN
JENIS MULTIAXIAL UNTUK KAPAL
TRIAXIAL
DBL 600 ndash
APLIKASI PADA INDUSTRI PENERBANGAN
PEMASANGAN KHUSUS PADA
SAMBUNGAN BADAN DAN SAYAP
PESAWAT
JENIS MULTIAXIAL UNTUK PESAWAT
QUADRAXIAL
DBLT 800 ndash
APLIKASI PADA INDUSTRI ENERGI
DITERAPKAN UNTUK KEBUTUHAN PEMBANGKIT
LISTRIK ENERGI ANGIN
MULTIAXIAL UNTUK ENERGI
INDUSTRI KIMIA OLAHRAGA AUTOMOTIF
MULTIAXIAL UNTUK INDUSTRI LAINNYA
COMPOSITES
GUNAKAN MATERIAL FIBERGLASS
YANG SUDAH DISERTIFIKASI
BKI
FIBERGLASS UNTUK PEMBANGUNAN BAKAP
PERATURAN MENTERI PERHUBUNGAN
NOMOR PM 7 TAHUN 2013
TENTANG KEWAJIBAN KLASIFIKASI BAGI KAPAL BERBENDERA INDONESIA
PADA BADAN KLASIFIKASI
BADAN SERTIFIKASI MARITIM
Biro Klasifikasi IndonesiaDet Norske Veritas Germanischer Lloyds
PERATURAN BKI
Untuk Kapal Non-Metal
2006
PERSYARATAN MINIMUM
kekuatan material yang
harus digunakan
untuk membangun
Kapal Fiberglass
PEMBESARAN
Table 21
FIBERGLASS TRIAXIS COMPOSITES
TELAH BERSERTIFIKASI BKI
Biro Klasifikasi Indonesia
65
TEKNIK MANUFAKTUR
COMPOSITES
Wet hand lay-up
1) Peletakan
Dry Reinforcement
bull Dry reinforcement dan resin (+ katalis) ditaruh pada permukaan cetakan
2) Pemasukanpenekanan resin
bull Resin ditekan untuk meng-impregnasi serat dengan menggunakan rol
3) Pengulangan proses untuk lapisan lain
bull Beberapa lapisan dapat ditambahkan secara bertahap
4) Resin curing
bull Reaksi dimulai komponen dilepaskan setelah komponen mengeras
(fully cured)
Wet hand lay-up
Manufaktur komponen dapat dikerjakan dengan menggunakan beberapa lapis komposit
dengan memperhatikan kompatibilitas material dan tahapan curing Modifikasi proses dapat
dilakukan seperti
Vacuum bagging
setelah lay-up
Glass Roving
Bulk Resin
Catalyst
3) De-molding
2) Resin Cure
bull Curing dimulai dan komponen dilepaskan setelah pengerasan selesai
bull Serat gelas resin dan katalis dimasukkan kedalam spray gun
1) Spray-up
bull Campuran disemprotkan pada permukaan cetakan
Spray-up
69
Penyemprotan bakal komponen
Komponen
dilepaskan
dari cetakan
Full dispensing
system Chopper Roving
Atomised resin
and catalyst
Spray-up
Prepreg
1) LaminateAssembly 5) De-molding
3) Resin Melts Layup Consolidates
bull Prepreg serat yang sudah diimpregnasi oleh resin+katalis dalam kondisi padat
bull Lapisan prepreg digunting sesuai bentuk yang diinginkan kemudian diletakkan pada permukaan cetakan
sesuai bentuk komponen yang diinginkan Lay-up mudah dilakukan karena sifat ldquotackynessrdquo dari prepreg
2) Applied Vacuum Pressure and Heat
bull Tekanan dan panas diberikan resin mencair terjadi konsolidasi pada komponen
4) Resin Cures
bull Temperatur dinaikkan untuk memulai curing
Prepreg
Variasi proses Autoclave
Komponen dalam
vacuum-bag
bull Campuran resin (+katalis) dan chopped glass strands diperoleh dalam bentuk premixed compound Bulk molding
Compound (BMC) dalam bentuk adonan atau Sheet molding Compound (SMC) dalam bentuk lembaran
bull Ketika panas dan tekanan diberikan oleh cetakan compound mengalir sesuai bentuk komponen yang diinginkan
1) Placement of Charge
5) De-molding3) Squeeze to final dimensions
2) Mould Closure4) Resin Cure
bull Curing dimulai komponen dilepaskan setelah terjadi pengerasan yang cukup
Compression Molding
bull Preform atau dry reinforcement dimasukkan kedalam cetakan sesuai dengan bentuk komponen yang
diinginkan
bull Resin mengalir dengan penekanan atau pem-vakuman dan meng-impregnasi preform dan
mendorongmengeluarkan udara yang ada dalam preform
1) Preform Manufacture
2) Preform Compression
5) De-molding3) Resin Injection
4) Resin Cure
bull Curing terjadi cetakan dibuka setelah terjadi pengerasan yang mencukupi
Liquid Molding (RTM VARI VARTM)
Pultrusion
bull Dry roving or fabrics ditarik melalui bak berisi
campuran resin dan katalis
bull Campuran yang basah ditarik melalui cetakan
bull Sisa resin keluar cetakan
bull Pemanasan dilakukan untuk proses curing
bull Pendinginan dilakukan untuk mempercepat siklus
produksi
Cut-off
Cooling
Die sections
Resin bath
Fibre creel
Filament Winding
bull Dry roving ditarik melalui bak berisi campuran resin dan katalis
bull Wet roving digulungkan dalam keadaan tegang kepada mandrel
bull Kontrol mekanik dari pembawa serat mengatur orientasi peletakan serat pada
mandrel
INDUSTRI COMPOSITES
AEROSPACE
HISTORY
1950 ndash Boeing
1960 ndash F14 Tomcat
1981 ndash AV-8B Harrier
Source
Low-Cost Composite Materials and Structures for Aircraft Applications
httpwwwreinforcedplasticscom
httpwwwcentennialofflightgovessayEvolution_of_TechnologycompositesTech40htm
Automotive
Composite material is used in a number of applications in the automotive
industry due to its temperature resistance rigidity and fatigue strength
The benefits of using composites include greater fuel efficiency
corrosion resistance light weight and strength Composites also provide
a low-cost way to help keep designs looking fresh
Composites are used in
- interior parts (cockpit trimming seats instrument panels)
- exterior structure (body panels openings underbody frontrear
modules)
- engine compartment and fuelmechanical area parts (axles and
suspensions fuel and exhaust systems)
- electrical and electronic components
Lamborghinis Sesto Element carbon fiber
ldquoFat men cannot run as fast as thin men but we build most of our vehicles as though dead-weight fat increased speedhellip I cannot
imagine where the delusion that weight means strength
came fromhelliprdquo mdashHenry Ford
The mix of automotive materials is changing showing a boost for FRP in helping original
equipment manufacturers meet fuel economy and emissions challenges
(Source 2011 DuPont AutomotiveSAE survey of design engineers performed by Signet Research Inc)
Source
httpwwwtoraycomcsrhighlight2009hig_001_01html
The MonoCell tub for the McLaren MP4-12C supercar is moulded as a single
piece and weighs less than 80 kg (176 lbs)
COMPOSITES IN MARINE
TRIMARAN BOAT
AMERICA NAVYINDONESIAN NAVY
Visby Class corvette
Total length is 72 meters
The beam is 1040 meters
The displacement is 600 metric tones
fully equipped the worlds largest CRP
construction
The design of the Visby aims to minimize
the optical and infrared signature above
water acoustic and hydroa coustic
signature underwater electrical potential
and magnetic signature pressure signature
radar cross section and actively emitted
signals
A stealth corvette of the YS 2000 design
has a detection range of 13km in rough
seas and 22km in calm sea without
jamming In a jammed environment the
Visby would be detected at a range of 8km
in rough sea and 11km in calm sea
The material provides high strength and
rigidity low weight good shock resistance
low radar and magnetic signature
1996
Visby is a class of stealth corvettes for the Swedish Navy
ldquoReduced 50 of a Conventional Steelrdquo
Source
Hull Construction with composite materials for ships over 100m in length 2002
Massachusetts Institute of Technology
httpwwwnaval-technologycomprojectsvisby
YACHTS
KAL YUDISTIRAMARATHON 100 ADMIRAL YACHT
LOA 3050 MWidth 6 MFuel Tank 8000 LWater Tank 3000 LIce Box 500 LAccommodation Max 35 Personnel
2 x CATERPILLAR 3412E 1200 HPMARINE DIESEL ENGINE
PC 40 ndash KRI Krait 827Department of Indonesian Navy
LOA 40 MWidth 73 MPower 190Weapon Twin Cannon Barrels
127 mm Heavy Machine GunSpeed Knot 25 KnotDisplacement 105 tonAccommodation 23 personnel
PATROL BOAT
Rigid Inflatable BoatPATROL BOAT
Yachts
36m Luxury Yacht Moonraker
36m Luxury Yacht GoldenEye
50m Luxury Yacht Casino
Royale
45m Luxury Yacht Seashaw
Boat Parts
Barovans for Seismic Sweep
Centrifugal Liftfan House for Surface Effect
Ships
Composite Boat PropellersRTM
Deckhouses for Pilot Boats
Fairing Parts for Submarines
Flybridges for Motor yachts
Light Weight Gangway
MTB Launcher Mock-up
Pleasure Boats
12m Sailboat
12m Sail-Catamaranone-off
Canoes
Dragonfly 1000Catamaran Sailboat
Fantasy 37Sailboat
Farr 60Luxury Sailboat
EurodingyOlympic Dingy Class for
Woman
Hydrolift F23 Racing Boats
Kajacs
Najad 42Sailboat
Najad 520Sailboat
Najad 441Sailboat
Najad 391Sailboat
Nordwest 900Motorboat
Nordwest 1100Motorboat
Quatro 44Motorboat
Racemaster Competition Boats
Storebro 420
Storebro 345
Sweden Yacht 370Sailboat
Sweden Yacht 69Sailboat
Windy 41Motorboat
X-632Sailboat
X-362Sailboat
Commercial Boats
175m High Speed AmbulancePassenger Boat
19m High Speed Passenger Boat
20m High Speed Passenger Boat
364m Surface Effect Passenger Ship
45m Surface Effect Passenger Ship
120m Hull Structural Parts HSSS Catamaran Ferry
APPENDIX
Marine Vessel
1188m Fast Attack Vessel FMV 90 E
20m SAV-Surface Auxiliary Vessels
34m Personnel TransportCoast Guard Vessel
40ft Experimental SES
40m Landsort-Class Mine Hunters
54m Mine Counter Measure Vehicles SES
74m Coastal Patrol Boats
Fishing Boats
30 GT
12 GT
10 GT
5 GT
WISEWings In Surface Effect
HOVERCRAFT
Designed specifically for the tourist and transport industries the
Pioneer Mk3 hovercraft is amphibious and comfortably seats 25
passengers plus 1-crew The air-conditioned cabin allows for
maximum visibility for all aboard The Pioneer Mk3 is robust and
dynamic in its performance
Commercial hovercraft
Mk3 AirLift Hovercraft - 1215m
Power is economicaly provided by one Deutz diesel engine of
330kW (442hp) to cruise easily at 40 knots with much higher
speeds available according to the surface conditions The hull is
manufactured from fibreglassPVC foam composite sandwich
the windows are glass and the skirt is urethane coated nylon A
Military version is available with increased payload and systems
redundancy Power for the Military version comes from two Steyr
diesel engines with a total installed power of 320kW (429hp) All
transmission electrical hydraulic and air systems are duplicated
for maximum redundancy The increased performance of the
Military version comes from the reduced engine weight of the twin
Steyr installation cf the Deutz installation
Source
httpwwwnauticexpocomprodairlift-hovercraftcommercial-hovercrafts-25251-142868html
HOVERFLIGHT
BALLISTIC amp UNIT DEFENCED
Triaxis Composites Collaboration with Institute of Aeronautics and Space in the development of Missile Nose Cone
Polymer composites is the evolution of the military defence
Thin steel was the helmet material of
WWII and remained the principal material until around the 1980rsquos
The advantages of using steel
included a simple technology for manufacture of the helmets low cost and reasonably good
impact protection However these helmets were found to provide only marginal protection
against fragments
During the Vietnam War the US Army experimented with fiber-reinforced inserts in the
helmets These inserts improved ballistic protection but at the same time added weight and
reduced the air space between the head and the helmet
By the early part of the 1980rsquos the US military had developed the first all-composite
100 fiber-reinforced helmet This development resulted in even better ballistic protection
without altering the weight of the helmet Other improvements included better head coverage and
more space for ventilation
Source
Composites Armor - A difficult but huge market
by A Brent Strong Brigham Young University
MILITARY VEHICLES
HIGH SPEED TRAIN SHINKANSEN
Advanced Composites provide lightweight solutions for railway vehicles
saving as much as 50-80 of the weight compared with traditional
components
A lower overall weight translates into less stress faster acceleration and
higher speeds as well as reduced starting and stopping inertia Today
these are important criteria in global high-speed and metropolitan
railway projects
Fire smoke and toxic fumes are key safety criteria for interior
components of railway carriages Any material selected for an interior
component must meet international fire retardant standards
for Rail Interiors and Exteriors
Ceiling Panels Stairs
Seating Vestibules
Window Panels Door Pillars
Partition WallsDiffusers
Gangway and Cabinet Panels Cabin and
Desk panels
Door Pillars Lavatory Modules (standard and
Front and Rear EndsRoof Panels
Nose Cones Under Fairings
Source
httpwwwpctaerail_compositesphp
101
SKY BUS
2009
Europe is the world leader in offshore wind with
828 wind turbines and a cumulative capacity of 2056 MW spread across 38 offshore wind farms in 9
European countries
The UK and Denmark are the current leaders with a 44 and 30 share respectively In 2009
five countries built new offshore wind farms
UK (284 MW)
Demark (230 MW)
Sweden (30 MW)
Germany (30 MW)
Norway (23 MW)
2010
Asia leads the growth in global wind power which grew 358 GW in 2010 bringing
total global capacity to 1944 GW ndash up 225 from 2009
the Global Wind Energy Council (GWEC)
Asia accounted for 19 GW of new global wind power installations driven by China which installed 165
GW
ldquoChina now has 423 GW of wind powerrdquo
ldquoThis puts China firmly on a path to reach 200 GW of installed wind power by 2020 At the same
time China has become the worldrsquos largest producer of wind energy equipmentrdquo
Source
httpwwwreinforcedplasticscomview15655asia-leads-global-wind-power-growth
httpimgdeusmcomdesignnews288288605-Sandia_Sizes_up_Wind_Turbine_Blade_Design_C_largegif
WIND ENERGY
Marine Current Turbines
Source
httpwwwsiemenscompressenpressreleasepress=enpressrelease2011solar-hydroex201111005htm
httpwwwmarineturbinescom
A commercial marine current turbine consists of
two rotors which are fixed on a structure within the
sea current The twin rotors rotate with the
movement of the tidal flow and the blades pitch
through 180 degrees to optimally track tidal current
(Press picture Marine Current Turbines)
Wave Star Energys Multi-point Absorber
CFRP COLUMN REINFORCEMENT
INDUSTRIAL TANKS
107
INDUSTRIAL PIPES
PRESSURE TANKS
109
ldquoLetrsquos Make with Compositesrdquo
Karakteristik Woven Roving
bull Glass Content 45
bull Resin Content 55
Woven Roving
Resin
|
|
|
|
|
|
|
|
|
|
|
|
|
|
bull Kekuatan Tarik
JENIS FIBERGLASS
No Resin Rich Area
Karakteristik Multiaxial
bull Glass Content 60
bull Resin Content 40
Produk Fiberglass Ketiga MULTIAXIAL
JENIS FIBERGLASS
Perbedaan Woven Roving dan Multiaxial ndash Tampak Samping
JENIS FIBERGLASS
WR FRP
8 Ply WR 800
8 Ply CSM 450
Glass Weight 1 kg
Composite Weight 15kgm2
CSM FRP
22 Ply CSM 450
Glass Weight 1 kg
Composite Weight 18 kgm2
MULTIAXIAL FRP
13 Ply DB 800
Glass Weight 1 kg
Composite Weight
13 kgm2
JENIS FIBERGLASS
Multiaxial
FRP
Woven Roving
FRP
Chopped Strands Mat FRP
MULTIAXIAL
FAKTA
TEBAL BUKAN BERARTI KUAT
UNSUR MATRIX (RESIN)
TIDAK ADA KEKUATAN
ldquoMore than 50 of the glass fibers used for reinforcement is
E-glassrdquo
KarakteristikKekuatan
CSM WR MAX
Kekuatan Tarik 175 MPa 250 MPa 425 MPa
CSM 142
WR 70
KEKUATAN TARIK
Properties CSM Lamination WR Lamination MAX Lamination
Fabric Weight (kgm2) 1 1 1
Composite Weight (kgm2) 18 15 13
Resin usage (kgm2) 15 1 08
Amount of Fabric 22 Ply 16 Ply 13 Ply
Thickness 15 mm 12 mm 10 mm
Tensile Strength (Mpa) 125 1796 400
Tensile Strength (Nmmsup2) 28463 30958 4576
Processing Time High Med Low
Labour Cost High Med Low
MULTIAXIAL
Total Penggunaan Resin -51
Total Berat Kapal -40
Kekuatan Bangunan Kapal +59
Efisiensi Tenaga Kerja
Waktu Pengerjaan Lebih Cepat
KEUNGGULAN MATERIAL
Resapan Resin Lebih Baik amp Merata
Lapisan Lebih Sedikit
Meningkatkan Kekuatan Kapal
KEUNGGULAN MATERIAL
TRIAXIAL
DBL series DBT series
BIAXIAL
LT series DB series
UNIDIRECTIONAL
L series T series
QUADRIAXIAL
DBLT series
JENIS MULTIAXIAL
UNIDIRECTIONAL
DCMU 900 E ndash
KHUSUS UNTUK MEMPERKUAT BENDING KAPAL
PEMASANGAN KHUSUS PADA KEEL DAN TULANGAN
JENIS MULTIAXIAL UNTUK KAPAL
TRIAXIAL
DBL 600 ndash
APLIKASI PADA INDUSTRI PENERBANGAN
PEMASANGAN KHUSUS PADA
SAMBUNGAN BADAN DAN SAYAP
PESAWAT
JENIS MULTIAXIAL UNTUK PESAWAT
QUADRAXIAL
DBLT 800 ndash
APLIKASI PADA INDUSTRI ENERGI
DITERAPKAN UNTUK KEBUTUHAN PEMBANGKIT
LISTRIK ENERGI ANGIN
MULTIAXIAL UNTUK ENERGI
INDUSTRI KIMIA OLAHRAGA AUTOMOTIF
MULTIAXIAL UNTUK INDUSTRI LAINNYA
COMPOSITES
GUNAKAN MATERIAL FIBERGLASS
YANG SUDAH DISERTIFIKASI
BKI
FIBERGLASS UNTUK PEMBANGUNAN BAKAP
PERATURAN MENTERI PERHUBUNGAN
NOMOR PM 7 TAHUN 2013
TENTANG KEWAJIBAN KLASIFIKASI BAGI KAPAL BERBENDERA INDONESIA
PADA BADAN KLASIFIKASI
BADAN SERTIFIKASI MARITIM
Biro Klasifikasi IndonesiaDet Norske Veritas Germanischer Lloyds
PERATURAN BKI
Untuk Kapal Non-Metal
2006
PERSYARATAN MINIMUM
kekuatan material yang
harus digunakan
untuk membangun
Kapal Fiberglass
PEMBESARAN
Table 21
FIBERGLASS TRIAXIS COMPOSITES
TELAH BERSERTIFIKASI BKI
Biro Klasifikasi Indonesia
65
TEKNIK MANUFAKTUR
COMPOSITES
Wet hand lay-up
1) Peletakan
Dry Reinforcement
bull Dry reinforcement dan resin (+ katalis) ditaruh pada permukaan cetakan
2) Pemasukanpenekanan resin
bull Resin ditekan untuk meng-impregnasi serat dengan menggunakan rol
3) Pengulangan proses untuk lapisan lain
bull Beberapa lapisan dapat ditambahkan secara bertahap
4) Resin curing
bull Reaksi dimulai komponen dilepaskan setelah komponen mengeras
(fully cured)
Wet hand lay-up
Manufaktur komponen dapat dikerjakan dengan menggunakan beberapa lapis komposit
dengan memperhatikan kompatibilitas material dan tahapan curing Modifikasi proses dapat
dilakukan seperti
Vacuum bagging
setelah lay-up
Glass Roving
Bulk Resin
Catalyst
3) De-molding
2) Resin Cure
bull Curing dimulai dan komponen dilepaskan setelah pengerasan selesai
bull Serat gelas resin dan katalis dimasukkan kedalam spray gun
1) Spray-up
bull Campuran disemprotkan pada permukaan cetakan
Spray-up
69
Penyemprotan bakal komponen
Komponen
dilepaskan
dari cetakan
Full dispensing
system Chopper Roving
Atomised resin
and catalyst
Spray-up
Prepreg
1) LaminateAssembly 5) De-molding
3) Resin Melts Layup Consolidates
bull Prepreg serat yang sudah diimpregnasi oleh resin+katalis dalam kondisi padat
bull Lapisan prepreg digunting sesuai bentuk yang diinginkan kemudian diletakkan pada permukaan cetakan
sesuai bentuk komponen yang diinginkan Lay-up mudah dilakukan karena sifat ldquotackynessrdquo dari prepreg
2) Applied Vacuum Pressure and Heat
bull Tekanan dan panas diberikan resin mencair terjadi konsolidasi pada komponen
4) Resin Cures
bull Temperatur dinaikkan untuk memulai curing
Prepreg
Variasi proses Autoclave
Komponen dalam
vacuum-bag
bull Campuran resin (+katalis) dan chopped glass strands diperoleh dalam bentuk premixed compound Bulk molding
Compound (BMC) dalam bentuk adonan atau Sheet molding Compound (SMC) dalam bentuk lembaran
bull Ketika panas dan tekanan diberikan oleh cetakan compound mengalir sesuai bentuk komponen yang diinginkan
1) Placement of Charge
5) De-molding3) Squeeze to final dimensions
2) Mould Closure4) Resin Cure
bull Curing dimulai komponen dilepaskan setelah terjadi pengerasan yang cukup
Compression Molding
bull Preform atau dry reinforcement dimasukkan kedalam cetakan sesuai dengan bentuk komponen yang
diinginkan
bull Resin mengalir dengan penekanan atau pem-vakuman dan meng-impregnasi preform dan
mendorongmengeluarkan udara yang ada dalam preform
1) Preform Manufacture
2) Preform Compression
5) De-molding3) Resin Injection
4) Resin Cure
bull Curing terjadi cetakan dibuka setelah terjadi pengerasan yang mencukupi
Liquid Molding (RTM VARI VARTM)
Pultrusion
bull Dry roving or fabrics ditarik melalui bak berisi
campuran resin dan katalis
bull Campuran yang basah ditarik melalui cetakan
bull Sisa resin keluar cetakan
bull Pemanasan dilakukan untuk proses curing
bull Pendinginan dilakukan untuk mempercepat siklus
produksi
Cut-off
Cooling
Die sections
Resin bath
Fibre creel
Filament Winding
bull Dry roving ditarik melalui bak berisi campuran resin dan katalis
bull Wet roving digulungkan dalam keadaan tegang kepada mandrel
bull Kontrol mekanik dari pembawa serat mengatur orientasi peletakan serat pada
mandrel
INDUSTRI COMPOSITES
AEROSPACE
HISTORY
1950 ndash Boeing
1960 ndash F14 Tomcat
1981 ndash AV-8B Harrier
Source
Low-Cost Composite Materials and Structures for Aircraft Applications
httpwwwreinforcedplasticscom
httpwwwcentennialofflightgovessayEvolution_of_TechnologycompositesTech40htm
Automotive
Composite material is used in a number of applications in the automotive
industry due to its temperature resistance rigidity and fatigue strength
The benefits of using composites include greater fuel efficiency
corrosion resistance light weight and strength Composites also provide
a low-cost way to help keep designs looking fresh
Composites are used in
- interior parts (cockpit trimming seats instrument panels)
- exterior structure (body panels openings underbody frontrear
modules)
- engine compartment and fuelmechanical area parts (axles and
suspensions fuel and exhaust systems)
- electrical and electronic components
Lamborghinis Sesto Element carbon fiber
ldquoFat men cannot run as fast as thin men but we build most of our vehicles as though dead-weight fat increased speedhellip I cannot
imagine where the delusion that weight means strength
came fromhelliprdquo mdashHenry Ford
The mix of automotive materials is changing showing a boost for FRP in helping original
equipment manufacturers meet fuel economy and emissions challenges
(Source 2011 DuPont AutomotiveSAE survey of design engineers performed by Signet Research Inc)
Source
httpwwwtoraycomcsrhighlight2009hig_001_01html
The MonoCell tub for the McLaren MP4-12C supercar is moulded as a single
piece and weighs less than 80 kg (176 lbs)
COMPOSITES IN MARINE
TRIMARAN BOAT
AMERICA NAVYINDONESIAN NAVY
Visby Class corvette
Total length is 72 meters
The beam is 1040 meters
The displacement is 600 metric tones
fully equipped the worlds largest CRP
construction
The design of the Visby aims to minimize
the optical and infrared signature above
water acoustic and hydroa coustic
signature underwater electrical potential
and magnetic signature pressure signature
radar cross section and actively emitted
signals
A stealth corvette of the YS 2000 design
has a detection range of 13km in rough
seas and 22km in calm sea without
jamming In a jammed environment the
Visby would be detected at a range of 8km
in rough sea and 11km in calm sea
The material provides high strength and
rigidity low weight good shock resistance
low radar and magnetic signature
1996
Visby is a class of stealth corvettes for the Swedish Navy
ldquoReduced 50 of a Conventional Steelrdquo
Source
Hull Construction with composite materials for ships over 100m in length 2002
Massachusetts Institute of Technology
httpwwwnaval-technologycomprojectsvisby
YACHTS
KAL YUDISTIRAMARATHON 100 ADMIRAL YACHT
LOA 3050 MWidth 6 MFuel Tank 8000 LWater Tank 3000 LIce Box 500 LAccommodation Max 35 Personnel
2 x CATERPILLAR 3412E 1200 HPMARINE DIESEL ENGINE
PC 40 ndash KRI Krait 827Department of Indonesian Navy
LOA 40 MWidth 73 MPower 190Weapon Twin Cannon Barrels
127 mm Heavy Machine GunSpeed Knot 25 KnotDisplacement 105 tonAccommodation 23 personnel
PATROL BOAT
Rigid Inflatable BoatPATROL BOAT
Yachts
36m Luxury Yacht Moonraker
36m Luxury Yacht GoldenEye
50m Luxury Yacht Casino
Royale
45m Luxury Yacht Seashaw
Boat Parts
Barovans for Seismic Sweep
Centrifugal Liftfan House for Surface Effect
Ships
Composite Boat PropellersRTM
Deckhouses for Pilot Boats
Fairing Parts for Submarines
Flybridges for Motor yachts
Light Weight Gangway
MTB Launcher Mock-up
Pleasure Boats
12m Sailboat
12m Sail-Catamaranone-off
Canoes
Dragonfly 1000Catamaran Sailboat
Fantasy 37Sailboat
Farr 60Luxury Sailboat
EurodingyOlympic Dingy Class for
Woman
Hydrolift F23 Racing Boats
Kajacs
Najad 42Sailboat
Najad 520Sailboat
Najad 441Sailboat
Najad 391Sailboat
Nordwest 900Motorboat
Nordwest 1100Motorboat
Quatro 44Motorboat
Racemaster Competition Boats
Storebro 420
Storebro 345
Sweden Yacht 370Sailboat
Sweden Yacht 69Sailboat
Windy 41Motorboat
X-632Sailboat
X-362Sailboat
Commercial Boats
175m High Speed AmbulancePassenger Boat
19m High Speed Passenger Boat
20m High Speed Passenger Boat
364m Surface Effect Passenger Ship
45m Surface Effect Passenger Ship
120m Hull Structural Parts HSSS Catamaran Ferry
APPENDIX
Marine Vessel
1188m Fast Attack Vessel FMV 90 E
20m SAV-Surface Auxiliary Vessels
34m Personnel TransportCoast Guard Vessel
40ft Experimental SES
40m Landsort-Class Mine Hunters
54m Mine Counter Measure Vehicles SES
74m Coastal Patrol Boats
Fishing Boats
30 GT
12 GT
10 GT
5 GT
WISEWings In Surface Effect
HOVERCRAFT
Designed specifically for the tourist and transport industries the
Pioneer Mk3 hovercraft is amphibious and comfortably seats 25
passengers plus 1-crew The air-conditioned cabin allows for
maximum visibility for all aboard The Pioneer Mk3 is robust and
dynamic in its performance
Commercial hovercraft
Mk3 AirLift Hovercraft - 1215m
Power is economicaly provided by one Deutz diesel engine of
330kW (442hp) to cruise easily at 40 knots with much higher
speeds available according to the surface conditions The hull is
manufactured from fibreglassPVC foam composite sandwich
the windows are glass and the skirt is urethane coated nylon A
Military version is available with increased payload and systems
redundancy Power for the Military version comes from two Steyr
diesel engines with a total installed power of 320kW (429hp) All
transmission electrical hydraulic and air systems are duplicated
for maximum redundancy The increased performance of the
Military version comes from the reduced engine weight of the twin
Steyr installation cf the Deutz installation
Source
httpwwwnauticexpocomprodairlift-hovercraftcommercial-hovercrafts-25251-142868html
HOVERFLIGHT
BALLISTIC amp UNIT DEFENCED
Triaxis Composites Collaboration with Institute of Aeronautics and Space in the development of Missile Nose Cone
Polymer composites is the evolution of the military defence
Thin steel was the helmet material of
WWII and remained the principal material until around the 1980rsquos
The advantages of using steel
included a simple technology for manufacture of the helmets low cost and reasonably good
impact protection However these helmets were found to provide only marginal protection
against fragments
During the Vietnam War the US Army experimented with fiber-reinforced inserts in the
helmets These inserts improved ballistic protection but at the same time added weight and
reduced the air space between the head and the helmet
By the early part of the 1980rsquos the US military had developed the first all-composite
100 fiber-reinforced helmet This development resulted in even better ballistic protection
without altering the weight of the helmet Other improvements included better head coverage and
more space for ventilation
Source
Composites Armor - A difficult but huge market
by A Brent Strong Brigham Young University
MILITARY VEHICLES
HIGH SPEED TRAIN SHINKANSEN
Advanced Composites provide lightweight solutions for railway vehicles
saving as much as 50-80 of the weight compared with traditional
components
A lower overall weight translates into less stress faster acceleration and
higher speeds as well as reduced starting and stopping inertia Today
these are important criteria in global high-speed and metropolitan
railway projects
Fire smoke and toxic fumes are key safety criteria for interior
components of railway carriages Any material selected for an interior
component must meet international fire retardant standards
for Rail Interiors and Exteriors
Ceiling Panels Stairs
Seating Vestibules
Window Panels Door Pillars
Partition WallsDiffusers
Gangway and Cabinet Panels Cabin and
Desk panels
Door Pillars Lavatory Modules (standard and
Front and Rear EndsRoof Panels
Nose Cones Under Fairings
Source
httpwwwpctaerail_compositesphp
101
SKY BUS
2009
Europe is the world leader in offshore wind with
828 wind turbines and a cumulative capacity of 2056 MW spread across 38 offshore wind farms in 9
European countries
The UK and Denmark are the current leaders with a 44 and 30 share respectively In 2009
five countries built new offshore wind farms
UK (284 MW)
Demark (230 MW)
Sweden (30 MW)
Germany (30 MW)
Norway (23 MW)
2010
Asia leads the growth in global wind power which grew 358 GW in 2010 bringing
total global capacity to 1944 GW ndash up 225 from 2009
the Global Wind Energy Council (GWEC)
Asia accounted for 19 GW of new global wind power installations driven by China which installed 165
GW
ldquoChina now has 423 GW of wind powerrdquo
ldquoThis puts China firmly on a path to reach 200 GW of installed wind power by 2020 At the same
time China has become the worldrsquos largest producer of wind energy equipmentrdquo
Source
httpwwwreinforcedplasticscomview15655asia-leads-global-wind-power-growth
httpimgdeusmcomdesignnews288288605-Sandia_Sizes_up_Wind_Turbine_Blade_Design_C_largegif
WIND ENERGY
Marine Current Turbines
Source
httpwwwsiemenscompressenpressreleasepress=enpressrelease2011solar-hydroex201111005htm
httpwwwmarineturbinescom
A commercial marine current turbine consists of
two rotors which are fixed on a structure within the
sea current The twin rotors rotate with the
movement of the tidal flow and the blades pitch
through 180 degrees to optimally track tidal current
(Press picture Marine Current Turbines)
Wave Star Energys Multi-point Absorber
CFRP COLUMN REINFORCEMENT
INDUSTRIAL TANKS
107
INDUSTRIAL PIPES
PRESSURE TANKS
109
ldquoLetrsquos Make with Compositesrdquo
No Resin Rich Area
Karakteristik Multiaxial
bull Glass Content 60
bull Resin Content 40
Produk Fiberglass Ketiga MULTIAXIAL
JENIS FIBERGLASS
Perbedaan Woven Roving dan Multiaxial ndash Tampak Samping
JENIS FIBERGLASS
WR FRP
8 Ply WR 800
8 Ply CSM 450
Glass Weight 1 kg
Composite Weight 15kgm2
CSM FRP
22 Ply CSM 450
Glass Weight 1 kg
Composite Weight 18 kgm2
MULTIAXIAL FRP
13 Ply DB 800
Glass Weight 1 kg
Composite Weight
13 kgm2
JENIS FIBERGLASS
Multiaxial
FRP
Woven Roving
FRP
Chopped Strands Mat FRP
MULTIAXIAL
FAKTA
TEBAL BUKAN BERARTI KUAT
UNSUR MATRIX (RESIN)
TIDAK ADA KEKUATAN
ldquoMore than 50 of the glass fibers used for reinforcement is
E-glassrdquo
KarakteristikKekuatan
CSM WR MAX
Kekuatan Tarik 175 MPa 250 MPa 425 MPa
CSM 142
WR 70
KEKUATAN TARIK
Properties CSM Lamination WR Lamination MAX Lamination
Fabric Weight (kgm2) 1 1 1
Composite Weight (kgm2) 18 15 13
Resin usage (kgm2) 15 1 08
Amount of Fabric 22 Ply 16 Ply 13 Ply
Thickness 15 mm 12 mm 10 mm
Tensile Strength (Mpa) 125 1796 400
Tensile Strength (Nmmsup2) 28463 30958 4576
Processing Time High Med Low
Labour Cost High Med Low
MULTIAXIAL
Total Penggunaan Resin -51
Total Berat Kapal -40
Kekuatan Bangunan Kapal +59
Efisiensi Tenaga Kerja
Waktu Pengerjaan Lebih Cepat
KEUNGGULAN MATERIAL
Resapan Resin Lebih Baik amp Merata
Lapisan Lebih Sedikit
Meningkatkan Kekuatan Kapal
KEUNGGULAN MATERIAL
TRIAXIAL
DBL series DBT series
BIAXIAL
LT series DB series
UNIDIRECTIONAL
L series T series
QUADRIAXIAL
DBLT series
JENIS MULTIAXIAL
UNIDIRECTIONAL
DCMU 900 E ndash
KHUSUS UNTUK MEMPERKUAT BENDING KAPAL
PEMASANGAN KHUSUS PADA KEEL DAN TULANGAN
JENIS MULTIAXIAL UNTUK KAPAL
TRIAXIAL
DBL 600 ndash
APLIKASI PADA INDUSTRI PENERBANGAN
PEMASANGAN KHUSUS PADA
SAMBUNGAN BADAN DAN SAYAP
PESAWAT
JENIS MULTIAXIAL UNTUK PESAWAT
QUADRAXIAL
DBLT 800 ndash
APLIKASI PADA INDUSTRI ENERGI
DITERAPKAN UNTUK KEBUTUHAN PEMBANGKIT
LISTRIK ENERGI ANGIN
MULTIAXIAL UNTUK ENERGI
INDUSTRI KIMIA OLAHRAGA AUTOMOTIF
MULTIAXIAL UNTUK INDUSTRI LAINNYA
COMPOSITES
GUNAKAN MATERIAL FIBERGLASS
YANG SUDAH DISERTIFIKASI
BKI
FIBERGLASS UNTUK PEMBANGUNAN BAKAP
PERATURAN MENTERI PERHUBUNGAN
NOMOR PM 7 TAHUN 2013
TENTANG KEWAJIBAN KLASIFIKASI BAGI KAPAL BERBENDERA INDONESIA
PADA BADAN KLASIFIKASI
BADAN SERTIFIKASI MARITIM
Biro Klasifikasi IndonesiaDet Norske Veritas Germanischer Lloyds
PERATURAN BKI
Untuk Kapal Non-Metal
2006
PERSYARATAN MINIMUM
kekuatan material yang
harus digunakan
untuk membangun
Kapal Fiberglass
PEMBESARAN
Table 21
FIBERGLASS TRIAXIS COMPOSITES
TELAH BERSERTIFIKASI BKI
Biro Klasifikasi Indonesia
65
TEKNIK MANUFAKTUR
COMPOSITES
Wet hand lay-up
1) Peletakan
Dry Reinforcement
bull Dry reinforcement dan resin (+ katalis) ditaruh pada permukaan cetakan
2) Pemasukanpenekanan resin
bull Resin ditekan untuk meng-impregnasi serat dengan menggunakan rol
3) Pengulangan proses untuk lapisan lain
bull Beberapa lapisan dapat ditambahkan secara bertahap
4) Resin curing
bull Reaksi dimulai komponen dilepaskan setelah komponen mengeras
(fully cured)
Wet hand lay-up
Manufaktur komponen dapat dikerjakan dengan menggunakan beberapa lapis komposit
dengan memperhatikan kompatibilitas material dan tahapan curing Modifikasi proses dapat
dilakukan seperti
Vacuum bagging
setelah lay-up
Glass Roving
Bulk Resin
Catalyst
3) De-molding
2) Resin Cure
bull Curing dimulai dan komponen dilepaskan setelah pengerasan selesai
bull Serat gelas resin dan katalis dimasukkan kedalam spray gun
1) Spray-up
bull Campuran disemprotkan pada permukaan cetakan
Spray-up
69
Penyemprotan bakal komponen
Komponen
dilepaskan
dari cetakan
Full dispensing
system Chopper Roving
Atomised resin
and catalyst
Spray-up
Prepreg
1) LaminateAssembly 5) De-molding
3) Resin Melts Layup Consolidates
bull Prepreg serat yang sudah diimpregnasi oleh resin+katalis dalam kondisi padat
bull Lapisan prepreg digunting sesuai bentuk yang diinginkan kemudian diletakkan pada permukaan cetakan
sesuai bentuk komponen yang diinginkan Lay-up mudah dilakukan karena sifat ldquotackynessrdquo dari prepreg
2) Applied Vacuum Pressure and Heat
bull Tekanan dan panas diberikan resin mencair terjadi konsolidasi pada komponen
4) Resin Cures
bull Temperatur dinaikkan untuk memulai curing
Prepreg
Variasi proses Autoclave
Komponen dalam
vacuum-bag
bull Campuran resin (+katalis) dan chopped glass strands diperoleh dalam bentuk premixed compound Bulk molding
Compound (BMC) dalam bentuk adonan atau Sheet molding Compound (SMC) dalam bentuk lembaran
bull Ketika panas dan tekanan diberikan oleh cetakan compound mengalir sesuai bentuk komponen yang diinginkan
1) Placement of Charge
5) De-molding3) Squeeze to final dimensions
2) Mould Closure4) Resin Cure
bull Curing dimulai komponen dilepaskan setelah terjadi pengerasan yang cukup
Compression Molding
bull Preform atau dry reinforcement dimasukkan kedalam cetakan sesuai dengan bentuk komponen yang
diinginkan
bull Resin mengalir dengan penekanan atau pem-vakuman dan meng-impregnasi preform dan
mendorongmengeluarkan udara yang ada dalam preform
1) Preform Manufacture
2) Preform Compression
5) De-molding3) Resin Injection
4) Resin Cure
bull Curing terjadi cetakan dibuka setelah terjadi pengerasan yang mencukupi
Liquid Molding (RTM VARI VARTM)
Pultrusion
bull Dry roving or fabrics ditarik melalui bak berisi
campuran resin dan katalis
bull Campuran yang basah ditarik melalui cetakan
bull Sisa resin keluar cetakan
bull Pemanasan dilakukan untuk proses curing
bull Pendinginan dilakukan untuk mempercepat siklus
produksi
Cut-off
Cooling
Die sections
Resin bath
Fibre creel
Filament Winding
bull Dry roving ditarik melalui bak berisi campuran resin dan katalis
bull Wet roving digulungkan dalam keadaan tegang kepada mandrel
bull Kontrol mekanik dari pembawa serat mengatur orientasi peletakan serat pada
mandrel
INDUSTRI COMPOSITES
AEROSPACE
HISTORY
1950 ndash Boeing
1960 ndash F14 Tomcat
1981 ndash AV-8B Harrier
Source
Low-Cost Composite Materials and Structures for Aircraft Applications
httpwwwreinforcedplasticscom
httpwwwcentennialofflightgovessayEvolution_of_TechnologycompositesTech40htm
Automotive
Composite material is used in a number of applications in the automotive
industry due to its temperature resistance rigidity and fatigue strength
The benefits of using composites include greater fuel efficiency
corrosion resistance light weight and strength Composites also provide
a low-cost way to help keep designs looking fresh
Composites are used in
- interior parts (cockpit trimming seats instrument panels)
- exterior structure (body panels openings underbody frontrear
modules)
- engine compartment and fuelmechanical area parts (axles and
suspensions fuel and exhaust systems)
- electrical and electronic components
Lamborghinis Sesto Element carbon fiber
ldquoFat men cannot run as fast as thin men but we build most of our vehicles as though dead-weight fat increased speedhellip I cannot
imagine where the delusion that weight means strength
came fromhelliprdquo mdashHenry Ford
The mix of automotive materials is changing showing a boost for FRP in helping original
equipment manufacturers meet fuel economy and emissions challenges
(Source 2011 DuPont AutomotiveSAE survey of design engineers performed by Signet Research Inc)
Source
httpwwwtoraycomcsrhighlight2009hig_001_01html
The MonoCell tub for the McLaren MP4-12C supercar is moulded as a single
piece and weighs less than 80 kg (176 lbs)
COMPOSITES IN MARINE
TRIMARAN BOAT
AMERICA NAVYINDONESIAN NAVY
Visby Class corvette
Total length is 72 meters
The beam is 1040 meters
The displacement is 600 metric tones
fully equipped the worlds largest CRP
construction
The design of the Visby aims to minimize
the optical and infrared signature above
water acoustic and hydroa coustic
signature underwater electrical potential
and magnetic signature pressure signature
radar cross section and actively emitted
signals
A stealth corvette of the YS 2000 design
has a detection range of 13km in rough
seas and 22km in calm sea without
jamming In a jammed environment the
Visby would be detected at a range of 8km
in rough sea and 11km in calm sea
The material provides high strength and
rigidity low weight good shock resistance
low radar and magnetic signature
1996
Visby is a class of stealth corvettes for the Swedish Navy
ldquoReduced 50 of a Conventional Steelrdquo
Source
Hull Construction with composite materials for ships over 100m in length 2002
Massachusetts Institute of Technology
httpwwwnaval-technologycomprojectsvisby
YACHTS
KAL YUDISTIRAMARATHON 100 ADMIRAL YACHT
LOA 3050 MWidth 6 MFuel Tank 8000 LWater Tank 3000 LIce Box 500 LAccommodation Max 35 Personnel
2 x CATERPILLAR 3412E 1200 HPMARINE DIESEL ENGINE
PC 40 ndash KRI Krait 827Department of Indonesian Navy
LOA 40 MWidth 73 MPower 190Weapon Twin Cannon Barrels
127 mm Heavy Machine GunSpeed Knot 25 KnotDisplacement 105 tonAccommodation 23 personnel
PATROL BOAT
Rigid Inflatable BoatPATROL BOAT
Yachts
36m Luxury Yacht Moonraker
36m Luxury Yacht GoldenEye
50m Luxury Yacht Casino
Royale
45m Luxury Yacht Seashaw
Boat Parts
Barovans for Seismic Sweep
Centrifugal Liftfan House for Surface Effect
Ships
Composite Boat PropellersRTM
Deckhouses for Pilot Boats
Fairing Parts for Submarines
Flybridges for Motor yachts
Light Weight Gangway
MTB Launcher Mock-up
Pleasure Boats
12m Sailboat
12m Sail-Catamaranone-off
Canoes
Dragonfly 1000Catamaran Sailboat
Fantasy 37Sailboat
Farr 60Luxury Sailboat
EurodingyOlympic Dingy Class for
Woman
Hydrolift F23 Racing Boats
Kajacs
Najad 42Sailboat
Najad 520Sailboat
Najad 441Sailboat
Najad 391Sailboat
Nordwest 900Motorboat
Nordwest 1100Motorboat
Quatro 44Motorboat
Racemaster Competition Boats
Storebro 420
Storebro 345
Sweden Yacht 370Sailboat
Sweden Yacht 69Sailboat
Windy 41Motorboat
X-632Sailboat
X-362Sailboat
Commercial Boats
175m High Speed AmbulancePassenger Boat
19m High Speed Passenger Boat
20m High Speed Passenger Boat
364m Surface Effect Passenger Ship
45m Surface Effect Passenger Ship
120m Hull Structural Parts HSSS Catamaran Ferry
APPENDIX
Marine Vessel
1188m Fast Attack Vessel FMV 90 E
20m SAV-Surface Auxiliary Vessels
34m Personnel TransportCoast Guard Vessel
40ft Experimental SES
40m Landsort-Class Mine Hunters
54m Mine Counter Measure Vehicles SES
74m Coastal Patrol Boats
Fishing Boats
30 GT
12 GT
10 GT
5 GT
WISEWings In Surface Effect
HOVERCRAFT
Designed specifically for the tourist and transport industries the
Pioneer Mk3 hovercraft is amphibious and comfortably seats 25
passengers plus 1-crew The air-conditioned cabin allows for
maximum visibility for all aboard The Pioneer Mk3 is robust and
dynamic in its performance
Commercial hovercraft
Mk3 AirLift Hovercraft - 1215m
Power is economicaly provided by one Deutz diesel engine of
330kW (442hp) to cruise easily at 40 knots with much higher
speeds available according to the surface conditions The hull is
manufactured from fibreglassPVC foam composite sandwich
the windows are glass and the skirt is urethane coated nylon A
Military version is available with increased payload and systems
redundancy Power for the Military version comes from two Steyr
diesel engines with a total installed power of 320kW (429hp) All
transmission electrical hydraulic and air systems are duplicated
for maximum redundancy The increased performance of the
Military version comes from the reduced engine weight of the twin
Steyr installation cf the Deutz installation
Source
httpwwwnauticexpocomprodairlift-hovercraftcommercial-hovercrafts-25251-142868html
HOVERFLIGHT
BALLISTIC amp UNIT DEFENCED
Triaxis Composites Collaboration with Institute of Aeronautics and Space in the development of Missile Nose Cone
Polymer composites is the evolution of the military defence
Thin steel was the helmet material of
WWII and remained the principal material until around the 1980rsquos
The advantages of using steel
included a simple technology for manufacture of the helmets low cost and reasonably good
impact protection However these helmets were found to provide only marginal protection
against fragments
During the Vietnam War the US Army experimented with fiber-reinforced inserts in the
helmets These inserts improved ballistic protection but at the same time added weight and
reduced the air space between the head and the helmet
By the early part of the 1980rsquos the US military had developed the first all-composite
100 fiber-reinforced helmet This development resulted in even better ballistic protection
without altering the weight of the helmet Other improvements included better head coverage and
more space for ventilation
Source
Composites Armor - A difficult but huge market
by A Brent Strong Brigham Young University
MILITARY VEHICLES
HIGH SPEED TRAIN SHINKANSEN
Advanced Composites provide lightweight solutions for railway vehicles
saving as much as 50-80 of the weight compared with traditional
components
A lower overall weight translates into less stress faster acceleration and
higher speeds as well as reduced starting and stopping inertia Today
these are important criteria in global high-speed and metropolitan
railway projects
Fire smoke and toxic fumes are key safety criteria for interior
components of railway carriages Any material selected for an interior
component must meet international fire retardant standards
for Rail Interiors and Exteriors
Ceiling Panels Stairs
Seating Vestibules
Window Panels Door Pillars
Partition WallsDiffusers
Gangway and Cabinet Panels Cabin and
Desk panels
Door Pillars Lavatory Modules (standard and
Front and Rear EndsRoof Panels
Nose Cones Under Fairings
Source
httpwwwpctaerail_compositesphp
101
SKY BUS
2009
Europe is the world leader in offshore wind with
828 wind turbines and a cumulative capacity of 2056 MW spread across 38 offshore wind farms in 9
European countries
The UK and Denmark are the current leaders with a 44 and 30 share respectively In 2009
five countries built new offshore wind farms
UK (284 MW)
Demark (230 MW)
Sweden (30 MW)
Germany (30 MW)
Norway (23 MW)
2010
Asia leads the growth in global wind power which grew 358 GW in 2010 bringing
total global capacity to 1944 GW ndash up 225 from 2009
the Global Wind Energy Council (GWEC)
Asia accounted for 19 GW of new global wind power installations driven by China which installed 165
GW
ldquoChina now has 423 GW of wind powerrdquo
ldquoThis puts China firmly on a path to reach 200 GW of installed wind power by 2020 At the same
time China has become the worldrsquos largest producer of wind energy equipmentrdquo
Source
httpwwwreinforcedplasticscomview15655asia-leads-global-wind-power-growth
httpimgdeusmcomdesignnews288288605-Sandia_Sizes_up_Wind_Turbine_Blade_Design_C_largegif
WIND ENERGY
Marine Current Turbines
Source
httpwwwsiemenscompressenpressreleasepress=enpressrelease2011solar-hydroex201111005htm
httpwwwmarineturbinescom
A commercial marine current turbine consists of
two rotors which are fixed on a structure within the
sea current The twin rotors rotate with the
movement of the tidal flow and the blades pitch
through 180 degrees to optimally track tidal current
(Press picture Marine Current Turbines)
Wave Star Energys Multi-point Absorber
CFRP COLUMN REINFORCEMENT
INDUSTRIAL TANKS
107
INDUSTRIAL PIPES
PRESSURE TANKS
109
ldquoLetrsquos Make with Compositesrdquo
Perbedaan Woven Roving dan Multiaxial ndash Tampak Samping
JENIS FIBERGLASS
WR FRP
8 Ply WR 800
8 Ply CSM 450
Glass Weight 1 kg
Composite Weight 15kgm2
CSM FRP
22 Ply CSM 450
Glass Weight 1 kg
Composite Weight 18 kgm2
MULTIAXIAL FRP
13 Ply DB 800
Glass Weight 1 kg
Composite Weight
13 kgm2
JENIS FIBERGLASS
Multiaxial
FRP
Woven Roving
FRP
Chopped Strands Mat FRP
MULTIAXIAL
FAKTA
TEBAL BUKAN BERARTI KUAT
UNSUR MATRIX (RESIN)
TIDAK ADA KEKUATAN
ldquoMore than 50 of the glass fibers used for reinforcement is
E-glassrdquo
KarakteristikKekuatan
CSM WR MAX
Kekuatan Tarik 175 MPa 250 MPa 425 MPa
CSM 142
WR 70
KEKUATAN TARIK
Properties CSM Lamination WR Lamination MAX Lamination
Fabric Weight (kgm2) 1 1 1
Composite Weight (kgm2) 18 15 13
Resin usage (kgm2) 15 1 08
Amount of Fabric 22 Ply 16 Ply 13 Ply
Thickness 15 mm 12 mm 10 mm
Tensile Strength (Mpa) 125 1796 400
Tensile Strength (Nmmsup2) 28463 30958 4576
Processing Time High Med Low
Labour Cost High Med Low
MULTIAXIAL
Total Penggunaan Resin -51
Total Berat Kapal -40
Kekuatan Bangunan Kapal +59
Efisiensi Tenaga Kerja
Waktu Pengerjaan Lebih Cepat
KEUNGGULAN MATERIAL
Resapan Resin Lebih Baik amp Merata
Lapisan Lebih Sedikit
Meningkatkan Kekuatan Kapal
KEUNGGULAN MATERIAL
TRIAXIAL
DBL series DBT series
BIAXIAL
LT series DB series
UNIDIRECTIONAL
L series T series
QUADRIAXIAL
DBLT series
JENIS MULTIAXIAL
UNIDIRECTIONAL
DCMU 900 E ndash
KHUSUS UNTUK MEMPERKUAT BENDING KAPAL
PEMASANGAN KHUSUS PADA KEEL DAN TULANGAN
JENIS MULTIAXIAL UNTUK KAPAL
TRIAXIAL
DBL 600 ndash
APLIKASI PADA INDUSTRI PENERBANGAN
PEMASANGAN KHUSUS PADA
SAMBUNGAN BADAN DAN SAYAP
PESAWAT
JENIS MULTIAXIAL UNTUK PESAWAT
QUADRAXIAL
DBLT 800 ndash
APLIKASI PADA INDUSTRI ENERGI
DITERAPKAN UNTUK KEBUTUHAN PEMBANGKIT
LISTRIK ENERGI ANGIN
MULTIAXIAL UNTUK ENERGI
INDUSTRI KIMIA OLAHRAGA AUTOMOTIF
MULTIAXIAL UNTUK INDUSTRI LAINNYA
COMPOSITES
GUNAKAN MATERIAL FIBERGLASS
YANG SUDAH DISERTIFIKASI
BKI
FIBERGLASS UNTUK PEMBANGUNAN BAKAP
PERATURAN MENTERI PERHUBUNGAN
NOMOR PM 7 TAHUN 2013
TENTANG KEWAJIBAN KLASIFIKASI BAGI KAPAL BERBENDERA INDONESIA
PADA BADAN KLASIFIKASI
BADAN SERTIFIKASI MARITIM
Biro Klasifikasi IndonesiaDet Norske Veritas Germanischer Lloyds
PERATURAN BKI
Untuk Kapal Non-Metal
2006
PERSYARATAN MINIMUM
kekuatan material yang
harus digunakan
untuk membangun
Kapal Fiberglass
PEMBESARAN
Table 21
FIBERGLASS TRIAXIS COMPOSITES
TELAH BERSERTIFIKASI BKI
Biro Klasifikasi Indonesia
65
TEKNIK MANUFAKTUR
COMPOSITES
Wet hand lay-up
1) Peletakan
Dry Reinforcement
bull Dry reinforcement dan resin (+ katalis) ditaruh pada permukaan cetakan
2) Pemasukanpenekanan resin
bull Resin ditekan untuk meng-impregnasi serat dengan menggunakan rol
3) Pengulangan proses untuk lapisan lain
bull Beberapa lapisan dapat ditambahkan secara bertahap
4) Resin curing
bull Reaksi dimulai komponen dilepaskan setelah komponen mengeras
(fully cured)
Wet hand lay-up
Manufaktur komponen dapat dikerjakan dengan menggunakan beberapa lapis komposit
dengan memperhatikan kompatibilitas material dan tahapan curing Modifikasi proses dapat
dilakukan seperti
Vacuum bagging
setelah lay-up
Glass Roving
Bulk Resin
Catalyst
3) De-molding
2) Resin Cure
bull Curing dimulai dan komponen dilepaskan setelah pengerasan selesai
bull Serat gelas resin dan katalis dimasukkan kedalam spray gun
1) Spray-up
bull Campuran disemprotkan pada permukaan cetakan
Spray-up
69
Penyemprotan bakal komponen
Komponen
dilepaskan
dari cetakan
Full dispensing
system Chopper Roving
Atomised resin
and catalyst
Spray-up
Prepreg
1) LaminateAssembly 5) De-molding
3) Resin Melts Layup Consolidates
bull Prepreg serat yang sudah diimpregnasi oleh resin+katalis dalam kondisi padat
bull Lapisan prepreg digunting sesuai bentuk yang diinginkan kemudian diletakkan pada permukaan cetakan
sesuai bentuk komponen yang diinginkan Lay-up mudah dilakukan karena sifat ldquotackynessrdquo dari prepreg
2) Applied Vacuum Pressure and Heat
bull Tekanan dan panas diberikan resin mencair terjadi konsolidasi pada komponen
4) Resin Cures
bull Temperatur dinaikkan untuk memulai curing
Prepreg
Variasi proses Autoclave
Komponen dalam
vacuum-bag
bull Campuran resin (+katalis) dan chopped glass strands diperoleh dalam bentuk premixed compound Bulk molding
Compound (BMC) dalam bentuk adonan atau Sheet molding Compound (SMC) dalam bentuk lembaran
bull Ketika panas dan tekanan diberikan oleh cetakan compound mengalir sesuai bentuk komponen yang diinginkan
1) Placement of Charge
5) De-molding3) Squeeze to final dimensions
2) Mould Closure4) Resin Cure
bull Curing dimulai komponen dilepaskan setelah terjadi pengerasan yang cukup
Compression Molding
bull Preform atau dry reinforcement dimasukkan kedalam cetakan sesuai dengan bentuk komponen yang
diinginkan
bull Resin mengalir dengan penekanan atau pem-vakuman dan meng-impregnasi preform dan
mendorongmengeluarkan udara yang ada dalam preform
1) Preform Manufacture
2) Preform Compression
5) De-molding3) Resin Injection
4) Resin Cure
bull Curing terjadi cetakan dibuka setelah terjadi pengerasan yang mencukupi
Liquid Molding (RTM VARI VARTM)
Pultrusion
bull Dry roving or fabrics ditarik melalui bak berisi
campuran resin dan katalis
bull Campuran yang basah ditarik melalui cetakan
bull Sisa resin keluar cetakan
bull Pemanasan dilakukan untuk proses curing
bull Pendinginan dilakukan untuk mempercepat siklus
produksi
Cut-off
Cooling
Die sections
Resin bath
Fibre creel
Filament Winding
bull Dry roving ditarik melalui bak berisi campuran resin dan katalis
bull Wet roving digulungkan dalam keadaan tegang kepada mandrel
bull Kontrol mekanik dari pembawa serat mengatur orientasi peletakan serat pada
mandrel
INDUSTRI COMPOSITES
AEROSPACE
HISTORY
1950 ndash Boeing
1960 ndash F14 Tomcat
1981 ndash AV-8B Harrier
Source
Low-Cost Composite Materials and Structures for Aircraft Applications
httpwwwreinforcedplasticscom
httpwwwcentennialofflightgovessayEvolution_of_TechnologycompositesTech40htm
Automotive
Composite material is used in a number of applications in the automotive
industry due to its temperature resistance rigidity and fatigue strength
The benefits of using composites include greater fuel efficiency
corrosion resistance light weight and strength Composites also provide
a low-cost way to help keep designs looking fresh
Composites are used in
- interior parts (cockpit trimming seats instrument panels)
- exterior structure (body panels openings underbody frontrear
modules)
- engine compartment and fuelmechanical area parts (axles and
suspensions fuel and exhaust systems)
- electrical and electronic components
Lamborghinis Sesto Element carbon fiber
ldquoFat men cannot run as fast as thin men but we build most of our vehicles as though dead-weight fat increased speedhellip I cannot
imagine where the delusion that weight means strength
came fromhelliprdquo mdashHenry Ford
The mix of automotive materials is changing showing a boost for FRP in helping original
equipment manufacturers meet fuel economy and emissions challenges
(Source 2011 DuPont AutomotiveSAE survey of design engineers performed by Signet Research Inc)
Source
httpwwwtoraycomcsrhighlight2009hig_001_01html
The MonoCell tub for the McLaren MP4-12C supercar is moulded as a single
piece and weighs less than 80 kg (176 lbs)
COMPOSITES IN MARINE
TRIMARAN BOAT
AMERICA NAVYINDONESIAN NAVY
Visby Class corvette
Total length is 72 meters
The beam is 1040 meters
The displacement is 600 metric tones
fully equipped the worlds largest CRP
construction
The design of the Visby aims to minimize
the optical and infrared signature above
water acoustic and hydroa coustic
signature underwater electrical potential
and magnetic signature pressure signature
radar cross section and actively emitted
signals
A stealth corvette of the YS 2000 design
has a detection range of 13km in rough
seas and 22km in calm sea without
jamming In a jammed environment the
Visby would be detected at a range of 8km
in rough sea and 11km in calm sea
The material provides high strength and
rigidity low weight good shock resistance
low radar and magnetic signature
1996
Visby is a class of stealth corvettes for the Swedish Navy
ldquoReduced 50 of a Conventional Steelrdquo
Source
Hull Construction with composite materials for ships over 100m in length 2002
Massachusetts Institute of Technology
httpwwwnaval-technologycomprojectsvisby
YACHTS
KAL YUDISTIRAMARATHON 100 ADMIRAL YACHT
LOA 3050 MWidth 6 MFuel Tank 8000 LWater Tank 3000 LIce Box 500 LAccommodation Max 35 Personnel
2 x CATERPILLAR 3412E 1200 HPMARINE DIESEL ENGINE
PC 40 ndash KRI Krait 827Department of Indonesian Navy
LOA 40 MWidth 73 MPower 190Weapon Twin Cannon Barrels
127 mm Heavy Machine GunSpeed Knot 25 KnotDisplacement 105 tonAccommodation 23 personnel
PATROL BOAT
Rigid Inflatable BoatPATROL BOAT
Yachts
36m Luxury Yacht Moonraker
36m Luxury Yacht GoldenEye
50m Luxury Yacht Casino
Royale
45m Luxury Yacht Seashaw
Boat Parts
Barovans for Seismic Sweep
Centrifugal Liftfan House for Surface Effect
Ships
Composite Boat PropellersRTM
Deckhouses for Pilot Boats
Fairing Parts for Submarines
Flybridges for Motor yachts
Light Weight Gangway
MTB Launcher Mock-up
Pleasure Boats
12m Sailboat
12m Sail-Catamaranone-off
Canoes
Dragonfly 1000Catamaran Sailboat
Fantasy 37Sailboat
Farr 60Luxury Sailboat
EurodingyOlympic Dingy Class for
Woman
Hydrolift F23 Racing Boats
Kajacs
Najad 42Sailboat
Najad 520Sailboat
Najad 441Sailboat
Najad 391Sailboat
Nordwest 900Motorboat
Nordwest 1100Motorboat
Quatro 44Motorboat
Racemaster Competition Boats
Storebro 420
Storebro 345
Sweden Yacht 370Sailboat
Sweden Yacht 69Sailboat
Windy 41Motorboat
X-632Sailboat
X-362Sailboat
Commercial Boats
175m High Speed AmbulancePassenger Boat
19m High Speed Passenger Boat
20m High Speed Passenger Boat
364m Surface Effect Passenger Ship
45m Surface Effect Passenger Ship
120m Hull Structural Parts HSSS Catamaran Ferry
APPENDIX
Marine Vessel
1188m Fast Attack Vessel FMV 90 E
20m SAV-Surface Auxiliary Vessels
34m Personnel TransportCoast Guard Vessel
40ft Experimental SES
40m Landsort-Class Mine Hunters
54m Mine Counter Measure Vehicles SES
74m Coastal Patrol Boats
Fishing Boats
30 GT
12 GT
10 GT
5 GT
WISEWings In Surface Effect
HOVERCRAFT
Designed specifically for the tourist and transport industries the
Pioneer Mk3 hovercraft is amphibious and comfortably seats 25
passengers plus 1-crew The air-conditioned cabin allows for
maximum visibility for all aboard The Pioneer Mk3 is robust and
dynamic in its performance
Commercial hovercraft
Mk3 AirLift Hovercraft - 1215m
Power is economicaly provided by one Deutz diesel engine of
330kW (442hp) to cruise easily at 40 knots with much higher
speeds available according to the surface conditions The hull is
manufactured from fibreglassPVC foam composite sandwich
the windows are glass and the skirt is urethane coated nylon A
Military version is available with increased payload and systems
redundancy Power for the Military version comes from two Steyr
diesel engines with a total installed power of 320kW (429hp) All
transmission electrical hydraulic and air systems are duplicated
for maximum redundancy The increased performance of the
Military version comes from the reduced engine weight of the twin
Steyr installation cf the Deutz installation
Source
httpwwwnauticexpocomprodairlift-hovercraftcommercial-hovercrafts-25251-142868html
HOVERFLIGHT
BALLISTIC amp UNIT DEFENCED
Triaxis Composites Collaboration with Institute of Aeronautics and Space in the development of Missile Nose Cone
Polymer composites is the evolution of the military defence
Thin steel was the helmet material of
WWII and remained the principal material until around the 1980rsquos
The advantages of using steel
included a simple technology for manufacture of the helmets low cost and reasonably good
impact protection However these helmets were found to provide only marginal protection
against fragments
During the Vietnam War the US Army experimented with fiber-reinforced inserts in the
helmets These inserts improved ballistic protection but at the same time added weight and
reduced the air space between the head and the helmet
By the early part of the 1980rsquos the US military had developed the first all-composite
100 fiber-reinforced helmet This development resulted in even better ballistic protection
without altering the weight of the helmet Other improvements included better head coverage and
more space for ventilation
Source
Composites Armor - A difficult but huge market
by A Brent Strong Brigham Young University
MILITARY VEHICLES
HIGH SPEED TRAIN SHINKANSEN
Advanced Composites provide lightweight solutions for railway vehicles
saving as much as 50-80 of the weight compared with traditional
components
A lower overall weight translates into less stress faster acceleration and
higher speeds as well as reduced starting and stopping inertia Today
these are important criteria in global high-speed and metropolitan
railway projects
Fire smoke and toxic fumes are key safety criteria for interior
components of railway carriages Any material selected for an interior
component must meet international fire retardant standards
for Rail Interiors and Exteriors
Ceiling Panels Stairs
Seating Vestibules
Window Panels Door Pillars
Partition WallsDiffusers
Gangway and Cabinet Panels Cabin and
Desk panels
Door Pillars Lavatory Modules (standard and
Front and Rear EndsRoof Panels
Nose Cones Under Fairings
Source
httpwwwpctaerail_compositesphp
101
SKY BUS
2009
Europe is the world leader in offshore wind with
828 wind turbines and a cumulative capacity of 2056 MW spread across 38 offshore wind farms in 9
European countries
The UK and Denmark are the current leaders with a 44 and 30 share respectively In 2009
five countries built new offshore wind farms
UK (284 MW)
Demark (230 MW)
Sweden (30 MW)
Germany (30 MW)
Norway (23 MW)
2010
Asia leads the growth in global wind power which grew 358 GW in 2010 bringing
total global capacity to 1944 GW ndash up 225 from 2009
the Global Wind Energy Council (GWEC)
Asia accounted for 19 GW of new global wind power installations driven by China which installed 165
GW
ldquoChina now has 423 GW of wind powerrdquo
ldquoThis puts China firmly on a path to reach 200 GW of installed wind power by 2020 At the same
time China has become the worldrsquos largest producer of wind energy equipmentrdquo
Source
httpwwwreinforcedplasticscomview15655asia-leads-global-wind-power-growth
httpimgdeusmcomdesignnews288288605-Sandia_Sizes_up_Wind_Turbine_Blade_Design_C_largegif
WIND ENERGY
Marine Current Turbines
Source
httpwwwsiemenscompressenpressreleasepress=enpressrelease2011solar-hydroex201111005htm
httpwwwmarineturbinescom
A commercial marine current turbine consists of
two rotors which are fixed on a structure within the
sea current The twin rotors rotate with the
movement of the tidal flow and the blades pitch
through 180 degrees to optimally track tidal current
(Press picture Marine Current Turbines)
Wave Star Energys Multi-point Absorber
CFRP COLUMN REINFORCEMENT
INDUSTRIAL TANKS
107
INDUSTRIAL PIPES
PRESSURE TANKS
109
ldquoLetrsquos Make with Compositesrdquo
WR FRP
8 Ply WR 800
8 Ply CSM 450
Glass Weight 1 kg
Composite Weight 15kgm2
CSM FRP
22 Ply CSM 450
Glass Weight 1 kg
Composite Weight 18 kgm2
MULTIAXIAL FRP
13 Ply DB 800
Glass Weight 1 kg
Composite Weight
13 kgm2
JENIS FIBERGLASS
Multiaxial
FRP
Woven Roving
FRP
Chopped Strands Mat FRP
MULTIAXIAL
FAKTA
TEBAL BUKAN BERARTI KUAT
UNSUR MATRIX (RESIN)
TIDAK ADA KEKUATAN
ldquoMore than 50 of the glass fibers used for reinforcement is
E-glassrdquo
KarakteristikKekuatan
CSM WR MAX
Kekuatan Tarik 175 MPa 250 MPa 425 MPa
CSM 142
WR 70
KEKUATAN TARIK
Properties CSM Lamination WR Lamination MAX Lamination
Fabric Weight (kgm2) 1 1 1
Composite Weight (kgm2) 18 15 13
Resin usage (kgm2) 15 1 08
Amount of Fabric 22 Ply 16 Ply 13 Ply
Thickness 15 mm 12 mm 10 mm
Tensile Strength (Mpa) 125 1796 400
Tensile Strength (Nmmsup2) 28463 30958 4576
Processing Time High Med Low
Labour Cost High Med Low
MULTIAXIAL
Total Penggunaan Resin -51
Total Berat Kapal -40
Kekuatan Bangunan Kapal +59
Efisiensi Tenaga Kerja
Waktu Pengerjaan Lebih Cepat
KEUNGGULAN MATERIAL
Resapan Resin Lebih Baik amp Merata
Lapisan Lebih Sedikit
Meningkatkan Kekuatan Kapal
KEUNGGULAN MATERIAL
TRIAXIAL
DBL series DBT series
BIAXIAL
LT series DB series
UNIDIRECTIONAL
L series T series
QUADRIAXIAL
DBLT series
JENIS MULTIAXIAL
UNIDIRECTIONAL
DCMU 900 E ndash
KHUSUS UNTUK MEMPERKUAT BENDING KAPAL
PEMASANGAN KHUSUS PADA KEEL DAN TULANGAN
JENIS MULTIAXIAL UNTUK KAPAL
TRIAXIAL
DBL 600 ndash
APLIKASI PADA INDUSTRI PENERBANGAN
PEMASANGAN KHUSUS PADA
SAMBUNGAN BADAN DAN SAYAP
PESAWAT
JENIS MULTIAXIAL UNTUK PESAWAT
QUADRAXIAL
DBLT 800 ndash
APLIKASI PADA INDUSTRI ENERGI
DITERAPKAN UNTUK KEBUTUHAN PEMBANGKIT
LISTRIK ENERGI ANGIN
MULTIAXIAL UNTUK ENERGI
INDUSTRI KIMIA OLAHRAGA AUTOMOTIF
MULTIAXIAL UNTUK INDUSTRI LAINNYA
COMPOSITES
GUNAKAN MATERIAL FIBERGLASS
YANG SUDAH DISERTIFIKASI
BKI
FIBERGLASS UNTUK PEMBANGUNAN BAKAP
PERATURAN MENTERI PERHUBUNGAN
NOMOR PM 7 TAHUN 2013
TENTANG KEWAJIBAN KLASIFIKASI BAGI KAPAL BERBENDERA INDONESIA
PADA BADAN KLASIFIKASI
BADAN SERTIFIKASI MARITIM
Biro Klasifikasi IndonesiaDet Norske Veritas Germanischer Lloyds
PERATURAN BKI
Untuk Kapal Non-Metal
2006
PERSYARATAN MINIMUM
kekuatan material yang
harus digunakan
untuk membangun
Kapal Fiberglass
PEMBESARAN
Table 21
FIBERGLASS TRIAXIS COMPOSITES
TELAH BERSERTIFIKASI BKI
Biro Klasifikasi Indonesia
65
TEKNIK MANUFAKTUR
COMPOSITES
Wet hand lay-up
1) Peletakan
Dry Reinforcement
bull Dry reinforcement dan resin (+ katalis) ditaruh pada permukaan cetakan
2) Pemasukanpenekanan resin
bull Resin ditekan untuk meng-impregnasi serat dengan menggunakan rol
3) Pengulangan proses untuk lapisan lain
bull Beberapa lapisan dapat ditambahkan secara bertahap
4) Resin curing
bull Reaksi dimulai komponen dilepaskan setelah komponen mengeras
(fully cured)
Wet hand lay-up
Manufaktur komponen dapat dikerjakan dengan menggunakan beberapa lapis komposit
dengan memperhatikan kompatibilitas material dan tahapan curing Modifikasi proses dapat
dilakukan seperti
Vacuum bagging
setelah lay-up
Glass Roving
Bulk Resin
Catalyst
3) De-molding
2) Resin Cure
bull Curing dimulai dan komponen dilepaskan setelah pengerasan selesai
bull Serat gelas resin dan katalis dimasukkan kedalam spray gun
1) Spray-up
bull Campuran disemprotkan pada permukaan cetakan
Spray-up
69
Penyemprotan bakal komponen
Komponen
dilepaskan
dari cetakan
Full dispensing
system Chopper Roving
Atomised resin
and catalyst
Spray-up
Prepreg
1) LaminateAssembly 5) De-molding
3) Resin Melts Layup Consolidates
bull Prepreg serat yang sudah diimpregnasi oleh resin+katalis dalam kondisi padat
bull Lapisan prepreg digunting sesuai bentuk yang diinginkan kemudian diletakkan pada permukaan cetakan
sesuai bentuk komponen yang diinginkan Lay-up mudah dilakukan karena sifat ldquotackynessrdquo dari prepreg
2) Applied Vacuum Pressure and Heat
bull Tekanan dan panas diberikan resin mencair terjadi konsolidasi pada komponen
4) Resin Cures
bull Temperatur dinaikkan untuk memulai curing
Prepreg
Variasi proses Autoclave
Komponen dalam
vacuum-bag
bull Campuran resin (+katalis) dan chopped glass strands diperoleh dalam bentuk premixed compound Bulk molding
Compound (BMC) dalam bentuk adonan atau Sheet molding Compound (SMC) dalam bentuk lembaran
bull Ketika panas dan tekanan diberikan oleh cetakan compound mengalir sesuai bentuk komponen yang diinginkan
1) Placement of Charge
5) De-molding3) Squeeze to final dimensions
2) Mould Closure4) Resin Cure
bull Curing dimulai komponen dilepaskan setelah terjadi pengerasan yang cukup
Compression Molding
bull Preform atau dry reinforcement dimasukkan kedalam cetakan sesuai dengan bentuk komponen yang
diinginkan
bull Resin mengalir dengan penekanan atau pem-vakuman dan meng-impregnasi preform dan
mendorongmengeluarkan udara yang ada dalam preform
1) Preform Manufacture
2) Preform Compression
5) De-molding3) Resin Injection
4) Resin Cure
bull Curing terjadi cetakan dibuka setelah terjadi pengerasan yang mencukupi
Liquid Molding (RTM VARI VARTM)
Pultrusion
bull Dry roving or fabrics ditarik melalui bak berisi
campuran resin dan katalis
bull Campuran yang basah ditarik melalui cetakan
bull Sisa resin keluar cetakan
bull Pemanasan dilakukan untuk proses curing
bull Pendinginan dilakukan untuk mempercepat siklus
produksi
Cut-off
Cooling
Die sections
Resin bath
Fibre creel
Filament Winding
bull Dry roving ditarik melalui bak berisi campuran resin dan katalis
bull Wet roving digulungkan dalam keadaan tegang kepada mandrel
bull Kontrol mekanik dari pembawa serat mengatur orientasi peletakan serat pada
mandrel
INDUSTRI COMPOSITES
AEROSPACE
HISTORY
1950 ndash Boeing
1960 ndash F14 Tomcat
1981 ndash AV-8B Harrier
Source
Low-Cost Composite Materials and Structures for Aircraft Applications
httpwwwreinforcedplasticscom
httpwwwcentennialofflightgovessayEvolution_of_TechnologycompositesTech40htm
Automotive
Composite material is used in a number of applications in the automotive
industry due to its temperature resistance rigidity and fatigue strength
The benefits of using composites include greater fuel efficiency
corrosion resistance light weight and strength Composites also provide
a low-cost way to help keep designs looking fresh
Composites are used in
- interior parts (cockpit trimming seats instrument panels)
- exterior structure (body panels openings underbody frontrear
modules)
- engine compartment and fuelmechanical area parts (axles and
suspensions fuel and exhaust systems)
- electrical and electronic components
Lamborghinis Sesto Element carbon fiber
ldquoFat men cannot run as fast as thin men but we build most of our vehicles as though dead-weight fat increased speedhellip I cannot
imagine where the delusion that weight means strength
came fromhelliprdquo mdashHenry Ford
The mix of automotive materials is changing showing a boost for FRP in helping original
equipment manufacturers meet fuel economy and emissions challenges
(Source 2011 DuPont AutomotiveSAE survey of design engineers performed by Signet Research Inc)
Source
httpwwwtoraycomcsrhighlight2009hig_001_01html
The MonoCell tub for the McLaren MP4-12C supercar is moulded as a single
piece and weighs less than 80 kg (176 lbs)
COMPOSITES IN MARINE
TRIMARAN BOAT
AMERICA NAVYINDONESIAN NAVY
Visby Class corvette
Total length is 72 meters
The beam is 1040 meters
The displacement is 600 metric tones
fully equipped the worlds largest CRP
construction
The design of the Visby aims to minimize
the optical and infrared signature above
water acoustic and hydroa coustic
signature underwater electrical potential
and magnetic signature pressure signature
radar cross section and actively emitted
signals
A stealth corvette of the YS 2000 design
has a detection range of 13km in rough
seas and 22km in calm sea without
jamming In a jammed environment the
Visby would be detected at a range of 8km
in rough sea and 11km in calm sea
The material provides high strength and
rigidity low weight good shock resistance
low radar and magnetic signature
1996
Visby is a class of stealth corvettes for the Swedish Navy
ldquoReduced 50 of a Conventional Steelrdquo
Source
Hull Construction with composite materials for ships over 100m in length 2002
Massachusetts Institute of Technology
httpwwwnaval-technologycomprojectsvisby
YACHTS
KAL YUDISTIRAMARATHON 100 ADMIRAL YACHT
LOA 3050 MWidth 6 MFuel Tank 8000 LWater Tank 3000 LIce Box 500 LAccommodation Max 35 Personnel
2 x CATERPILLAR 3412E 1200 HPMARINE DIESEL ENGINE
PC 40 ndash KRI Krait 827Department of Indonesian Navy
LOA 40 MWidth 73 MPower 190Weapon Twin Cannon Barrels
127 mm Heavy Machine GunSpeed Knot 25 KnotDisplacement 105 tonAccommodation 23 personnel
PATROL BOAT
Rigid Inflatable BoatPATROL BOAT
Yachts
36m Luxury Yacht Moonraker
36m Luxury Yacht GoldenEye
50m Luxury Yacht Casino
Royale
45m Luxury Yacht Seashaw
Boat Parts
Barovans for Seismic Sweep
Centrifugal Liftfan House for Surface Effect
Ships
Composite Boat PropellersRTM
Deckhouses for Pilot Boats
Fairing Parts for Submarines
Flybridges for Motor yachts
Light Weight Gangway
MTB Launcher Mock-up
Pleasure Boats
12m Sailboat
12m Sail-Catamaranone-off
Canoes
Dragonfly 1000Catamaran Sailboat
Fantasy 37Sailboat
Farr 60Luxury Sailboat
EurodingyOlympic Dingy Class for
Woman
Hydrolift F23 Racing Boats
Kajacs
Najad 42Sailboat
Najad 520Sailboat
Najad 441Sailboat
Najad 391Sailboat
Nordwest 900Motorboat
Nordwest 1100Motorboat
Quatro 44Motorboat
Racemaster Competition Boats
Storebro 420
Storebro 345
Sweden Yacht 370Sailboat
Sweden Yacht 69Sailboat
Windy 41Motorboat
X-632Sailboat
X-362Sailboat
Commercial Boats
175m High Speed AmbulancePassenger Boat
19m High Speed Passenger Boat
20m High Speed Passenger Boat
364m Surface Effect Passenger Ship
45m Surface Effect Passenger Ship
120m Hull Structural Parts HSSS Catamaran Ferry
APPENDIX
Marine Vessel
1188m Fast Attack Vessel FMV 90 E
20m SAV-Surface Auxiliary Vessels
34m Personnel TransportCoast Guard Vessel
40ft Experimental SES
40m Landsort-Class Mine Hunters
54m Mine Counter Measure Vehicles SES
74m Coastal Patrol Boats
Fishing Boats
30 GT
12 GT
10 GT
5 GT
WISEWings In Surface Effect
HOVERCRAFT
Designed specifically for the tourist and transport industries the
Pioneer Mk3 hovercraft is amphibious and comfortably seats 25
passengers plus 1-crew The air-conditioned cabin allows for
maximum visibility for all aboard The Pioneer Mk3 is robust and
dynamic in its performance
Commercial hovercraft
Mk3 AirLift Hovercraft - 1215m
Power is economicaly provided by one Deutz diesel engine of
330kW (442hp) to cruise easily at 40 knots with much higher
speeds available according to the surface conditions The hull is
manufactured from fibreglassPVC foam composite sandwich
the windows are glass and the skirt is urethane coated nylon A
Military version is available with increased payload and systems
redundancy Power for the Military version comes from two Steyr
diesel engines with a total installed power of 320kW (429hp) All
transmission electrical hydraulic and air systems are duplicated
for maximum redundancy The increased performance of the
Military version comes from the reduced engine weight of the twin
Steyr installation cf the Deutz installation
Source
httpwwwnauticexpocomprodairlift-hovercraftcommercial-hovercrafts-25251-142868html
HOVERFLIGHT
BALLISTIC amp UNIT DEFENCED
Triaxis Composites Collaboration with Institute of Aeronautics and Space in the development of Missile Nose Cone
Polymer composites is the evolution of the military defence
Thin steel was the helmet material of
WWII and remained the principal material until around the 1980rsquos
The advantages of using steel
included a simple technology for manufacture of the helmets low cost and reasonably good
impact protection However these helmets were found to provide only marginal protection
against fragments
During the Vietnam War the US Army experimented with fiber-reinforced inserts in the
helmets These inserts improved ballistic protection but at the same time added weight and
reduced the air space between the head and the helmet
By the early part of the 1980rsquos the US military had developed the first all-composite
100 fiber-reinforced helmet This development resulted in even better ballistic protection
without altering the weight of the helmet Other improvements included better head coverage and
more space for ventilation
Source
Composites Armor - A difficult but huge market
by A Brent Strong Brigham Young University
MILITARY VEHICLES
HIGH SPEED TRAIN SHINKANSEN
Advanced Composites provide lightweight solutions for railway vehicles
saving as much as 50-80 of the weight compared with traditional
components
A lower overall weight translates into less stress faster acceleration and
higher speeds as well as reduced starting and stopping inertia Today
these are important criteria in global high-speed and metropolitan
railway projects
Fire smoke and toxic fumes are key safety criteria for interior
components of railway carriages Any material selected for an interior
component must meet international fire retardant standards
for Rail Interiors and Exteriors
Ceiling Panels Stairs
Seating Vestibules
Window Panels Door Pillars
Partition WallsDiffusers
Gangway and Cabinet Panels Cabin and
Desk panels
Door Pillars Lavatory Modules (standard and
Front and Rear EndsRoof Panels
Nose Cones Under Fairings
Source
httpwwwpctaerail_compositesphp
101
SKY BUS
2009
Europe is the world leader in offshore wind with
828 wind turbines and a cumulative capacity of 2056 MW spread across 38 offshore wind farms in 9
European countries
The UK and Denmark are the current leaders with a 44 and 30 share respectively In 2009
five countries built new offshore wind farms
UK (284 MW)
Demark (230 MW)
Sweden (30 MW)
Germany (30 MW)
Norway (23 MW)
2010
Asia leads the growth in global wind power which grew 358 GW in 2010 bringing
total global capacity to 1944 GW ndash up 225 from 2009
the Global Wind Energy Council (GWEC)
Asia accounted for 19 GW of new global wind power installations driven by China which installed 165
GW
ldquoChina now has 423 GW of wind powerrdquo
ldquoThis puts China firmly on a path to reach 200 GW of installed wind power by 2020 At the same
time China has become the worldrsquos largest producer of wind energy equipmentrdquo
Source
httpwwwreinforcedplasticscomview15655asia-leads-global-wind-power-growth
httpimgdeusmcomdesignnews288288605-Sandia_Sizes_up_Wind_Turbine_Blade_Design_C_largegif
WIND ENERGY
Marine Current Turbines
Source
httpwwwsiemenscompressenpressreleasepress=enpressrelease2011solar-hydroex201111005htm
httpwwwmarineturbinescom
A commercial marine current turbine consists of
two rotors which are fixed on a structure within the
sea current The twin rotors rotate with the
movement of the tidal flow and the blades pitch
through 180 degrees to optimally track tidal current
(Press picture Marine Current Turbines)
Wave Star Energys Multi-point Absorber
CFRP COLUMN REINFORCEMENT
INDUSTRIAL TANKS
107
INDUSTRIAL PIPES
PRESSURE TANKS
109
ldquoLetrsquos Make with Compositesrdquo
Multiaxial
FRP
Woven Roving
FRP
Chopped Strands Mat FRP
MULTIAXIAL
FAKTA
TEBAL BUKAN BERARTI KUAT
UNSUR MATRIX (RESIN)
TIDAK ADA KEKUATAN
ldquoMore than 50 of the glass fibers used for reinforcement is
E-glassrdquo
KarakteristikKekuatan
CSM WR MAX
Kekuatan Tarik 175 MPa 250 MPa 425 MPa
CSM 142
WR 70
KEKUATAN TARIK
Properties CSM Lamination WR Lamination MAX Lamination
Fabric Weight (kgm2) 1 1 1
Composite Weight (kgm2) 18 15 13
Resin usage (kgm2) 15 1 08
Amount of Fabric 22 Ply 16 Ply 13 Ply
Thickness 15 mm 12 mm 10 mm
Tensile Strength (Mpa) 125 1796 400
Tensile Strength (Nmmsup2) 28463 30958 4576
Processing Time High Med Low
Labour Cost High Med Low
MULTIAXIAL
Total Penggunaan Resin -51
Total Berat Kapal -40
Kekuatan Bangunan Kapal +59
Efisiensi Tenaga Kerja
Waktu Pengerjaan Lebih Cepat
KEUNGGULAN MATERIAL
Resapan Resin Lebih Baik amp Merata
Lapisan Lebih Sedikit
Meningkatkan Kekuatan Kapal
KEUNGGULAN MATERIAL
TRIAXIAL
DBL series DBT series
BIAXIAL
LT series DB series
UNIDIRECTIONAL
L series T series
QUADRIAXIAL
DBLT series
JENIS MULTIAXIAL
UNIDIRECTIONAL
DCMU 900 E ndash
KHUSUS UNTUK MEMPERKUAT BENDING KAPAL
PEMASANGAN KHUSUS PADA KEEL DAN TULANGAN
JENIS MULTIAXIAL UNTUK KAPAL
TRIAXIAL
DBL 600 ndash
APLIKASI PADA INDUSTRI PENERBANGAN
PEMASANGAN KHUSUS PADA
SAMBUNGAN BADAN DAN SAYAP
PESAWAT
JENIS MULTIAXIAL UNTUK PESAWAT
QUADRAXIAL
DBLT 800 ndash
APLIKASI PADA INDUSTRI ENERGI
DITERAPKAN UNTUK KEBUTUHAN PEMBANGKIT
LISTRIK ENERGI ANGIN
MULTIAXIAL UNTUK ENERGI
INDUSTRI KIMIA OLAHRAGA AUTOMOTIF
MULTIAXIAL UNTUK INDUSTRI LAINNYA
COMPOSITES
GUNAKAN MATERIAL FIBERGLASS
YANG SUDAH DISERTIFIKASI
BKI
FIBERGLASS UNTUK PEMBANGUNAN BAKAP
PERATURAN MENTERI PERHUBUNGAN
NOMOR PM 7 TAHUN 2013
TENTANG KEWAJIBAN KLASIFIKASI BAGI KAPAL BERBENDERA INDONESIA
PADA BADAN KLASIFIKASI
BADAN SERTIFIKASI MARITIM
Biro Klasifikasi IndonesiaDet Norske Veritas Germanischer Lloyds
PERATURAN BKI
Untuk Kapal Non-Metal
2006
PERSYARATAN MINIMUM
kekuatan material yang
harus digunakan
untuk membangun
Kapal Fiberglass
PEMBESARAN
Table 21
FIBERGLASS TRIAXIS COMPOSITES
TELAH BERSERTIFIKASI BKI
Biro Klasifikasi Indonesia
65
TEKNIK MANUFAKTUR
COMPOSITES
Wet hand lay-up
1) Peletakan
Dry Reinforcement
bull Dry reinforcement dan resin (+ katalis) ditaruh pada permukaan cetakan
2) Pemasukanpenekanan resin
bull Resin ditekan untuk meng-impregnasi serat dengan menggunakan rol
3) Pengulangan proses untuk lapisan lain
bull Beberapa lapisan dapat ditambahkan secara bertahap
4) Resin curing
bull Reaksi dimulai komponen dilepaskan setelah komponen mengeras
(fully cured)
Wet hand lay-up
Manufaktur komponen dapat dikerjakan dengan menggunakan beberapa lapis komposit
dengan memperhatikan kompatibilitas material dan tahapan curing Modifikasi proses dapat
dilakukan seperti
Vacuum bagging
setelah lay-up
Glass Roving
Bulk Resin
Catalyst
3) De-molding
2) Resin Cure
bull Curing dimulai dan komponen dilepaskan setelah pengerasan selesai
bull Serat gelas resin dan katalis dimasukkan kedalam spray gun
1) Spray-up
bull Campuran disemprotkan pada permukaan cetakan
Spray-up
69
Penyemprotan bakal komponen
Komponen
dilepaskan
dari cetakan
Full dispensing
system Chopper Roving
Atomised resin
and catalyst
Spray-up
Prepreg
1) LaminateAssembly 5) De-molding
3) Resin Melts Layup Consolidates
bull Prepreg serat yang sudah diimpregnasi oleh resin+katalis dalam kondisi padat
bull Lapisan prepreg digunting sesuai bentuk yang diinginkan kemudian diletakkan pada permukaan cetakan
sesuai bentuk komponen yang diinginkan Lay-up mudah dilakukan karena sifat ldquotackynessrdquo dari prepreg
2) Applied Vacuum Pressure and Heat
bull Tekanan dan panas diberikan resin mencair terjadi konsolidasi pada komponen
4) Resin Cures
bull Temperatur dinaikkan untuk memulai curing
Prepreg
Variasi proses Autoclave
Komponen dalam
vacuum-bag
bull Campuran resin (+katalis) dan chopped glass strands diperoleh dalam bentuk premixed compound Bulk molding
Compound (BMC) dalam bentuk adonan atau Sheet molding Compound (SMC) dalam bentuk lembaran
bull Ketika panas dan tekanan diberikan oleh cetakan compound mengalir sesuai bentuk komponen yang diinginkan
1) Placement of Charge
5) De-molding3) Squeeze to final dimensions
2) Mould Closure4) Resin Cure
bull Curing dimulai komponen dilepaskan setelah terjadi pengerasan yang cukup
Compression Molding
bull Preform atau dry reinforcement dimasukkan kedalam cetakan sesuai dengan bentuk komponen yang
diinginkan
bull Resin mengalir dengan penekanan atau pem-vakuman dan meng-impregnasi preform dan
mendorongmengeluarkan udara yang ada dalam preform
1) Preform Manufacture
2) Preform Compression
5) De-molding3) Resin Injection
4) Resin Cure
bull Curing terjadi cetakan dibuka setelah terjadi pengerasan yang mencukupi
Liquid Molding (RTM VARI VARTM)
Pultrusion
bull Dry roving or fabrics ditarik melalui bak berisi
campuran resin dan katalis
bull Campuran yang basah ditarik melalui cetakan
bull Sisa resin keluar cetakan
bull Pemanasan dilakukan untuk proses curing
bull Pendinginan dilakukan untuk mempercepat siklus
produksi
Cut-off
Cooling
Die sections
Resin bath
Fibre creel
Filament Winding
bull Dry roving ditarik melalui bak berisi campuran resin dan katalis
bull Wet roving digulungkan dalam keadaan tegang kepada mandrel
bull Kontrol mekanik dari pembawa serat mengatur orientasi peletakan serat pada
mandrel
INDUSTRI COMPOSITES
AEROSPACE
HISTORY
1950 ndash Boeing
1960 ndash F14 Tomcat
1981 ndash AV-8B Harrier
Source
Low-Cost Composite Materials and Structures for Aircraft Applications
httpwwwreinforcedplasticscom
httpwwwcentennialofflightgovessayEvolution_of_TechnologycompositesTech40htm
Automotive
Composite material is used in a number of applications in the automotive
industry due to its temperature resistance rigidity and fatigue strength
The benefits of using composites include greater fuel efficiency
corrosion resistance light weight and strength Composites also provide
a low-cost way to help keep designs looking fresh
Composites are used in
- interior parts (cockpit trimming seats instrument panels)
- exterior structure (body panels openings underbody frontrear
modules)
- engine compartment and fuelmechanical area parts (axles and
suspensions fuel and exhaust systems)
- electrical and electronic components
Lamborghinis Sesto Element carbon fiber
ldquoFat men cannot run as fast as thin men but we build most of our vehicles as though dead-weight fat increased speedhellip I cannot
imagine where the delusion that weight means strength
came fromhelliprdquo mdashHenry Ford
The mix of automotive materials is changing showing a boost for FRP in helping original
equipment manufacturers meet fuel economy and emissions challenges
(Source 2011 DuPont AutomotiveSAE survey of design engineers performed by Signet Research Inc)
Source
httpwwwtoraycomcsrhighlight2009hig_001_01html
The MonoCell tub for the McLaren MP4-12C supercar is moulded as a single
piece and weighs less than 80 kg (176 lbs)
COMPOSITES IN MARINE
TRIMARAN BOAT
AMERICA NAVYINDONESIAN NAVY
Visby Class corvette
Total length is 72 meters
The beam is 1040 meters
The displacement is 600 metric tones
fully equipped the worlds largest CRP
construction
The design of the Visby aims to minimize
the optical and infrared signature above
water acoustic and hydroa coustic
signature underwater electrical potential
and magnetic signature pressure signature
radar cross section and actively emitted
signals
A stealth corvette of the YS 2000 design
has a detection range of 13km in rough
seas and 22km in calm sea without
jamming In a jammed environment the
Visby would be detected at a range of 8km
in rough sea and 11km in calm sea
The material provides high strength and
rigidity low weight good shock resistance
low radar and magnetic signature
1996
Visby is a class of stealth corvettes for the Swedish Navy
ldquoReduced 50 of a Conventional Steelrdquo
Source
Hull Construction with composite materials for ships over 100m in length 2002
Massachusetts Institute of Technology
httpwwwnaval-technologycomprojectsvisby
YACHTS
KAL YUDISTIRAMARATHON 100 ADMIRAL YACHT
LOA 3050 MWidth 6 MFuel Tank 8000 LWater Tank 3000 LIce Box 500 LAccommodation Max 35 Personnel
2 x CATERPILLAR 3412E 1200 HPMARINE DIESEL ENGINE
PC 40 ndash KRI Krait 827Department of Indonesian Navy
LOA 40 MWidth 73 MPower 190Weapon Twin Cannon Barrels
127 mm Heavy Machine GunSpeed Knot 25 KnotDisplacement 105 tonAccommodation 23 personnel
PATROL BOAT
Rigid Inflatable BoatPATROL BOAT
Yachts
36m Luxury Yacht Moonraker
36m Luxury Yacht GoldenEye
50m Luxury Yacht Casino
Royale
45m Luxury Yacht Seashaw
Boat Parts
Barovans for Seismic Sweep
Centrifugal Liftfan House for Surface Effect
Ships
Composite Boat PropellersRTM
Deckhouses for Pilot Boats
Fairing Parts for Submarines
Flybridges for Motor yachts
Light Weight Gangway
MTB Launcher Mock-up
Pleasure Boats
12m Sailboat
12m Sail-Catamaranone-off
Canoes
Dragonfly 1000Catamaran Sailboat
Fantasy 37Sailboat
Farr 60Luxury Sailboat
EurodingyOlympic Dingy Class for
Woman
Hydrolift F23 Racing Boats
Kajacs
Najad 42Sailboat
Najad 520Sailboat
Najad 441Sailboat
Najad 391Sailboat
Nordwest 900Motorboat
Nordwest 1100Motorboat
Quatro 44Motorboat
Racemaster Competition Boats
Storebro 420
Storebro 345
Sweden Yacht 370Sailboat
Sweden Yacht 69Sailboat
Windy 41Motorboat
X-632Sailboat
X-362Sailboat
Commercial Boats
175m High Speed AmbulancePassenger Boat
19m High Speed Passenger Boat
20m High Speed Passenger Boat
364m Surface Effect Passenger Ship
45m Surface Effect Passenger Ship
120m Hull Structural Parts HSSS Catamaran Ferry
APPENDIX
Marine Vessel
1188m Fast Attack Vessel FMV 90 E
20m SAV-Surface Auxiliary Vessels
34m Personnel TransportCoast Guard Vessel
40ft Experimental SES
40m Landsort-Class Mine Hunters
54m Mine Counter Measure Vehicles SES
74m Coastal Patrol Boats
Fishing Boats
30 GT
12 GT
10 GT
5 GT
WISEWings In Surface Effect
HOVERCRAFT
Designed specifically for the tourist and transport industries the
Pioneer Mk3 hovercraft is amphibious and comfortably seats 25
passengers plus 1-crew The air-conditioned cabin allows for
maximum visibility for all aboard The Pioneer Mk3 is robust and
dynamic in its performance
Commercial hovercraft
Mk3 AirLift Hovercraft - 1215m
Power is economicaly provided by one Deutz diesel engine of
330kW (442hp) to cruise easily at 40 knots with much higher
speeds available according to the surface conditions The hull is
manufactured from fibreglassPVC foam composite sandwich
the windows are glass and the skirt is urethane coated nylon A
Military version is available with increased payload and systems
redundancy Power for the Military version comes from two Steyr
diesel engines with a total installed power of 320kW (429hp) All
transmission electrical hydraulic and air systems are duplicated
for maximum redundancy The increased performance of the
Military version comes from the reduced engine weight of the twin
Steyr installation cf the Deutz installation
Source
httpwwwnauticexpocomprodairlift-hovercraftcommercial-hovercrafts-25251-142868html
HOVERFLIGHT
BALLISTIC amp UNIT DEFENCED
Triaxis Composites Collaboration with Institute of Aeronautics and Space in the development of Missile Nose Cone
Polymer composites is the evolution of the military defence
Thin steel was the helmet material of
WWII and remained the principal material until around the 1980rsquos
The advantages of using steel
included a simple technology for manufacture of the helmets low cost and reasonably good
impact protection However these helmets were found to provide only marginal protection
against fragments
During the Vietnam War the US Army experimented with fiber-reinforced inserts in the
helmets These inserts improved ballistic protection but at the same time added weight and
reduced the air space between the head and the helmet
By the early part of the 1980rsquos the US military had developed the first all-composite
100 fiber-reinforced helmet This development resulted in even better ballistic protection
without altering the weight of the helmet Other improvements included better head coverage and
more space for ventilation
Source
Composites Armor - A difficult but huge market
by A Brent Strong Brigham Young University
MILITARY VEHICLES
HIGH SPEED TRAIN SHINKANSEN
Advanced Composites provide lightweight solutions for railway vehicles
saving as much as 50-80 of the weight compared with traditional
components
A lower overall weight translates into less stress faster acceleration and
higher speeds as well as reduced starting and stopping inertia Today
these are important criteria in global high-speed and metropolitan
railway projects
Fire smoke and toxic fumes are key safety criteria for interior
components of railway carriages Any material selected for an interior
component must meet international fire retardant standards
for Rail Interiors and Exteriors
Ceiling Panels Stairs
Seating Vestibules
Window Panels Door Pillars
Partition WallsDiffusers
Gangway and Cabinet Panels Cabin and
Desk panels
Door Pillars Lavatory Modules (standard and
Front and Rear EndsRoof Panels
Nose Cones Under Fairings
Source
httpwwwpctaerail_compositesphp
101
SKY BUS
2009
Europe is the world leader in offshore wind with
828 wind turbines and a cumulative capacity of 2056 MW spread across 38 offshore wind farms in 9
European countries
The UK and Denmark are the current leaders with a 44 and 30 share respectively In 2009
five countries built new offshore wind farms
UK (284 MW)
Demark (230 MW)
Sweden (30 MW)
Germany (30 MW)
Norway (23 MW)
2010
Asia leads the growth in global wind power which grew 358 GW in 2010 bringing
total global capacity to 1944 GW ndash up 225 from 2009
the Global Wind Energy Council (GWEC)
Asia accounted for 19 GW of new global wind power installations driven by China which installed 165
GW
ldquoChina now has 423 GW of wind powerrdquo
ldquoThis puts China firmly on a path to reach 200 GW of installed wind power by 2020 At the same
time China has become the worldrsquos largest producer of wind energy equipmentrdquo
Source
httpwwwreinforcedplasticscomview15655asia-leads-global-wind-power-growth
httpimgdeusmcomdesignnews288288605-Sandia_Sizes_up_Wind_Turbine_Blade_Design_C_largegif
WIND ENERGY
Marine Current Turbines
Source
httpwwwsiemenscompressenpressreleasepress=enpressrelease2011solar-hydroex201111005htm
httpwwwmarineturbinescom
A commercial marine current turbine consists of
two rotors which are fixed on a structure within the
sea current The twin rotors rotate with the
movement of the tidal flow and the blades pitch
through 180 degrees to optimally track tidal current
(Press picture Marine Current Turbines)
Wave Star Energys Multi-point Absorber
CFRP COLUMN REINFORCEMENT
INDUSTRIAL TANKS
107
INDUSTRIAL PIPES
PRESSURE TANKS
109
ldquoLetrsquos Make with Compositesrdquo
KarakteristikKekuatan
CSM WR MAX
Kekuatan Tarik 175 MPa 250 MPa 425 MPa
CSM 142
WR 70
KEKUATAN TARIK
Properties CSM Lamination WR Lamination MAX Lamination
Fabric Weight (kgm2) 1 1 1
Composite Weight (kgm2) 18 15 13
Resin usage (kgm2) 15 1 08
Amount of Fabric 22 Ply 16 Ply 13 Ply
Thickness 15 mm 12 mm 10 mm
Tensile Strength (Mpa) 125 1796 400
Tensile Strength (Nmmsup2) 28463 30958 4576
Processing Time High Med Low
Labour Cost High Med Low
MULTIAXIAL
Total Penggunaan Resin -51
Total Berat Kapal -40
Kekuatan Bangunan Kapal +59
Efisiensi Tenaga Kerja
Waktu Pengerjaan Lebih Cepat
KEUNGGULAN MATERIAL
Resapan Resin Lebih Baik amp Merata
Lapisan Lebih Sedikit
Meningkatkan Kekuatan Kapal
KEUNGGULAN MATERIAL
TRIAXIAL
DBL series DBT series
BIAXIAL
LT series DB series
UNIDIRECTIONAL
L series T series
QUADRIAXIAL
DBLT series
JENIS MULTIAXIAL
UNIDIRECTIONAL
DCMU 900 E ndash
KHUSUS UNTUK MEMPERKUAT BENDING KAPAL
PEMASANGAN KHUSUS PADA KEEL DAN TULANGAN
JENIS MULTIAXIAL UNTUK KAPAL
TRIAXIAL
DBL 600 ndash
APLIKASI PADA INDUSTRI PENERBANGAN
PEMASANGAN KHUSUS PADA
SAMBUNGAN BADAN DAN SAYAP
PESAWAT
JENIS MULTIAXIAL UNTUK PESAWAT
QUADRAXIAL
DBLT 800 ndash
APLIKASI PADA INDUSTRI ENERGI
DITERAPKAN UNTUK KEBUTUHAN PEMBANGKIT
LISTRIK ENERGI ANGIN
MULTIAXIAL UNTUK ENERGI
INDUSTRI KIMIA OLAHRAGA AUTOMOTIF
MULTIAXIAL UNTUK INDUSTRI LAINNYA
COMPOSITES
GUNAKAN MATERIAL FIBERGLASS
YANG SUDAH DISERTIFIKASI
BKI
FIBERGLASS UNTUK PEMBANGUNAN BAKAP
PERATURAN MENTERI PERHUBUNGAN
NOMOR PM 7 TAHUN 2013
TENTANG KEWAJIBAN KLASIFIKASI BAGI KAPAL BERBENDERA INDONESIA
PADA BADAN KLASIFIKASI
BADAN SERTIFIKASI MARITIM
Biro Klasifikasi IndonesiaDet Norske Veritas Germanischer Lloyds
PERATURAN BKI
Untuk Kapal Non-Metal
2006
PERSYARATAN MINIMUM
kekuatan material yang
harus digunakan
untuk membangun
Kapal Fiberglass
PEMBESARAN
Table 21
FIBERGLASS TRIAXIS COMPOSITES
TELAH BERSERTIFIKASI BKI
Biro Klasifikasi Indonesia
65
TEKNIK MANUFAKTUR
COMPOSITES
Wet hand lay-up
1) Peletakan
Dry Reinforcement
bull Dry reinforcement dan resin (+ katalis) ditaruh pada permukaan cetakan
2) Pemasukanpenekanan resin
bull Resin ditekan untuk meng-impregnasi serat dengan menggunakan rol
3) Pengulangan proses untuk lapisan lain
bull Beberapa lapisan dapat ditambahkan secara bertahap
4) Resin curing
bull Reaksi dimulai komponen dilepaskan setelah komponen mengeras
(fully cured)
Wet hand lay-up
Manufaktur komponen dapat dikerjakan dengan menggunakan beberapa lapis komposit
dengan memperhatikan kompatibilitas material dan tahapan curing Modifikasi proses dapat
dilakukan seperti
Vacuum bagging
setelah lay-up
Glass Roving
Bulk Resin
Catalyst
3) De-molding
2) Resin Cure
bull Curing dimulai dan komponen dilepaskan setelah pengerasan selesai
bull Serat gelas resin dan katalis dimasukkan kedalam spray gun
1) Spray-up
bull Campuran disemprotkan pada permukaan cetakan
Spray-up
69
Penyemprotan bakal komponen
Komponen
dilepaskan
dari cetakan
Full dispensing
system Chopper Roving
Atomised resin
and catalyst
Spray-up
Prepreg
1) LaminateAssembly 5) De-molding
3) Resin Melts Layup Consolidates
bull Prepreg serat yang sudah diimpregnasi oleh resin+katalis dalam kondisi padat
bull Lapisan prepreg digunting sesuai bentuk yang diinginkan kemudian diletakkan pada permukaan cetakan
sesuai bentuk komponen yang diinginkan Lay-up mudah dilakukan karena sifat ldquotackynessrdquo dari prepreg
2) Applied Vacuum Pressure and Heat
bull Tekanan dan panas diberikan resin mencair terjadi konsolidasi pada komponen
4) Resin Cures
bull Temperatur dinaikkan untuk memulai curing
Prepreg
Variasi proses Autoclave
Komponen dalam
vacuum-bag
bull Campuran resin (+katalis) dan chopped glass strands diperoleh dalam bentuk premixed compound Bulk molding
Compound (BMC) dalam bentuk adonan atau Sheet molding Compound (SMC) dalam bentuk lembaran
bull Ketika panas dan tekanan diberikan oleh cetakan compound mengalir sesuai bentuk komponen yang diinginkan
1) Placement of Charge
5) De-molding3) Squeeze to final dimensions
2) Mould Closure4) Resin Cure
bull Curing dimulai komponen dilepaskan setelah terjadi pengerasan yang cukup
Compression Molding
bull Preform atau dry reinforcement dimasukkan kedalam cetakan sesuai dengan bentuk komponen yang
diinginkan
bull Resin mengalir dengan penekanan atau pem-vakuman dan meng-impregnasi preform dan
mendorongmengeluarkan udara yang ada dalam preform
1) Preform Manufacture
2) Preform Compression
5) De-molding3) Resin Injection
4) Resin Cure
bull Curing terjadi cetakan dibuka setelah terjadi pengerasan yang mencukupi
Liquid Molding (RTM VARI VARTM)
Pultrusion
bull Dry roving or fabrics ditarik melalui bak berisi
campuran resin dan katalis
bull Campuran yang basah ditarik melalui cetakan
bull Sisa resin keluar cetakan
bull Pemanasan dilakukan untuk proses curing
bull Pendinginan dilakukan untuk mempercepat siklus
produksi
Cut-off
Cooling
Die sections
Resin bath
Fibre creel
Filament Winding
bull Dry roving ditarik melalui bak berisi campuran resin dan katalis
bull Wet roving digulungkan dalam keadaan tegang kepada mandrel
bull Kontrol mekanik dari pembawa serat mengatur orientasi peletakan serat pada
mandrel
INDUSTRI COMPOSITES
AEROSPACE
HISTORY
1950 ndash Boeing
1960 ndash F14 Tomcat
1981 ndash AV-8B Harrier
Source
Low-Cost Composite Materials and Structures for Aircraft Applications
httpwwwreinforcedplasticscom
httpwwwcentennialofflightgovessayEvolution_of_TechnologycompositesTech40htm
Automotive
Composite material is used in a number of applications in the automotive
industry due to its temperature resistance rigidity and fatigue strength
The benefits of using composites include greater fuel efficiency
corrosion resistance light weight and strength Composites also provide
a low-cost way to help keep designs looking fresh
Composites are used in
- interior parts (cockpit trimming seats instrument panels)
- exterior structure (body panels openings underbody frontrear
modules)
- engine compartment and fuelmechanical area parts (axles and
suspensions fuel and exhaust systems)
- electrical and electronic components
Lamborghinis Sesto Element carbon fiber
ldquoFat men cannot run as fast as thin men but we build most of our vehicles as though dead-weight fat increased speedhellip I cannot
imagine where the delusion that weight means strength
came fromhelliprdquo mdashHenry Ford
The mix of automotive materials is changing showing a boost for FRP in helping original
equipment manufacturers meet fuel economy and emissions challenges
(Source 2011 DuPont AutomotiveSAE survey of design engineers performed by Signet Research Inc)
Source
httpwwwtoraycomcsrhighlight2009hig_001_01html
The MonoCell tub for the McLaren MP4-12C supercar is moulded as a single
piece and weighs less than 80 kg (176 lbs)
COMPOSITES IN MARINE
TRIMARAN BOAT
AMERICA NAVYINDONESIAN NAVY
Visby Class corvette
Total length is 72 meters
The beam is 1040 meters
The displacement is 600 metric tones
fully equipped the worlds largest CRP
construction
The design of the Visby aims to minimize
the optical and infrared signature above
water acoustic and hydroa coustic
signature underwater electrical potential
and magnetic signature pressure signature
radar cross section and actively emitted
signals
A stealth corvette of the YS 2000 design
has a detection range of 13km in rough
seas and 22km in calm sea without
jamming In a jammed environment the
Visby would be detected at a range of 8km
in rough sea and 11km in calm sea
The material provides high strength and
rigidity low weight good shock resistance
low radar and magnetic signature
1996
Visby is a class of stealth corvettes for the Swedish Navy
ldquoReduced 50 of a Conventional Steelrdquo
Source
Hull Construction with composite materials for ships over 100m in length 2002
Massachusetts Institute of Technology
httpwwwnaval-technologycomprojectsvisby
YACHTS
KAL YUDISTIRAMARATHON 100 ADMIRAL YACHT
LOA 3050 MWidth 6 MFuel Tank 8000 LWater Tank 3000 LIce Box 500 LAccommodation Max 35 Personnel
2 x CATERPILLAR 3412E 1200 HPMARINE DIESEL ENGINE
PC 40 ndash KRI Krait 827Department of Indonesian Navy
LOA 40 MWidth 73 MPower 190Weapon Twin Cannon Barrels
127 mm Heavy Machine GunSpeed Knot 25 KnotDisplacement 105 tonAccommodation 23 personnel
PATROL BOAT
Rigid Inflatable BoatPATROL BOAT
Yachts
36m Luxury Yacht Moonraker
36m Luxury Yacht GoldenEye
50m Luxury Yacht Casino
Royale
45m Luxury Yacht Seashaw
Boat Parts
Barovans for Seismic Sweep
Centrifugal Liftfan House for Surface Effect
Ships
Composite Boat PropellersRTM
Deckhouses for Pilot Boats
Fairing Parts for Submarines
Flybridges for Motor yachts
Light Weight Gangway
MTB Launcher Mock-up
Pleasure Boats
12m Sailboat
12m Sail-Catamaranone-off
Canoes
Dragonfly 1000Catamaran Sailboat
Fantasy 37Sailboat
Farr 60Luxury Sailboat
EurodingyOlympic Dingy Class for
Woman
Hydrolift F23 Racing Boats
Kajacs
Najad 42Sailboat
Najad 520Sailboat
Najad 441Sailboat
Najad 391Sailboat
Nordwest 900Motorboat
Nordwest 1100Motorboat
Quatro 44Motorboat
Racemaster Competition Boats
Storebro 420
Storebro 345
Sweden Yacht 370Sailboat
Sweden Yacht 69Sailboat
Windy 41Motorboat
X-632Sailboat
X-362Sailboat
Commercial Boats
175m High Speed AmbulancePassenger Boat
19m High Speed Passenger Boat
20m High Speed Passenger Boat
364m Surface Effect Passenger Ship
45m Surface Effect Passenger Ship
120m Hull Structural Parts HSSS Catamaran Ferry
APPENDIX
Marine Vessel
1188m Fast Attack Vessel FMV 90 E
20m SAV-Surface Auxiliary Vessels
34m Personnel TransportCoast Guard Vessel
40ft Experimental SES
40m Landsort-Class Mine Hunters
54m Mine Counter Measure Vehicles SES
74m Coastal Patrol Boats
Fishing Boats
30 GT
12 GT
10 GT
5 GT
WISEWings In Surface Effect
HOVERCRAFT
Designed specifically for the tourist and transport industries the
Pioneer Mk3 hovercraft is amphibious and comfortably seats 25
passengers plus 1-crew The air-conditioned cabin allows for
maximum visibility for all aboard The Pioneer Mk3 is robust and
dynamic in its performance
Commercial hovercraft
Mk3 AirLift Hovercraft - 1215m
Power is economicaly provided by one Deutz diesel engine of
330kW (442hp) to cruise easily at 40 knots with much higher
speeds available according to the surface conditions The hull is
manufactured from fibreglassPVC foam composite sandwich
the windows are glass and the skirt is urethane coated nylon A
Military version is available with increased payload and systems
redundancy Power for the Military version comes from two Steyr
diesel engines with a total installed power of 320kW (429hp) All
transmission electrical hydraulic and air systems are duplicated
for maximum redundancy The increased performance of the
Military version comes from the reduced engine weight of the twin
Steyr installation cf the Deutz installation
Source
httpwwwnauticexpocomprodairlift-hovercraftcommercial-hovercrafts-25251-142868html
HOVERFLIGHT
BALLISTIC amp UNIT DEFENCED
Triaxis Composites Collaboration with Institute of Aeronautics and Space in the development of Missile Nose Cone
Polymer composites is the evolution of the military defence
Thin steel was the helmet material of
WWII and remained the principal material until around the 1980rsquos
The advantages of using steel
included a simple technology for manufacture of the helmets low cost and reasonably good
impact protection However these helmets were found to provide only marginal protection
against fragments
During the Vietnam War the US Army experimented with fiber-reinforced inserts in the
helmets These inserts improved ballistic protection but at the same time added weight and
reduced the air space between the head and the helmet
By the early part of the 1980rsquos the US military had developed the first all-composite
100 fiber-reinforced helmet This development resulted in even better ballistic protection
without altering the weight of the helmet Other improvements included better head coverage and
more space for ventilation
Source
Composites Armor - A difficult but huge market
by A Brent Strong Brigham Young University
MILITARY VEHICLES
HIGH SPEED TRAIN SHINKANSEN
Advanced Composites provide lightweight solutions for railway vehicles
saving as much as 50-80 of the weight compared with traditional
components
A lower overall weight translates into less stress faster acceleration and
higher speeds as well as reduced starting and stopping inertia Today
these are important criteria in global high-speed and metropolitan
railway projects
Fire smoke and toxic fumes are key safety criteria for interior
components of railway carriages Any material selected for an interior
component must meet international fire retardant standards
for Rail Interiors and Exteriors
Ceiling Panels Stairs
Seating Vestibules
Window Panels Door Pillars
Partition WallsDiffusers
Gangway and Cabinet Panels Cabin and
Desk panels
Door Pillars Lavatory Modules (standard and
Front and Rear EndsRoof Panels
Nose Cones Under Fairings
Source
httpwwwpctaerail_compositesphp
101
SKY BUS
2009
Europe is the world leader in offshore wind with
828 wind turbines and a cumulative capacity of 2056 MW spread across 38 offshore wind farms in 9
European countries
The UK and Denmark are the current leaders with a 44 and 30 share respectively In 2009
five countries built new offshore wind farms
UK (284 MW)
Demark (230 MW)
Sweden (30 MW)
Germany (30 MW)
Norway (23 MW)
2010
Asia leads the growth in global wind power which grew 358 GW in 2010 bringing
total global capacity to 1944 GW ndash up 225 from 2009
the Global Wind Energy Council (GWEC)
Asia accounted for 19 GW of new global wind power installations driven by China which installed 165
GW
ldquoChina now has 423 GW of wind powerrdquo
ldquoThis puts China firmly on a path to reach 200 GW of installed wind power by 2020 At the same
time China has become the worldrsquos largest producer of wind energy equipmentrdquo
Source
httpwwwreinforcedplasticscomview15655asia-leads-global-wind-power-growth
httpimgdeusmcomdesignnews288288605-Sandia_Sizes_up_Wind_Turbine_Blade_Design_C_largegif
WIND ENERGY
Marine Current Turbines
Source
httpwwwsiemenscompressenpressreleasepress=enpressrelease2011solar-hydroex201111005htm
httpwwwmarineturbinescom
A commercial marine current turbine consists of
two rotors which are fixed on a structure within the
sea current The twin rotors rotate with the
movement of the tidal flow and the blades pitch
through 180 degrees to optimally track tidal current
(Press picture Marine Current Turbines)
Wave Star Energys Multi-point Absorber
CFRP COLUMN REINFORCEMENT
INDUSTRIAL TANKS
107
INDUSTRIAL PIPES
PRESSURE TANKS
109
ldquoLetrsquos Make with Compositesrdquo
Properties CSM Lamination WR Lamination MAX Lamination
Fabric Weight (kgm2) 1 1 1
Composite Weight (kgm2) 18 15 13
Resin usage (kgm2) 15 1 08
Amount of Fabric 22 Ply 16 Ply 13 Ply
Thickness 15 mm 12 mm 10 mm
Tensile Strength (Mpa) 125 1796 400
Tensile Strength (Nmmsup2) 28463 30958 4576
Processing Time High Med Low
Labour Cost High Med Low
MULTIAXIAL
Total Penggunaan Resin -51
Total Berat Kapal -40
Kekuatan Bangunan Kapal +59
Efisiensi Tenaga Kerja
Waktu Pengerjaan Lebih Cepat
KEUNGGULAN MATERIAL
Resapan Resin Lebih Baik amp Merata
Lapisan Lebih Sedikit
Meningkatkan Kekuatan Kapal
KEUNGGULAN MATERIAL
TRIAXIAL
DBL series DBT series
BIAXIAL
LT series DB series
UNIDIRECTIONAL
L series T series
QUADRIAXIAL
DBLT series
JENIS MULTIAXIAL
UNIDIRECTIONAL
DCMU 900 E ndash
KHUSUS UNTUK MEMPERKUAT BENDING KAPAL
PEMASANGAN KHUSUS PADA KEEL DAN TULANGAN
JENIS MULTIAXIAL UNTUK KAPAL
TRIAXIAL
DBL 600 ndash
APLIKASI PADA INDUSTRI PENERBANGAN
PEMASANGAN KHUSUS PADA
SAMBUNGAN BADAN DAN SAYAP
PESAWAT
JENIS MULTIAXIAL UNTUK PESAWAT
QUADRAXIAL
DBLT 800 ndash
APLIKASI PADA INDUSTRI ENERGI
DITERAPKAN UNTUK KEBUTUHAN PEMBANGKIT
LISTRIK ENERGI ANGIN
MULTIAXIAL UNTUK ENERGI
INDUSTRI KIMIA OLAHRAGA AUTOMOTIF
MULTIAXIAL UNTUK INDUSTRI LAINNYA
COMPOSITES
GUNAKAN MATERIAL FIBERGLASS
YANG SUDAH DISERTIFIKASI
BKI
FIBERGLASS UNTUK PEMBANGUNAN BAKAP
PERATURAN MENTERI PERHUBUNGAN
NOMOR PM 7 TAHUN 2013
TENTANG KEWAJIBAN KLASIFIKASI BAGI KAPAL BERBENDERA INDONESIA
PADA BADAN KLASIFIKASI
BADAN SERTIFIKASI MARITIM
Biro Klasifikasi IndonesiaDet Norske Veritas Germanischer Lloyds
PERATURAN BKI
Untuk Kapal Non-Metal
2006
PERSYARATAN MINIMUM
kekuatan material yang
harus digunakan
untuk membangun
Kapal Fiberglass
PEMBESARAN
Table 21
FIBERGLASS TRIAXIS COMPOSITES
TELAH BERSERTIFIKASI BKI
Biro Klasifikasi Indonesia
65
TEKNIK MANUFAKTUR
COMPOSITES
Wet hand lay-up
1) Peletakan
Dry Reinforcement
bull Dry reinforcement dan resin (+ katalis) ditaruh pada permukaan cetakan
2) Pemasukanpenekanan resin
bull Resin ditekan untuk meng-impregnasi serat dengan menggunakan rol
3) Pengulangan proses untuk lapisan lain
bull Beberapa lapisan dapat ditambahkan secara bertahap
4) Resin curing
bull Reaksi dimulai komponen dilepaskan setelah komponen mengeras
(fully cured)
Wet hand lay-up
Manufaktur komponen dapat dikerjakan dengan menggunakan beberapa lapis komposit
dengan memperhatikan kompatibilitas material dan tahapan curing Modifikasi proses dapat
dilakukan seperti
Vacuum bagging
setelah lay-up
Glass Roving
Bulk Resin
Catalyst
3) De-molding
2) Resin Cure
bull Curing dimulai dan komponen dilepaskan setelah pengerasan selesai
bull Serat gelas resin dan katalis dimasukkan kedalam spray gun
1) Spray-up
bull Campuran disemprotkan pada permukaan cetakan
Spray-up
69
Penyemprotan bakal komponen
Komponen
dilepaskan
dari cetakan
Full dispensing
system Chopper Roving
Atomised resin
and catalyst
Spray-up
Prepreg
1) LaminateAssembly 5) De-molding
3) Resin Melts Layup Consolidates
bull Prepreg serat yang sudah diimpregnasi oleh resin+katalis dalam kondisi padat
bull Lapisan prepreg digunting sesuai bentuk yang diinginkan kemudian diletakkan pada permukaan cetakan
sesuai bentuk komponen yang diinginkan Lay-up mudah dilakukan karena sifat ldquotackynessrdquo dari prepreg
2) Applied Vacuum Pressure and Heat
bull Tekanan dan panas diberikan resin mencair terjadi konsolidasi pada komponen
4) Resin Cures
bull Temperatur dinaikkan untuk memulai curing
Prepreg
Variasi proses Autoclave
Komponen dalam
vacuum-bag
bull Campuran resin (+katalis) dan chopped glass strands diperoleh dalam bentuk premixed compound Bulk molding
Compound (BMC) dalam bentuk adonan atau Sheet molding Compound (SMC) dalam bentuk lembaran
bull Ketika panas dan tekanan diberikan oleh cetakan compound mengalir sesuai bentuk komponen yang diinginkan
1) Placement of Charge
5) De-molding3) Squeeze to final dimensions
2) Mould Closure4) Resin Cure
bull Curing dimulai komponen dilepaskan setelah terjadi pengerasan yang cukup
Compression Molding
bull Preform atau dry reinforcement dimasukkan kedalam cetakan sesuai dengan bentuk komponen yang
diinginkan
bull Resin mengalir dengan penekanan atau pem-vakuman dan meng-impregnasi preform dan
mendorongmengeluarkan udara yang ada dalam preform
1) Preform Manufacture
2) Preform Compression
5) De-molding3) Resin Injection
4) Resin Cure
bull Curing terjadi cetakan dibuka setelah terjadi pengerasan yang mencukupi
Liquid Molding (RTM VARI VARTM)
Pultrusion
bull Dry roving or fabrics ditarik melalui bak berisi
campuran resin dan katalis
bull Campuran yang basah ditarik melalui cetakan
bull Sisa resin keluar cetakan
bull Pemanasan dilakukan untuk proses curing
bull Pendinginan dilakukan untuk mempercepat siklus
produksi
Cut-off
Cooling
Die sections
Resin bath
Fibre creel
Filament Winding
bull Dry roving ditarik melalui bak berisi campuran resin dan katalis
bull Wet roving digulungkan dalam keadaan tegang kepada mandrel
bull Kontrol mekanik dari pembawa serat mengatur orientasi peletakan serat pada
mandrel
INDUSTRI COMPOSITES
AEROSPACE
HISTORY
1950 ndash Boeing
1960 ndash F14 Tomcat
1981 ndash AV-8B Harrier
Source
Low-Cost Composite Materials and Structures for Aircraft Applications
httpwwwreinforcedplasticscom
httpwwwcentennialofflightgovessayEvolution_of_TechnologycompositesTech40htm
Automotive
Composite material is used in a number of applications in the automotive
industry due to its temperature resistance rigidity and fatigue strength
The benefits of using composites include greater fuel efficiency
corrosion resistance light weight and strength Composites also provide
a low-cost way to help keep designs looking fresh
Composites are used in
- interior parts (cockpit trimming seats instrument panels)
- exterior structure (body panels openings underbody frontrear
modules)
- engine compartment and fuelmechanical area parts (axles and
suspensions fuel and exhaust systems)
- electrical and electronic components
Lamborghinis Sesto Element carbon fiber
ldquoFat men cannot run as fast as thin men but we build most of our vehicles as though dead-weight fat increased speedhellip I cannot
imagine where the delusion that weight means strength
came fromhelliprdquo mdashHenry Ford
The mix of automotive materials is changing showing a boost for FRP in helping original
equipment manufacturers meet fuel economy and emissions challenges
(Source 2011 DuPont AutomotiveSAE survey of design engineers performed by Signet Research Inc)
Source
httpwwwtoraycomcsrhighlight2009hig_001_01html
The MonoCell tub for the McLaren MP4-12C supercar is moulded as a single
piece and weighs less than 80 kg (176 lbs)
COMPOSITES IN MARINE
TRIMARAN BOAT
AMERICA NAVYINDONESIAN NAVY
Visby Class corvette
Total length is 72 meters
The beam is 1040 meters
The displacement is 600 metric tones
fully equipped the worlds largest CRP
construction
The design of the Visby aims to minimize
the optical and infrared signature above
water acoustic and hydroa coustic
signature underwater electrical potential
and magnetic signature pressure signature
radar cross section and actively emitted
signals
A stealth corvette of the YS 2000 design
has a detection range of 13km in rough
seas and 22km in calm sea without
jamming In a jammed environment the
Visby would be detected at a range of 8km
in rough sea and 11km in calm sea
The material provides high strength and
rigidity low weight good shock resistance
low radar and magnetic signature
1996
Visby is a class of stealth corvettes for the Swedish Navy
ldquoReduced 50 of a Conventional Steelrdquo
Source
Hull Construction with composite materials for ships over 100m in length 2002
Massachusetts Institute of Technology
httpwwwnaval-technologycomprojectsvisby
YACHTS
KAL YUDISTIRAMARATHON 100 ADMIRAL YACHT
LOA 3050 MWidth 6 MFuel Tank 8000 LWater Tank 3000 LIce Box 500 LAccommodation Max 35 Personnel
2 x CATERPILLAR 3412E 1200 HPMARINE DIESEL ENGINE
PC 40 ndash KRI Krait 827Department of Indonesian Navy
LOA 40 MWidth 73 MPower 190Weapon Twin Cannon Barrels
127 mm Heavy Machine GunSpeed Knot 25 KnotDisplacement 105 tonAccommodation 23 personnel
PATROL BOAT
Rigid Inflatable BoatPATROL BOAT
Yachts
36m Luxury Yacht Moonraker
36m Luxury Yacht GoldenEye
50m Luxury Yacht Casino
Royale
45m Luxury Yacht Seashaw
Boat Parts
Barovans for Seismic Sweep
Centrifugal Liftfan House for Surface Effect
Ships
Composite Boat PropellersRTM
Deckhouses for Pilot Boats
Fairing Parts for Submarines
Flybridges for Motor yachts
Light Weight Gangway
MTB Launcher Mock-up
Pleasure Boats
12m Sailboat
12m Sail-Catamaranone-off
Canoes
Dragonfly 1000Catamaran Sailboat
Fantasy 37Sailboat
Farr 60Luxury Sailboat
EurodingyOlympic Dingy Class for
Woman
Hydrolift F23 Racing Boats
Kajacs
Najad 42Sailboat
Najad 520Sailboat
Najad 441Sailboat
Najad 391Sailboat
Nordwest 900Motorboat
Nordwest 1100Motorboat
Quatro 44Motorboat
Racemaster Competition Boats
Storebro 420
Storebro 345
Sweden Yacht 370Sailboat
Sweden Yacht 69Sailboat
Windy 41Motorboat
X-632Sailboat
X-362Sailboat
Commercial Boats
175m High Speed AmbulancePassenger Boat
19m High Speed Passenger Boat
20m High Speed Passenger Boat
364m Surface Effect Passenger Ship
45m Surface Effect Passenger Ship
120m Hull Structural Parts HSSS Catamaran Ferry
APPENDIX
Marine Vessel
1188m Fast Attack Vessel FMV 90 E
20m SAV-Surface Auxiliary Vessels
34m Personnel TransportCoast Guard Vessel
40ft Experimental SES
40m Landsort-Class Mine Hunters
54m Mine Counter Measure Vehicles SES
74m Coastal Patrol Boats
Fishing Boats
30 GT
12 GT
10 GT
5 GT
WISEWings In Surface Effect
HOVERCRAFT
Designed specifically for the tourist and transport industries the
Pioneer Mk3 hovercraft is amphibious and comfortably seats 25
passengers plus 1-crew The air-conditioned cabin allows for
maximum visibility for all aboard The Pioneer Mk3 is robust and
dynamic in its performance
Commercial hovercraft
Mk3 AirLift Hovercraft - 1215m
Power is economicaly provided by one Deutz diesel engine of
330kW (442hp) to cruise easily at 40 knots with much higher
speeds available according to the surface conditions The hull is
manufactured from fibreglassPVC foam composite sandwich
the windows are glass and the skirt is urethane coated nylon A
Military version is available with increased payload and systems
redundancy Power for the Military version comes from two Steyr
diesel engines with a total installed power of 320kW (429hp) All
transmission electrical hydraulic and air systems are duplicated
for maximum redundancy The increased performance of the
Military version comes from the reduced engine weight of the twin
Steyr installation cf the Deutz installation
Source
httpwwwnauticexpocomprodairlift-hovercraftcommercial-hovercrafts-25251-142868html
HOVERFLIGHT
BALLISTIC amp UNIT DEFENCED
Triaxis Composites Collaboration with Institute of Aeronautics and Space in the development of Missile Nose Cone
Polymer composites is the evolution of the military defence
Thin steel was the helmet material of
WWII and remained the principal material until around the 1980rsquos
The advantages of using steel
included a simple technology for manufacture of the helmets low cost and reasonably good
impact protection However these helmets were found to provide only marginal protection
against fragments
During the Vietnam War the US Army experimented with fiber-reinforced inserts in the
helmets These inserts improved ballistic protection but at the same time added weight and
reduced the air space between the head and the helmet
By the early part of the 1980rsquos the US military had developed the first all-composite
100 fiber-reinforced helmet This development resulted in even better ballistic protection
without altering the weight of the helmet Other improvements included better head coverage and
more space for ventilation
Source
Composites Armor - A difficult but huge market
by A Brent Strong Brigham Young University
MILITARY VEHICLES
HIGH SPEED TRAIN SHINKANSEN
Advanced Composites provide lightweight solutions for railway vehicles
saving as much as 50-80 of the weight compared with traditional
components
A lower overall weight translates into less stress faster acceleration and
higher speeds as well as reduced starting and stopping inertia Today
these are important criteria in global high-speed and metropolitan
railway projects
Fire smoke and toxic fumes are key safety criteria for interior
components of railway carriages Any material selected for an interior
component must meet international fire retardant standards
for Rail Interiors and Exteriors
Ceiling Panels Stairs
Seating Vestibules
Window Panels Door Pillars
Partition WallsDiffusers
Gangway and Cabinet Panels Cabin and
Desk panels
Door Pillars Lavatory Modules (standard and
Front and Rear EndsRoof Panels
Nose Cones Under Fairings
Source
httpwwwpctaerail_compositesphp
101
SKY BUS
2009
Europe is the world leader in offshore wind with
828 wind turbines and a cumulative capacity of 2056 MW spread across 38 offshore wind farms in 9
European countries
The UK and Denmark are the current leaders with a 44 and 30 share respectively In 2009
five countries built new offshore wind farms
UK (284 MW)
Demark (230 MW)
Sweden (30 MW)
Germany (30 MW)
Norway (23 MW)
2010
Asia leads the growth in global wind power which grew 358 GW in 2010 bringing
total global capacity to 1944 GW ndash up 225 from 2009
the Global Wind Energy Council (GWEC)
Asia accounted for 19 GW of new global wind power installations driven by China which installed 165
GW
ldquoChina now has 423 GW of wind powerrdquo
ldquoThis puts China firmly on a path to reach 200 GW of installed wind power by 2020 At the same
time China has become the worldrsquos largest producer of wind energy equipmentrdquo
Source
httpwwwreinforcedplasticscomview15655asia-leads-global-wind-power-growth
httpimgdeusmcomdesignnews288288605-Sandia_Sizes_up_Wind_Turbine_Blade_Design_C_largegif
WIND ENERGY
Marine Current Turbines
Source
httpwwwsiemenscompressenpressreleasepress=enpressrelease2011solar-hydroex201111005htm
httpwwwmarineturbinescom
A commercial marine current turbine consists of
two rotors which are fixed on a structure within the
sea current The twin rotors rotate with the
movement of the tidal flow and the blades pitch
through 180 degrees to optimally track tidal current
(Press picture Marine Current Turbines)
Wave Star Energys Multi-point Absorber
CFRP COLUMN REINFORCEMENT
INDUSTRIAL TANKS
107
INDUSTRIAL PIPES
PRESSURE TANKS
109
ldquoLetrsquos Make with Compositesrdquo
Total Penggunaan Resin -51
Total Berat Kapal -40
Kekuatan Bangunan Kapal +59
Efisiensi Tenaga Kerja
Waktu Pengerjaan Lebih Cepat
KEUNGGULAN MATERIAL
Resapan Resin Lebih Baik amp Merata
Lapisan Lebih Sedikit
Meningkatkan Kekuatan Kapal
KEUNGGULAN MATERIAL
TRIAXIAL
DBL series DBT series
BIAXIAL
LT series DB series
UNIDIRECTIONAL
L series T series
QUADRIAXIAL
DBLT series
JENIS MULTIAXIAL
UNIDIRECTIONAL
DCMU 900 E ndash
KHUSUS UNTUK MEMPERKUAT BENDING KAPAL
PEMASANGAN KHUSUS PADA KEEL DAN TULANGAN
JENIS MULTIAXIAL UNTUK KAPAL
TRIAXIAL
DBL 600 ndash
APLIKASI PADA INDUSTRI PENERBANGAN
PEMASANGAN KHUSUS PADA
SAMBUNGAN BADAN DAN SAYAP
PESAWAT
JENIS MULTIAXIAL UNTUK PESAWAT
QUADRAXIAL
DBLT 800 ndash
APLIKASI PADA INDUSTRI ENERGI
DITERAPKAN UNTUK KEBUTUHAN PEMBANGKIT
LISTRIK ENERGI ANGIN
MULTIAXIAL UNTUK ENERGI
INDUSTRI KIMIA OLAHRAGA AUTOMOTIF
MULTIAXIAL UNTUK INDUSTRI LAINNYA
COMPOSITES
GUNAKAN MATERIAL FIBERGLASS
YANG SUDAH DISERTIFIKASI
BKI
FIBERGLASS UNTUK PEMBANGUNAN BAKAP
PERATURAN MENTERI PERHUBUNGAN
NOMOR PM 7 TAHUN 2013
TENTANG KEWAJIBAN KLASIFIKASI BAGI KAPAL BERBENDERA INDONESIA
PADA BADAN KLASIFIKASI
BADAN SERTIFIKASI MARITIM
Biro Klasifikasi IndonesiaDet Norske Veritas Germanischer Lloyds
PERATURAN BKI
Untuk Kapal Non-Metal
2006
PERSYARATAN MINIMUM
kekuatan material yang
harus digunakan
untuk membangun
Kapal Fiberglass
PEMBESARAN
Table 21
FIBERGLASS TRIAXIS COMPOSITES
TELAH BERSERTIFIKASI BKI
Biro Klasifikasi Indonesia
65
TEKNIK MANUFAKTUR
COMPOSITES
Wet hand lay-up
1) Peletakan
Dry Reinforcement
bull Dry reinforcement dan resin (+ katalis) ditaruh pada permukaan cetakan
2) Pemasukanpenekanan resin
bull Resin ditekan untuk meng-impregnasi serat dengan menggunakan rol
3) Pengulangan proses untuk lapisan lain
bull Beberapa lapisan dapat ditambahkan secara bertahap
4) Resin curing
bull Reaksi dimulai komponen dilepaskan setelah komponen mengeras
(fully cured)
Wet hand lay-up
Manufaktur komponen dapat dikerjakan dengan menggunakan beberapa lapis komposit
dengan memperhatikan kompatibilitas material dan tahapan curing Modifikasi proses dapat
dilakukan seperti
Vacuum bagging
setelah lay-up
Glass Roving
Bulk Resin
Catalyst
3) De-molding
2) Resin Cure
bull Curing dimulai dan komponen dilepaskan setelah pengerasan selesai
bull Serat gelas resin dan katalis dimasukkan kedalam spray gun
1) Spray-up
bull Campuran disemprotkan pada permukaan cetakan
Spray-up
69
Penyemprotan bakal komponen
Komponen
dilepaskan
dari cetakan
Full dispensing
system Chopper Roving
Atomised resin
and catalyst
Spray-up
Prepreg
1) LaminateAssembly 5) De-molding
3) Resin Melts Layup Consolidates
bull Prepreg serat yang sudah diimpregnasi oleh resin+katalis dalam kondisi padat
bull Lapisan prepreg digunting sesuai bentuk yang diinginkan kemudian diletakkan pada permukaan cetakan
sesuai bentuk komponen yang diinginkan Lay-up mudah dilakukan karena sifat ldquotackynessrdquo dari prepreg
2) Applied Vacuum Pressure and Heat
bull Tekanan dan panas diberikan resin mencair terjadi konsolidasi pada komponen
4) Resin Cures
bull Temperatur dinaikkan untuk memulai curing
Prepreg
Variasi proses Autoclave
Komponen dalam
vacuum-bag
bull Campuran resin (+katalis) dan chopped glass strands diperoleh dalam bentuk premixed compound Bulk molding
Compound (BMC) dalam bentuk adonan atau Sheet molding Compound (SMC) dalam bentuk lembaran
bull Ketika panas dan tekanan diberikan oleh cetakan compound mengalir sesuai bentuk komponen yang diinginkan
1) Placement of Charge
5) De-molding3) Squeeze to final dimensions
2) Mould Closure4) Resin Cure
bull Curing dimulai komponen dilepaskan setelah terjadi pengerasan yang cukup
Compression Molding
bull Preform atau dry reinforcement dimasukkan kedalam cetakan sesuai dengan bentuk komponen yang
diinginkan
bull Resin mengalir dengan penekanan atau pem-vakuman dan meng-impregnasi preform dan
mendorongmengeluarkan udara yang ada dalam preform
1) Preform Manufacture
2) Preform Compression
5) De-molding3) Resin Injection
4) Resin Cure
bull Curing terjadi cetakan dibuka setelah terjadi pengerasan yang mencukupi
Liquid Molding (RTM VARI VARTM)
Pultrusion
bull Dry roving or fabrics ditarik melalui bak berisi
campuran resin dan katalis
bull Campuran yang basah ditarik melalui cetakan
bull Sisa resin keluar cetakan
bull Pemanasan dilakukan untuk proses curing
bull Pendinginan dilakukan untuk mempercepat siklus
produksi
Cut-off
Cooling
Die sections
Resin bath
Fibre creel
Filament Winding
bull Dry roving ditarik melalui bak berisi campuran resin dan katalis
bull Wet roving digulungkan dalam keadaan tegang kepada mandrel
bull Kontrol mekanik dari pembawa serat mengatur orientasi peletakan serat pada
mandrel
INDUSTRI COMPOSITES
AEROSPACE
HISTORY
1950 ndash Boeing
1960 ndash F14 Tomcat
1981 ndash AV-8B Harrier
Source
Low-Cost Composite Materials and Structures for Aircraft Applications
httpwwwreinforcedplasticscom
httpwwwcentennialofflightgovessayEvolution_of_TechnologycompositesTech40htm
Automotive
Composite material is used in a number of applications in the automotive
industry due to its temperature resistance rigidity and fatigue strength
The benefits of using composites include greater fuel efficiency
corrosion resistance light weight and strength Composites also provide
a low-cost way to help keep designs looking fresh
Composites are used in
- interior parts (cockpit trimming seats instrument panels)
- exterior structure (body panels openings underbody frontrear
modules)
- engine compartment and fuelmechanical area parts (axles and
suspensions fuel and exhaust systems)
- electrical and electronic components
Lamborghinis Sesto Element carbon fiber
ldquoFat men cannot run as fast as thin men but we build most of our vehicles as though dead-weight fat increased speedhellip I cannot
imagine where the delusion that weight means strength
came fromhelliprdquo mdashHenry Ford
The mix of automotive materials is changing showing a boost for FRP in helping original
equipment manufacturers meet fuel economy and emissions challenges
(Source 2011 DuPont AutomotiveSAE survey of design engineers performed by Signet Research Inc)
Source
httpwwwtoraycomcsrhighlight2009hig_001_01html
The MonoCell tub for the McLaren MP4-12C supercar is moulded as a single
piece and weighs less than 80 kg (176 lbs)
COMPOSITES IN MARINE
TRIMARAN BOAT
AMERICA NAVYINDONESIAN NAVY
Visby Class corvette
Total length is 72 meters
The beam is 1040 meters
The displacement is 600 metric tones
fully equipped the worlds largest CRP
construction
The design of the Visby aims to minimize
the optical and infrared signature above
water acoustic and hydroa coustic
signature underwater electrical potential
and magnetic signature pressure signature
radar cross section and actively emitted
signals
A stealth corvette of the YS 2000 design
has a detection range of 13km in rough
seas and 22km in calm sea without
jamming In a jammed environment the
Visby would be detected at a range of 8km
in rough sea and 11km in calm sea
The material provides high strength and
rigidity low weight good shock resistance
low radar and magnetic signature
1996
Visby is a class of stealth corvettes for the Swedish Navy
ldquoReduced 50 of a Conventional Steelrdquo
Source
Hull Construction with composite materials for ships over 100m in length 2002
Massachusetts Institute of Technology
httpwwwnaval-technologycomprojectsvisby
YACHTS
KAL YUDISTIRAMARATHON 100 ADMIRAL YACHT
LOA 3050 MWidth 6 MFuel Tank 8000 LWater Tank 3000 LIce Box 500 LAccommodation Max 35 Personnel
2 x CATERPILLAR 3412E 1200 HPMARINE DIESEL ENGINE
PC 40 ndash KRI Krait 827Department of Indonesian Navy
LOA 40 MWidth 73 MPower 190Weapon Twin Cannon Barrels
127 mm Heavy Machine GunSpeed Knot 25 KnotDisplacement 105 tonAccommodation 23 personnel
PATROL BOAT
Rigid Inflatable BoatPATROL BOAT
Yachts
36m Luxury Yacht Moonraker
36m Luxury Yacht GoldenEye
50m Luxury Yacht Casino
Royale
45m Luxury Yacht Seashaw
Boat Parts
Barovans for Seismic Sweep
Centrifugal Liftfan House for Surface Effect
Ships
Composite Boat PropellersRTM
Deckhouses for Pilot Boats
Fairing Parts for Submarines
Flybridges for Motor yachts
Light Weight Gangway
MTB Launcher Mock-up
Pleasure Boats
12m Sailboat
12m Sail-Catamaranone-off
Canoes
Dragonfly 1000Catamaran Sailboat
Fantasy 37Sailboat
Farr 60Luxury Sailboat
EurodingyOlympic Dingy Class for
Woman
Hydrolift F23 Racing Boats
Kajacs
Najad 42Sailboat
Najad 520Sailboat
Najad 441Sailboat
Najad 391Sailboat
Nordwest 900Motorboat
Nordwest 1100Motorboat
Quatro 44Motorboat
Racemaster Competition Boats
Storebro 420
Storebro 345
Sweden Yacht 370Sailboat
Sweden Yacht 69Sailboat
Windy 41Motorboat
X-632Sailboat
X-362Sailboat
Commercial Boats
175m High Speed AmbulancePassenger Boat
19m High Speed Passenger Boat
20m High Speed Passenger Boat
364m Surface Effect Passenger Ship
45m Surface Effect Passenger Ship
120m Hull Structural Parts HSSS Catamaran Ferry
APPENDIX
Marine Vessel
1188m Fast Attack Vessel FMV 90 E
20m SAV-Surface Auxiliary Vessels
34m Personnel TransportCoast Guard Vessel
40ft Experimental SES
40m Landsort-Class Mine Hunters
54m Mine Counter Measure Vehicles SES
74m Coastal Patrol Boats
Fishing Boats
30 GT
12 GT
10 GT
5 GT
WISEWings In Surface Effect
HOVERCRAFT
Designed specifically for the tourist and transport industries the
Pioneer Mk3 hovercraft is amphibious and comfortably seats 25
passengers plus 1-crew The air-conditioned cabin allows for
maximum visibility for all aboard The Pioneer Mk3 is robust and
dynamic in its performance
Commercial hovercraft
Mk3 AirLift Hovercraft - 1215m
Power is economicaly provided by one Deutz diesel engine of
330kW (442hp) to cruise easily at 40 knots with much higher
speeds available according to the surface conditions The hull is
manufactured from fibreglassPVC foam composite sandwich
the windows are glass and the skirt is urethane coated nylon A
Military version is available with increased payload and systems
redundancy Power for the Military version comes from two Steyr
diesel engines with a total installed power of 320kW (429hp) All
transmission electrical hydraulic and air systems are duplicated
for maximum redundancy The increased performance of the
Military version comes from the reduced engine weight of the twin
Steyr installation cf the Deutz installation
Source
httpwwwnauticexpocomprodairlift-hovercraftcommercial-hovercrafts-25251-142868html
HOVERFLIGHT
BALLISTIC amp UNIT DEFENCED
Triaxis Composites Collaboration with Institute of Aeronautics and Space in the development of Missile Nose Cone
Polymer composites is the evolution of the military defence
Thin steel was the helmet material of
WWII and remained the principal material until around the 1980rsquos
The advantages of using steel
included a simple technology for manufacture of the helmets low cost and reasonably good
impact protection However these helmets were found to provide only marginal protection
against fragments
During the Vietnam War the US Army experimented with fiber-reinforced inserts in the
helmets These inserts improved ballistic protection but at the same time added weight and
reduced the air space between the head and the helmet
By the early part of the 1980rsquos the US military had developed the first all-composite
100 fiber-reinforced helmet This development resulted in even better ballistic protection
without altering the weight of the helmet Other improvements included better head coverage and
more space for ventilation
Source
Composites Armor - A difficult but huge market
by A Brent Strong Brigham Young University
MILITARY VEHICLES
HIGH SPEED TRAIN SHINKANSEN
Advanced Composites provide lightweight solutions for railway vehicles
saving as much as 50-80 of the weight compared with traditional
components
A lower overall weight translates into less stress faster acceleration and
higher speeds as well as reduced starting and stopping inertia Today
these are important criteria in global high-speed and metropolitan
railway projects
Fire smoke and toxic fumes are key safety criteria for interior
components of railway carriages Any material selected for an interior
component must meet international fire retardant standards
for Rail Interiors and Exteriors
Ceiling Panels Stairs
Seating Vestibules
Window Panels Door Pillars
Partition WallsDiffusers
Gangway and Cabinet Panels Cabin and
Desk panels
Door Pillars Lavatory Modules (standard and
Front and Rear EndsRoof Panels
Nose Cones Under Fairings
Source
httpwwwpctaerail_compositesphp
101
SKY BUS
2009
Europe is the world leader in offshore wind with
828 wind turbines and a cumulative capacity of 2056 MW spread across 38 offshore wind farms in 9
European countries
The UK and Denmark are the current leaders with a 44 and 30 share respectively In 2009
five countries built new offshore wind farms
UK (284 MW)
Demark (230 MW)
Sweden (30 MW)
Germany (30 MW)
Norway (23 MW)
2010
Asia leads the growth in global wind power which grew 358 GW in 2010 bringing
total global capacity to 1944 GW ndash up 225 from 2009
the Global Wind Energy Council (GWEC)
Asia accounted for 19 GW of new global wind power installations driven by China which installed 165
GW
ldquoChina now has 423 GW of wind powerrdquo
ldquoThis puts China firmly on a path to reach 200 GW of installed wind power by 2020 At the same
time China has become the worldrsquos largest producer of wind energy equipmentrdquo
Source
httpwwwreinforcedplasticscomview15655asia-leads-global-wind-power-growth
httpimgdeusmcomdesignnews288288605-Sandia_Sizes_up_Wind_Turbine_Blade_Design_C_largegif
WIND ENERGY
Marine Current Turbines
Source
httpwwwsiemenscompressenpressreleasepress=enpressrelease2011solar-hydroex201111005htm
httpwwwmarineturbinescom
A commercial marine current turbine consists of
two rotors which are fixed on a structure within the
sea current The twin rotors rotate with the
movement of the tidal flow and the blades pitch
through 180 degrees to optimally track tidal current
(Press picture Marine Current Turbines)
Wave Star Energys Multi-point Absorber
CFRP COLUMN REINFORCEMENT
INDUSTRIAL TANKS
107
INDUSTRIAL PIPES
PRESSURE TANKS
109
ldquoLetrsquos Make with Compositesrdquo
Resapan Resin Lebih Baik amp Merata
Lapisan Lebih Sedikit
Meningkatkan Kekuatan Kapal
KEUNGGULAN MATERIAL
TRIAXIAL
DBL series DBT series
BIAXIAL
LT series DB series
UNIDIRECTIONAL
L series T series
QUADRIAXIAL
DBLT series
JENIS MULTIAXIAL
UNIDIRECTIONAL
DCMU 900 E ndash
KHUSUS UNTUK MEMPERKUAT BENDING KAPAL
PEMASANGAN KHUSUS PADA KEEL DAN TULANGAN
JENIS MULTIAXIAL UNTUK KAPAL
TRIAXIAL
DBL 600 ndash
APLIKASI PADA INDUSTRI PENERBANGAN
PEMASANGAN KHUSUS PADA
SAMBUNGAN BADAN DAN SAYAP
PESAWAT
JENIS MULTIAXIAL UNTUK PESAWAT
QUADRAXIAL
DBLT 800 ndash
APLIKASI PADA INDUSTRI ENERGI
DITERAPKAN UNTUK KEBUTUHAN PEMBANGKIT
LISTRIK ENERGI ANGIN
MULTIAXIAL UNTUK ENERGI
INDUSTRI KIMIA OLAHRAGA AUTOMOTIF
MULTIAXIAL UNTUK INDUSTRI LAINNYA
COMPOSITES
GUNAKAN MATERIAL FIBERGLASS
YANG SUDAH DISERTIFIKASI
BKI
FIBERGLASS UNTUK PEMBANGUNAN BAKAP
PERATURAN MENTERI PERHUBUNGAN
NOMOR PM 7 TAHUN 2013
TENTANG KEWAJIBAN KLASIFIKASI BAGI KAPAL BERBENDERA INDONESIA
PADA BADAN KLASIFIKASI
BADAN SERTIFIKASI MARITIM
Biro Klasifikasi IndonesiaDet Norske Veritas Germanischer Lloyds
PERATURAN BKI
Untuk Kapal Non-Metal
2006
PERSYARATAN MINIMUM
kekuatan material yang
harus digunakan
untuk membangun
Kapal Fiberglass
PEMBESARAN
Table 21
FIBERGLASS TRIAXIS COMPOSITES
TELAH BERSERTIFIKASI BKI
Biro Klasifikasi Indonesia
65
TEKNIK MANUFAKTUR
COMPOSITES
Wet hand lay-up
1) Peletakan
Dry Reinforcement
bull Dry reinforcement dan resin (+ katalis) ditaruh pada permukaan cetakan
2) Pemasukanpenekanan resin
bull Resin ditekan untuk meng-impregnasi serat dengan menggunakan rol
3) Pengulangan proses untuk lapisan lain
bull Beberapa lapisan dapat ditambahkan secara bertahap
4) Resin curing
bull Reaksi dimulai komponen dilepaskan setelah komponen mengeras
(fully cured)
Wet hand lay-up
Manufaktur komponen dapat dikerjakan dengan menggunakan beberapa lapis komposit
dengan memperhatikan kompatibilitas material dan tahapan curing Modifikasi proses dapat
dilakukan seperti
Vacuum bagging
setelah lay-up
Glass Roving
Bulk Resin
Catalyst
3) De-molding
2) Resin Cure
bull Curing dimulai dan komponen dilepaskan setelah pengerasan selesai
bull Serat gelas resin dan katalis dimasukkan kedalam spray gun
1) Spray-up
bull Campuran disemprotkan pada permukaan cetakan
Spray-up
69
Penyemprotan bakal komponen
Komponen
dilepaskan
dari cetakan
Full dispensing
system Chopper Roving
Atomised resin
and catalyst
Spray-up
Prepreg
1) LaminateAssembly 5) De-molding
3) Resin Melts Layup Consolidates
bull Prepreg serat yang sudah diimpregnasi oleh resin+katalis dalam kondisi padat
bull Lapisan prepreg digunting sesuai bentuk yang diinginkan kemudian diletakkan pada permukaan cetakan
sesuai bentuk komponen yang diinginkan Lay-up mudah dilakukan karena sifat ldquotackynessrdquo dari prepreg
2) Applied Vacuum Pressure and Heat
bull Tekanan dan panas diberikan resin mencair terjadi konsolidasi pada komponen
4) Resin Cures
bull Temperatur dinaikkan untuk memulai curing
Prepreg
Variasi proses Autoclave
Komponen dalam
vacuum-bag
bull Campuran resin (+katalis) dan chopped glass strands diperoleh dalam bentuk premixed compound Bulk molding
Compound (BMC) dalam bentuk adonan atau Sheet molding Compound (SMC) dalam bentuk lembaran
bull Ketika panas dan tekanan diberikan oleh cetakan compound mengalir sesuai bentuk komponen yang diinginkan
1) Placement of Charge
5) De-molding3) Squeeze to final dimensions
2) Mould Closure4) Resin Cure
bull Curing dimulai komponen dilepaskan setelah terjadi pengerasan yang cukup
Compression Molding
bull Preform atau dry reinforcement dimasukkan kedalam cetakan sesuai dengan bentuk komponen yang
diinginkan
bull Resin mengalir dengan penekanan atau pem-vakuman dan meng-impregnasi preform dan
mendorongmengeluarkan udara yang ada dalam preform
1) Preform Manufacture
2) Preform Compression
5) De-molding3) Resin Injection
4) Resin Cure
bull Curing terjadi cetakan dibuka setelah terjadi pengerasan yang mencukupi
Liquid Molding (RTM VARI VARTM)
Pultrusion
bull Dry roving or fabrics ditarik melalui bak berisi
campuran resin dan katalis
bull Campuran yang basah ditarik melalui cetakan
bull Sisa resin keluar cetakan
bull Pemanasan dilakukan untuk proses curing
bull Pendinginan dilakukan untuk mempercepat siklus
produksi
Cut-off
Cooling
Die sections
Resin bath
Fibre creel
Filament Winding
bull Dry roving ditarik melalui bak berisi campuran resin dan katalis
bull Wet roving digulungkan dalam keadaan tegang kepada mandrel
bull Kontrol mekanik dari pembawa serat mengatur orientasi peletakan serat pada
mandrel
INDUSTRI COMPOSITES
AEROSPACE
HISTORY
1950 ndash Boeing
1960 ndash F14 Tomcat
1981 ndash AV-8B Harrier
Source
Low-Cost Composite Materials and Structures for Aircraft Applications
httpwwwreinforcedplasticscom
httpwwwcentennialofflightgovessayEvolution_of_TechnologycompositesTech40htm
Automotive
Composite material is used in a number of applications in the automotive
industry due to its temperature resistance rigidity and fatigue strength
The benefits of using composites include greater fuel efficiency
corrosion resistance light weight and strength Composites also provide
a low-cost way to help keep designs looking fresh
Composites are used in
- interior parts (cockpit trimming seats instrument panels)
- exterior structure (body panels openings underbody frontrear
modules)
- engine compartment and fuelmechanical area parts (axles and
suspensions fuel and exhaust systems)
- electrical and electronic components
Lamborghinis Sesto Element carbon fiber
ldquoFat men cannot run as fast as thin men but we build most of our vehicles as though dead-weight fat increased speedhellip I cannot
imagine where the delusion that weight means strength
came fromhelliprdquo mdashHenry Ford
The mix of automotive materials is changing showing a boost for FRP in helping original
equipment manufacturers meet fuel economy and emissions challenges
(Source 2011 DuPont AutomotiveSAE survey of design engineers performed by Signet Research Inc)
Source
httpwwwtoraycomcsrhighlight2009hig_001_01html
The MonoCell tub for the McLaren MP4-12C supercar is moulded as a single
piece and weighs less than 80 kg (176 lbs)
COMPOSITES IN MARINE
TRIMARAN BOAT
AMERICA NAVYINDONESIAN NAVY
Visby Class corvette
Total length is 72 meters
The beam is 1040 meters
The displacement is 600 metric tones
fully equipped the worlds largest CRP
construction
The design of the Visby aims to minimize
the optical and infrared signature above
water acoustic and hydroa coustic
signature underwater electrical potential
and magnetic signature pressure signature
radar cross section and actively emitted
signals
A stealth corvette of the YS 2000 design
has a detection range of 13km in rough
seas and 22km in calm sea without
jamming In a jammed environment the
Visby would be detected at a range of 8km
in rough sea and 11km in calm sea
The material provides high strength and
rigidity low weight good shock resistance
low radar and magnetic signature
1996
Visby is a class of stealth corvettes for the Swedish Navy
ldquoReduced 50 of a Conventional Steelrdquo
Source
Hull Construction with composite materials for ships over 100m in length 2002
Massachusetts Institute of Technology
httpwwwnaval-technologycomprojectsvisby
YACHTS
KAL YUDISTIRAMARATHON 100 ADMIRAL YACHT
LOA 3050 MWidth 6 MFuel Tank 8000 LWater Tank 3000 LIce Box 500 LAccommodation Max 35 Personnel
2 x CATERPILLAR 3412E 1200 HPMARINE DIESEL ENGINE
PC 40 ndash KRI Krait 827Department of Indonesian Navy
LOA 40 MWidth 73 MPower 190Weapon Twin Cannon Barrels
127 mm Heavy Machine GunSpeed Knot 25 KnotDisplacement 105 tonAccommodation 23 personnel
PATROL BOAT
Rigid Inflatable BoatPATROL BOAT
Yachts
36m Luxury Yacht Moonraker
36m Luxury Yacht GoldenEye
50m Luxury Yacht Casino
Royale
45m Luxury Yacht Seashaw
Boat Parts
Barovans for Seismic Sweep
Centrifugal Liftfan House for Surface Effect
Ships
Composite Boat PropellersRTM
Deckhouses for Pilot Boats
Fairing Parts for Submarines
Flybridges for Motor yachts
Light Weight Gangway
MTB Launcher Mock-up
Pleasure Boats
12m Sailboat
12m Sail-Catamaranone-off
Canoes
Dragonfly 1000Catamaran Sailboat
Fantasy 37Sailboat
Farr 60Luxury Sailboat
EurodingyOlympic Dingy Class for
Woman
Hydrolift F23 Racing Boats
Kajacs
Najad 42Sailboat
Najad 520Sailboat
Najad 441Sailboat
Najad 391Sailboat
Nordwest 900Motorboat
Nordwest 1100Motorboat
Quatro 44Motorboat
Racemaster Competition Boats
Storebro 420
Storebro 345
Sweden Yacht 370Sailboat
Sweden Yacht 69Sailboat
Windy 41Motorboat
X-632Sailboat
X-362Sailboat
Commercial Boats
175m High Speed AmbulancePassenger Boat
19m High Speed Passenger Boat
20m High Speed Passenger Boat
364m Surface Effect Passenger Ship
45m Surface Effect Passenger Ship
120m Hull Structural Parts HSSS Catamaran Ferry
APPENDIX
Marine Vessel
1188m Fast Attack Vessel FMV 90 E
20m SAV-Surface Auxiliary Vessels
34m Personnel TransportCoast Guard Vessel
40ft Experimental SES
40m Landsort-Class Mine Hunters
54m Mine Counter Measure Vehicles SES
74m Coastal Patrol Boats
Fishing Boats
30 GT
12 GT
10 GT
5 GT
WISEWings In Surface Effect
HOVERCRAFT
Designed specifically for the tourist and transport industries the
Pioneer Mk3 hovercraft is amphibious and comfortably seats 25
passengers plus 1-crew The air-conditioned cabin allows for
maximum visibility for all aboard The Pioneer Mk3 is robust and
dynamic in its performance
Commercial hovercraft
Mk3 AirLift Hovercraft - 1215m
Power is economicaly provided by one Deutz diesel engine of
330kW (442hp) to cruise easily at 40 knots with much higher
speeds available according to the surface conditions The hull is
manufactured from fibreglassPVC foam composite sandwich
the windows are glass and the skirt is urethane coated nylon A
Military version is available with increased payload and systems
redundancy Power for the Military version comes from two Steyr
diesel engines with a total installed power of 320kW (429hp) All
transmission electrical hydraulic and air systems are duplicated
for maximum redundancy The increased performance of the
Military version comes from the reduced engine weight of the twin
Steyr installation cf the Deutz installation
Source
httpwwwnauticexpocomprodairlift-hovercraftcommercial-hovercrafts-25251-142868html
HOVERFLIGHT
BALLISTIC amp UNIT DEFENCED
Triaxis Composites Collaboration with Institute of Aeronautics and Space in the development of Missile Nose Cone
Polymer composites is the evolution of the military defence
Thin steel was the helmet material of
WWII and remained the principal material until around the 1980rsquos
The advantages of using steel
included a simple technology for manufacture of the helmets low cost and reasonably good
impact protection However these helmets were found to provide only marginal protection
against fragments
During the Vietnam War the US Army experimented with fiber-reinforced inserts in the
helmets These inserts improved ballistic protection but at the same time added weight and
reduced the air space between the head and the helmet
By the early part of the 1980rsquos the US military had developed the first all-composite
100 fiber-reinforced helmet This development resulted in even better ballistic protection
without altering the weight of the helmet Other improvements included better head coverage and
more space for ventilation
Source
Composites Armor - A difficult but huge market
by A Brent Strong Brigham Young University
MILITARY VEHICLES
HIGH SPEED TRAIN SHINKANSEN
Advanced Composites provide lightweight solutions for railway vehicles
saving as much as 50-80 of the weight compared with traditional
components
A lower overall weight translates into less stress faster acceleration and
higher speeds as well as reduced starting and stopping inertia Today
these are important criteria in global high-speed and metropolitan
railway projects
Fire smoke and toxic fumes are key safety criteria for interior
components of railway carriages Any material selected for an interior
component must meet international fire retardant standards
for Rail Interiors and Exteriors
Ceiling Panels Stairs
Seating Vestibules
Window Panels Door Pillars
Partition WallsDiffusers
Gangway and Cabinet Panels Cabin and
Desk panels
Door Pillars Lavatory Modules (standard and
Front and Rear EndsRoof Panels
Nose Cones Under Fairings
Source
httpwwwpctaerail_compositesphp
101
SKY BUS
2009
Europe is the world leader in offshore wind with
828 wind turbines and a cumulative capacity of 2056 MW spread across 38 offshore wind farms in 9
European countries
The UK and Denmark are the current leaders with a 44 and 30 share respectively In 2009
five countries built new offshore wind farms
UK (284 MW)
Demark (230 MW)
Sweden (30 MW)
Germany (30 MW)
Norway (23 MW)
2010
Asia leads the growth in global wind power which grew 358 GW in 2010 bringing
total global capacity to 1944 GW ndash up 225 from 2009
the Global Wind Energy Council (GWEC)
Asia accounted for 19 GW of new global wind power installations driven by China which installed 165
GW
ldquoChina now has 423 GW of wind powerrdquo
ldquoThis puts China firmly on a path to reach 200 GW of installed wind power by 2020 At the same
time China has become the worldrsquos largest producer of wind energy equipmentrdquo
Source
httpwwwreinforcedplasticscomview15655asia-leads-global-wind-power-growth
httpimgdeusmcomdesignnews288288605-Sandia_Sizes_up_Wind_Turbine_Blade_Design_C_largegif
WIND ENERGY
Marine Current Turbines
Source
httpwwwsiemenscompressenpressreleasepress=enpressrelease2011solar-hydroex201111005htm
httpwwwmarineturbinescom
A commercial marine current turbine consists of
two rotors which are fixed on a structure within the
sea current The twin rotors rotate with the
movement of the tidal flow and the blades pitch
through 180 degrees to optimally track tidal current
(Press picture Marine Current Turbines)
Wave Star Energys Multi-point Absorber
CFRP COLUMN REINFORCEMENT
INDUSTRIAL TANKS
107
INDUSTRIAL PIPES
PRESSURE TANKS
109
ldquoLetrsquos Make with Compositesrdquo
TRIAXIAL
DBL series DBT series
BIAXIAL
LT series DB series
UNIDIRECTIONAL
L series T series
QUADRIAXIAL
DBLT series
JENIS MULTIAXIAL
UNIDIRECTIONAL
DCMU 900 E ndash
KHUSUS UNTUK MEMPERKUAT BENDING KAPAL
PEMASANGAN KHUSUS PADA KEEL DAN TULANGAN
JENIS MULTIAXIAL UNTUK KAPAL
TRIAXIAL
DBL 600 ndash
APLIKASI PADA INDUSTRI PENERBANGAN
PEMASANGAN KHUSUS PADA
SAMBUNGAN BADAN DAN SAYAP
PESAWAT
JENIS MULTIAXIAL UNTUK PESAWAT
QUADRAXIAL
DBLT 800 ndash
APLIKASI PADA INDUSTRI ENERGI
DITERAPKAN UNTUK KEBUTUHAN PEMBANGKIT
LISTRIK ENERGI ANGIN
MULTIAXIAL UNTUK ENERGI
INDUSTRI KIMIA OLAHRAGA AUTOMOTIF
MULTIAXIAL UNTUK INDUSTRI LAINNYA
COMPOSITES
GUNAKAN MATERIAL FIBERGLASS
YANG SUDAH DISERTIFIKASI
BKI
FIBERGLASS UNTUK PEMBANGUNAN BAKAP
PERATURAN MENTERI PERHUBUNGAN
NOMOR PM 7 TAHUN 2013
TENTANG KEWAJIBAN KLASIFIKASI BAGI KAPAL BERBENDERA INDONESIA
PADA BADAN KLASIFIKASI
BADAN SERTIFIKASI MARITIM
Biro Klasifikasi IndonesiaDet Norske Veritas Germanischer Lloyds
PERATURAN BKI
Untuk Kapal Non-Metal
2006
PERSYARATAN MINIMUM
kekuatan material yang
harus digunakan
untuk membangun
Kapal Fiberglass
PEMBESARAN
Table 21
FIBERGLASS TRIAXIS COMPOSITES
TELAH BERSERTIFIKASI BKI
Biro Klasifikasi Indonesia
65
TEKNIK MANUFAKTUR
COMPOSITES
Wet hand lay-up
1) Peletakan
Dry Reinforcement
bull Dry reinforcement dan resin (+ katalis) ditaruh pada permukaan cetakan
2) Pemasukanpenekanan resin
bull Resin ditekan untuk meng-impregnasi serat dengan menggunakan rol
3) Pengulangan proses untuk lapisan lain
bull Beberapa lapisan dapat ditambahkan secara bertahap
4) Resin curing
bull Reaksi dimulai komponen dilepaskan setelah komponen mengeras
(fully cured)
Wet hand lay-up
Manufaktur komponen dapat dikerjakan dengan menggunakan beberapa lapis komposit
dengan memperhatikan kompatibilitas material dan tahapan curing Modifikasi proses dapat
dilakukan seperti
Vacuum bagging
setelah lay-up
Glass Roving
Bulk Resin
Catalyst
3) De-molding
2) Resin Cure
bull Curing dimulai dan komponen dilepaskan setelah pengerasan selesai
bull Serat gelas resin dan katalis dimasukkan kedalam spray gun
1) Spray-up
bull Campuran disemprotkan pada permukaan cetakan
Spray-up
69
Penyemprotan bakal komponen
Komponen
dilepaskan
dari cetakan
Full dispensing
system Chopper Roving
Atomised resin
and catalyst
Spray-up
Prepreg
1) LaminateAssembly 5) De-molding
3) Resin Melts Layup Consolidates
bull Prepreg serat yang sudah diimpregnasi oleh resin+katalis dalam kondisi padat
bull Lapisan prepreg digunting sesuai bentuk yang diinginkan kemudian diletakkan pada permukaan cetakan
sesuai bentuk komponen yang diinginkan Lay-up mudah dilakukan karena sifat ldquotackynessrdquo dari prepreg
2) Applied Vacuum Pressure and Heat
bull Tekanan dan panas diberikan resin mencair terjadi konsolidasi pada komponen
4) Resin Cures
bull Temperatur dinaikkan untuk memulai curing
Prepreg
Variasi proses Autoclave
Komponen dalam
vacuum-bag
bull Campuran resin (+katalis) dan chopped glass strands diperoleh dalam bentuk premixed compound Bulk molding
Compound (BMC) dalam bentuk adonan atau Sheet molding Compound (SMC) dalam bentuk lembaran
bull Ketika panas dan tekanan diberikan oleh cetakan compound mengalir sesuai bentuk komponen yang diinginkan
1) Placement of Charge
5) De-molding3) Squeeze to final dimensions
2) Mould Closure4) Resin Cure
bull Curing dimulai komponen dilepaskan setelah terjadi pengerasan yang cukup
Compression Molding
bull Preform atau dry reinforcement dimasukkan kedalam cetakan sesuai dengan bentuk komponen yang
diinginkan
bull Resin mengalir dengan penekanan atau pem-vakuman dan meng-impregnasi preform dan
mendorongmengeluarkan udara yang ada dalam preform
1) Preform Manufacture
2) Preform Compression
5) De-molding3) Resin Injection
4) Resin Cure
bull Curing terjadi cetakan dibuka setelah terjadi pengerasan yang mencukupi
Liquid Molding (RTM VARI VARTM)
Pultrusion
bull Dry roving or fabrics ditarik melalui bak berisi
campuran resin dan katalis
bull Campuran yang basah ditarik melalui cetakan
bull Sisa resin keluar cetakan
bull Pemanasan dilakukan untuk proses curing
bull Pendinginan dilakukan untuk mempercepat siklus
produksi
Cut-off
Cooling
Die sections
Resin bath
Fibre creel
Filament Winding
bull Dry roving ditarik melalui bak berisi campuran resin dan katalis
bull Wet roving digulungkan dalam keadaan tegang kepada mandrel
bull Kontrol mekanik dari pembawa serat mengatur orientasi peletakan serat pada
mandrel
INDUSTRI COMPOSITES
AEROSPACE
HISTORY
1950 ndash Boeing
1960 ndash F14 Tomcat
1981 ndash AV-8B Harrier
Source
Low-Cost Composite Materials and Structures for Aircraft Applications
httpwwwreinforcedplasticscom
httpwwwcentennialofflightgovessayEvolution_of_TechnologycompositesTech40htm
Automotive
Composite material is used in a number of applications in the automotive
industry due to its temperature resistance rigidity and fatigue strength
The benefits of using composites include greater fuel efficiency
corrosion resistance light weight and strength Composites also provide
a low-cost way to help keep designs looking fresh
Composites are used in
- interior parts (cockpit trimming seats instrument panels)
- exterior structure (body panels openings underbody frontrear
modules)
- engine compartment and fuelmechanical area parts (axles and
suspensions fuel and exhaust systems)
- electrical and electronic components
Lamborghinis Sesto Element carbon fiber
ldquoFat men cannot run as fast as thin men but we build most of our vehicles as though dead-weight fat increased speedhellip I cannot
imagine where the delusion that weight means strength
came fromhelliprdquo mdashHenry Ford
The mix of automotive materials is changing showing a boost for FRP in helping original
equipment manufacturers meet fuel economy and emissions challenges
(Source 2011 DuPont AutomotiveSAE survey of design engineers performed by Signet Research Inc)
Source
httpwwwtoraycomcsrhighlight2009hig_001_01html
The MonoCell tub for the McLaren MP4-12C supercar is moulded as a single
piece and weighs less than 80 kg (176 lbs)
COMPOSITES IN MARINE
TRIMARAN BOAT
AMERICA NAVYINDONESIAN NAVY
Visby Class corvette
Total length is 72 meters
The beam is 1040 meters
The displacement is 600 metric tones
fully equipped the worlds largest CRP
construction
The design of the Visby aims to minimize
the optical and infrared signature above
water acoustic and hydroa coustic
signature underwater electrical potential
and magnetic signature pressure signature
radar cross section and actively emitted
signals
A stealth corvette of the YS 2000 design
has a detection range of 13km in rough
seas and 22km in calm sea without
jamming In a jammed environment the
Visby would be detected at a range of 8km
in rough sea and 11km in calm sea
The material provides high strength and
rigidity low weight good shock resistance
low radar and magnetic signature
1996
Visby is a class of stealth corvettes for the Swedish Navy
ldquoReduced 50 of a Conventional Steelrdquo
Source
Hull Construction with composite materials for ships over 100m in length 2002
Massachusetts Institute of Technology
httpwwwnaval-technologycomprojectsvisby
YACHTS
KAL YUDISTIRAMARATHON 100 ADMIRAL YACHT
LOA 3050 MWidth 6 MFuel Tank 8000 LWater Tank 3000 LIce Box 500 LAccommodation Max 35 Personnel
2 x CATERPILLAR 3412E 1200 HPMARINE DIESEL ENGINE
PC 40 ndash KRI Krait 827Department of Indonesian Navy
LOA 40 MWidth 73 MPower 190Weapon Twin Cannon Barrels
127 mm Heavy Machine GunSpeed Knot 25 KnotDisplacement 105 tonAccommodation 23 personnel
PATROL BOAT
Rigid Inflatable BoatPATROL BOAT
Yachts
36m Luxury Yacht Moonraker
36m Luxury Yacht GoldenEye
50m Luxury Yacht Casino
Royale
45m Luxury Yacht Seashaw
Boat Parts
Barovans for Seismic Sweep
Centrifugal Liftfan House for Surface Effect
Ships
Composite Boat PropellersRTM
Deckhouses for Pilot Boats
Fairing Parts for Submarines
Flybridges for Motor yachts
Light Weight Gangway
MTB Launcher Mock-up
Pleasure Boats
12m Sailboat
12m Sail-Catamaranone-off
Canoes
Dragonfly 1000Catamaran Sailboat
Fantasy 37Sailboat
Farr 60Luxury Sailboat
EurodingyOlympic Dingy Class for
Woman
Hydrolift F23 Racing Boats
Kajacs
Najad 42Sailboat
Najad 520Sailboat
Najad 441Sailboat
Najad 391Sailboat
Nordwest 900Motorboat
Nordwest 1100Motorboat
Quatro 44Motorboat
Racemaster Competition Boats
Storebro 420
Storebro 345
Sweden Yacht 370Sailboat
Sweden Yacht 69Sailboat
Windy 41Motorboat
X-632Sailboat
X-362Sailboat
Commercial Boats
175m High Speed AmbulancePassenger Boat
19m High Speed Passenger Boat
20m High Speed Passenger Boat
364m Surface Effect Passenger Ship
45m Surface Effect Passenger Ship
120m Hull Structural Parts HSSS Catamaran Ferry
APPENDIX
Marine Vessel
1188m Fast Attack Vessel FMV 90 E
20m SAV-Surface Auxiliary Vessels
34m Personnel TransportCoast Guard Vessel
40ft Experimental SES
40m Landsort-Class Mine Hunters
54m Mine Counter Measure Vehicles SES
74m Coastal Patrol Boats
Fishing Boats
30 GT
12 GT
10 GT
5 GT
WISEWings In Surface Effect
HOVERCRAFT
Designed specifically for the tourist and transport industries the
Pioneer Mk3 hovercraft is amphibious and comfortably seats 25
passengers plus 1-crew The air-conditioned cabin allows for
maximum visibility for all aboard The Pioneer Mk3 is robust and
dynamic in its performance
Commercial hovercraft
Mk3 AirLift Hovercraft - 1215m
Power is economicaly provided by one Deutz diesel engine of
330kW (442hp) to cruise easily at 40 knots with much higher
speeds available according to the surface conditions The hull is
manufactured from fibreglassPVC foam composite sandwich
the windows are glass and the skirt is urethane coated nylon A
Military version is available with increased payload and systems
redundancy Power for the Military version comes from two Steyr
diesel engines with a total installed power of 320kW (429hp) All
transmission electrical hydraulic and air systems are duplicated
for maximum redundancy The increased performance of the
Military version comes from the reduced engine weight of the twin
Steyr installation cf the Deutz installation
Source
httpwwwnauticexpocomprodairlift-hovercraftcommercial-hovercrafts-25251-142868html
HOVERFLIGHT
BALLISTIC amp UNIT DEFENCED
Triaxis Composites Collaboration with Institute of Aeronautics and Space in the development of Missile Nose Cone
Polymer composites is the evolution of the military defence
Thin steel was the helmet material of
WWII and remained the principal material until around the 1980rsquos
The advantages of using steel
included a simple technology for manufacture of the helmets low cost and reasonably good
impact protection However these helmets were found to provide only marginal protection
against fragments
During the Vietnam War the US Army experimented with fiber-reinforced inserts in the
helmets These inserts improved ballistic protection but at the same time added weight and
reduced the air space between the head and the helmet
By the early part of the 1980rsquos the US military had developed the first all-composite
100 fiber-reinforced helmet This development resulted in even better ballistic protection
without altering the weight of the helmet Other improvements included better head coverage and
more space for ventilation
Source
Composites Armor - A difficult but huge market
by A Brent Strong Brigham Young University
MILITARY VEHICLES
HIGH SPEED TRAIN SHINKANSEN
Advanced Composites provide lightweight solutions for railway vehicles
saving as much as 50-80 of the weight compared with traditional
components
A lower overall weight translates into less stress faster acceleration and
higher speeds as well as reduced starting and stopping inertia Today
these are important criteria in global high-speed and metropolitan
railway projects
Fire smoke and toxic fumes are key safety criteria for interior
components of railway carriages Any material selected for an interior
component must meet international fire retardant standards
for Rail Interiors and Exteriors
Ceiling Panels Stairs
Seating Vestibules
Window Panels Door Pillars
Partition WallsDiffusers
Gangway and Cabinet Panels Cabin and
Desk panels
Door Pillars Lavatory Modules (standard and
Front and Rear EndsRoof Panels
Nose Cones Under Fairings
Source
httpwwwpctaerail_compositesphp
101
SKY BUS
2009
Europe is the world leader in offshore wind with
828 wind turbines and a cumulative capacity of 2056 MW spread across 38 offshore wind farms in 9
European countries
The UK and Denmark are the current leaders with a 44 and 30 share respectively In 2009
five countries built new offshore wind farms
UK (284 MW)
Demark (230 MW)
Sweden (30 MW)
Germany (30 MW)
Norway (23 MW)
2010
Asia leads the growth in global wind power which grew 358 GW in 2010 bringing
total global capacity to 1944 GW ndash up 225 from 2009
the Global Wind Energy Council (GWEC)
Asia accounted for 19 GW of new global wind power installations driven by China which installed 165
GW
ldquoChina now has 423 GW of wind powerrdquo
ldquoThis puts China firmly on a path to reach 200 GW of installed wind power by 2020 At the same
time China has become the worldrsquos largest producer of wind energy equipmentrdquo
Source
httpwwwreinforcedplasticscomview15655asia-leads-global-wind-power-growth
httpimgdeusmcomdesignnews288288605-Sandia_Sizes_up_Wind_Turbine_Blade_Design_C_largegif
WIND ENERGY
Marine Current Turbines
Source
httpwwwsiemenscompressenpressreleasepress=enpressrelease2011solar-hydroex201111005htm
httpwwwmarineturbinescom
A commercial marine current turbine consists of
two rotors which are fixed on a structure within the
sea current The twin rotors rotate with the
movement of the tidal flow and the blades pitch
through 180 degrees to optimally track tidal current
(Press picture Marine Current Turbines)
Wave Star Energys Multi-point Absorber
CFRP COLUMN REINFORCEMENT
INDUSTRIAL TANKS
107
INDUSTRIAL PIPES
PRESSURE TANKS
109
ldquoLetrsquos Make with Compositesrdquo
UNIDIRECTIONAL
DCMU 900 E ndash
KHUSUS UNTUK MEMPERKUAT BENDING KAPAL
PEMASANGAN KHUSUS PADA KEEL DAN TULANGAN
JENIS MULTIAXIAL UNTUK KAPAL
TRIAXIAL
DBL 600 ndash
APLIKASI PADA INDUSTRI PENERBANGAN
PEMASANGAN KHUSUS PADA
SAMBUNGAN BADAN DAN SAYAP
PESAWAT
JENIS MULTIAXIAL UNTUK PESAWAT
QUADRAXIAL
DBLT 800 ndash
APLIKASI PADA INDUSTRI ENERGI
DITERAPKAN UNTUK KEBUTUHAN PEMBANGKIT
LISTRIK ENERGI ANGIN
MULTIAXIAL UNTUK ENERGI
INDUSTRI KIMIA OLAHRAGA AUTOMOTIF
MULTIAXIAL UNTUK INDUSTRI LAINNYA
COMPOSITES
GUNAKAN MATERIAL FIBERGLASS
YANG SUDAH DISERTIFIKASI
BKI
FIBERGLASS UNTUK PEMBANGUNAN BAKAP
PERATURAN MENTERI PERHUBUNGAN
NOMOR PM 7 TAHUN 2013
TENTANG KEWAJIBAN KLASIFIKASI BAGI KAPAL BERBENDERA INDONESIA
PADA BADAN KLASIFIKASI
BADAN SERTIFIKASI MARITIM
Biro Klasifikasi IndonesiaDet Norske Veritas Germanischer Lloyds
PERATURAN BKI
Untuk Kapal Non-Metal
2006
PERSYARATAN MINIMUM
kekuatan material yang
harus digunakan
untuk membangun
Kapal Fiberglass
PEMBESARAN
Table 21
FIBERGLASS TRIAXIS COMPOSITES
TELAH BERSERTIFIKASI BKI
Biro Klasifikasi Indonesia
65
TEKNIK MANUFAKTUR
COMPOSITES
Wet hand lay-up
1) Peletakan
Dry Reinforcement
bull Dry reinforcement dan resin (+ katalis) ditaruh pada permukaan cetakan
2) Pemasukanpenekanan resin
bull Resin ditekan untuk meng-impregnasi serat dengan menggunakan rol
3) Pengulangan proses untuk lapisan lain
bull Beberapa lapisan dapat ditambahkan secara bertahap
4) Resin curing
bull Reaksi dimulai komponen dilepaskan setelah komponen mengeras
(fully cured)
Wet hand lay-up
Manufaktur komponen dapat dikerjakan dengan menggunakan beberapa lapis komposit
dengan memperhatikan kompatibilitas material dan tahapan curing Modifikasi proses dapat
dilakukan seperti
Vacuum bagging
setelah lay-up
Glass Roving
Bulk Resin
Catalyst
3) De-molding
2) Resin Cure
bull Curing dimulai dan komponen dilepaskan setelah pengerasan selesai
bull Serat gelas resin dan katalis dimasukkan kedalam spray gun
1) Spray-up
bull Campuran disemprotkan pada permukaan cetakan
Spray-up
69
Penyemprotan bakal komponen
Komponen
dilepaskan
dari cetakan
Full dispensing
system Chopper Roving
Atomised resin
and catalyst
Spray-up
Prepreg
1) LaminateAssembly 5) De-molding
3) Resin Melts Layup Consolidates
bull Prepreg serat yang sudah diimpregnasi oleh resin+katalis dalam kondisi padat
bull Lapisan prepreg digunting sesuai bentuk yang diinginkan kemudian diletakkan pada permukaan cetakan
sesuai bentuk komponen yang diinginkan Lay-up mudah dilakukan karena sifat ldquotackynessrdquo dari prepreg
2) Applied Vacuum Pressure and Heat
bull Tekanan dan panas diberikan resin mencair terjadi konsolidasi pada komponen
4) Resin Cures
bull Temperatur dinaikkan untuk memulai curing
Prepreg
Variasi proses Autoclave
Komponen dalam
vacuum-bag
bull Campuran resin (+katalis) dan chopped glass strands diperoleh dalam bentuk premixed compound Bulk molding
Compound (BMC) dalam bentuk adonan atau Sheet molding Compound (SMC) dalam bentuk lembaran
bull Ketika panas dan tekanan diberikan oleh cetakan compound mengalir sesuai bentuk komponen yang diinginkan
1) Placement of Charge
5) De-molding3) Squeeze to final dimensions
2) Mould Closure4) Resin Cure
bull Curing dimulai komponen dilepaskan setelah terjadi pengerasan yang cukup
Compression Molding
bull Preform atau dry reinforcement dimasukkan kedalam cetakan sesuai dengan bentuk komponen yang
diinginkan
bull Resin mengalir dengan penekanan atau pem-vakuman dan meng-impregnasi preform dan
mendorongmengeluarkan udara yang ada dalam preform
1) Preform Manufacture
2) Preform Compression
5) De-molding3) Resin Injection
4) Resin Cure
bull Curing terjadi cetakan dibuka setelah terjadi pengerasan yang mencukupi
Liquid Molding (RTM VARI VARTM)
Pultrusion
bull Dry roving or fabrics ditarik melalui bak berisi
campuran resin dan katalis
bull Campuran yang basah ditarik melalui cetakan
bull Sisa resin keluar cetakan
bull Pemanasan dilakukan untuk proses curing
bull Pendinginan dilakukan untuk mempercepat siklus
produksi
Cut-off
Cooling
Die sections
Resin bath
Fibre creel
Filament Winding
bull Dry roving ditarik melalui bak berisi campuran resin dan katalis
bull Wet roving digulungkan dalam keadaan tegang kepada mandrel
bull Kontrol mekanik dari pembawa serat mengatur orientasi peletakan serat pada
mandrel
INDUSTRI COMPOSITES
AEROSPACE
HISTORY
1950 ndash Boeing
1960 ndash F14 Tomcat
1981 ndash AV-8B Harrier
Source
Low-Cost Composite Materials and Structures for Aircraft Applications
httpwwwreinforcedplasticscom
httpwwwcentennialofflightgovessayEvolution_of_TechnologycompositesTech40htm
Automotive
Composite material is used in a number of applications in the automotive
industry due to its temperature resistance rigidity and fatigue strength
The benefits of using composites include greater fuel efficiency
corrosion resistance light weight and strength Composites also provide
a low-cost way to help keep designs looking fresh
Composites are used in
- interior parts (cockpit trimming seats instrument panels)
- exterior structure (body panels openings underbody frontrear
modules)
- engine compartment and fuelmechanical area parts (axles and
suspensions fuel and exhaust systems)
- electrical and electronic components
Lamborghinis Sesto Element carbon fiber
ldquoFat men cannot run as fast as thin men but we build most of our vehicles as though dead-weight fat increased speedhellip I cannot
imagine where the delusion that weight means strength
came fromhelliprdquo mdashHenry Ford
The mix of automotive materials is changing showing a boost for FRP in helping original
equipment manufacturers meet fuel economy and emissions challenges
(Source 2011 DuPont AutomotiveSAE survey of design engineers performed by Signet Research Inc)
Source
httpwwwtoraycomcsrhighlight2009hig_001_01html
The MonoCell tub for the McLaren MP4-12C supercar is moulded as a single
piece and weighs less than 80 kg (176 lbs)
COMPOSITES IN MARINE
TRIMARAN BOAT
AMERICA NAVYINDONESIAN NAVY
Visby Class corvette
Total length is 72 meters
The beam is 1040 meters
The displacement is 600 metric tones
fully equipped the worlds largest CRP
construction
The design of the Visby aims to minimize
the optical and infrared signature above
water acoustic and hydroa coustic
signature underwater electrical potential
and magnetic signature pressure signature
radar cross section and actively emitted
signals
A stealth corvette of the YS 2000 design
has a detection range of 13km in rough
seas and 22km in calm sea without
jamming In a jammed environment the
Visby would be detected at a range of 8km
in rough sea and 11km in calm sea
The material provides high strength and
rigidity low weight good shock resistance
low radar and magnetic signature
1996
Visby is a class of stealth corvettes for the Swedish Navy
ldquoReduced 50 of a Conventional Steelrdquo
Source
Hull Construction with composite materials for ships over 100m in length 2002
Massachusetts Institute of Technology
httpwwwnaval-technologycomprojectsvisby
YACHTS
KAL YUDISTIRAMARATHON 100 ADMIRAL YACHT
LOA 3050 MWidth 6 MFuel Tank 8000 LWater Tank 3000 LIce Box 500 LAccommodation Max 35 Personnel
2 x CATERPILLAR 3412E 1200 HPMARINE DIESEL ENGINE
PC 40 ndash KRI Krait 827Department of Indonesian Navy
LOA 40 MWidth 73 MPower 190Weapon Twin Cannon Barrels
127 mm Heavy Machine GunSpeed Knot 25 KnotDisplacement 105 tonAccommodation 23 personnel
PATROL BOAT
Rigid Inflatable BoatPATROL BOAT
Yachts
36m Luxury Yacht Moonraker
36m Luxury Yacht GoldenEye
50m Luxury Yacht Casino
Royale
45m Luxury Yacht Seashaw
Boat Parts
Barovans for Seismic Sweep
Centrifugal Liftfan House for Surface Effect
Ships
Composite Boat PropellersRTM
Deckhouses for Pilot Boats
Fairing Parts for Submarines
Flybridges for Motor yachts
Light Weight Gangway
MTB Launcher Mock-up
Pleasure Boats
12m Sailboat
12m Sail-Catamaranone-off
Canoes
Dragonfly 1000Catamaran Sailboat
Fantasy 37Sailboat
Farr 60Luxury Sailboat
EurodingyOlympic Dingy Class for
Woman
Hydrolift F23 Racing Boats
Kajacs
Najad 42Sailboat
Najad 520Sailboat
Najad 441Sailboat
Najad 391Sailboat
Nordwest 900Motorboat
Nordwest 1100Motorboat
Quatro 44Motorboat
Racemaster Competition Boats
Storebro 420
Storebro 345
Sweden Yacht 370Sailboat
Sweden Yacht 69Sailboat
Windy 41Motorboat
X-632Sailboat
X-362Sailboat
Commercial Boats
175m High Speed AmbulancePassenger Boat
19m High Speed Passenger Boat
20m High Speed Passenger Boat
364m Surface Effect Passenger Ship
45m Surface Effect Passenger Ship
120m Hull Structural Parts HSSS Catamaran Ferry
APPENDIX
Marine Vessel
1188m Fast Attack Vessel FMV 90 E
20m SAV-Surface Auxiliary Vessels
34m Personnel TransportCoast Guard Vessel
40ft Experimental SES
40m Landsort-Class Mine Hunters
54m Mine Counter Measure Vehicles SES
74m Coastal Patrol Boats
Fishing Boats
30 GT
12 GT
10 GT
5 GT
WISEWings In Surface Effect
HOVERCRAFT
Designed specifically for the tourist and transport industries the
Pioneer Mk3 hovercraft is amphibious and comfortably seats 25
passengers plus 1-crew The air-conditioned cabin allows for
maximum visibility for all aboard The Pioneer Mk3 is robust and
dynamic in its performance
Commercial hovercraft
Mk3 AirLift Hovercraft - 1215m
Power is economicaly provided by one Deutz diesel engine of
330kW (442hp) to cruise easily at 40 knots with much higher
speeds available according to the surface conditions The hull is
manufactured from fibreglassPVC foam composite sandwich
the windows are glass and the skirt is urethane coated nylon A
Military version is available with increased payload and systems
redundancy Power for the Military version comes from two Steyr
diesel engines with a total installed power of 320kW (429hp) All
transmission electrical hydraulic and air systems are duplicated
for maximum redundancy The increased performance of the
Military version comes from the reduced engine weight of the twin
Steyr installation cf the Deutz installation
Source
httpwwwnauticexpocomprodairlift-hovercraftcommercial-hovercrafts-25251-142868html
HOVERFLIGHT
BALLISTIC amp UNIT DEFENCED
Triaxis Composites Collaboration with Institute of Aeronautics and Space in the development of Missile Nose Cone
Polymer composites is the evolution of the military defence
Thin steel was the helmet material of
WWII and remained the principal material until around the 1980rsquos
The advantages of using steel
included a simple technology for manufacture of the helmets low cost and reasonably good
impact protection However these helmets were found to provide only marginal protection
against fragments
During the Vietnam War the US Army experimented with fiber-reinforced inserts in the
helmets These inserts improved ballistic protection but at the same time added weight and
reduced the air space between the head and the helmet
By the early part of the 1980rsquos the US military had developed the first all-composite
100 fiber-reinforced helmet This development resulted in even better ballistic protection
without altering the weight of the helmet Other improvements included better head coverage and
more space for ventilation
Source
Composites Armor - A difficult but huge market
by A Brent Strong Brigham Young University
MILITARY VEHICLES
HIGH SPEED TRAIN SHINKANSEN
Advanced Composites provide lightweight solutions for railway vehicles
saving as much as 50-80 of the weight compared with traditional
components
A lower overall weight translates into less stress faster acceleration and
higher speeds as well as reduced starting and stopping inertia Today
these are important criteria in global high-speed and metropolitan
railway projects
Fire smoke and toxic fumes are key safety criteria for interior
components of railway carriages Any material selected for an interior
component must meet international fire retardant standards
for Rail Interiors and Exteriors
Ceiling Panels Stairs
Seating Vestibules
Window Panels Door Pillars
Partition WallsDiffusers
Gangway and Cabinet Panels Cabin and
Desk panels
Door Pillars Lavatory Modules (standard and
Front and Rear EndsRoof Panels
Nose Cones Under Fairings
Source
httpwwwpctaerail_compositesphp
101
SKY BUS
2009
Europe is the world leader in offshore wind with
828 wind turbines and a cumulative capacity of 2056 MW spread across 38 offshore wind farms in 9
European countries
The UK and Denmark are the current leaders with a 44 and 30 share respectively In 2009
five countries built new offshore wind farms
UK (284 MW)
Demark (230 MW)
Sweden (30 MW)
Germany (30 MW)
Norway (23 MW)
2010
Asia leads the growth in global wind power which grew 358 GW in 2010 bringing
total global capacity to 1944 GW ndash up 225 from 2009
the Global Wind Energy Council (GWEC)
Asia accounted for 19 GW of new global wind power installations driven by China which installed 165
GW
ldquoChina now has 423 GW of wind powerrdquo
ldquoThis puts China firmly on a path to reach 200 GW of installed wind power by 2020 At the same
time China has become the worldrsquos largest producer of wind energy equipmentrdquo
Source
httpwwwreinforcedplasticscomview15655asia-leads-global-wind-power-growth
httpimgdeusmcomdesignnews288288605-Sandia_Sizes_up_Wind_Turbine_Blade_Design_C_largegif
WIND ENERGY
Marine Current Turbines
Source
httpwwwsiemenscompressenpressreleasepress=enpressrelease2011solar-hydroex201111005htm
httpwwwmarineturbinescom
A commercial marine current turbine consists of
two rotors which are fixed on a structure within the
sea current The twin rotors rotate with the
movement of the tidal flow and the blades pitch
through 180 degrees to optimally track tidal current
(Press picture Marine Current Turbines)
Wave Star Energys Multi-point Absorber
CFRP COLUMN REINFORCEMENT
INDUSTRIAL TANKS
107
INDUSTRIAL PIPES
PRESSURE TANKS
109
ldquoLetrsquos Make with Compositesrdquo
TRIAXIAL
DBL 600 ndash
APLIKASI PADA INDUSTRI PENERBANGAN
PEMASANGAN KHUSUS PADA
SAMBUNGAN BADAN DAN SAYAP
PESAWAT
JENIS MULTIAXIAL UNTUK PESAWAT
QUADRAXIAL
DBLT 800 ndash
APLIKASI PADA INDUSTRI ENERGI
DITERAPKAN UNTUK KEBUTUHAN PEMBANGKIT
LISTRIK ENERGI ANGIN
MULTIAXIAL UNTUK ENERGI
INDUSTRI KIMIA OLAHRAGA AUTOMOTIF
MULTIAXIAL UNTUK INDUSTRI LAINNYA
COMPOSITES
GUNAKAN MATERIAL FIBERGLASS
YANG SUDAH DISERTIFIKASI
BKI
FIBERGLASS UNTUK PEMBANGUNAN BAKAP
PERATURAN MENTERI PERHUBUNGAN
NOMOR PM 7 TAHUN 2013
TENTANG KEWAJIBAN KLASIFIKASI BAGI KAPAL BERBENDERA INDONESIA
PADA BADAN KLASIFIKASI
BADAN SERTIFIKASI MARITIM
Biro Klasifikasi IndonesiaDet Norske Veritas Germanischer Lloyds
PERATURAN BKI
Untuk Kapal Non-Metal
2006
PERSYARATAN MINIMUM
kekuatan material yang
harus digunakan
untuk membangun
Kapal Fiberglass
PEMBESARAN
Table 21
FIBERGLASS TRIAXIS COMPOSITES
TELAH BERSERTIFIKASI BKI
Biro Klasifikasi Indonesia
65
TEKNIK MANUFAKTUR
COMPOSITES
Wet hand lay-up
1) Peletakan
Dry Reinforcement
bull Dry reinforcement dan resin (+ katalis) ditaruh pada permukaan cetakan
2) Pemasukanpenekanan resin
bull Resin ditekan untuk meng-impregnasi serat dengan menggunakan rol
3) Pengulangan proses untuk lapisan lain
bull Beberapa lapisan dapat ditambahkan secara bertahap
4) Resin curing
bull Reaksi dimulai komponen dilepaskan setelah komponen mengeras
(fully cured)
Wet hand lay-up
Manufaktur komponen dapat dikerjakan dengan menggunakan beberapa lapis komposit
dengan memperhatikan kompatibilitas material dan tahapan curing Modifikasi proses dapat
dilakukan seperti
Vacuum bagging
setelah lay-up
Glass Roving
Bulk Resin
Catalyst
3) De-molding
2) Resin Cure
bull Curing dimulai dan komponen dilepaskan setelah pengerasan selesai
bull Serat gelas resin dan katalis dimasukkan kedalam spray gun
1) Spray-up
bull Campuran disemprotkan pada permukaan cetakan
Spray-up
69
Penyemprotan bakal komponen
Komponen
dilepaskan
dari cetakan
Full dispensing
system Chopper Roving
Atomised resin
and catalyst
Spray-up
Prepreg
1) LaminateAssembly 5) De-molding
3) Resin Melts Layup Consolidates
bull Prepreg serat yang sudah diimpregnasi oleh resin+katalis dalam kondisi padat
bull Lapisan prepreg digunting sesuai bentuk yang diinginkan kemudian diletakkan pada permukaan cetakan
sesuai bentuk komponen yang diinginkan Lay-up mudah dilakukan karena sifat ldquotackynessrdquo dari prepreg
2) Applied Vacuum Pressure and Heat
bull Tekanan dan panas diberikan resin mencair terjadi konsolidasi pada komponen
4) Resin Cures
bull Temperatur dinaikkan untuk memulai curing
Prepreg
Variasi proses Autoclave
Komponen dalam
vacuum-bag
bull Campuran resin (+katalis) dan chopped glass strands diperoleh dalam bentuk premixed compound Bulk molding
Compound (BMC) dalam bentuk adonan atau Sheet molding Compound (SMC) dalam bentuk lembaran
bull Ketika panas dan tekanan diberikan oleh cetakan compound mengalir sesuai bentuk komponen yang diinginkan
1) Placement of Charge
5) De-molding3) Squeeze to final dimensions
2) Mould Closure4) Resin Cure
bull Curing dimulai komponen dilepaskan setelah terjadi pengerasan yang cukup
Compression Molding
bull Preform atau dry reinforcement dimasukkan kedalam cetakan sesuai dengan bentuk komponen yang
diinginkan
bull Resin mengalir dengan penekanan atau pem-vakuman dan meng-impregnasi preform dan
mendorongmengeluarkan udara yang ada dalam preform
1) Preform Manufacture
2) Preform Compression
5) De-molding3) Resin Injection
4) Resin Cure
bull Curing terjadi cetakan dibuka setelah terjadi pengerasan yang mencukupi
Liquid Molding (RTM VARI VARTM)
Pultrusion
bull Dry roving or fabrics ditarik melalui bak berisi
campuran resin dan katalis
bull Campuran yang basah ditarik melalui cetakan
bull Sisa resin keluar cetakan
bull Pemanasan dilakukan untuk proses curing
bull Pendinginan dilakukan untuk mempercepat siklus
produksi
Cut-off
Cooling
Die sections
Resin bath
Fibre creel
Filament Winding
bull Dry roving ditarik melalui bak berisi campuran resin dan katalis
bull Wet roving digulungkan dalam keadaan tegang kepada mandrel
bull Kontrol mekanik dari pembawa serat mengatur orientasi peletakan serat pada
mandrel
INDUSTRI COMPOSITES
AEROSPACE
HISTORY
1950 ndash Boeing
1960 ndash F14 Tomcat
1981 ndash AV-8B Harrier
Source
Low-Cost Composite Materials and Structures for Aircraft Applications
httpwwwreinforcedplasticscom
httpwwwcentennialofflightgovessayEvolution_of_TechnologycompositesTech40htm
Automotive
Composite material is used in a number of applications in the automotive
industry due to its temperature resistance rigidity and fatigue strength
The benefits of using composites include greater fuel efficiency
corrosion resistance light weight and strength Composites also provide
a low-cost way to help keep designs looking fresh
Composites are used in
- interior parts (cockpit trimming seats instrument panels)
- exterior structure (body panels openings underbody frontrear
modules)
- engine compartment and fuelmechanical area parts (axles and
suspensions fuel and exhaust systems)
- electrical and electronic components
Lamborghinis Sesto Element carbon fiber
ldquoFat men cannot run as fast as thin men but we build most of our vehicles as though dead-weight fat increased speedhellip I cannot
imagine where the delusion that weight means strength
came fromhelliprdquo mdashHenry Ford
The mix of automotive materials is changing showing a boost for FRP in helping original
equipment manufacturers meet fuel economy and emissions challenges
(Source 2011 DuPont AutomotiveSAE survey of design engineers performed by Signet Research Inc)
Source
httpwwwtoraycomcsrhighlight2009hig_001_01html
The MonoCell tub for the McLaren MP4-12C supercar is moulded as a single
piece and weighs less than 80 kg (176 lbs)
COMPOSITES IN MARINE
TRIMARAN BOAT
AMERICA NAVYINDONESIAN NAVY
Visby Class corvette
Total length is 72 meters
The beam is 1040 meters
The displacement is 600 metric tones
fully equipped the worlds largest CRP
construction
The design of the Visby aims to minimize
the optical and infrared signature above
water acoustic and hydroa coustic
signature underwater electrical potential
and magnetic signature pressure signature
radar cross section and actively emitted
signals
A stealth corvette of the YS 2000 design
has a detection range of 13km in rough
seas and 22km in calm sea without
jamming In a jammed environment the
Visby would be detected at a range of 8km
in rough sea and 11km in calm sea
The material provides high strength and
rigidity low weight good shock resistance
low radar and magnetic signature
1996
Visby is a class of stealth corvettes for the Swedish Navy
ldquoReduced 50 of a Conventional Steelrdquo
Source
Hull Construction with composite materials for ships over 100m in length 2002
Massachusetts Institute of Technology
httpwwwnaval-technologycomprojectsvisby
YACHTS
KAL YUDISTIRAMARATHON 100 ADMIRAL YACHT
LOA 3050 MWidth 6 MFuel Tank 8000 LWater Tank 3000 LIce Box 500 LAccommodation Max 35 Personnel
2 x CATERPILLAR 3412E 1200 HPMARINE DIESEL ENGINE
PC 40 ndash KRI Krait 827Department of Indonesian Navy
LOA 40 MWidth 73 MPower 190Weapon Twin Cannon Barrels
127 mm Heavy Machine GunSpeed Knot 25 KnotDisplacement 105 tonAccommodation 23 personnel
PATROL BOAT
Rigid Inflatable BoatPATROL BOAT
Yachts
36m Luxury Yacht Moonraker
36m Luxury Yacht GoldenEye
50m Luxury Yacht Casino
Royale
45m Luxury Yacht Seashaw
Boat Parts
Barovans for Seismic Sweep
Centrifugal Liftfan House for Surface Effect
Ships
Composite Boat PropellersRTM
Deckhouses for Pilot Boats
Fairing Parts for Submarines
Flybridges for Motor yachts
Light Weight Gangway
MTB Launcher Mock-up
Pleasure Boats
12m Sailboat
12m Sail-Catamaranone-off
Canoes
Dragonfly 1000Catamaran Sailboat
Fantasy 37Sailboat
Farr 60Luxury Sailboat
EurodingyOlympic Dingy Class for
Woman
Hydrolift F23 Racing Boats
Kajacs
Najad 42Sailboat
Najad 520Sailboat
Najad 441Sailboat
Najad 391Sailboat
Nordwest 900Motorboat
Nordwest 1100Motorboat
Quatro 44Motorboat
Racemaster Competition Boats
Storebro 420
Storebro 345
Sweden Yacht 370Sailboat
Sweden Yacht 69Sailboat
Windy 41Motorboat
X-632Sailboat
X-362Sailboat
Commercial Boats
175m High Speed AmbulancePassenger Boat
19m High Speed Passenger Boat
20m High Speed Passenger Boat
364m Surface Effect Passenger Ship
45m Surface Effect Passenger Ship
120m Hull Structural Parts HSSS Catamaran Ferry
APPENDIX
Marine Vessel
1188m Fast Attack Vessel FMV 90 E
20m SAV-Surface Auxiliary Vessels
34m Personnel TransportCoast Guard Vessel
40ft Experimental SES
40m Landsort-Class Mine Hunters
54m Mine Counter Measure Vehicles SES
74m Coastal Patrol Boats
Fishing Boats
30 GT
12 GT
10 GT
5 GT
WISEWings In Surface Effect
HOVERCRAFT
Designed specifically for the tourist and transport industries the
Pioneer Mk3 hovercraft is amphibious and comfortably seats 25
passengers plus 1-crew The air-conditioned cabin allows for
maximum visibility for all aboard The Pioneer Mk3 is robust and
dynamic in its performance
Commercial hovercraft
Mk3 AirLift Hovercraft - 1215m
Power is economicaly provided by one Deutz diesel engine of
330kW (442hp) to cruise easily at 40 knots with much higher
speeds available according to the surface conditions The hull is
manufactured from fibreglassPVC foam composite sandwich
the windows are glass and the skirt is urethane coated nylon A
Military version is available with increased payload and systems
redundancy Power for the Military version comes from two Steyr
diesel engines with a total installed power of 320kW (429hp) All
transmission electrical hydraulic and air systems are duplicated
for maximum redundancy The increased performance of the
Military version comes from the reduced engine weight of the twin
Steyr installation cf the Deutz installation
Source
httpwwwnauticexpocomprodairlift-hovercraftcommercial-hovercrafts-25251-142868html
HOVERFLIGHT
BALLISTIC amp UNIT DEFENCED
Triaxis Composites Collaboration with Institute of Aeronautics and Space in the development of Missile Nose Cone
Polymer composites is the evolution of the military defence
Thin steel was the helmet material of
WWII and remained the principal material until around the 1980rsquos
The advantages of using steel
included a simple technology for manufacture of the helmets low cost and reasonably good
impact protection However these helmets were found to provide only marginal protection
against fragments
During the Vietnam War the US Army experimented with fiber-reinforced inserts in the
helmets These inserts improved ballistic protection but at the same time added weight and
reduced the air space between the head and the helmet
By the early part of the 1980rsquos the US military had developed the first all-composite
100 fiber-reinforced helmet This development resulted in even better ballistic protection
without altering the weight of the helmet Other improvements included better head coverage and
more space for ventilation
Source
Composites Armor - A difficult but huge market
by A Brent Strong Brigham Young University
MILITARY VEHICLES
HIGH SPEED TRAIN SHINKANSEN
Advanced Composites provide lightweight solutions for railway vehicles
saving as much as 50-80 of the weight compared with traditional
components
A lower overall weight translates into less stress faster acceleration and
higher speeds as well as reduced starting and stopping inertia Today
these are important criteria in global high-speed and metropolitan
railway projects
Fire smoke and toxic fumes are key safety criteria for interior
components of railway carriages Any material selected for an interior
component must meet international fire retardant standards
for Rail Interiors and Exteriors
Ceiling Panels Stairs
Seating Vestibules
Window Panels Door Pillars
Partition WallsDiffusers
Gangway and Cabinet Panels Cabin and
Desk panels
Door Pillars Lavatory Modules (standard and
Front and Rear EndsRoof Panels
Nose Cones Under Fairings
Source
httpwwwpctaerail_compositesphp
101
SKY BUS
2009
Europe is the world leader in offshore wind with
828 wind turbines and a cumulative capacity of 2056 MW spread across 38 offshore wind farms in 9
European countries
The UK and Denmark are the current leaders with a 44 and 30 share respectively In 2009
five countries built new offshore wind farms
UK (284 MW)
Demark (230 MW)
Sweden (30 MW)
Germany (30 MW)
Norway (23 MW)
2010
Asia leads the growth in global wind power which grew 358 GW in 2010 bringing
total global capacity to 1944 GW ndash up 225 from 2009
the Global Wind Energy Council (GWEC)
Asia accounted for 19 GW of new global wind power installations driven by China which installed 165
GW
ldquoChina now has 423 GW of wind powerrdquo
ldquoThis puts China firmly on a path to reach 200 GW of installed wind power by 2020 At the same
time China has become the worldrsquos largest producer of wind energy equipmentrdquo
Source
httpwwwreinforcedplasticscomview15655asia-leads-global-wind-power-growth
httpimgdeusmcomdesignnews288288605-Sandia_Sizes_up_Wind_Turbine_Blade_Design_C_largegif
WIND ENERGY
Marine Current Turbines
Source
httpwwwsiemenscompressenpressreleasepress=enpressrelease2011solar-hydroex201111005htm
httpwwwmarineturbinescom
A commercial marine current turbine consists of
two rotors which are fixed on a structure within the
sea current The twin rotors rotate with the
movement of the tidal flow and the blades pitch
through 180 degrees to optimally track tidal current
(Press picture Marine Current Turbines)
Wave Star Energys Multi-point Absorber
CFRP COLUMN REINFORCEMENT
INDUSTRIAL TANKS
107
INDUSTRIAL PIPES
PRESSURE TANKS
109
ldquoLetrsquos Make with Compositesrdquo
QUADRAXIAL
DBLT 800 ndash
APLIKASI PADA INDUSTRI ENERGI
DITERAPKAN UNTUK KEBUTUHAN PEMBANGKIT
LISTRIK ENERGI ANGIN
MULTIAXIAL UNTUK ENERGI
INDUSTRI KIMIA OLAHRAGA AUTOMOTIF
MULTIAXIAL UNTUK INDUSTRI LAINNYA
COMPOSITES
GUNAKAN MATERIAL FIBERGLASS
YANG SUDAH DISERTIFIKASI
BKI
FIBERGLASS UNTUK PEMBANGUNAN BAKAP
PERATURAN MENTERI PERHUBUNGAN
NOMOR PM 7 TAHUN 2013
TENTANG KEWAJIBAN KLASIFIKASI BAGI KAPAL BERBENDERA INDONESIA
PADA BADAN KLASIFIKASI
BADAN SERTIFIKASI MARITIM
Biro Klasifikasi IndonesiaDet Norske Veritas Germanischer Lloyds
PERATURAN BKI
Untuk Kapal Non-Metal
2006
PERSYARATAN MINIMUM
kekuatan material yang
harus digunakan
untuk membangun
Kapal Fiberglass
PEMBESARAN
Table 21
FIBERGLASS TRIAXIS COMPOSITES
TELAH BERSERTIFIKASI BKI
Biro Klasifikasi Indonesia
65
TEKNIK MANUFAKTUR
COMPOSITES
Wet hand lay-up
1) Peletakan
Dry Reinforcement
bull Dry reinforcement dan resin (+ katalis) ditaruh pada permukaan cetakan
2) Pemasukanpenekanan resin
bull Resin ditekan untuk meng-impregnasi serat dengan menggunakan rol
3) Pengulangan proses untuk lapisan lain
bull Beberapa lapisan dapat ditambahkan secara bertahap
4) Resin curing
bull Reaksi dimulai komponen dilepaskan setelah komponen mengeras
(fully cured)
Wet hand lay-up
Manufaktur komponen dapat dikerjakan dengan menggunakan beberapa lapis komposit
dengan memperhatikan kompatibilitas material dan tahapan curing Modifikasi proses dapat
dilakukan seperti
Vacuum bagging
setelah lay-up
Glass Roving
Bulk Resin
Catalyst
3) De-molding
2) Resin Cure
bull Curing dimulai dan komponen dilepaskan setelah pengerasan selesai
bull Serat gelas resin dan katalis dimasukkan kedalam spray gun
1) Spray-up
bull Campuran disemprotkan pada permukaan cetakan
Spray-up
69
Penyemprotan bakal komponen
Komponen
dilepaskan
dari cetakan
Full dispensing
system Chopper Roving
Atomised resin
and catalyst
Spray-up
Prepreg
1) LaminateAssembly 5) De-molding
3) Resin Melts Layup Consolidates
bull Prepreg serat yang sudah diimpregnasi oleh resin+katalis dalam kondisi padat
bull Lapisan prepreg digunting sesuai bentuk yang diinginkan kemudian diletakkan pada permukaan cetakan
sesuai bentuk komponen yang diinginkan Lay-up mudah dilakukan karena sifat ldquotackynessrdquo dari prepreg
2) Applied Vacuum Pressure and Heat
bull Tekanan dan panas diberikan resin mencair terjadi konsolidasi pada komponen
4) Resin Cures
bull Temperatur dinaikkan untuk memulai curing
Prepreg
Variasi proses Autoclave
Komponen dalam
vacuum-bag
bull Campuran resin (+katalis) dan chopped glass strands diperoleh dalam bentuk premixed compound Bulk molding
Compound (BMC) dalam bentuk adonan atau Sheet molding Compound (SMC) dalam bentuk lembaran
bull Ketika panas dan tekanan diberikan oleh cetakan compound mengalir sesuai bentuk komponen yang diinginkan
1) Placement of Charge
5) De-molding3) Squeeze to final dimensions
2) Mould Closure4) Resin Cure
bull Curing dimulai komponen dilepaskan setelah terjadi pengerasan yang cukup
Compression Molding
bull Preform atau dry reinforcement dimasukkan kedalam cetakan sesuai dengan bentuk komponen yang
diinginkan
bull Resin mengalir dengan penekanan atau pem-vakuman dan meng-impregnasi preform dan
mendorongmengeluarkan udara yang ada dalam preform
1) Preform Manufacture
2) Preform Compression
5) De-molding3) Resin Injection
4) Resin Cure
bull Curing terjadi cetakan dibuka setelah terjadi pengerasan yang mencukupi
Liquid Molding (RTM VARI VARTM)
Pultrusion
bull Dry roving or fabrics ditarik melalui bak berisi
campuran resin dan katalis
bull Campuran yang basah ditarik melalui cetakan
bull Sisa resin keluar cetakan
bull Pemanasan dilakukan untuk proses curing
bull Pendinginan dilakukan untuk mempercepat siklus
produksi
Cut-off
Cooling
Die sections
Resin bath
Fibre creel
Filament Winding
bull Dry roving ditarik melalui bak berisi campuran resin dan katalis
bull Wet roving digulungkan dalam keadaan tegang kepada mandrel
bull Kontrol mekanik dari pembawa serat mengatur orientasi peletakan serat pada
mandrel
INDUSTRI COMPOSITES
AEROSPACE
HISTORY
1950 ndash Boeing
1960 ndash F14 Tomcat
1981 ndash AV-8B Harrier
Source
Low-Cost Composite Materials and Structures for Aircraft Applications
httpwwwreinforcedplasticscom
httpwwwcentennialofflightgovessayEvolution_of_TechnologycompositesTech40htm
Automotive
Composite material is used in a number of applications in the automotive
industry due to its temperature resistance rigidity and fatigue strength
The benefits of using composites include greater fuel efficiency
corrosion resistance light weight and strength Composites also provide
a low-cost way to help keep designs looking fresh
Composites are used in
- interior parts (cockpit trimming seats instrument panels)
- exterior structure (body panels openings underbody frontrear
modules)
- engine compartment and fuelmechanical area parts (axles and
suspensions fuel and exhaust systems)
- electrical and electronic components
Lamborghinis Sesto Element carbon fiber
ldquoFat men cannot run as fast as thin men but we build most of our vehicles as though dead-weight fat increased speedhellip I cannot
imagine where the delusion that weight means strength
came fromhelliprdquo mdashHenry Ford
The mix of automotive materials is changing showing a boost for FRP in helping original
equipment manufacturers meet fuel economy and emissions challenges
(Source 2011 DuPont AutomotiveSAE survey of design engineers performed by Signet Research Inc)
Source
httpwwwtoraycomcsrhighlight2009hig_001_01html
The MonoCell tub for the McLaren MP4-12C supercar is moulded as a single
piece and weighs less than 80 kg (176 lbs)
COMPOSITES IN MARINE
TRIMARAN BOAT
AMERICA NAVYINDONESIAN NAVY
Visby Class corvette
Total length is 72 meters
The beam is 1040 meters
The displacement is 600 metric tones
fully equipped the worlds largest CRP
construction
The design of the Visby aims to minimize
the optical and infrared signature above
water acoustic and hydroa coustic
signature underwater electrical potential
and magnetic signature pressure signature
radar cross section and actively emitted
signals
A stealth corvette of the YS 2000 design
has a detection range of 13km in rough
seas and 22km in calm sea without
jamming In a jammed environment the
Visby would be detected at a range of 8km
in rough sea and 11km in calm sea
The material provides high strength and
rigidity low weight good shock resistance
low radar and magnetic signature
1996
Visby is a class of stealth corvettes for the Swedish Navy
ldquoReduced 50 of a Conventional Steelrdquo
Source
Hull Construction with composite materials for ships over 100m in length 2002
Massachusetts Institute of Technology
httpwwwnaval-technologycomprojectsvisby
YACHTS
KAL YUDISTIRAMARATHON 100 ADMIRAL YACHT
LOA 3050 MWidth 6 MFuel Tank 8000 LWater Tank 3000 LIce Box 500 LAccommodation Max 35 Personnel
2 x CATERPILLAR 3412E 1200 HPMARINE DIESEL ENGINE
PC 40 ndash KRI Krait 827Department of Indonesian Navy
LOA 40 MWidth 73 MPower 190Weapon Twin Cannon Barrels
127 mm Heavy Machine GunSpeed Knot 25 KnotDisplacement 105 tonAccommodation 23 personnel
PATROL BOAT
Rigid Inflatable BoatPATROL BOAT
Yachts
36m Luxury Yacht Moonraker
36m Luxury Yacht GoldenEye
50m Luxury Yacht Casino
Royale
45m Luxury Yacht Seashaw
Boat Parts
Barovans for Seismic Sweep
Centrifugal Liftfan House for Surface Effect
Ships
Composite Boat PropellersRTM
Deckhouses for Pilot Boats
Fairing Parts for Submarines
Flybridges for Motor yachts
Light Weight Gangway
MTB Launcher Mock-up
Pleasure Boats
12m Sailboat
12m Sail-Catamaranone-off
Canoes
Dragonfly 1000Catamaran Sailboat
Fantasy 37Sailboat
Farr 60Luxury Sailboat
EurodingyOlympic Dingy Class for
Woman
Hydrolift F23 Racing Boats
Kajacs
Najad 42Sailboat
Najad 520Sailboat
Najad 441Sailboat
Najad 391Sailboat
Nordwest 900Motorboat
Nordwest 1100Motorboat
Quatro 44Motorboat
Racemaster Competition Boats
Storebro 420
Storebro 345
Sweden Yacht 370Sailboat
Sweden Yacht 69Sailboat
Windy 41Motorboat
X-632Sailboat
X-362Sailboat
Commercial Boats
175m High Speed AmbulancePassenger Boat
19m High Speed Passenger Boat
20m High Speed Passenger Boat
364m Surface Effect Passenger Ship
45m Surface Effect Passenger Ship
120m Hull Structural Parts HSSS Catamaran Ferry
APPENDIX
Marine Vessel
1188m Fast Attack Vessel FMV 90 E
20m SAV-Surface Auxiliary Vessels
34m Personnel TransportCoast Guard Vessel
40ft Experimental SES
40m Landsort-Class Mine Hunters
54m Mine Counter Measure Vehicles SES
74m Coastal Patrol Boats
Fishing Boats
30 GT
12 GT
10 GT
5 GT
WISEWings In Surface Effect
HOVERCRAFT
Designed specifically for the tourist and transport industries the
Pioneer Mk3 hovercraft is amphibious and comfortably seats 25
passengers plus 1-crew The air-conditioned cabin allows for
maximum visibility for all aboard The Pioneer Mk3 is robust and
dynamic in its performance
Commercial hovercraft
Mk3 AirLift Hovercraft - 1215m
Power is economicaly provided by one Deutz diesel engine of
330kW (442hp) to cruise easily at 40 knots with much higher
speeds available according to the surface conditions The hull is
manufactured from fibreglassPVC foam composite sandwich
the windows are glass and the skirt is urethane coated nylon A
Military version is available with increased payload and systems
redundancy Power for the Military version comes from two Steyr
diesel engines with a total installed power of 320kW (429hp) All
transmission electrical hydraulic and air systems are duplicated
for maximum redundancy The increased performance of the
Military version comes from the reduced engine weight of the twin
Steyr installation cf the Deutz installation
Source
httpwwwnauticexpocomprodairlift-hovercraftcommercial-hovercrafts-25251-142868html
HOVERFLIGHT
BALLISTIC amp UNIT DEFENCED
Triaxis Composites Collaboration with Institute of Aeronautics and Space in the development of Missile Nose Cone
Polymer composites is the evolution of the military defence
Thin steel was the helmet material of
WWII and remained the principal material until around the 1980rsquos
The advantages of using steel
included a simple technology for manufacture of the helmets low cost and reasonably good
impact protection However these helmets were found to provide only marginal protection
against fragments
During the Vietnam War the US Army experimented with fiber-reinforced inserts in the
helmets These inserts improved ballistic protection but at the same time added weight and
reduced the air space between the head and the helmet
By the early part of the 1980rsquos the US military had developed the first all-composite
100 fiber-reinforced helmet This development resulted in even better ballistic protection
without altering the weight of the helmet Other improvements included better head coverage and
more space for ventilation
Source
Composites Armor - A difficult but huge market
by A Brent Strong Brigham Young University
MILITARY VEHICLES
HIGH SPEED TRAIN SHINKANSEN
Advanced Composites provide lightweight solutions for railway vehicles
saving as much as 50-80 of the weight compared with traditional
components
A lower overall weight translates into less stress faster acceleration and
higher speeds as well as reduced starting and stopping inertia Today
these are important criteria in global high-speed and metropolitan
railway projects
Fire smoke and toxic fumes are key safety criteria for interior
components of railway carriages Any material selected for an interior
component must meet international fire retardant standards
for Rail Interiors and Exteriors
Ceiling Panels Stairs
Seating Vestibules
Window Panels Door Pillars
Partition WallsDiffusers
Gangway and Cabinet Panels Cabin and
Desk panels
Door Pillars Lavatory Modules (standard and
Front and Rear EndsRoof Panels
Nose Cones Under Fairings
Source
httpwwwpctaerail_compositesphp
101
SKY BUS
2009
Europe is the world leader in offshore wind with
828 wind turbines and a cumulative capacity of 2056 MW spread across 38 offshore wind farms in 9
European countries
The UK and Denmark are the current leaders with a 44 and 30 share respectively In 2009
five countries built new offshore wind farms
UK (284 MW)
Demark (230 MW)
Sweden (30 MW)
Germany (30 MW)
Norway (23 MW)
2010
Asia leads the growth in global wind power which grew 358 GW in 2010 bringing
total global capacity to 1944 GW ndash up 225 from 2009
the Global Wind Energy Council (GWEC)
Asia accounted for 19 GW of new global wind power installations driven by China which installed 165
GW
ldquoChina now has 423 GW of wind powerrdquo
ldquoThis puts China firmly on a path to reach 200 GW of installed wind power by 2020 At the same
time China has become the worldrsquos largest producer of wind energy equipmentrdquo
Source
httpwwwreinforcedplasticscomview15655asia-leads-global-wind-power-growth
httpimgdeusmcomdesignnews288288605-Sandia_Sizes_up_Wind_Turbine_Blade_Design_C_largegif
WIND ENERGY
Marine Current Turbines
Source
httpwwwsiemenscompressenpressreleasepress=enpressrelease2011solar-hydroex201111005htm
httpwwwmarineturbinescom
A commercial marine current turbine consists of
two rotors which are fixed on a structure within the
sea current The twin rotors rotate with the
movement of the tidal flow and the blades pitch
through 180 degrees to optimally track tidal current
(Press picture Marine Current Turbines)
Wave Star Energys Multi-point Absorber
CFRP COLUMN REINFORCEMENT
INDUSTRIAL TANKS
107
INDUSTRIAL PIPES
PRESSURE TANKS
109
ldquoLetrsquos Make with Compositesrdquo
INDUSTRI KIMIA OLAHRAGA AUTOMOTIF
MULTIAXIAL UNTUK INDUSTRI LAINNYA
COMPOSITES
GUNAKAN MATERIAL FIBERGLASS
YANG SUDAH DISERTIFIKASI
BKI
FIBERGLASS UNTUK PEMBANGUNAN BAKAP
PERATURAN MENTERI PERHUBUNGAN
NOMOR PM 7 TAHUN 2013
TENTANG KEWAJIBAN KLASIFIKASI BAGI KAPAL BERBENDERA INDONESIA
PADA BADAN KLASIFIKASI
BADAN SERTIFIKASI MARITIM
Biro Klasifikasi IndonesiaDet Norske Veritas Germanischer Lloyds
PERATURAN BKI
Untuk Kapal Non-Metal
2006
PERSYARATAN MINIMUM
kekuatan material yang
harus digunakan
untuk membangun
Kapal Fiberglass
PEMBESARAN
Table 21
FIBERGLASS TRIAXIS COMPOSITES
TELAH BERSERTIFIKASI BKI
Biro Klasifikasi Indonesia
65
TEKNIK MANUFAKTUR
COMPOSITES
Wet hand lay-up
1) Peletakan
Dry Reinforcement
bull Dry reinforcement dan resin (+ katalis) ditaruh pada permukaan cetakan
2) Pemasukanpenekanan resin
bull Resin ditekan untuk meng-impregnasi serat dengan menggunakan rol
3) Pengulangan proses untuk lapisan lain
bull Beberapa lapisan dapat ditambahkan secara bertahap
4) Resin curing
bull Reaksi dimulai komponen dilepaskan setelah komponen mengeras
(fully cured)
Wet hand lay-up
Manufaktur komponen dapat dikerjakan dengan menggunakan beberapa lapis komposit
dengan memperhatikan kompatibilitas material dan tahapan curing Modifikasi proses dapat
dilakukan seperti
Vacuum bagging
setelah lay-up
Glass Roving
Bulk Resin
Catalyst
3) De-molding
2) Resin Cure
bull Curing dimulai dan komponen dilepaskan setelah pengerasan selesai
bull Serat gelas resin dan katalis dimasukkan kedalam spray gun
1) Spray-up
bull Campuran disemprotkan pada permukaan cetakan
Spray-up
69
Penyemprotan bakal komponen
Komponen
dilepaskan
dari cetakan
Full dispensing
system Chopper Roving
Atomised resin
and catalyst
Spray-up
Prepreg
1) LaminateAssembly 5) De-molding
3) Resin Melts Layup Consolidates
bull Prepreg serat yang sudah diimpregnasi oleh resin+katalis dalam kondisi padat
bull Lapisan prepreg digunting sesuai bentuk yang diinginkan kemudian diletakkan pada permukaan cetakan
sesuai bentuk komponen yang diinginkan Lay-up mudah dilakukan karena sifat ldquotackynessrdquo dari prepreg
2) Applied Vacuum Pressure and Heat
bull Tekanan dan panas diberikan resin mencair terjadi konsolidasi pada komponen
4) Resin Cures
bull Temperatur dinaikkan untuk memulai curing
Prepreg
Variasi proses Autoclave
Komponen dalam
vacuum-bag
bull Campuran resin (+katalis) dan chopped glass strands diperoleh dalam bentuk premixed compound Bulk molding
Compound (BMC) dalam bentuk adonan atau Sheet molding Compound (SMC) dalam bentuk lembaran
bull Ketika panas dan tekanan diberikan oleh cetakan compound mengalir sesuai bentuk komponen yang diinginkan
1) Placement of Charge
5) De-molding3) Squeeze to final dimensions
2) Mould Closure4) Resin Cure
bull Curing dimulai komponen dilepaskan setelah terjadi pengerasan yang cukup
Compression Molding
bull Preform atau dry reinforcement dimasukkan kedalam cetakan sesuai dengan bentuk komponen yang
diinginkan
bull Resin mengalir dengan penekanan atau pem-vakuman dan meng-impregnasi preform dan
mendorongmengeluarkan udara yang ada dalam preform
1) Preform Manufacture
2) Preform Compression
5) De-molding3) Resin Injection
4) Resin Cure
bull Curing terjadi cetakan dibuka setelah terjadi pengerasan yang mencukupi
Liquid Molding (RTM VARI VARTM)
Pultrusion
bull Dry roving or fabrics ditarik melalui bak berisi
campuran resin dan katalis
bull Campuran yang basah ditarik melalui cetakan
bull Sisa resin keluar cetakan
bull Pemanasan dilakukan untuk proses curing
bull Pendinginan dilakukan untuk mempercepat siklus
produksi
Cut-off
Cooling
Die sections
Resin bath
Fibre creel
Filament Winding
bull Dry roving ditarik melalui bak berisi campuran resin dan katalis
bull Wet roving digulungkan dalam keadaan tegang kepada mandrel
bull Kontrol mekanik dari pembawa serat mengatur orientasi peletakan serat pada
mandrel
INDUSTRI COMPOSITES
AEROSPACE
HISTORY
1950 ndash Boeing
1960 ndash F14 Tomcat
1981 ndash AV-8B Harrier
Source
Low-Cost Composite Materials and Structures for Aircraft Applications
httpwwwreinforcedplasticscom
httpwwwcentennialofflightgovessayEvolution_of_TechnologycompositesTech40htm
Automotive
Composite material is used in a number of applications in the automotive
industry due to its temperature resistance rigidity and fatigue strength
The benefits of using composites include greater fuel efficiency
corrosion resistance light weight and strength Composites also provide
a low-cost way to help keep designs looking fresh
Composites are used in
- interior parts (cockpit trimming seats instrument panels)
- exterior structure (body panels openings underbody frontrear
modules)
- engine compartment and fuelmechanical area parts (axles and
suspensions fuel and exhaust systems)
- electrical and electronic components
Lamborghinis Sesto Element carbon fiber
ldquoFat men cannot run as fast as thin men but we build most of our vehicles as though dead-weight fat increased speedhellip I cannot
imagine where the delusion that weight means strength
came fromhelliprdquo mdashHenry Ford
The mix of automotive materials is changing showing a boost for FRP in helping original
equipment manufacturers meet fuel economy and emissions challenges
(Source 2011 DuPont AutomotiveSAE survey of design engineers performed by Signet Research Inc)
Source
httpwwwtoraycomcsrhighlight2009hig_001_01html
The MonoCell tub for the McLaren MP4-12C supercar is moulded as a single
piece and weighs less than 80 kg (176 lbs)
COMPOSITES IN MARINE
TRIMARAN BOAT
AMERICA NAVYINDONESIAN NAVY
Visby Class corvette
Total length is 72 meters
The beam is 1040 meters
The displacement is 600 metric tones
fully equipped the worlds largest CRP
construction
The design of the Visby aims to minimize
the optical and infrared signature above
water acoustic and hydroa coustic
signature underwater electrical potential
and magnetic signature pressure signature
radar cross section and actively emitted
signals
A stealth corvette of the YS 2000 design
has a detection range of 13km in rough
seas and 22km in calm sea without
jamming In a jammed environment the
Visby would be detected at a range of 8km
in rough sea and 11km in calm sea
The material provides high strength and
rigidity low weight good shock resistance
low radar and magnetic signature
1996
Visby is a class of stealth corvettes for the Swedish Navy
ldquoReduced 50 of a Conventional Steelrdquo
Source
Hull Construction with composite materials for ships over 100m in length 2002
Massachusetts Institute of Technology
httpwwwnaval-technologycomprojectsvisby
YACHTS
KAL YUDISTIRAMARATHON 100 ADMIRAL YACHT
LOA 3050 MWidth 6 MFuel Tank 8000 LWater Tank 3000 LIce Box 500 LAccommodation Max 35 Personnel
2 x CATERPILLAR 3412E 1200 HPMARINE DIESEL ENGINE
PC 40 ndash KRI Krait 827Department of Indonesian Navy
LOA 40 MWidth 73 MPower 190Weapon Twin Cannon Barrels
127 mm Heavy Machine GunSpeed Knot 25 KnotDisplacement 105 tonAccommodation 23 personnel
PATROL BOAT
Rigid Inflatable BoatPATROL BOAT
Yachts
36m Luxury Yacht Moonraker
36m Luxury Yacht GoldenEye
50m Luxury Yacht Casino
Royale
45m Luxury Yacht Seashaw
Boat Parts
Barovans for Seismic Sweep
Centrifugal Liftfan House for Surface Effect
Ships
Composite Boat PropellersRTM
Deckhouses for Pilot Boats
Fairing Parts for Submarines
Flybridges for Motor yachts
Light Weight Gangway
MTB Launcher Mock-up
Pleasure Boats
12m Sailboat
12m Sail-Catamaranone-off
Canoes
Dragonfly 1000Catamaran Sailboat
Fantasy 37Sailboat
Farr 60Luxury Sailboat
EurodingyOlympic Dingy Class for
Woman
Hydrolift F23 Racing Boats
Kajacs
Najad 42Sailboat
Najad 520Sailboat
Najad 441Sailboat
Najad 391Sailboat
Nordwest 900Motorboat
Nordwest 1100Motorboat
Quatro 44Motorboat
Racemaster Competition Boats
Storebro 420
Storebro 345
Sweden Yacht 370Sailboat
Sweden Yacht 69Sailboat
Windy 41Motorboat
X-632Sailboat
X-362Sailboat
Commercial Boats
175m High Speed AmbulancePassenger Boat
19m High Speed Passenger Boat
20m High Speed Passenger Boat
364m Surface Effect Passenger Ship
45m Surface Effect Passenger Ship
120m Hull Structural Parts HSSS Catamaran Ferry
APPENDIX
Marine Vessel
1188m Fast Attack Vessel FMV 90 E
20m SAV-Surface Auxiliary Vessels
34m Personnel TransportCoast Guard Vessel
40ft Experimental SES
40m Landsort-Class Mine Hunters
54m Mine Counter Measure Vehicles SES
74m Coastal Patrol Boats
Fishing Boats
30 GT
12 GT
10 GT
5 GT
WISEWings In Surface Effect
HOVERCRAFT
Designed specifically for the tourist and transport industries the
Pioneer Mk3 hovercraft is amphibious and comfortably seats 25
passengers plus 1-crew The air-conditioned cabin allows for
maximum visibility for all aboard The Pioneer Mk3 is robust and
dynamic in its performance
Commercial hovercraft
Mk3 AirLift Hovercraft - 1215m
Power is economicaly provided by one Deutz diesel engine of
330kW (442hp) to cruise easily at 40 knots with much higher
speeds available according to the surface conditions The hull is
manufactured from fibreglassPVC foam composite sandwich
the windows are glass and the skirt is urethane coated nylon A
Military version is available with increased payload and systems
redundancy Power for the Military version comes from two Steyr
diesel engines with a total installed power of 320kW (429hp) All
transmission electrical hydraulic and air systems are duplicated
for maximum redundancy The increased performance of the
Military version comes from the reduced engine weight of the twin
Steyr installation cf the Deutz installation
Source
httpwwwnauticexpocomprodairlift-hovercraftcommercial-hovercrafts-25251-142868html
HOVERFLIGHT
BALLISTIC amp UNIT DEFENCED
Triaxis Composites Collaboration with Institute of Aeronautics and Space in the development of Missile Nose Cone
Polymer composites is the evolution of the military defence
Thin steel was the helmet material of
WWII and remained the principal material until around the 1980rsquos
The advantages of using steel
included a simple technology for manufacture of the helmets low cost and reasonably good
impact protection However these helmets were found to provide only marginal protection
against fragments
During the Vietnam War the US Army experimented with fiber-reinforced inserts in the
helmets These inserts improved ballistic protection but at the same time added weight and
reduced the air space between the head and the helmet
By the early part of the 1980rsquos the US military had developed the first all-composite
100 fiber-reinforced helmet This development resulted in even better ballistic protection
without altering the weight of the helmet Other improvements included better head coverage and
more space for ventilation
Source
Composites Armor - A difficult but huge market
by A Brent Strong Brigham Young University
MILITARY VEHICLES
HIGH SPEED TRAIN SHINKANSEN
Advanced Composites provide lightweight solutions for railway vehicles
saving as much as 50-80 of the weight compared with traditional
components
A lower overall weight translates into less stress faster acceleration and
higher speeds as well as reduced starting and stopping inertia Today
these are important criteria in global high-speed and metropolitan
railway projects
Fire smoke and toxic fumes are key safety criteria for interior
components of railway carriages Any material selected for an interior
component must meet international fire retardant standards
for Rail Interiors and Exteriors
Ceiling Panels Stairs
Seating Vestibules
Window Panels Door Pillars
Partition WallsDiffusers
Gangway and Cabinet Panels Cabin and
Desk panels
Door Pillars Lavatory Modules (standard and
Front and Rear EndsRoof Panels
Nose Cones Under Fairings
Source
httpwwwpctaerail_compositesphp
101
SKY BUS
2009
Europe is the world leader in offshore wind with
828 wind turbines and a cumulative capacity of 2056 MW spread across 38 offshore wind farms in 9
European countries
The UK and Denmark are the current leaders with a 44 and 30 share respectively In 2009
five countries built new offshore wind farms
UK (284 MW)
Demark (230 MW)
Sweden (30 MW)
Germany (30 MW)
Norway (23 MW)
2010
Asia leads the growth in global wind power which grew 358 GW in 2010 bringing
total global capacity to 1944 GW ndash up 225 from 2009
the Global Wind Energy Council (GWEC)
Asia accounted for 19 GW of new global wind power installations driven by China which installed 165
GW
ldquoChina now has 423 GW of wind powerrdquo
ldquoThis puts China firmly on a path to reach 200 GW of installed wind power by 2020 At the same
time China has become the worldrsquos largest producer of wind energy equipmentrdquo
Source
httpwwwreinforcedplasticscomview15655asia-leads-global-wind-power-growth
httpimgdeusmcomdesignnews288288605-Sandia_Sizes_up_Wind_Turbine_Blade_Design_C_largegif
WIND ENERGY
Marine Current Turbines
Source
httpwwwsiemenscompressenpressreleasepress=enpressrelease2011solar-hydroex201111005htm
httpwwwmarineturbinescom
A commercial marine current turbine consists of
two rotors which are fixed on a structure within the
sea current The twin rotors rotate with the
movement of the tidal flow and the blades pitch
through 180 degrees to optimally track tidal current
(Press picture Marine Current Turbines)
Wave Star Energys Multi-point Absorber
CFRP COLUMN REINFORCEMENT
INDUSTRIAL TANKS
107
INDUSTRIAL PIPES
PRESSURE TANKS
109
ldquoLetrsquos Make with Compositesrdquo
COMPOSITES
GUNAKAN MATERIAL FIBERGLASS
YANG SUDAH DISERTIFIKASI
BKI
FIBERGLASS UNTUK PEMBANGUNAN BAKAP
PERATURAN MENTERI PERHUBUNGAN
NOMOR PM 7 TAHUN 2013
TENTANG KEWAJIBAN KLASIFIKASI BAGI KAPAL BERBENDERA INDONESIA
PADA BADAN KLASIFIKASI
BADAN SERTIFIKASI MARITIM
Biro Klasifikasi IndonesiaDet Norske Veritas Germanischer Lloyds
PERATURAN BKI
Untuk Kapal Non-Metal
2006
PERSYARATAN MINIMUM
kekuatan material yang
harus digunakan
untuk membangun
Kapal Fiberglass
PEMBESARAN
Table 21
FIBERGLASS TRIAXIS COMPOSITES
TELAH BERSERTIFIKASI BKI
Biro Klasifikasi Indonesia
65
TEKNIK MANUFAKTUR
COMPOSITES
Wet hand lay-up
1) Peletakan
Dry Reinforcement
bull Dry reinforcement dan resin (+ katalis) ditaruh pada permukaan cetakan
2) Pemasukanpenekanan resin
bull Resin ditekan untuk meng-impregnasi serat dengan menggunakan rol
3) Pengulangan proses untuk lapisan lain
bull Beberapa lapisan dapat ditambahkan secara bertahap
4) Resin curing
bull Reaksi dimulai komponen dilepaskan setelah komponen mengeras
(fully cured)
Wet hand lay-up
Manufaktur komponen dapat dikerjakan dengan menggunakan beberapa lapis komposit
dengan memperhatikan kompatibilitas material dan tahapan curing Modifikasi proses dapat
dilakukan seperti
Vacuum bagging
setelah lay-up
Glass Roving
Bulk Resin
Catalyst
3) De-molding
2) Resin Cure
bull Curing dimulai dan komponen dilepaskan setelah pengerasan selesai
bull Serat gelas resin dan katalis dimasukkan kedalam spray gun
1) Spray-up
bull Campuran disemprotkan pada permukaan cetakan
Spray-up
69
Penyemprotan bakal komponen
Komponen
dilepaskan
dari cetakan
Full dispensing
system Chopper Roving
Atomised resin
and catalyst
Spray-up
Prepreg
1) LaminateAssembly 5) De-molding
3) Resin Melts Layup Consolidates
bull Prepreg serat yang sudah diimpregnasi oleh resin+katalis dalam kondisi padat
bull Lapisan prepreg digunting sesuai bentuk yang diinginkan kemudian diletakkan pada permukaan cetakan
sesuai bentuk komponen yang diinginkan Lay-up mudah dilakukan karena sifat ldquotackynessrdquo dari prepreg
2) Applied Vacuum Pressure and Heat
bull Tekanan dan panas diberikan resin mencair terjadi konsolidasi pada komponen
4) Resin Cures
bull Temperatur dinaikkan untuk memulai curing
Prepreg
Variasi proses Autoclave
Komponen dalam
vacuum-bag
bull Campuran resin (+katalis) dan chopped glass strands diperoleh dalam bentuk premixed compound Bulk molding
Compound (BMC) dalam bentuk adonan atau Sheet molding Compound (SMC) dalam bentuk lembaran
bull Ketika panas dan tekanan diberikan oleh cetakan compound mengalir sesuai bentuk komponen yang diinginkan
1) Placement of Charge
5) De-molding3) Squeeze to final dimensions
2) Mould Closure4) Resin Cure
bull Curing dimulai komponen dilepaskan setelah terjadi pengerasan yang cukup
Compression Molding
bull Preform atau dry reinforcement dimasukkan kedalam cetakan sesuai dengan bentuk komponen yang
diinginkan
bull Resin mengalir dengan penekanan atau pem-vakuman dan meng-impregnasi preform dan
mendorongmengeluarkan udara yang ada dalam preform
1) Preform Manufacture
2) Preform Compression
5) De-molding3) Resin Injection
4) Resin Cure
bull Curing terjadi cetakan dibuka setelah terjadi pengerasan yang mencukupi
Liquid Molding (RTM VARI VARTM)
Pultrusion
bull Dry roving or fabrics ditarik melalui bak berisi
campuran resin dan katalis
bull Campuran yang basah ditarik melalui cetakan
bull Sisa resin keluar cetakan
bull Pemanasan dilakukan untuk proses curing
bull Pendinginan dilakukan untuk mempercepat siklus
produksi
Cut-off
Cooling
Die sections
Resin bath
Fibre creel
Filament Winding
bull Dry roving ditarik melalui bak berisi campuran resin dan katalis
bull Wet roving digulungkan dalam keadaan tegang kepada mandrel
bull Kontrol mekanik dari pembawa serat mengatur orientasi peletakan serat pada
mandrel
INDUSTRI COMPOSITES
AEROSPACE
HISTORY
1950 ndash Boeing
1960 ndash F14 Tomcat
1981 ndash AV-8B Harrier
Source
Low-Cost Composite Materials and Structures for Aircraft Applications
httpwwwreinforcedplasticscom
httpwwwcentennialofflightgovessayEvolution_of_TechnologycompositesTech40htm
Automotive
Composite material is used in a number of applications in the automotive
industry due to its temperature resistance rigidity and fatigue strength
The benefits of using composites include greater fuel efficiency
corrosion resistance light weight and strength Composites also provide
a low-cost way to help keep designs looking fresh
Composites are used in
- interior parts (cockpit trimming seats instrument panels)
- exterior structure (body panels openings underbody frontrear
modules)
- engine compartment and fuelmechanical area parts (axles and
suspensions fuel and exhaust systems)
- electrical and electronic components
Lamborghinis Sesto Element carbon fiber
ldquoFat men cannot run as fast as thin men but we build most of our vehicles as though dead-weight fat increased speedhellip I cannot
imagine where the delusion that weight means strength
came fromhelliprdquo mdashHenry Ford
The mix of automotive materials is changing showing a boost for FRP in helping original
equipment manufacturers meet fuel economy and emissions challenges
(Source 2011 DuPont AutomotiveSAE survey of design engineers performed by Signet Research Inc)
Source
httpwwwtoraycomcsrhighlight2009hig_001_01html
The MonoCell tub for the McLaren MP4-12C supercar is moulded as a single
piece and weighs less than 80 kg (176 lbs)
COMPOSITES IN MARINE
TRIMARAN BOAT
AMERICA NAVYINDONESIAN NAVY
Visby Class corvette
Total length is 72 meters
The beam is 1040 meters
The displacement is 600 metric tones
fully equipped the worlds largest CRP
construction
The design of the Visby aims to minimize
the optical and infrared signature above
water acoustic and hydroa coustic
signature underwater electrical potential
and magnetic signature pressure signature
radar cross section and actively emitted
signals
A stealth corvette of the YS 2000 design
has a detection range of 13km in rough
seas and 22km in calm sea without
jamming In a jammed environment the
Visby would be detected at a range of 8km
in rough sea and 11km in calm sea
The material provides high strength and
rigidity low weight good shock resistance
low radar and magnetic signature
1996
Visby is a class of stealth corvettes for the Swedish Navy
ldquoReduced 50 of a Conventional Steelrdquo
Source
Hull Construction with composite materials for ships over 100m in length 2002
Massachusetts Institute of Technology
httpwwwnaval-technologycomprojectsvisby
YACHTS
KAL YUDISTIRAMARATHON 100 ADMIRAL YACHT
LOA 3050 MWidth 6 MFuel Tank 8000 LWater Tank 3000 LIce Box 500 LAccommodation Max 35 Personnel
2 x CATERPILLAR 3412E 1200 HPMARINE DIESEL ENGINE
PC 40 ndash KRI Krait 827Department of Indonesian Navy
LOA 40 MWidth 73 MPower 190Weapon Twin Cannon Barrels
127 mm Heavy Machine GunSpeed Knot 25 KnotDisplacement 105 tonAccommodation 23 personnel
PATROL BOAT
Rigid Inflatable BoatPATROL BOAT
Yachts
36m Luxury Yacht Moonraker
36m Luxury Yacht GoldenEye
50m Luxury Yacht Casino
Royale
45m Luxury Yacht Seashaw
Boat Parts
Barovans for Seismic Sweep
Centrifugal Liftfan House for Surface Effect
Ships
Composite Boat PropellersRTM
Deckhouses for Pilot Boats
Fairing Parts for Submarines
Flybridges for Motor yachts
Light Weight Gangway
MTB Launcher Mock-up
Pleasure Boats
12m Sailboat
12m Sail-Catamaranone-off
Canoes
Dragonfly 1000Catamaran Sailboat
Fantasy 37Sailboat
Farr 60Luxury Sailboat
EurodingyOlympic Dingy Class for
Woman
Hydrolift F23 Racing Boats
Kajacs
Najad 42Sailboat
Najad 520Sailboat
Najad 441Sailboat
Najad 391Sailboat
Nordwest 900Motorboat
Nordwest 1100Motorboat
Quatro 44Motorboat
Racemaster Competition Boats
Storebro 420
Storebro 345
Sweden Yacht 370Sailboat
Sweden Yacht 69Sailboat
Windy 41Motorboat
X-632Sailboat
X-362Sailboat
Commercial Boats
175m High Speed AmbulancePassenger Boat
19m High Speed Passenger Boat
20m High Speed Passenger Boat
364m Surface Effect Passenger Ship
45m Surface Effect Passenger Ship
120m Hull Structural Parts HSSS Catamaran Ferry
APPENDIX
Marine Vessel
1188m Fast Attack Vessel FMV 90 E
20m SAV-Surface Auxiliary Vessels
34m Personnel TransportCoast Guard Vessel
40ft Experimental SES
40m Landsort-Class Mine Hunters
54m Mine Counter Measure Vehicles SES
74m Coastal Patrol Boats
Fishing Boats
30 GT
12 GT
10 GT
5 GT
WISEWings In Surface Effect
HOVERCRAFT
Designed specifically for the tourist and transport industries the
Pioneer Mk3 hovercraft is amphibious and comfortably seats 25
passengers plus 1-crew The air-conditioned cabin allows for
maximum visibility for all aboard The Pioneer Mk3 is robust and
dynamic in its performance
Commercial hovercraft
Mk3 AirLift Hovercraft - 1215m
Power is economicaly provided by one Deutz diesel engine of
330kW (442hp) to cruise easily at 40 knots with much higher
speeds available according to the surface conditions The hull is
manufactured from fibreglassPVC foam composite sandwich
the windows are glass and the skirt is urethane coated nylon A
Military version is available with increased payload and systems
redundancy Power for the Military version comes from two Steyr
diesel engines with a total installed power of 320kW (429hp) All
transmission electrical hydraulic and air systems are duplicated
for maximum redundancy The increased performance of the
Military version comes from the reduced engine weight of the twin
Steyr installation cf the Deutz installation
Source
httpwwwnauticexpocomprodairlift-hovercraftcommercial-hovercrafts-25251-142868html
HOVERFLIGHT
BALLISTIC amp UNIT DEFENCED
Triaxis Composites Collaboration with Institute of Aeronautics and Space in the development of Missile Nose Cone
Polymer composites is the evolution of the military defence
Thin steel was the helmet material of
WWII and remained the principal material until around the 1980rsquos
The advantages of using steel
included a simple technology for manufacture of the helmets low cost and reasonably good
impact protection However these helmets were found to provide only marginal protection
against fragments
During the Vietnam War the US Army experimented with fiber-reinforced inserts in the
helmets These inserts improved ballistic protection but at the same time added weight and
reduced the air space between the head and the helmet
By the early part of the 1980rsquos the US military had developed the first all-composite
100 fiber-reinforced helmet This development resulted in even better ballistic protection
without altering the weight of the helmet Other improvements included better head coverage and
more space for ventilation
Source
Composites Armor - A difficult but huge market
by A Brent Strong Brigham Young University
MILITARY VEHICLES
HIGH SPEED TRAIN SHINKANSEN
Advanced Composites provide lightweight solutions for railway vehicles
saving as much as 50-80 of the weight compared with traditional
components
A lower overall weight translates into less stress faster acceleration and
higher speeds as well as reduced starting and stopping inertia Today
these are important criteria in global high-speed and metropolitan
railway projects
Fire smoke and toxic fumes are key safety criteria for interior
components of railway carriages Any material selected for an interior
component must meet international fire retardant standards
for Rail Interiors and Exteriors
Ceiling Panels Stairs
Seating Vestibules
Window Panels Door Pillars
Partition WallsDiffusers
Gangway and Cabinet Panels Cabin and
Desk panels
Door Pillars Lavatory Modules (standard and
Front and Rear EndsRoof Panels
Nose Cones Under Fairings
Source
httpwwwpctaerail_compositesphp
101
SKY BUS
2009
Europe is the world leader in offshore wind with
828 wind turbines and a cumulative capacity of 2056 MW spread across 38 offshore wind farms in 9
European countries
The UK and Denmark are the current leaders with a 44 and 30 share respectively In 2009
five countries built new offshore wind farms
UK (284 MW)
Demark (230 MW)
Sweden (30 MW)
Germany (30 MW)
Norway (23 MW)
2010
Asia leads the growth in global wind power which grew 358 GW in 2010 bringing
total global capacity to 1944 GW ndash up 225 from 2009
the Global Wind Energy Council (GWEC)
Asia accounted for 19 GW of new global wind power installations driven by China which installed 165
GW
ldquoChina now has 423 GW of wind powerrdquo
ldquoThis puts China firmly on a path to reach 200 GW of installed wind power by 2020 At the same
time China has become the worldrsquos largest producer of wind energy equipmentrdquo
Source
httpwwwreinforcedplasticscomview15655asia-leads-global-wind-power-growth
httpimgdeusmcomdesignnews288288605-Sandia_Sizes_up_Wind_Turbine_Blade_Design_C_largegif
WIND ENERGY
Marine Current Turbines
Source
httpwwwsiemenscompressenpressreleasepress=enpressrelease2011solar-hydroex201111005htm
httpwwwmarineturbinescom
A commercial marine current turbine consists of
two rotors which are fixed on a structure within the
sea current The twin rotors rotate with the
movement of the tidal flow and the blades pitch
through 180 degrees to optimally track tidal current
(Press picture Marine Current Turbines)
Wave Star Energys Multi-point Absorber
CFRP COLUMN REINFORCEMENT
INDUSTRIAL TANKS
107
INDUSTRIAL PIPES
PRESSURE TANKS
109
ldquoLetrsquos Make with Compositesrdquo
GUNAKAN MATERIAL FIBERGLASS
YANG SUDAH DISERTIFIKASI
BKI
FIBERGLASS UNTUK PEMBANGUNAN BAKAP
PERATURAN MENTERI PERHUBUNGAN
NOMOR PM 7 TAHUN 2013
TENTANG KEWAJIBAN KLASIFIKASI BAGI KAPAL BERBENDERA INDONESIA
PADA BADAN KLASIFIKASI
BADAN SERTIFIKASI MARITIM
Biro Klasifikasi IndonesiaDet Norske Veritas Germanischer Lloyds
PERATURAN BKI
Untuk Kapal Non-Metal
2006
PERSYARATAN MINIMUM
kekuatan material yang
harus digunakan
untuk membangun
Kapal Fiberglass
PEMBESARAN
Table 21
FIBERGLASS TRIAXIS COMPOSITES
TELAH BERSERTIFIKASI BKI
Biro Klasifikasi Indonesia
65
TEKNIK MANUFAKTUR
COMPOSITES
Wet hand lay-up
1) Peletakan
Dry Reinforcement
bull Dry reinforcement dan resin (+ katalis) ditaruh pada permukaan cetakan
2) Pemasukanpenekanan resin
bull Resin ditekan untuk meng-impregnasi serat dengan menggunakan rol
3) Pengulangan proses untuk lapisan lain
bull Beberapa lapisan dapat ditambahkan secara bertahap
4) Resin curing
bull Reaksi dimulai komponen dilepaskan setelah komponen mengeras
(fully cured)
Wet hand lay-up
Manufaktur komponen dapat dikerjakan dengan menggunakan beberapa lapis komposit
dengan memperhatikan kompatibilitas material dan tahapan curing Modifikasi proses dapat
dilakukan seperti
Vacuum bagging
setelah lay-up
Glass Roving
Bulk Resin
Catalyst
3) De-molding
2) Resin Cure
bull Curing dimulai dan komponen dilepaskan setelah pengerasan selesai
bull Serat gelas resin dan katalis dimasukkan kedalam spray gun
1) Spray-up
bull Campuran disemprotkan pada permukaan cetakan
Spray-up
69
Penyemprotan bakal komponen
Komponen
dilepaskan
dari cetakan
Full dispensing
system Chopper Roving
Atomised resin
and catalyst
Spray-up
Prepreg
1) LaminateAssembly 5) De-molding
3) Resin Melts Layup Consolidates
bull Prepreg serat yang sudah diimpregnasi oleh resin+katalis dalam kondisi padat
bull Lapisan prepreg digunting sesuai bentuk yang diinginkan kemudian diletakkan pada permukaan cetakan
sesuai bentuk komponen yang diinginkan Lay-up mudah dilakukan karena sifat ldquotackynessrdquo dari prepreg
2) Applied Vacuum Pressure and Heat
bull Tekanan dan panas diberikan resin mencair terjadi konsolidasi pada komponen
4) Resin Cures
bull Temperatur dinaikkan untuk memulai curing
Prepreg
Variasi proses Autoclave
Komponen dalam
vacuum-bag
bull Campuran resin (+katalis) dan chopped glass strands diperoleh dalam bentuk premixed compound Bulk molding
Compound (BMC) dalam bentuk adonan atau Sheet molding Compound (SMC) dalam bentuk lembaran
bull Ketika panas dan tekanan diberikan oleh cetakan compound mengalir sesuai bentuk komponen yang diinginkan
1) Placement of Charge
5) De-molding3) Squeeze to final dimensions
2) Mould Closure4) Resin Cure
bull Curing dimulai komponen dilepaskan setelah terjadi pengerasan yang cukup
Compression Molding
bull Preform atau dry reinforcement dimasukkan kedalam cetakan sesuai dengan bentuk komponen yang
diinginkan
bull Resin mengalir dengan penekanan atau pem-vakuman dan meng-impregnasi preform dan
mendorongmengeluarkan udara yang ada dalam preform
1) Preform Manufacture
2) Preform Compression
5) De-molding3) Resin Injection
4) Resin Cure
bull Curing terjadi cetakan dibuka setelah terjadi pengerasan yang mencukupi
Liquid Molding (RTM VARI VARTM)
Pultrusion
bull Dry roving or fabrics ditarik melalui bak berisi
campuran resin dan katalis
bull Campuran yang basah ditarik melalui cetakan
bull Sisa resin keluar cetakan
bull Pemanasan dilakukan untuk proses curing
bull Pendinginan dilakukan untuk mempercepat siklus
produksi
Cut-off
Cooling
Die sections
Resin bath
Fibre creel
Filament Winding
bull Dry roving ditarik melalui bak berisi campuran resin dan katalis
bull Wet roving digulungkan dalam keadaan tegang kepada mandrel
bull Kontrol mekanik dari pembawa serat mengatur orientasi peletakan serat pada
mandrel
INDUSTRI COMPOSITES
AEROSPACE
HISTORY
1950 ndash Boeing
1960 ndash F14 Tomcat
1981 ndash AV-8B Harrier
Source
Low-Cost Composite Materials and Structures for Aircraft Applications
httpwwwreinforcedplasticscom
httpwwwcentennialofflightgovessayEvolution_of_TechnologycompositesTech40htm
Automotive
Composite material is used in a number of applications in the automotive
industry due to its temperature resistance rigidity and fatigue strength
The benefits of using composites include greater fuel efficiency
corrosion resistance light weight and strength Composites also provide
a low-cost way to help keep designs looking fresh
Composites are used in
- interior parts (cockpit trimming seats instrument panels)
- exterior structure (body panels openings underbody frontrear
modules)
- engine compartment and fuelmechanical area parts (axles and
suspensions fuel and exhaust systems)
- electrical and electronic components
Lamborghinis Sesto Element carbon fiber
ldquoFat men cannot run as fast as thin men but we build most of our vehicles as though dead-weight fat increased speedhellip I cannot
imagine where the delusion that weight means strength
came fromhelliprdquo mdashHenry Ford
The mix of automotive materials is changing showing a boost for FRP in helping original
equipment manufacturers meet fuel economy and emissions challenges
(Source 2011 DuPont AutomotiveSAE survey of design engineers performed by Signet Research Inc)
Source
httpwwwtoraycomcsrhighlight2009hig_001_01html
The MonoCell tub for the McLaren MP4-12C supercar is moulded as a single
piece and weighs less than 80 kg (176 lbs)
COMPOSITES IN MARINE
TRIMARAN BOAT
AMERICA NAVYINDONESIAN NAVY
Visby Class corvette
Total length is 72 meters
The beam is 1040 meters
The displacement is 600 metric tones
fully equipped the worlds largest CRP
construction
The design of the Visby aims to minimize
the optical and infrared signature above
water acoustic and hydroa coustic
signature underwater electrical potential
and magnetic signature pressure signature
radar cross section and actively emitted
signals
A stealth corvette of the YS 2000 design
has a detection range of 13km in rough
seas and 22km in calm sea without
jamming In a jammed environment the
Visby would be detected at a range of 8km
in rough sea and 11km in calm sea
The material provides high strength and
rigidity low weight good shock resistance
low radar and magnetic signature
1996
Visby is a class of stealth corvettes for the Swedish Navy
ldquoReduced 50 of a Conventional Steelrdquo
Source
Hull Construction with composite materials for ships over 100m in length 2002
Massachusetts Institute of Technology
httpwwwnaval-technologycomprojectsvisby
YACHTS
KAL YUDISTIRAMARATHON 100 ADMIRAL YACHT
LOA 3050 MWidth 6 MFuel Tank 8000 LWater Tank 3000 LIce Box 500 LAccommodation Max 35 Personnel
2 x CATERPILLAR 3412E 1200 HPMARINE DIESEL ENGINE
PC 40 ndash KRI Krait 827Department of Indonesian Navy
LOA 40 MWidth 73 MPower 190Weapon Twin Cannon Barrels
127 mm Heavy Machine GunSpeed Knot 25 KnotDisplacement 105 tonAccommodation 23 personnel
PATROL BOAT
Rigid Inflatable BoatPATROL BOAT
Yachts
36m Luxury Yacht Moonraker
36m Luxury Yacht GoldenEye
50m Luxury Yacht Casino
Royale
45m Luxury Yacht Seashaw
Boat Parts
Barovans for Seismic Sweep
Centrifugal Liftfan House for Surface Effect
Ships
Composite Boat PropellersRTM
Deckhouses for Pilot Boats
Fairing Parts for Submarines
Flybridges for Motor yachts
Light Weight Gangway
MTB Launcher Mock-up
Pleasure Boats
12m Sailboat
12m Sail-Catamaranone-off
Canoes
Dragonfly 1000Catamaran Sailboat
Fantasy 37Sailboat
Farr 60Luxury Sailboat
EurodingyOlympic Dingy Class for
Woman
Hydrolift F23 Racing Boats
Kajacs
Najad 42Sailboat
Najad 520Sailboat
Najad 441Sailboat
Najad 391Sailboat
Nordwest 900Motorboat
Nordwest 1100Motorboat
Quatro 44Motorboat
Racemaster Competition Boats
Storebro 420
Storebro 345
Sweden Yacht 370Sailboat
Sweden Yacht 69Sailboat
Windy 41Motorboat
X-632Sailboat
X-362Sailboat
Commercial Boats
175m High Speed AmbulancePassenger Boat
19m High Speed Passenger Boat
20m High Speed Passenger Boat
364m Surface Effect Passenger Ship
45m Surface Effect Passenger Ship
120m Hull Structural Parts HSSS Catamaran Ferry
APPENDIX
Marine Vessel
1188m Fast Attack Vessel FMV 90 E
20m SAV-Surface Auxiliary Vessels
34m Personnel TransportCoast Guard Vessel
40ft Experimental SES
40m Landsort-Class Mine Hunters
54m Mine Counter Measure Vehicles SES
74m Coastal Patrol Boats
Fishing Boats
30 GT
12 GT
10 GT
5 GT
WISEWings In Surface Effect
HOVERCRAFT
Designed specifically for the tourist and transport industries the
Pioneer Mk3 hovercraft is amphibious and comfortably seats 25
passengers plus 1-crew The air-conditioned cabin allows for
maximum visibility for all aboard The Pioneer Mk3 is robust and
dynamic in its performance
Commercial hovercraft
Mk3 AirLift Hovercraft - 1215m
Power is economicaly provided by one Deutz diesel engine of
330kW (442hp) to cruise easily at 40 knots with much higher
speeds available according to the surface conditions The hull is
manufactured from fibreglassPVC foam composite sandwich
the windows are glass and the skirt is urethane coated nylon A
Military version is available with increased payload and systems
redundancy Power for the Military version comes from two Steyr
diesel engines with a total installed power of 320kW (429hp) All
transmission electrical hydraulic and air systems are duplicated
for maximum redundancy The increased performance of the
Military version comes from the reduced engine weight of the twin
Steyr installation cf the Deutz installation
Source
httpwwwnauticexpocomprodairlift-hovercraftcommercial-hovercrafts-25251-142868html
HOVERFLIGHT
BALLISTIC amp UNIT DEFENCED
Triaxis Composites Collaboration with Institute of Aeronautics and Space in the development of Missile Nose Cone
Polymer composites is the evolution of the military defence
Thin steel was the helmet material of
WWII and remained the principal material until around the 1980rsquos
The advantages of using steel
included a simple technology for manufacture of the helmets low cost and reasonably good
impact protection However these helmets were found to provide only marginal protection
against fragments
During the Vietnam War the US Army experimented with fiber-reinforced inserts in the
helmets These inserts improved ballistic protection but at the same time added weight and
reduced the air space between the head and the helmet
By the early part of the 1980rsquos the US military had developed the first all-composite
100 fiber-reinforced helmet This development resulted in even better ballistic protection
without altering the weight of the helmet Other improvements included better head coverage and
more space for ventilation
Source
Composites Armor - A difficult but huge market
by A Brent Strong Brigham Young University
MILITARY VEHICLES
HIGH SPEED TRAIN SHINKANSEN
Advanced Composites provide lightweight solutions for railway vehicles
saving as much as 50-80 of the weight compared with traditional
components
A lower overall weight translates into less stress faster acceleration and
higher speeds as well as reduced starting and stopping inertia Today
these are important criteria in global high-speed and metropolitan
railway projects
Fire smoke and toxic fumes are key safety criteria for interior
components of railway carriages Any material selected for an interior
component must meet international fire retardant standards
for Rail Interiors and Exteriors
Ceiling Panels Stairs
Seating Vestibules
Window Panels Door Pillars
Partition WallsDiffusers
Gangway and Cabinet Panels Cabin and
Desk panels
Door Pillars Lavatory Modules (standard and
Front and Rear EndsRoof Panels
Nose Cones Under Fairings
Source
httpwwwpctaerail_compositesphp
101
SKY BUS
2009
Europe is the world leader in offshore wind with
828 wind turbines and a cumulative capacity of 2056 MW spread across 38 offshore wind farms in 9
European countries
The UK and Denmark are the current leaders with a 44 and 30 share respectively In 2009
five countries built new offshore wind farms
UK (284 MW)
Demark (230 MW)
Sweden (30 MW)
Germany (30 MW)
Norway (23 MW)
2010
Asia leads the growth in global wind power which grew 358 GW in 2010 bringing
total global capacity to 1944 GW ndash up 225 from 2009
the Global Wind Energy Council (GWEC)
Asia accounted for 19 GW of new global wind power installations driven by China which installed 165
GW
ldquoChina now has 423 GW of wind powerrdquo
ldquoThis puts China firmly on a path to reach 200 GW of installed wind power by 2020 At the same
time China has become the worldrsquos largest producer of wind energy equipmentrdquo
Source
httpwwwreinforcedplasticscomview15655asia-leads-global-wind-power-growth
httpimgdeusmcomdesignnews288288605-Sandia_Sizes_up_Wind_Turbine_Blade_Design_C_largegif
WIND ENERGY
Marine Current Turbines
Source
httpwwwsiemenscompressenpressreleasepress=enpressrelease2011solar-hydroex201111005htm
httpwwwmarineturbinescom
A commercial marine current turbine consists of
two rotors which are fixed on a structure within the
sea current The twin rotors rotate with the
movement of the tidal flow and the blades pitch
through 180 degrees to optimally track tidal current
(Press picture Marine Current Turbines)
Wave Star Energys Multi-point Absorber
CFRP COLUMN REINFORCEMENT
INDUSTRIAL TANKS
107
INDUSTRIAL PIPES
PRESSURE TANKS
109
ldquoLetrsquos Make with Compositesrdquo
BADAN SERTIFIKASI MARITIM
Biro Klasifikasi IndonesiaDet Norske Veritas Germanischer Lloyds
PERATURAN BKI
Untuk Kapal Non-Metal
2006
PERSYARATAN MINIMUM
kekuatan material yang
harus digunakan
untuk membangun
Kapal Fiberglass
PEMBESARAN
Table 21
FIBERGLASS TRIAXIS COMPOSITES
TELAH BERSERTIFIKASI BKI
Biro Klasifikasi Indonesia
65
TEKNIK MANUFAKTUR
COMPOSITES
Wet hand lay-up
1) Peletakan
Dry Reinforcement
bull Dry reinforcement dan resin (+ katalis) ditaruh pada permukaan cetakan
2) Pemasukanpenekanan resin
bull Resin ditekan untuk meng-impregnasi serat dengan menggunakan rol
3) Pengulangan proses untuk lapisan lain
bull Beberapa lapisan dapat ditambahkan secara bertahap
4) Resin curing
bull Reaksi dimulai komponen dilepaskan setelah komponen mengeras
(fully cured)
Wet hand lay-up
Manufaktur komponen dapat dikerjakan dengan menggunakan beberapa lapis komposit
dengan memperhatikan kompatibilitas material dan tahapan curing Modifikasi proses dapat
dilakukan seperti
Vacuum bagging
setelah lay-up
Glass Roving
Bulk Resin
Catalyst
3) De-molding
2) Resin Cure
bull Curing dimulai dan komponen dilepaskan setelah pengerasan selesai
bull Serat gelas resin dan katalis dimasukkan kedalam spray gun
1) Spray-up
bull Campuran disemprotkan pada permukaan cetakan
Spray-up
69
Penyemprotan bakal komponen
Komponen
dilepaskan
dari cetakan
Full dispensing
system Chopper Roving
Atomised resin
and catalyst
Spray-up
Prepreg
1) LaminateAssembly 5) De-molding
3) Resin Melts Layup Consolidates
bull Prepreg serat yang sudah diimpregnasi oleh resin+katalis dalam kondisi padat
bull Lapisan prepreg digunting sesuai bentuk yang diinginkan kemudian diletakkan pada permukaan cetakan
sesuai bentuk komponen yang diinginkan Lay-up mudah dilakukan karena sifat ldquotackynessrdquo dari prepreg
2) Applied Vacuum Pressure and Heat
bull Tekanan dan panas diberikan resin mencair terjadi konsolidasi pada komponen
4) Resin Cures
bull Temperatur dinaikkan untuk memulai curing
Prepreg
Variasi proses Autoclave
Komponen dalam
vacuum-bag
bull Campuran resin (+katalis) dan chopped glass strands diperoleh dalam bentuk premixed compound Bulk molding
Compound (BMC) dalam bentuk adonan atau Sheet molding Compound (SMC) dalam bentuk lembaran
bull Ketika panas dan tekanan diberikan oleh cetakan compound mengalir sesuai bentuk komponen yang diinginkan
1) Placement of Charge
5) De-molding3) Squeeze to final dimensions
2) Mould Closure4) Resin Cure
bull Curing dimulai komponen dilepaskan setelah terjadi pengerasan yang cukup
Compression Molding
bull Preform atau dry reinforcement dimasukkan kedalam cetakan sesuai dengan bentuk komponen yang
diinginkan
bull Resin mengalir dengan penekanan atau pem-vakuman dan meng-impregnasi preform dan
mendorongmengeluarkan udara yang ada dalam preform
1) Preform Manufacture
2) Preform Compression
5) De-molding3) Resin Injection
4) Resin Cure
bull Curing terjadi cetakan dibuka setelah terjadi pengerasan yang mencukupi
Liquid Molding (RTM VARI VARTM)
Pultrusion
bull Dry roving or fabrics ditarik melalui bak berisi
campuran resin dan katalis
bull Campuran yang basah ditarik melalui cetakan
bull Sisa resin keluar cetakan
bull Pemanasan dilakukan untuk proses curing
bull Pendinginan dilakukan untuk mempercepat siklus
produksi
Cut-off
Cooling
Die sections
Resin bath
Fibre creel
Filament Winding
bull Dry roving ditarik melalui bak berisi campuran resin dan katalis
bull Wet roving digulungkan dalam keadaan tegang kepada mandrel
bull Kontrol mekanik dari pembawa serat mengatur orientasi peletakan serat pada
mandrel
INDUSTRI COMPOSITES
AEROSPACE
HISTORY
1950 ndash Boeing
1960 ndash F14 Tomcat
1981 ndash AV-8B Harrier
Source
Low-Cost Composite Materials and Structures for Aircraft Applications
httpwwwreinforcedplasticscom
httpwwwcentennialofflightgovessayEvolution_of_TechnologycompositesTech40htm
Automotive
Composite material is used in a number of applications in the automotive
industry due to its temperature resistance rigidity and fatigue strength
The benefits of using composites include greater fuel efficiency
corrosion resistance light weight and strength Composites also provide
a low-cost way to help keep designs looking fresh
Composites are used in
- interior parts (cockpit trimming seats instrument panels)
- exterior structure (body panels openings underbody frontrear
modules)
- engine compartment and fuelmechanical area parts (axles and
suspensions fuel and exhaust systems)
- electrical and electronic components
Lamborghinis Sesto Element carbon fiber
ldquoFat men cannot run as fast as thin men but we build most of our vehicles as though dead-weight fat increased speedhellip I cannot
imagine where the delusion that weight means strength
came fromhelliprdquo mdashHenry Ford
The mix of automotive materials is changing showing a boost for FRP in helping original
equipment manufacturers meet fuel economy and emissions challenges
(Source 2011 DuPont AutomotiveSAE survey of design engineers performed by Signet Research Inc)
Source
httpwwwtoraycomcsrhighlight2009hig_001_01html
The MonoCell tub for the McLaren MP4-12C supercar is moulded as a single
piece and weighs less than 80 kg (176 lbs)
COMPOSITES IN MARINE
TRIMARAN BOAT
AMERICA NAVYINDONESIAN NAVY
Visby Class corvette
Total length is 72 meters
The beam is 1040 meters
The displacement is 600 metric tones
fully equipped the worlds largest CRP
construction
The design of the Visby aims to minimize
the optical and infrared signature above
water acoustic and hydroa coustic
signature underwater electrical potential
and magnetic signature pressure signature
radar cross section and actively emitted
signals
A stealth corvette of the YS 2000 design
has a detection range of 13km in rough
seas and 22km in calm sea without
jamming In a jammed environment the
Visby would be detected at a range of 8km
in rough sea and 11km in calm sea
The material provides high strength and
rigidity low weight good shock resistance
low radar and magnetic signature
1996
Visby is a class of stealth corvettes for the Swedish Navy
ldquoReduced 50 of a Conventional Steelrdquo
Source
Hull Construction with composite materials for ships over 100m in length 2002
Massachusetts Institute of Technology
httpwwwnaval-technologycomprojectsvisby
YACHTS
KAL YUDISTIRAMARATHON 100 ADMIRAL YACHT
LOA 3050 MWidth 6 MFuel Tank 8000 LWater Tank 3000 LIce Box 500 LAccommodation Max 35 Personnel
2 x CATERPILLAR 3412E 1200 HPMARINE DIESEL ENGINE
PC 40 ndash KRI Krait 827Department of Indonesian Navy
LOA 40 MWidth 73 MPower 190Weapon Twin Cannon Barrels
127 mm Heavy Machine GunSpeed Knot 25 KnotDisplacement 105 tonAccommodation 23 personnel
PATROL BOAT
Rigid Inflatable BoatPATROL BOAT
Yachts
36m Luxury Yacht Moonraker
36m Luxury Yacht GoldenEye
50m Luxury Yacht Casino
Royale
45m Luxury Yacht Seashaw
Boat Parts
Barovans for Seismic Sweep
Centrifugal Liftfan House for Surface Effect
Ships
Composite Boat PropellersRTM
Deckhouses for Pilot Boats
Fairing Parts for Submarines
Flybridges for Motor yachts
Light Weight Gangway
MTB Launcher Mock-up
Pleasure Boats
12m Sailboat
12m Sail-Catamaranone-off
Canoes
Dragonfly 1000Catamaran Sailboat
Fantasy 37Sailboat
Farr 60Luxury Sailboat
EurodingyOlympic Dingy Class for
Woman
Hydrolift F23 Racing Boats
Kajacs
Najad 42Sailboat
Najad 520Sailboat
Najad 441Sailboat
Najad 391Sailboat
Nordwest 900Motorboat
Nordwest 1100Motorboat
Quatro 44Motorboat
Racemaster Competition Boats
Storebro 420
Storebro 345
Sweden Yacht 370Sailboat
Sweden Yacht 69Sailboat
Windy 41Motorboat
X-632Sailboat
X-362Sailboat
Commercial Boats
175m High Speed AmbulancePassenger Boat
19m High Speed Passenger Boat
20m High Speed Passenger Boat
364m Surface Effect Passenger Ship
45m Surface Effect Passenger Ship
120m Hull Structural Parts HSSS Catamaran Ferry
APPENDIX
Marine Vessel
1188m Fast Attack Vessel FMV 90 E
20m SAV-Surface Auxiliary Vessels
34m Personnel TransportCoast Guard Vessel
40ft Experimental SES
40m Landsort-Class Mine Hunters
54m Mine Counter Measure Vehicles SES
74m Coastal Patrol Boats
Fishing Boats
30 GT
12 GT
10 GT
5 GT
WISEWings In Surface Effect
HOVERCRAFT
Designed specifically for the tourist and transport industries the
Pioneer Mk3 hovercraft is amphibious and comfortably seats 25
passengers plus 1-crew The air-conditioned cabin allows for
maximum visibility for all aboard The Pioneer Mk3 is robust and
dynamic in its performance
Commercial hovercraft
Mk3 AirLift Hovercraft - 1215m
Power is economicaly provided by one Deutz diesel engine of
330kW (442hp) to cruise easily at 40 knots with much higher
speeds available according to the surface conditions The hull is
manufactured from fibreglassPVC foam composite sandwich
the windows are glass and the skirt is urethane coated nylon A
Military version is available with increased payload and systems
redundancy Power for the Military version comes from two Steyr
diesel engines with a total installed power of 320kW (429hp) All
transmission electrical hydraulic and air systems are duplicated
for maximum redundancy The increased performance of the
Military version comes from the reduced engine weight of the twin
Steyr installation cf the Deutz installation
Source
httpwwwnauticexpocomprodairlift-hovercraftcommercial-hovercrafts-25251-142868html
HOVERFLIGHT
BALLISTIC amp UNIT DEFENCED
Triaxis Composites Collaboration with Institute of Aeronautics and Space in the development of Missile Nose Cone
Polymer composites is the evolution of the military defence
Thin steel was the helmet material of
WWII and remained the principal material until around the 1980rsquos
The advantages of using steel
included a simple technology for manufacture of the helmets low cost and reasonably good
impact protection However these helmets were found to provide only marginal protection
against fragments
During the Vietnam War the US Army experimented with fiber-reinforced inserts in the
helmets These inserts improved ballistic protection but at the same time added weight and
reduced the air space between the head and the helmet
By the early part of the 1980rsquos the US military had developed the first all-composite
100 fiber-reinforced helmet This development resulted in even better ballistic protection
without altering the weight of the helmet Other improvements included better head coverage and
more space for ventilation
Source
Composites Armor - A difficult but huge market
by A Brent Strong Brigham Young University
MILITARY VEHICLES
HIGH SPEED TRAIN SHINKANSEN
Advanced Composites provide lightweight solutions for railway vehicles
saving as much as 50-80 of the weight compared with traditional
components
A lower overall weight translates into less stress faster acceleration and
higher speeds as well as reduced starting and stopping inertia Today
these are important criteria in global high-speed and metropolitan
railway projects
Fire smoke and toxic fumes are key safety criteria for interior
components of railway carriages Any material selected for an interior
component must meet international fire retardant standards
for Rail Interiors and Exteriors
Ceiling Panels Stairs
Seating Vestibules
Window Panels Door Pillars
Partition WallsDiffusers
Gangway and Cabinet Panels Cabin and
Desk panels
Door Pillars Lavatory Modules (standard and
Front and Rear EndsRoof Panels
Nose Cones Under Fairings
Source
httpwwwpctaerail_compositesphp
101
SKY BUS
2009
Europe is the world leader in offshore wind with
828 wind turbines and a cumulative capacity of 2056 MW spread across 38 offshore wind farms in 9
European countries
The UK and Denmark are the current leaders with a 44 and 30 share respectively In 2009
five countries built new offshore wind farms
UK (284 MW)
Demark (230 MW)
Sweden (30 MW)
Germany (30 MW)
Norway (23 MW)
2010
Asia leads the growth in global wind power which grew 358 GW in 2010 bringing
total global capacity to 1944 GW ndash up 225 from 2009
the Global Wind Energy Council (GWEC)
Asia accounted for 19 GW of new global wind power installations driven by China which installed 165
GW
ldquoChina now has 423 GW of wind powerrdquo
ldquoThis puts China firmly on a path to reach 200 GW of installed wind power by 2020 At the same
time China has become the worldrsquos largest producer of wind energy equipmentrdquo
Source
httpwwwreinforcedplasticscomview15655asia-leads-global-wind-power-growth
httpimgdeusmcomdesignnews288288605-Sandia_Sizes_up_Wind_Turbine_Blade_Design_C_largegif
WIND ENERGY
Marine Current Turbines
Source
httpwwwsiemenscompressenpressreleasepress=enpressrelease2011solar-hydroex201111005htm
httpwwwmarineturbinescom
A commercial marine current turbine consists of
two rotors which are fixed on a structure within the
sea current The twin rotors rotate with the
movement of the tidal flow and the blades pitch
through 180 degrees to optimally track tidal current
(Press picture Marine Current Turbines)
Wave Star Energys Multi-point Absorber
CFRP COLUMN REINFORCEMENT
INDUSTRIAL TANKS
107
INDUSTRIAL PIPES
PRESSURE TANKS
109
ldquoLetrsquos Make with Compositesrdquo
PERATURAN BKI
Untuk Kapal Non-Metal
2006
PERSYARATAN MINIMUM
kekuatan material yang
harus digunakan
untuk membangun
Kapal Fiberglass
PEMBESARAN
Table 21
FIBERGLASS TRIAXIS COMPOSITES
TELAH BERSERTIFIKASI BKI
Biro Klasifikasi Indonesia
65
TEKNIK MANUFAKTUR
COMPOSITES
Wet hand lay-up
1) Peletakan
Dry Reinforcement
bull Dry reinforcement dan resin (+ katalis) ditaruh pada permukaan cetakan
2) Pemasukanpenekanan resin
bull Resin ditekan untuk meng-impregnasi serat dengan menggunakan rol
3) Pengulangan proses untuk lapisan lain
bull Beberapa lapisan dapat ditambahkan secara bertahap
4) Resin curing
bull Reaksi dimulai komponen dilepaskan setelah komponen mengeras
(fully cured)
Wet hand lay-up
Manufaktur komponen dapat dikerjakan dengan menggunakan beberapa lapis komposit
dengan memperhatikan kompatibilitas material dan tahapan curing Modifikasi proses dapat
dilakukan seperti
Vacuum bagging
setelah lay-up
Glass Roving
Bulk Resin
Catalyst
3) De-molding
2) Resin Cure
bull Curing dimulai dan komponen dilepaskan setelah pengerasan selesai
bull Serat gelas resin dan katalis dimasukkan kedalam spray gun
1) Spray-up
bull Campuran disemprotkan pada permukaan cetakan
Spray-up
69
Penyemprotan bakal komponen
Komponen
dilepaskan
dari cetakan
Full dispensing
system Chopper Roving
Atomised resin
and catalyst
Spray-up
Prepreg
1) LaminateAssembly 5) De-molding
3) Resin Melts Layup Consolidates
bull Prepreg serat yang sudah diimpregnasi oleh resin+katalis dalam kondisi padat
bull Lapisan prepreg digunting sesuai bentuk yang diinginkan kemudian diletakkan pada permukaan cetakan
sesuai bentuk komponen yang diinginkan Lay-up mudah dilakukan karena sifat ldquotackynessrdquo dari prepreg
2) Applied Vacuum Pressure and Heat
bull Tekanan dan panas diberikan resin mencair terjadi konsolidasi pada komponen
4) Resin Cures
bull Temperatur dinaikkan untuk memulai curing
Prepreg
Variasi proses Autoclave
Komponen dalam
vacuum-bag
bull Campuran resin (+katalis) dan chopped glass strands diperoleh dalam bentuk premixed compound Bulk molding
Compound (BMC) dalam bentuk adonan atau Sheet molding Compound (SMC) dalam bentuk lembaran
bull Ketika panas dan tekanan diberikan oleh cetakan compound mengalir sesuai bentuk komponen yang diinginkan
1) Placement of Charge
5) De-molding3) Squeeze to final dimensions
2) Mould Closure4) Resin Cure
bull Curing dimulai komponen dilepaskan setelah terjadi pengerasan yang cukup
Compression Molding
bull Preform atau dry reinforcement dimasukkan kedalam cetakan sesuai dengan bentuk komponen yang
diinginkan
bull Resin mengalir dengan penekanan atau pem-vakuman dan meng-impregnasi preform dan
mendorongmengeluarkan udara yang ada dalam preform
1) Preform Manufacture
2) Preform Compression
5) De-molding3) Resin Injection
4) Resin Cure
bull Curing terjadi cetakan dibuka setelah terjadi pengerasan yang mencukupi
Liquid Molding (RTM VARI VARTM)
Pultrusion
bull Dry roving or fabrics ditarik melalui bak berisi
campuran resin dan katalis
bull Campuran yang basah ditarik melalui cetakan
bull Sisa resin keluar cetakan
bull Pemanasan dilakukan untuk proses curing
bull Pendinginan dilakukan untuk mempercepat siklus
produksi
Cut-off
Cooling
Die sections
Resin bath
Fibre creel
Filament Winding
bull Dry roving ditarik melalui bak berisi campuran resin dan katalis
bull Wet roving digulungkan dalam keadaan tegang kepada mandrel
bull Kontrol mekanik dari pembawa serat mengatur orientasi peletakan serat pada
mandrel
INDUSTRI COMPOSITES
AEROSPACE
HISTORY
1950 ndash Boeing
1960 ndash F14 Tomcat
1981 ndash AV-8B Harrier
Source
Low-Cost Composite Materials and Structures for Aircraft Applications
httpwwwreinforcedplasticscom
httpwwwcentennialofflightgovessayEvolution_of_TechnologycompositesTech40htm
Automotive
Composite material is used in a number of applications in the automotive
industry due to its temperature resistance rigidity and fatigue strength
The benefits of using composites include greater fuel efficiency
corrosion resistance light weight and strength Composites also provide
a low-cost way to help keep designs looking fresh
Composites are used in
- interior parts (cockpit trimming seats instrument panels)
- exterior structure (body panels openings underbody frontrear
modules)
- engine compartment and fuelmechanical area parts (axles and
suspensions fuel and exhaust systems)
- electrical and electronic components
Lamborghinis Sesto Element carbon fiber
ldquoFat men cannot run as fast as thin men but we build most of our vehicles as though dead-weight fat increased speedhellip I cannot
imagine where the delusion that weight means strength
came fromhelliprdquo mdashHenry Ford
The mix of automotive materials is changing showing a boost for FRP in helping original
equipment manufacturers meet fuel economy and emissions challenges
(Source 2011 DuPont AutomotiveSAE survey of design engineers performed by Signet Research Inc)
Source
httpwwwtoraycomcsrhighlight2009hig_001_01html
The MonoCell tub for the McLaren MP4-12C supercar is moulded as a single
piece and weighs less than 80 kg (176 lbs)
COMPOSITES IN MARINE
TRIMARAN BOAT
AMERICA NAVYINDONESIAN NAVY
Visby Class corvette
Total length is 72 meters
The beam is 1040 meters
The displacement is 600 metric tones
fully equipped the worlds largest CRP
construction
The design of the Visby aims to minimize
the optical and infrared signature above
water acoustic and hydroa coustic
signature underwater electrical potential
and magnetic signature pressure signature
radar cross section and actively emitted
signals
A stealth corvette of the YS 2000 design
has a detection range of 13km in rough
seas and 22km in calm sea without
jamming In a jammed environment the
Visby would be detected at a range of 8km
in rough sea and 11km in calm sea
The material provides high strength and
rigidity low weight good shock resistance
low radar and magnetic signature
1996
Visby is a class of stealth corvettes for the Swedish Navy
ldquoReduced 50 of a Conventional Steelrdquo
Source
Hull Construction with composite materials for ships over 100m in length 2002
Massachusetts Institute of Technology
httpwwwnaval-technologycomprojectsvisby
YACHTS
KAL YUDISTIRAMARATHON 100 ADMIRAL YACHT
LOA 3050 MWidth 6 MFuel Tank 8000 LWater Tank 3000 LIce Box 500 LAccommodation Max 35 Personnel
2 x CATERPILLAR 3412E 1200 HPMARINE DIESEL ENGINE
PC 40 ndash KRI Krait 827Department of Indonesian Navy
LOA 40 MWidth 73 MPower 190Weapon Twin Cannon Barrels
127 mm Heavy Machine GunSpeed Knot 25 KnotDisplacement 105 tonAccommodation 23 personnel
PATROL BOAT
Rigid Inflatable BoatPATROL BOAT
Yachts
36m Luxury Yacht Moonraker
36m Luxury Yacht GoldenEye
50m Luxury Yacht Casino
Royale
45m Luxury Yacht Seashaw
Boat Parts
Barovans for Seismic Sweep
Centrifugal Liftfan House for Surface Effect
Ships
Composite Boat PropellersRTM
Deckhouses for Pilot Boats
Fairing Parts for Submarines
Flybridges for Motor yachts
Light Weight Gangway
MTB Launcher Mock-up
Pleasure Boats
12m Sailboat
12m Sail-Catamaranone-off
Canoes
Dragonfly 1000Catamaran Sailboat
Fantasy 37Sailboat
Farr 60Luxury Sailboat
EurodingyOlympic Dingy Class for
Woman
Hydrolift F23 Racing Boats
Kajacs
Najad 42Sailboat
Najad 520Sailboat
Najad 441Sailboat
Najad 391Sailboat
Nordwest 900Motorboat
Nordwest 1100Motorboat
Quatro 44Motorboat
Racemaster Competition Boats
Storebro 420
Storebro 345
Sweden Yacht 370Sailboat
Sweden Yacht 69Sailboat
Windy 41Motorboat
X-632Sailboat
X-362Sailboat
Commercial Boats
175m High Speed AmbulancePassenger Boat
19m High Speed Passenger Boat
20m High Speed Passenger Boat
364m Surface Effect Passenger Ship
45m Surface Effect Passenger Ship
120m Hull Structural Parts HSSS Catamaran Ferry
APPENDIX
Marine Vessel
1188m Fast Attack Vessel FMV 90 E
20m SAV-Surface Auxiliary Vessels
34m Personnel TransportCoast Guard Vessel
40ft Experimental SES
40m Landsort-Class Mine Hunters
54m Mine Counter Measure Vehicles SES
74m Coastal Patrol Boats
Fishing Boats
30 GT
12 GT
10 GT
5 GT
WISEWings In Surface Effect
HOVERCRAFT
Designed specifically for the tourist and transport industries the
Pioneer Mk3 hovercraft is amphibious and comfortably seats 25
passengers plus 1-crew The air-conditioned cabin allows for
maximum visibility for all aboard The Pioneer Mk3 is robust and
dynamic in its performance
Commercial hovercraft
Mk3 AirLift Hovercraft - 1215m
Power is economicaly provided by one Deutz diesel engine of
330kW (442hp) to cruise easily at 40 knots with much higher
speeds available according to the surface conditions The hull is
manufactured from fibreglassPVC foam composite sandwich
the windows are glass and the skirt is urethane coated nylon A
Military version is available with increased payload and systems
redundancy Power for the Military version comes from two Steyr
diesel engines with a total installed power of 320kW (429hp) All
transmission electrical hydraulic and air systems are duplicated
for maximum redundancy The increased performance of the
Military version comes from the reduced engine weight of the twin
Steyr installation cf the Deutz installation
Source
httpwwwnauticexpocomprodairlift-hovercraftcommercial-hovercrafts-25251-142868html
HOVERFLIGHT
BALLISTIC amp UNIT DEFENCED
Triaxis Composites Collaboration with Institute of Aeronautics and Space in the development of Missile Nose Cone
Polymer composites is the evolution of the military defence
Thin steel was the helmet material of
WWII and remained the principal material until around the 1980rsquos
The advantages of using steel
included a simple technology for manufacture of the helmets low cost and reasonably good
impact protection However these helmets were found to provide only marginal protection
against fragments
During the Vietnam War the US Army experimented with fiber-reinforced inserts in the
helmets These inserts improved ballistic protection but at the same time added weight and
reduced the air space between the head and the helmet
By the early part of the 1980rsquos the US military had developed the first all-composite
100 fiber-reinforced helmet This development resulted in even better ballistic protection
without altering the weight of the helmet Other improvements included better head coverage and
more space for ventilation
Source
Composites Armor - A difficult but huge market
by A Brent Strong Brigham Young University
MILITARY VEHICLES
HIGH SPEED TRAIN SHINKANSEN
Advanced Composites provide lightweight solutions for railway vehicles
saving as much as 50-80 of the weight compared with traditional
components
A lower overall weight translates into less stress faster acceleration and
higher speeds as well as reduced starting and stopping inertia Today
these are important criteria in global high-speed and metropolitan
railway projects
Fire smoke and toxic fumes are key safety criteria for interior
components of railway carriages Any material selected for an interior
component must meet international fire retardant standards
for Rail Interiors and Exteriors
Ceiling Panels Stairs
Seating Vestibules
Window Panels Door Pillars
Partition WallsDiffusers
Gangway and Cabinet Panels Cabin and
Desk panels
Door Pillars Lavatory Modules (standard and
Front and Rear EndsRoof Panels
Nose Cones Under Fairings
Source
httpwwwpctaerail_compositesphp
101
SKY BUS
2009
Europe is the world leader in offshore wind with
828 wind turbines and a cumulative capacity of 2056 MW spread across 38 offshore wind farms in 9
European countries
The UK and Denmark are the current leaders with a 44 and 30 share respectively In 2009
five countries built new offshore wind farms
UK (284 MW)
Demark (230 MW)
Sweden (30 MW)
Germany (30 MW)
Norway (23 MW)
2010
Asia leads the growth in global wind power which grew 358 GW in 2010 bringing
total global capacity to 1944 GW ndash up 225 from 2009
the Global Wind Energy Council (GWEC)
Asia accounted for 19 GW of new global wind power installations driven by China which installed 165
GW
ldquoChina now has 423 GW of wind powerrdquo
ldquoThis puts China firmly on a path to reach 200 GW of installed wind power by 2020 At the same
time China has become the worldrsquos largest producer of wind energy equipmentrdquo
Source
httpwwwreinforcedplasticscomview15655asia-leads-global-wind-power-growth
httpimgdeusmcomdesignnews288288605-Sandia_Sizes_up_Wind_Turbine_Blade_Design_C_largegif
WIND ENERGY
Marine Current Turbines
Source
httpwwwsiemenscompressenpressreleasepress=enpressrelease2011solar-hydroex201111005htm
httpwwwmarineturbinescom
A commercial marine current turbine consists of
two rotors which are fixed on a structure within the
sea current The twin rotors rotate with the
movement of the tidal flow and the blades pitch
through 180 degrees to optimally track tidal current
(Press picture Marine Current Turbines)
Wave Star Energys Multi-point Absorber
CFRP COLUMN REINFORCEMENT
INDUSTRIAL TANKS
107
INDUSTRIAL PIPES
PRESSURE TANKS
109
ldquoLetrsquos Make with Compositesrdquo
PERSYARATAN MINIMUM
kekuatan material yang
harus digunakan
untuk membangun
Kapal Fiberglass
PEMBESARAN
Table 21
FIBERGLASS TRIAXIS COMPOSITES
TELAH BERSERTIFIKASI BKI
Biro Klasifikasi Indonesia
65
TEKNIK MANUFAKTUR
COMPOSITES
Wet hand lay-up
1) Peletakan
Dry Reinforcement
bull Dry reinforcement dan resin (+ katalis) ditaruh pada permukaan cetakan
2) Pemasukanpenekanan resin
bull Resin ditekan untuk meng-impregnasi serat dengan menggunakan rol
3) Pengulangan proses untuk lapisan lain
bull Beberapa lapisan dapat ditambahkan secara bertahap
4) Resin curing
bull Reaksi dimulai komponen dilepaskan setelah komponen mengeras
(fully cured)
Wet hand lay-up
Manufaktur komponen dapat dikerjakan dengan menggunakan beberapa lapis komposit
dengan memperhatikan kompatibilitas material dan tahapan curing Modifikasi proses dapat
dilakukan seperti
Vacuum bagging
setelah lay-up
Glass Roving
Bulk Resin
Catalyst
3) De-molding
2) Resin Cure
bull Curing dimulai dan komponen dilepaskan setelah pengerasan selesai
bull Serat gelas resin dan katalis dimasukkan kedalam spray gun
1) Spray-up
bull Campuran disemprotkan pada permukaan cetakan
Spray-up
69
Penyemprotan bakal komponen
Komponen
dilepaskan
dari cetakan
Full dispensing
system Chopper Roving
Atomised resin
and catalyst
Spray-up
Prepreg
1) LaminateAssembly 5) De-molding
3) Resin Melts Layup Consolidates
bull Prepreg serat yang sudah diimpregnasi oleh resin+katalis dalam kondisi padat
bull Lapisan prepreg digunting sesuai bentuk yang diinginkan kemudian diletakkan pada permukaan cetakan
sesuai bentuk komponen yang diinginkan Lay-up mudah dilakukan karena sifat ldquotackynessrdquo dari prepreg
2) Applied Vacuum Pressure and Heat
bull Tekanan dan panas diberikan resin mencair terjadi konsolidasi pada komponen
4) Resin Cures
bull Temperatur dinaikkan untuk memulai curing
Prepreg
Variasi proses Autoclave
Komponen dalam
vacuum-bag
bull Campuran resin (+katalis) dan chopped glass strands diperoleh dalam bentuk premixed compound Bulk molding
Compound (BMC) dalam bentuk adonan atau Sheet molding Compound (SMC) dalam bentuk lembaran
bull Ketika panas dan tekanan diberikan oleh cetakan compound mengalir sesuai bentuk komponen yang diinginkan
1) Placement of Charge
5) De-molding3) Squeeze to final dimensions
2) Mould Closure4) Resin Cure
bull Curing dimulai komponen dilepaskan setelah terjadi pengerasan yang cukup
Compression Molding
bull Preform atau dry reinforcement dimasukkan kedalam cetakan sesuai dengan bentuk komponen yang
diinginkan
bull Resin mengalir dengan penekanan atau pem-vakuman dan meng-impregnasi preform dan
mendorongmengeluarkan udara yang ada dalam preform
1) Preform Manufacture
2) Preform Compression
5) De-molding3) Resin Injection
4) Resin Cure
bull Curing terjadi cetakan dibuka setelah terjadi pengerasan yang mencukupi
Liquid Molding (RTM VARI VARTM)
Pultrusion
bull Dry roving or fabrics ditarik melalui bak berisi
campuran resin dan katalis
bull Campuran yang basah ditarik melalui cetakan
bull Sisa resin keluar cetakan
bull Pemanasan dilakukan untuk proses curing
bull Pendinginan dilakukan untuk mempercepat siklus
produksi
Cut-off
Cooling
Die sections
Resin bath
Fibre creel
Filament Winding
bull Dry roving ditarik melalui bak berisi campuran resin dan katalis
bull Wet roving digulungkan dalam keadaan tegang kepada mandrel
bull Kontrol mekanik dari pembawa serat mengatur orientasi peletakan serat pada
mandrel
INDUSTRI COMPOSITES
AEROSPACE
HISTORY
1950 ndash Boeing
1960 ndash F14 Tomcat
1981 ndash AV-8B Harrier
Source
Low-Cost Composite Materials and Structures for Aircraft Applications
httpwwwreinforcedplasticscom
httpwwwcentennialofflightgovessayEvolution_of_TechnologycompositesTech40htm
Automotive
Composite material is used in a number of applications in the automotive
industry due to its temperature resistance rigidity and fatigue strength
The benefits of using composites include greater fuel efficiency
corrosion resistance light weight and strength Composites also provide
a low-cost way to help keep designs looking fresh
Composites are used in
- interior parts (cockpit trimming seats instrument panels)
- exterior structure (body panels openings underbody frontrear
modules)
- engine compartment and fuelmechanical area parts (axles and
suspensions fuel and exhaust systems)
- electrical and electronic components
Lamborghinis Sesto Element carbon fiber
ldquoFat men cannot run as fast as thin men but we build most of our vehicles as though dead-weight fat increased speedhellip I cannot
imagine where the delusion that weight means strength
came fromhelliprdquo mdashHenry Ford
The mix of automotive materials is changing showing a boost for FRP in helping original
equipment manufacturers meet fuel economy and emissions challenges
(Source 2011 DuPont AutomotiveSAE survey of design engineers performed by Signet Research Inc)
Source
httpwwwtoraycomcsrhighlight2009hig_001_01html
The MonoCell tub for the McLaren MP4-12C supercar is moulded as a single
piece and weighs less than 80 kg (176 lbs)
COMPOSITES IN MARINE
TRIMARAN BOAT
AMERICA NAVYINDONESIAN NAVY
Visby Class corvette
Total length is 72 meters
The beam is 1040 meters
The displacement is 600 metric tones
fully equipped the worlds largest CRP
construction
The design of the Visby aims to minimize
the optical and infrared signature above
water acoustic and hydroa coustic
signature underwater electrical potential
and magnetic signature pressure signature
radar cross section and actively emitted
signals
A stealth corvette of the YS 2000 design
has a detection range of 13km in rough
seas and 22km in calm sea without
jamming In a jammed environment the
Visby would be detected at a range of 8km
in rough sea and 11km in calm sea
The material provides high strength and
rigidity low weight good shock resistance
low radar and magnetic signature
1996
Visby is a class of stealth corvettes for the Swedish Navy
ldquoReduced 50 of a Conventional Steelrdquo
Source
Hull Construction with composite materials for ships over 100m in length 2002
Massachusetts Institute of Technology
httpwwwnaval-technologycomprojectsvisby
YACHTS
KAL YUDISTIRAMARATHON 100 ADMIRAL YACHT
LOA 3050 MWidth 6 MFuel Tank 8000 LWater Tank 3000 LIce Box 500 LAccommodation Max 35 Personnel
2 x CATERPILLAR 3412E 1200 HPMARINE DIESEL ENGINE
PC 40 ndash KRI Krait 827Department of Indonesian Navy
LOA 40 MWidth 73 MPower 190Weapon Twin Cannon Barrels
127 mm Heavy Machine GunSpeed Knot 25 KnotDisplacement 105 tonAccommodation 23 personnel
PATROL BOAT
Rigid Inflatable BoatPATROL BOAT
Yachts
36m Luxury Yacht Moonraker
36m Luxury Yacht GoldenEye
50m Luxury Yacht Casino
Royale
45m Luxury Yacht Seashaw
Boat Parts
Barovans for Seismic Sweep
Centrifugal Liftfan House for Surface Effect
Ships
Composite Boat PropellersRTM
Deckhouses for Pilot Boats
Fairing Parts for Submarines
Flybridges for Motor yachts
Light Weight Gangway
MTB Launcher Mock-up
Pleasure Boats
12m Sailboat
12m Sail-Catamaranone-off
Canoes
Dragonfly 1000Catamaran Sailboat
Fantasy 37Sailboat
Farr 60Luxury Sailboat
EurodingyOlympic Dingy Class for
Woman
Hydrolift F23 Racing Boats
Kajacs
Najad 42Sailboat
Najad 520Sailboat
Najad 441Sailboat
Najad 391Sailboat
Nordwest 900Motorboat
Nordwest 1100Motorboat
Quatro 44Motorboat
Racemaster Competition Boats
Storebro 420
Storebro 345
Sweden Yacht 370Sailboat
Sweden Yacht 69Sailboat
Windy 41Motorboat
X-632Sailboat
X-362Sailboat
Commercial Boats
175m High Speed AmbulancePassenger Boat
19m High Speed Passenger Boat
20m High Speed Passenger Boat
364m Surface Effect Passenger Ship
45m Surface Effect Passenger Ship
120m Hull Structural Parts HSSS Catamaran Ferry
APPENDIX
Marine Vessel
1188m Fast Attack Vessel FMV 90 E
20m SAV-Surface Auxiliary Vessels
34m Personnel TransportCoast Guard Vessel
40ft Experimental SES
40m Landsort-Class Mine Hunters
54m Mine Counter Measure Vehicles SES
74m Coastal Patrol Boats
Fishing Boats
30 GT
12 GT
10 GT
5 GT
WISEWings In Surface Effect
HOVERCRAFT
Designed specifically for the tourist and transport industries the
Pioneer Mk3 hovercraft is amphibious and comfortably seats 25
passengers plus 1-crew The air-conditioned cabin allows for
maximum visibility for all aboard The Pioneer Mk3 is robust and
dynamic in its performance
Commercial hovercraft
Mk3 AirLift Hovercraft - 1215m
Power is economicaly provided by one Deutz diesel engine of
330kW (442hp) to cruise easily at 40 knots with much higher
speeds available according to the surface conditions The hull is
manufactured from fibreglassPVC foam composite sandwich
the windows are glass and the skirt is urethane coated nylon A
Military version is available with increased payload and systems
redundancy Power for the Military version comes from two Steyr
diesel engines with a total installed power of 320kW (429hp) All
transmission electrical hydraulic and air systems are duplicated
for maximum redundancy The increased performance of the
Military version comes from the reduced engine weight of the twin
Steyr installation cf the Deutz installation
Source
httpwwwnauticexpocomprodairlift-hovercraftcommercial-hovercrafts-25251-142868html
HOVERFLIGHT
BALLISTIC amp UNIT DEFENCED
Triaxis Composites Collaboration with Institute of Aeronautics and Space in the development of Missile Nose Cone
Polymer composites is the evolution of the military defence
Thin steel was the helmet material of
WWII and remained the principal material until around the 1980rsquos
The advantages of using steel
included a simple technology for manufacture of the helmets low cost and reasonably good
impact protection However these helmets were found to provide only marginal protection
against fragments
During the Vietnam War the US Army experimented with fiber-reinforced inserts in the
helmets These inserts improved ballistic protection but at the same time added weight and
reduced the air space between the head and the helmet
By the early part of the 1980rsquos the US military had developed the first all-composite
100 fiber-reinforced helmet This development resulted in even better ballistic protection
without altering the weight of the helmet Other improvements included better head coverage and
more space for ventilation
Source
Composites Armor - A difficult but huge market
by A Brent Strong Brigham Young University
MILITARY VEHICLES
HIGH SPEED TRAIN SHINKANSEN
Advanced Composites provide lightweight solutions for railway vehicles
saving as much as 50-80 of the weight compared with traditional
components
A lower overall weight translates into less stress faster acceleration and
higher speeds as well as reduced starting and stopping inertia Today
these are important criteria in global high-speed and metropolitan
railway projects
Fire smoke and toxic fumes are key safety criteria for interior
components of railway carriages Any material selected for an interior
component must meet international fire retardant standards
for Rail Interiors and Exteriors
Ceiling Panels Stairs
Seating Vestibules
Window Panels Door Pillars
Partition WallsDiffusers
Gangway and Cabinet Panels Cabin and
Desk panels
Door Pillars Lavatory Modules (standard and
Front and Rear EndsRoof Panels
Nose Cones Under Fairings
Source
httpwwwpctaerail_compositesphp
101
SKY BUS
2009
Europe is the world leader in offshore wind with
828 wind turbines and a cumulative capacity of 2056 MW spread across 38 offshore wind farms in 9
European countries
The UK and Denmark are the current leaders with a 44 and 30 share respectively In 2009
five countries built new offshore wind farms
UK (284 MW)
Demark (230 MW)
Sweden (30 MW)
Germany (30 MW)
Norway (23 MW)
2010
Asia leads the growth in global wind power which grew 358 GW in 2010 bringing
total global capacity to 1944 GW ndash up 225 from 2009
the Global Wind Energy Council (GWEC)
Asia accounted for 19 GW of new global wind power installations driven by China which installed 165
GW
ldquoChina now has 423 GW of wind powerrdquo
ldquoThis puts China firmly on a path to reach 200 GW of installed wind power by 2020 At the same
time China has become the worldrsquos largest producer of wind energy equipmentrdquo
Source
httpwwwreinforcedplasticscomview15655asia-leads-global-wind-power-growth
httpimgdeusmcomdesignnews288288605-Sandia_Sizes_up_Wind_Turbine_Blade_Design_C_largegif
WIND ENERGY
Marine Current Turbines
Source
httpwwwsiemenscompressenpressreleasepress=enpressrelease2011solar-hydroex201111005htm
httpwwwmarineturbinescom
A commercial marine current turbine consists of
two rotors which are fixed on a structure within the
sea current The twin rotors rotate with the
movement of the tidal flow and the blades pitch
through 180 degrees to optimally track tidal current
(Press picture Marine Current Turbines)
Wave Star Energys Multi-point Absorber
CFRP COLUMN REINFORCEMENT
INDUSTRIAL TANKS
107
INDUSTRIAL PIPES
PRESSURE TANKS
109
ldquoLetrsquos Make with Compositesrdquo
PEMBESARAN
Table 21
FIBERGLASS TRIAXIS COMPOSITES
TELAH BERSERTIFIKASI BKI
Biro Klasifikasi Indonesia
65
TEKNIK MANUFAKTUR
COMPOSITES
Wet hand lay-up
1) Peletakan
Dry Reinforcement
bull Dry reinforcement dan resin (+ katalis) ditaruh pada permukaan cetakan
2) Pemasukanpenekanan resin
bull Resin ditekan untuk meng-impregnasi serat dengan menggunakan rol
3) Pengulangan proses untuk lapisan lain
bull Beberapa lapisan dapat ditambahkan secara bertahap
4) Resin curing
bull Reaksi dimulai komponen dilepaskan setelah komponen mengeras
(fully cured)
Wet hand lay-up
Manufaktur komponen dapat dikerjakan dengan menggunakan beberapa lapis komposit
dengan memperhatikan kompatibilitas material dan tahapan curing Modifikasi proses dapat
dilakukan seperti
Vacuum bagging
setelah lay-up
Glass Roving
Bulk Resin
Catalyst
3) De-molding
2) Resin Cure
bull Curing dimulai dan komponen dilepaskan setelah pengerasan selesai
bull Serat gelas resin dan katalis dimasukkan kedalam spray gun
1) Spray-up
bull Campuran disemprotkan pada permukaan cetakan
Spray-up
69
Penyemprotan bakal komponen
Komponen
dilepaskan
dari cetakan
Full dispensing
system Chopper Roving
Atomised resin
and catalyst
Spray-up
Prepreg
1) LaminateAssembly 5) De-molding
3) Resin Melts Layup Consolidates
bull Prepreg serat yang sudah diimpregnasi oleh resin+katalis dalam kondisi padat
bull Lapisan prepreg digunting sesuai bentuk yang diinginkan kemudian diletakkan pada permukaan cetakan
sesuai bentuk komponen yang diinginkan Lay-up mudah dilakukan karena sifat ldquotackynessrdquo dari prepreg
2) Applied Vacuum Pressure and Heat
bull Tekanan dan panas diberikan resin mencair terjadi konsolidasi pada komponen
4) Resin Cures
bull Temperatur dinaikkan untuk memulai curing
Prepreg
Variasi proses Autoclave
Komponen dalam
vacuum-bag
bull Campuran resin (+katalis) dan chopped glass strands diperoleh dalam bentuk premixed compound Bulk molding
Compound (BMC) dalam bentuk adonan atau Sheet molding Compound (SMC) dalam bentuk lembaran
bull Ketika panas dan tekanan diberikan oleh cetakan compound mengalir sesuai bentuk komponen yang diinginkan
1) Placement of Charge
5) De-molding3) Squeeze to final dimensions
2) Mould Closure4) Resin Cure
bull Curing dimulai komponen dilepaskan setelah terjadi pengerasan yang cukup
Compression Molding
bull Preform atau dry reinforcement dimasukkan kedalam cetakan sesuai dengan bentuk komponen yang
diinginkan
bull Resin mengalir dengan penekanan atau pem-vakuman dan meng-impregnasi preform dan
mendorongmengeluarkan udara yang ada dalam preform
1) Preform Manufacture
2) Preform Compression
5) De-molding3) Resin Injection
4) Resin Cure
bull Curing terjadi cetakan dibuka setelah terjadi pengerasan yang mencukupi
Liquid Molding (RTM VARI VARTM)
Pultrusion
bull Dry roving or fabrics ditarik melalui bak berisi
campuran resin dan katalis
bull Campuran yang basah ditarik melalui cetakan
bull Sisa resin keluar cetakan
bull Pemanasan dilakukan untuk proses curing
bull Pendinginan dilakukan untuk mempercepat siklus
produksi
Cut-off
Cooling
Die sections
Resin bath
Fibre creel
Filament Winding
bull Dry roving ditarik melalui bak berisi campuran resin dan katalis
bull Wet roving digulungkan dalam keadaan tegang kepada mandrel
bull Kontrol mekanik dari pembawa serat mengatur orientasi peletakan serat pada
mandrel
INDUSTRI COMPOSITES
AEROSPACE
HISTORY
1950 ndash Boeing
1960 ndash F14 Tomcat
1981 ndash AV-8B Harrier
Source
Low-Cost Composite Materials and Structures for Aircraft Applications
httpwwwreinforcedplasticscom
httpwwwcentennialofflightgovessayEvolution_of_TechnologycompositesTech40htm
Automotive
Composite material is used in a number of applications in the automotive
industry due to its temperature resistance rigidity and fatigue strength
The benefits of using composites include greater fuel efficiency
corrosion resistance light weight and strength Composites also provide
a low-cost way to help keep designs looking fresh
Composites are used in
- interior parts (cockpit trimming seats instrument panels)
- exterior structure (body panels openings underbody frontrear
modules)
- engine compartment and fuelmechanical area parts (axles and
suspensions fuel and exhaust systems)
- electrical and electronic components
Lamborghinis Sesto Element carbon fiber
ldquoFat men cannot run as fast as thin men but we build most of our vehicles as though dead-weight fat increased speedhellip I cannot
imagine where the delusion that weight means strength
came fromhelliprdquo mdashHenry Ford
The mix of automotive materials is changing showing a boost for FRP in helping original
equipment manufacturers meet fuel economy and emissions challenges
(Source 2011 DuPont AutomotiveSAE survey of design engineers performed by Signet Research Inc)
Source
httpwwwtoraycomcsrhighlight2009hig_001_01html
The MonoCell tub for the McLaren MP4-12C supercar is moulded as a single
piece and weighs less than 80 kg (176 lbs)
COMPOSITES IN MARINE
TRIMARAN BOAT
AMERICA NAVYINDONESIAN NAVY
Visby Class corvette
Total length is 72 meters
The beam is 1040 meters
The displacement is 600 metric tones
fully equipped the worlds largest CRP
construction
The design of the Visby aims to minimize
the optical and infrared signature above
water acoustic and hydroa coustic
signature underwater electrical potential
and magnetic signature pressure signature
radar cross section and actively emitted
signals
A stealth corvette of the YS 2000 design
has a detection range of 13km in rough
seas and 22km in calm sea without
jamming In a jammed environment the
Visby would be detected at a range of 8km
in rough sea and 11km in calm sea
The material provides high strength and
rigidity low weight good shock resistance
low radar and magnetic signature
1996
Visby is a class of stealth corvettes for the Swedish Navy
ldquoReduced 50 of a Conventional Steelrdquo
Source
Hull Construction with composite materials for ships over 100m in length 2002
Massachusetts Institute of Technology
httpwwwnaval-technologycomprojectsvisby
YACHTS
KAL YUDISTIRAMARATHON 100 ADMIRAL YACHT
LOA 3050 MWidth 6 MFuel Tank 8000 LWater Tank 3000 LIce Box 500 LAccommodation Max 35 Personnel
2 x CATERPILLAR 3412E 1200 HPMARINE DIESEL ENGINE
PC 40 ndash KRI Krait 827Department of Indonesian Navy
LOA 40 MWidth 73 MPower 190Weapon Twin Cannon Barrels
127 mm Heavy Machine GunSpeed Knot 25 KnotDisplacement 105 tonAccommodation 23 personnel
PATROL BOAT
Rigid Inflatable BoatPATROL BOAT
Yachts
36m Luxury Yacht Moonraker
36m Luxury Yacht GoldenEye
50m Luxury Yacht Casino
Royale
45m Luxury Yacht Seashaw
Boat Parts
Barovans for Seismic Sweep
Centrifugal Liftfan House for Surface Effect
Ships
Composite Boat PropellersRTM
Deckhouses for Pilot Boats
Fairing Parts for Submarines
Flybridges for Motor yachts
Light Weight Gangway
MTB Launcher Mock-up
Pleasure Boats
12m Sailboat
12m Sail-Catamaranone-off
Canoes
Dragonfly 1000Catamaran Sailboat
Fantasy 37Sailboat
Farr 60Luxury Sailboat
EurodingyOlympic Dingy Class for
Woman
Hydrolift F23 Racing Boats
Kajacs
Najad 42Sailboat
Najad 520Sailboat
Najad 441Sailboat
Najad 391Sailboat
Nordwest 900Motorboat
Nordwest 1100Motorboat
Quatro 44Motorboat
Racemaster Competition Boats
Storebro 420
Storebro 345
Sweden Yacht 370Sailboat
Sweden Yacht 69Sailboat
Windy 41Motorboat
X-632Sailboat
X-362Sailboat
Commercial Boats
175m High Speed AmbulancePassenger Boat
19m High Speed Passenger Boat
20m High Speed Passenger Boat
364m Surface Effect Passenger Ship
45m Surface Effect Passenger Ship
120m Hull Structural Parts HSSS Catamaran Ferry
APPENDIX
Marine Vessel
1188m Fast Attack Vessel FMV 90 E
20m SAV-Surface Auxiliary Vessels
34m Personnel TransportCoast Guard Vessel
40ft Experimental SES
40m Landsort-Class Mine Hunters
54m Mine Counter Measure Vehicles SES
74m Coastal Patrol Boats
Fishing Boats
30 GT
12 GT
10 GT
5 GT
WISEWings In Surface Effect
HOVERCRAFT
Designed specifically for the tourist and transport industries the
Pioneer Mk3 hovercraft is amphibious and comfortably seats 25
passengers plus 1-crew The air-conditioned cabin allows for
maximum visibility for all aboard The Pioneer Mk3 is robust and
dynamic in its performance
Commercial hovercraft
Mk3 AirLift Hovercraft - 1215m
Power is economicaly provided by one Deutz diesel engine of
330kW (442hp) to cruise easily at 40 knots with much higher
speeds available according to the surface conditions The hull is
manufactured from fibreglassPVC foam composite sandwich
the windows are glass and the skirt is urethane coated nylon A
Military version is available with increased payload and systems
redundancy Power for the Military version comes from two Steyr
diesel engines with a total installed power of 320kW (429hp) All
transmission electrical hydraulic and air systems are duplicated
for maximum redundancy The increased performance of the
Military version comes from the reduced engine weight of the twin
Steyr installation cf the Deutz installation
Source
httpwwwnauticexpocomprodairlift-hovercraftcommercial-hovercrafts-25251-142868html
HOVERFLIGHT
BALLISTIC amp UNIT DEFENCED
Triaxis Composites Collaboration with Institute of Aeronautics and Space in the development of Missile Nose Cone
Polymer composites is the evolution of the military defence
Thin steel was the helmet material of
WWII and remained the principal material until around the 1980rsquos
The advantages of using steel
included a simple technology for manufacture of the helmets low cost and reasonably good
impact protection However these helmets were found to provide only marginal protection
against fragments
During the Vietnam War the US Army experimented with fiber-reinforced inserts in the
helmets These inserts improved ballistic protection but at the same time added weight and
reduced the air space between the head and the helmet
By the early part of the 1980rsquos the US military had developed the first all-composite
100 fiber-reinforced helmet This development resulted in even better ballistic protection
without altering the weight of the helmet Other improvements included better head coverage and
more space for ventilation
Source
Composites Armor - A difficult but huge market
by A Brent Strong Brigham Young University
MILITARY VEHICLES
HIGH SPEED TRAIN SHINKANSEN
Advanced Composites provide lightweight solutions for railway vehicles
saving as much as 50-80 of the weight compared with traditional
components
A lower overall weight translates into less stress faster acceleration and
higher speeds as well as reduced starting and stopping inertia Today
these are important criteria in global high-speed and metropolitan
railway projects
Fire smoke and toxic fumes are key safety criteria for interior
components of railway carriages Any material selected for an interior
component must meet international fire retardant standards
for Rail Interiors and Exteriors
Ceiling Panels Stairs
Seating Vestibules
Window Panels Door Pillars
Partition WallsDiffusers
Gangway and Cabinet Panels Cabin and
Desk panels
Door Pillars Lavatory Modules (standard and
Front and Rear EndsRoof Panels
Nose Cones Under Fairings
Source
httpwwwpctaerail_compositesphp
101
SKY BUS
2009
Europe is the world leader in offshore wind with
828 wind turbines and a cumulative capacity of 2056 MW spread across 38 offshore wind farms in 9
European countries
The UK and Denmark are the current leaders with a 44 and 30 share respectively In 2009
five countries built new offshore wind farms
UK (284 MW)
Demark (230 MW)
Sweden (30 MW)
Germany (30 MW)
Norway (23 MW)
2010
Asia leads the growth in global wind power which grew 358 GW in 2010 bringing
total global capacity to 1944 GW ndash up 225 from 2009
the Global Wind Energy Council (GWEC)
Asia accounted for 19 GW of new global wind power installations driven by China which installed 165
GW
ldquoChina now has 423 GW of wind powerrdquo
ldquoThis puts China firmly on a path to reach 200 GW of installed wind power by 2020 At the same
time China has become the worldrsquos largest producer of wind energy equipmentrdquo
Source
httpwwwreinforcedplasticscomview15655asia-leads-global-wind-power-growth
httpimgdeusmcomdesignnews288288605-Sandia_Sizes_up_Wind_Turbine_Blade_Design_C_largegif
WIND ENERGY
Marine Current Turbines
Source
httpwwwsiemenscompressenpressreleasepress=enpressrelease2011solar-hydroex201111005htm
httpwwwmarineturbinescom
A commercial marine current turbine consists of
two rotors which are fixed on a structure within the
sea current The twin rotors rotate with the
movement of the tidal flow and the blades pitch
through 180 degrees to optimally track tidal current
(Press picture Marine Current Turbines)
Wave Star Energys Multi-point Absorber
CFRP COLUMN REINFORCEMENT
INDUSTRIAL TANKS
107
INDUSTRIAL PIPES
PRESSURE TANKS
109
ldquoLetrsquos Make with Compositesrdquo
FIBERGLASS TRIAXIS COMPOSITES
TELAH BERSERTIFIKASI BKI
Biro Klasifikasi Indonesia
65
TEKNIK MANUFAKTUR
COMPOSITES
Wet hand lay-up
1) Peletakan
Dry Reinforcement
bull Dry reinforcement dan resin (+ katalis) ditaruh pada permukaan cetakan
2) Pemasukanpenekanan resin
bull Resin ditekan untuk meng-impregnasi serat dengan menggunakan rol
3) Pengulangan proses untuk lapisan lain
bull Beberapa lapisan dapat ditambahkan secara bertahap
4) Resin curing
bull Reaksi dimulai komponen dilepaskan setelah komponen mengeras
(fully cured)
Wet hand lay-up
Manufaktur komponen dapat dikerjakan dengan menggunakan beberapa lapis komposit
dengan memperhatikan kompatibilitas material dan tahapan curing Modifikasi proses dapat
dilakukan seperti
Vacuum bagging
setelah lay-up
Glass Roving
Bulk Resin
Catalyst
3) De-molding
2) Resin Cure
bull Curing dimulai dan komponen dilepaskan setelah pengerasan selesai
bull Serat gelas resin dan katalis dimasukkan kedalam spray gun
1) Spray-up
bull Campuran disemprotkan pada permukaan cetakan
Spray-up
69
Penyemprotan bakal komponen
Komponen
dilepaskan
dari cetakan
Full dispensing
system Chopper Roving
Atomised resin
and catalyst
Spray-up
Prepreg
1) LaminateAssembly 5) De-molding
3) Resin Melts Layup Consolidates
bull Prepreg serat yang sudah diimpregnasi oleh resin+katalis dalam kondisi padat
bull Lapisan prepreg digunting sesuai bentuk yang diinginkan kemudian diletakkan pada permukaan cetakan
sesuai bentuk komponen yang diinginkan Lay-up mudah dilakukan karena sifat ldquotackynessrdquo dari prepreg
2) Applied Vacuum Pressure and Heat
bull Tekanan dan panas diberikan resin mencair terjadi konsolidasi pada komponen
4) Resin Cures
bull Temperatur dinaikkan untuk memulai curing
Prepreg
Variasi proses Autoclave
Komponen dalam
vacuum-bag
bull Campuran resin (+katalis) dan chopped glass strands diperoleh dalam bentuk premixed compound Bulk molding
Compound (BMC) dalam bentuk adonan atau Sheet molding Compound (SMC) dalam bentuk lembaran
bull Ketika panas dan tekanan diberikan oleh cetakan compound mengalir sesuai bentuk komponen yang diinginkan
1) Placement of Charge
5) De-molding3) Squeeze to final dimensions
2) Mould Closure4) Resin Cure
bull Curing dimulai komponen dilepaskan setelah terjadi pengerasan yang cukup
Compression Molding
bull Preform atau dry reinforcement dimasukkan kedalam cetakan sesuai dengan bentuk komponen yang
diinginkan
bull Resin mengalir dengan penekanan atau pem-vakuman dan meng-impregnasi preform dan
mendorongmengeluarkan udara yang ada dalam preform
1) Preform Manufacture
2) Preform Compression
5) De-molding3) Resin Injection
4) Resin Cure
bull Curing terjadi cetakan dibuka setelah terjadi pengerasan yang mencukupi
Liquid Molding (RTM VARI VARTM)
Pultrusion
bull Dry roving or fabrics ditarik melalui bak berisi
campuran resin dan katalis
bull Campuran yang basah ditarik melalui cetakan
bull Sisa resin keluar cetakan
bull Pemanasan dilakukan untuk proses curing
bull Pendinginan dilakukan untuk mempercepat siklus
produksi
Cut-off
Cooling
Die sections
Resin bath
Fibre creel
Filament Winding
bull Dry roving ditarik melalui bak berisi campuran resin dan katalis
bull Wet roving digulungkan dalam keadaan tegang kepada mandrel
bull Kontrol mekanik dari pembawa serat mengatur orientasi peletakan serat pada
mandrel
INDUSTRI COMPOSITES
AEROSPACE
HISTORY
1950 ndash Boeing
1960 ndash F14 Tomcat
1981 ndash AV-8B Harrier
Source
Low-Cost Composite Materials and Structures for Aircraft Applications
httpwwwreinforcedplasticscom
httpwwwcentennialofflightgovessayEvolution_of_TechnologycompositesTech40htm
Automotive
Composite material is used in a number of applications in the automotive
industry due to its temperature resistance rigidity and fatigue strength
The benefits of using composites include greater fuel efficiency
corrosion resistance light weight and strength Composites also provide
a low-cost way to help keep designs looking fresh
Composites are used in
- interior parts (cockpit trimming seats instrument panels)
- exterior structure (body panels openings underbody frontrear
modules)
- engine compartment and fuelmechanical area parts (axles and
suspensions fuel and exhaust systems)
- electrical and electronic components
Lamborghinis Sesto Element carbon fiber
ldquoFat men cannot run as fast as thin men but we build most of our vehicles as though dead-weight fat increased speedhellip I cannot
imagine where the delusion that weight means strength
came fromhelliprdquo mdashHenry Ford
The mix of automotive materials is changing showing a boost for FRP in helping original
equipment manufacturers meet fuel economy and emissions challenges
(Source 2011 DuPont AutomotiveSAE survey of design engineers performed by Signet Research Inc)
Source
httpwwwtoraycomcsrhighlight2009hig_001_01html
The MonoCell tub for the McLaren MP4-12C supercar is moulded as a single
piece and weighs less than 80 kg (176 lbs)
COMPOSITES IN MARINE
TRIMARAN BOAT
AMERICA NAVYINDONESIAN NAVY
Visby Class corvette
Total length is 72 meters
The beam is 1040 meters
The displacement is 600 metric tones
fully equipped the worlds largest CRP
construction
The design of the Visby aims to minimize
the optical and infrared signature above
water acoustic and hydroa coustic
signature underwater electrical potential
and magnetic signature pressure signature
radar cross section and actively emitted
signals
A stealth corvette of the YS 2000 design
has a detection range of 13km in rough
seas and 22km in calm sea without
jamming In a jammed environment the
Visby would be detected at a range of 8km
in rough sea and 11km in calm sea
The material provides high strength and
rigidity low weight good shock resistance
low radar and magnetic signature
1996
Visby is a class of stealth corvettes for the Swedish Navy
ldquoReduced 50 of a Conventional Steelrdquo
Source
Hull Construction with composite materials for ships over 100m in length 2002
Massachusetts Institute of Technology
httpwwwnaval-technologycomprojectsvisby
YACHTS
KAL YUDISTIRAMARATHON 100 ADMIRAL YACHT
LOA 3050 MWidth 6 MFuel Tank 8000 LWater Tank 3000 LIce Box 500 LAccommodation Max 35 Personnel
2 x CATERPILLAR 3412E 1200 HPMARINE DIESEL ENGINE
PC 40 ndash KRI Krait 827Department of Indonesian Navy
LOA 40 MWidth 73 MPower 190Weapon Twin Cannon Barrels
127 mm Heavy Machine GunSpeed Knot 25 KnotDisplacement 105 tonAccommodation 23 personnel
PATROL BOAT
Rigid Inflatable BoatPATROL BOAT
Yachts
36m Luxury Yacht Moonraker
36m Luxury Yacht GoldenEye
50m Luxury Yacht Casino
Royale
45m Luxury Yacht Seashaw
Boat Parts
Barovans for Seismic Sweep
Centrifugal Liftfan House for Surface Effect
Ships
Composite Boat PropellersRTM
Deckhouses for Pilot Boats
Fairing Parts for Submarines
Flybridges for Motor yachts
Light Weight Gangway
MTB Launcher Mock-up
Pleasure Boats
12m Sailboat
12m Sail-Catamaranone-off
Canoes
Dragonfly 1000Catamaran Sailboat
Fantasy 37Sailboat
Farr 60Luxury Sailboat
EurodingyOlympic Dingy Class for
Woman
Hydrolift F23 Racing Boats
Kajacs
Najad 42Sailboat
Najad 520Sailboat
Najad 441Sailboat
Najad 391Sailboat
Nordwest 900Motorboat
Nordwest 1100Motorboat
Quatro 44Motorboat
Racemaster Competition Boats
Storebro 420
Storebro 345
Sweden Yacht 370Sailboat
Sweden Yacht 69Sailboat
Windy 41Motorboat
X-632Sailboat
X-362Sailboat
Commercial Boats
175m High Speed AmbulancePassenger Boat
19m High Speed Passenger Boat
20m High Speed Passenger Boat
364m Surface Effect Passenger Ship
45m Surface Effect Passenger Ship
120m Hull Structural Parts HSSS Catamaran Ferry
APPENDIX
Marine Vessel
1188m Fast Attack Vessel FMV 90 E
20m SAV-Surface Auxiliary Vessels
34m Personnel TransportCoast Guard Vessel
40ft Experimental SES
40m Landsort-Class Mine Hunters
54m Mine Counter Measure Vehicles SES
74m Coastal Patrol Boats
Fishing Boats
30 GT
12 GT
10 GT
5 GT
WISEWings In Surface Effect
HOVERCRAFT
Designed specifically for the tourist and transport industries the
Pioneer Mk3 hovercraft is amphibious and comfortably seats 25
passengers plus 1-crew The air-conditioned cabin allows for
maximum visibility for all aboard The Pioneer Mk3 is robust and
dynamic in its performance
Commercial hovercraft
Mk3 AirLift Hovercraft - 1215m
Power is economicaly provided by one Deutz diesel engine of
330kW (442hp) to cruise easily at 40 knots with much higher
speeds available according to the surface conditions The hull is
manufactured from fibreglassPVC foam composite sandwich
the windows are glass and the skirt is urethane coated nylon A
Military version is available with increased payload and systems
redundancy Power for the Military version comes from two Steyr
diesel engines with a total installed power of 320kW (429hp) All
transmission electrical hydraulic and air systems are duplicated
for maximum redundancy The increased performance of the
Military version comes from the reduced engine weight of the twin
Steyr installation cf the Deutz installation
Source
httpwwwnauticexpocomprodairlift-hovercraftcommercial-hovercrafts-25251-142868html
HOVERFLIGHT
BALLISTIC amp UNIT DEFENCED
Triaxis Composites Collaboration with Institute of Aeronautics and Space in the development of Missile Nose Cone
Polymer composites is the evolution of the military defence
Thin steel was the helmet material of
WWII and remained the principal material until around the 1980rsquos
The advantages of using steel
included a simple technology for manufacture of the helmets low cost and reasonably good
impact protection However these helmets were found to provide only marginal protection
against fragments
During the Vietnam War the US Army experimented with fiber-reinforced inserts in the
helmets These inserts improved ballistic protection but at the same time added weight and
reduced the air space between the head and the helmet
By the early part of the 1980rsquos the US military had developed the first all-composite
100 fiber-reinforced helmet This development resulted in even better ballistic protection
without altering the weight of the helmet Other improvements included better head coverage and
more space for ventilation
Source
Composites Armor - A difficult but huge market
by A Brent Strong Brigham Young University
MILITARY VEHICLES
HIGH SPEED TRAIN SHINKANSEN
Advanced Composites provide lightweight solutions for railway vehicles
saving as much as 50-80 of the weight compared with traditional
components
A lower overall weight translates into less stress faster acceleration and
higher speeds as well as reduced starting and stopping inertia Today
these are important criteria in global high-speed and metropolitan
railway projects
Fire smoke and toxic fumes are key safety criteria for interior
components of railway carriages Any material selected for an interior
component must meet international fire retardant standards
for Rail Interiors and Exteriors
Ceiling Panels Stairs
Seating Vestibules
Window Panels Door Pillars
Partition WallsDiffusers
Gangway and Cabinet Panels Cabin and
Desk panels
Door Pillars Lavatory Modules (standard and
Front and Rear EndsRoof Panels
Nose Cones Under Fairings
Source
httpwwwpctaerail_compositesphp
101
SKY BUS
2009
Europe is the world leader in offshore wind with
828 wind turbines and a cumulative capacity of 2056 MW spread across 38 offshore wind farms in 9
European countries
The UK and Denmark are the current leaders with a 44 and 30 share respectively In 2009
five countries built new offshore wind farms
UK (284 MW)
Demark (230 MW)
Sweden (30 MW)
Germany (30 MW)
Norway (23 MW)
2010
Asia leads the growth in global wind power which grew 358 GW in 2010 bringing
total global capacity to 1944 GW ndash up 225 from 2009
the Global Wind Energy Council (GWEC)
Asia accounted for 19 GW of new global wind power installations driven by China which installed 165
GW
ldquoChina now has 423 GW of wind powerrdquo
ldquoThis puts China firmly on a path to reach 200 GW of installed wind power by 2020 At the same
time China has become the worldrsquos largest producer of wind energy equipmentrdquo
Source
httpwwwreinforcedplasticscomview15655asia-leads-global-wind-power-growth
httpimgdeusmcomdesignnews288288605-Sandia_Sizes_up_Wind_Turbine_Blade_Design_C_largegif
WIND ENERGY
Marine Current Turbines
Source
httpwwwsiemenscompressenpressreleasepress=enpressrelease2011solar-hydroex201111005htm
httpwwwmarineturbinescom
A commercial marine current turbine consists of
two rotors which are fixed on a structure within the
sea current The twin rotors rotate with the
movement of the tidal flow and the blades pitch
through 180 degrees to optimally track tidal current
(Press picture Marine Current Turbines)
Wave Star Energys Multi-point Absorber
CFRP COLUMN REINFORCEMENT
INDUSTRIAL TANKS
107
INDUSTRIAL PIPES
PRESSURE TANKS
109
ldquoLetrsquos Make with Compositesrdquo
65
TEKNIK MANUFAKTUR
COMPOSITES
Wet hand lay-up
1) Peletakan
Dry Reinforcement
bull Dry reinforcement dan resin (+ katalis) ditaruh pada permukaan cetakan
2) Pemasukanpenekanan resin
bull Resin ditekan untuk meng-impregnasi serat dengan menggunakan rol
3) Pengulangan proses untuk lapisan lain
bull Beberapa lapisan dapat ditambahkan secara bertahap
4) Resin curing
bull Reaksi dimulai komponen dilepaskan setelah komponen mengeras
(fully cured)
Wet hand lay-up
Manufaktur komponen dapat dikerjakan dengan menggunakan beberapa lapis komposit
dengan memperhatikan kompatibilitas material dan tahapan curing Modifikasi proses dapat
dilakukan seperti
Vacuum bagging
setelah lay-up
Glass Roving
Bulk Resin
Catalyst
3) De-molding
2) Resin Cure
bull Curing dimulai dan komponen dilepaskan setelah pengerasan selesai
bull Serat gelas resin dan katalis dimasukkan kedalam spray gun
1) Spray-up
bull Campuran disemprotkan pada permukaan cetakan
Spray-up
69
Penyemprotan bakal komponen
Komponen
dilepaskan
dari cetakan
Full dispensing
system Chopper Roving
Atomised resin
and catalyst
Spray-up
Prepreg
1) LaminateAssembly 5) De-molding
3) Resin Melts Layup Consolidates
bull Prepreg serat yang sudah diimpregnasi oleh resin+katalis dalam kondisi padat
bull Lapisan prepreg digunting sesuai bentuk yang diinginkan kemudian diletakkan pada permukaan cetakan
sesuai bentuk komponen yang diinginkan Lay-up mudah dilakukan karena sifat ldquotackynessrdquo dari prepreg
2) Applied Vacuum Pressure and Heat
bull Tekanan dan panas diberikan resin mencair terjadi konsolidasi pada komponen
4) Resin Cures
bull Temperatur dinaikkan untuk memulai curing
Prepreg
Variasi proses Autoclave
Komponen dalam
vacuum-bag
bull Campuran resin (+katalis) dan chopped glass strands diperoleh dalam bentuk premixed compound Bulk molding
Compound (BMC) dalam bentuk adonan atau Sheet molding Compound (SMC) dalam bentuk lembaran
bull Ketika panas dan tekanan diberikan oleh cetakan compound mengalir sesuai bentuk komponen yang diinginkan
1) Placement of Charge
5) De-molding3) Squeeze to final dimensions
2) Mould Closure4) Resin Cure
bull Curing dimulai komponen dilepaskan setelah terjadi pengerasan yang cukup
Compression Molding
bull Preform atau dry reinforcement dimasukkan kedalam cetakan sesuai dengan bentuk komponen yang
diinginkan
bull Resin mengalir dengan penekanan atau pem-vakuman dan meng-impregnasi preform dan
mendorongmengeluarkan udara yang ada dalam preform
1) Preform Manufacture
2) Preform Compression
5) De-molding3) Resin Injection
4) Resin Cure
bull Curing terjadi cetakan dibuka setelah terjadi pengerasan yang mencukupi
Liquid Molding (RTM VARI VARTM)
Pultrusion
bull Dry roving or fabrics ditarik melalui bak berisi
campuran resin dan katalis
bull Campuran yang basah ditarik melalui cetakan
bull Sisa resin keluar cetakan
bull Pemanasan dilakukan untuk proses curing
bull Pendinginan dilakukan untuk mempercepat siklus
produksi
Cut-off
Cooling
Die sections
Resin bath
Fibre creel
Filament Winding
bull Dry roving ditarik melalui bak berisi campuran resin dan katalis
bull Wet roving digulungkan dalam keadaan tegang kepada mandrel
bull Kontrol mekanik dari pembawa serat mengatur orientasi peletakan serat pada
mandrel
INDUSTRI COMPOSITES
AEROSPACE
HISTORY
1950 ndash Boeing
1960 ndash F14 Tomcat
1981 ndash AV-8B Harrier
Source
Low-Cost Composite Materials and Structures for Aircraft Applications
httpwwwreinforcedplasticscom
httpwwwcentennialofflightgovessayEvolution_of_TechnologycompositesTech40htm
Automotive
Composite material is used in a number of applications in the automotive
industry due to its temperature resistance rigidity and fatigue strength
The benefits of using composites include greater fuel efficiency
corrosion resistance light weight and strength Composites also provide
a low-cost way to help keep designs looking fresh
Composites are used in
- interior parts (cockpit trimming seats instrument panels)
- exterior structure (body panels openings underbody frontrear
modules)
- engine compartment and fuelmechanical area parts (axles and
suspensions fuel and exhaust systems)
- electrical and electronic components
Lamborghinis Sesto Element carbon fiber
ldquoFat men cannot run as fast as thin men but we build most of our vehicles as though dead-weight fat increased speedhellip I cannot
imagine where the delusion that weight means strength
came fromhelliprdquo mdashHenry Ford
The mix of automotive materials is changing showing a boost for FRP in helping original
equipment manufacturers meet fuel economy and emissions challenges
(Source 2011 DuPont AutomotiveSAE survey of design engineers performed by Signet Research Inc)
Source
httpwwwtoraycomcsrhighlight2009hig_001_01html
The MonoCell tub for the McLaren MP4-12C supercar is moulded as a single
piece and weighs less than 80 kg (176 lbs)
COMPOSITES IN MARINE
TRIMARAN BOAT
AMERICA NAVYINDONESIAN NAVY
Visby Class corvette
Total length is 72 meters
The beam is 1040 meters
The displacement is 600 metric tones
fully equipped the worlds largest CRP
construction
The design of the Visby aims to minimize
the optical and infrared signature above
water acoustic and hydroa coustic
signature underwater electrical potential
and magnetic signature pressure signature
radar cross section and actively emitted
signals
A stealth corvette of the YS 2000 design
has a detection range of 13km in rough
seas and 22km in calm sea without
jamming In a jammed environment the
Visby would be detected at a range of 8km
in rough sea and 11km in calm sea
The material provides high strength and
rigidity low weight good shock resistance
low radar and magnetic signature
1996
Visby is a class of stealth corvettes for the Swedish Navy
ldquoReduced 50 of a Conventional Steelrdquo
Source
Hull Construction with composite materials for ships over 100m in length 2002
Massachusetts Institute of Technology
httpwwwnaval-technologycomprojectsvisby
YACHTS
KAL YUDISTIRAMARATHON 100 ADMIRAL YACHT
LOA 3050 MWidth 6 MFuel Tank 8000 LWater Tank 3000 LIce Box 500 LAccommodation Max 35 Personnel
2 x CATERPILLAR 3412E 1200 HPMARINE DIESEL ENGINE
PC 40 ndash KRI Krait 827Department of Indonesian Navy
LOA 40 MWidth 73 MPower 190Weapon Twin Cannon Barrels
127 mm Heavy Machine GunSpeed Knot 25 KnotDisplacement 105 tonAccommodation 23 personnel
PATROL BOAT
Rigid Inflatable BoatPATROL BOAT
Yachts
36m Luxury Yacht Moonraker
36m Luxury Yacht GoldenEye
50m Luxury Yacht Casino
Royale
45m Luxury Yacht Seashaw
Boat Parts
Barovans for Seismic Sweep
Centrifugal Liftfan House for Surface Effect
Ships
Composite Boat PropellersRTM
Deckhouses for Pilot Boats
Fairing Parts for Submarines
Flybridges for Motor yachts
Light Weight Gangway
MTB Launcher Mock-up
Pleasure Boats
12m Sailboat
12m Sail-Catamaranone-off
Canoes
Dragonfly 1000Catamaran Sailboat
Fantasy 37Sailboat
Farr 60Luxury Sailboat
EurodingyOlympic Dingy Class for
Woman
Hydrolift F23 Racing Boats
Kajacs
Najad 42Sailboat
Najad 520Sailboat
Najad 441Sailboat
Najad 391Sailboat
Nordwest 900Motorboat
Nordwest 1100Motorboat
Quatro 44Motorboat
Racemaster Competition Boats
Storebro 420
Storebro 345
Sweden Yacht 370Sailboat
Sweden Yacht 69Sailboat
Windy 41Motorboat
X-632Sailboat
X-362Sailboat
Commercial Boats
175m High Speed AmbulancePassenger Boat
19m High Speed Passenger Boat
20m High Speed Passenger Boat
364m Surface Effect Passenger Ship
45m Surface Effect Passenger Ship
120m Hull Structural Parts HSSS Catamaran Ferry
APPENDIX
Marine Vessel
1188m Fast Attack Vessel FMV 90 E
20m SAV-Surface Auxiliary Vessels
34m Personnel TransportCoast Guard Vessel
40ft Experimental SES
40m Landsort-Class Mine Hunters
54m Mine Counter Measure Vehicles SES
74m Coastal Patrol Boats
Fishing Boats
30 GT
12 GT
10 GT
5 GT
WISEWings In Surface Effect
HOVERCRAFT
Designed specifically for the tourist and transport industries the
Pioneer Mk3 hovercraft is amphibious and comfortably seats 25
passengers plus 1-crew The air-conditioned cabin allows for
maximum visibility for all aboard The Pioneer Mk3 is robust and
dynamic in its performance
Commercial hovercraft
Mk3 AirLift Hovercraft - 1215m
Power is economicaly provided by one Deutz diesel engine of
330kW (442hp) to cruise easily at 40 knots with much higher
speeds available according to the surface conditions The hull is
manufactured from fibreglassPVC foam composite sandwich
the windows are glass and the skirt is urethane coated nylon A
Military version is available with increased payload and systems
redundancy Power for the Military version comes from two Steyr
diesel engines with a total installed power of 320kW (429hp) All
transmission electrical hydraulic and air systems are duplicated
for maximum redundancy The increased performance of the
Military version comes from the reduced engine weight of the twin
Steyr installation cf the Deutz installation
Source
httpwwwnauticexpocomprodairlift-hovercraftcommercial-hovercrafts-25251-142868html
HOVERFLIGHT
BALLISTIC amp UNIT DEFENCED
Triaxis Composites Collaboration with Institute of Aeronautics and Space in the development of Missile Nose Cone
Polymer composites is the evolution of the military defence
Thin steel was the helmet material of
WWII and remained the principal material until around the 1980rsquos
The advantages of using steel
included a simple technology for manufacture of the helmets low cost and reasonably good
impact protection However these helmets were found to provide only marginal protection
against fragments
During the Vietnam War the US Army experimented with fiber-reinforced inserts in the
helmets These inserts improved ballistic protection but at the same time added weight and
reduced the air space between the head and the helmet
By the early part of the 1980rsquos the US military had developed the first all-composite
100 fiber-reinforced helmet This development resulted in even better ballistic protection
without altering the weight of the helmet Other improvements included better head coverage and
more space for ventilation
Source
Composites Armor - A difficult but huge market
by A Brent Strong Brigham Young University
MILITARY VEHICLES
HIGH SPEED TRAIN SHINKANSEN
Advanced Composites provide lightweight solutions for railway vehicles
saving as much as 50-80 of the weight compared with traditional
components
A lower overall weight translates into less stress faster acceleration and
higher speeds as well as reduced starting and stopping inertia Today
these are important criteria in global high-speed and metropolitan
railway projects
Fire smoke and toxic fumes are key safety criteria for interior
components of railway carriages Any material selected for an interior
component must meet international fire retardant standards
for Rail Interiors and Exteriors
Ceiling Panels Stairs
Seating Vestibules
Window Panels Door Pillars
Partition WallsDiffusers
Gangway and Cabinet Panels Cabin and
Desk panels
Door Pillars Lavatory Modules (standard and
Front and Rear EndsRoof Panels
Nose Cones Under Fairings
Source
httpwwwpctaerail_compositesphp
101
SKY BUS
2009
Europe is the world leader in offshore wind with
828 wind turbines and a cumulative capacity of 2056 MW spread across 38 offshore wind farms in 9
European countries
The UK and Denmark are the current leaders with a 44 and 30 share respectively In 2009
five countries built new offshore wind farms
UK (284 MW)
Demark (230 MW)
Sweden (30 MW)
Germany (30 MW)
Norway (23 MW)
2010
Asia leads the growth in global wind power which grew 358 GW in 2010 bringing
total global capacity to 1944 GW ndash up 225 from 2009
the Global Wind Energy Council (GWEC)
Asia accounted for 19 GW of new global wind power installations driven by China which installed 165
GW
ldquoChina now has 423 GW of wind powerrdquo
ldquoThis puts China firmly on a path to reach 200 GW of installed wind power by 2020 At the same
time China has become the worldrsquos largest producer of wind energy equipmentrdquo
Source
httpwwwreinforcedplasticscomview15655asia-leads-global-wind-power-growth
httpimgdeusmcomdesignnews288288605-Sandia_Sizes_up_Wind_Turbine_Blade_Design_C_largegif
WIND ENERGY
Marine Current Turbines
Source
httpwwwsiemenscompressenpressreleasepress=enpressrelease2011solar-hydroex201111005htm
httpwwwmarineturbinescom
A commercial marine current turbine consists of
two rotors which are fixed on a structure within the
sea current The twin rotors rotate with the
movement of the tidal flow and the blades pitch
through 180 degrees to optimally track tidal current
(Press picture Marine Current Turbines)
Wave Star Energys Multi-point Absorber
CFRP COLUMN REINFORCEMENT
INDUSTRIAL TANKS
107
INDUSTRIAL PIPES
PRESSURE TANKS
109
ldquoLetrsquos Make with Compositesrdquo
Wet hand lay-up
1) Peletakan
Dry Reinforcement
bull Dry reinforcement dan resin (+ katalis) ditaruh pada permukaan cetakan
2) Pemasukanpenekanan resin
bull Resin ditekan untuk meng-impregnasi serat dengan menggunakan rol
3) Pengulangan proses untuk lapisan lain
bull Beberapa lapisan dapat ditambahkan secara bertahap
4) Resin curing
bull Reaksi dimulai komponen dilepaskan setelah komponen mengeras
(fully cured)
Wet hand lay-up
Manufaktur komponen dapat dikerjakan dengan menggunakan beberapa lapis komposit
dengan memperhatikan kompatibilitas material dan tahapan curing Modifikasi proses dapat
dilakukan seperti
Vacuum bagging
setelah lay-up
Glass Roving
Bulk Resin
Catalyst
3) De-molding
2) Resin Cure
bull Curing dimulai dan komponen dilepaskan setelah pengerasan selesai
bull Serat gelas resin dan katalis dimasukkan kedalam spray gun
1) Spray-up
bull Campuran disemprotkan pada permukaan cetakan
Spray-up
69
Penyemprotan bakal komponen
Komponen
dilepaskan
dari cetakan
Full dispensing
system Chopper Roving
Atomised resin
and catalyst
Spray-up
Prepreg
1) LaminateAssembly 5) De-molding
3) Resin Melts Layup Consolidates
bull Prepreg serat yang sudah diimpregnasi oleh resin+katalis dalam kondisi padat
bull Lapisan prepreg digunting sesuai bentuk yang diinginkan kemudian diletakkan pada permukaan cetakan
sesuai bentuk komponen yang diinginkan Lay-up mudah dilakukan karena sifat ldquotackynessrdquo dari prepreg
2) Applied Vacuum Pressure and Heat
bull Tekanan dan panas diberikan resin mencair terjadi konsolidasi pada komponen
4) Resin Cures
bull Temperatur dinaikkan untuk memulai curing
Prepreg
Variasi proses Autoclave
Komponen dalam
vacuum-bag
bull Campuran resin (+katalis) dan chopped glass strands diperoleh dalam bentuk premixed compound Bulk molding
Compound (BMC) dalam bentuk adonan atau Sheet molding Compound (SMC) dalam bentuk lembaran
bull Ketika panas dan tekanan diberikan oleh cetakan compound mengalir sesuai bentuk komponen yang diinginkan
1) Placement of Charge
5) De-molding3) Squeeze to final dimensions
2) Mould Closure4) Resin Cure
bull Curing dimulai komponen dilepaskan setelah terjadi pengerasan yang cukup
Compression Molding
bull Preform atau dry reinforcement dimasukkan kedalam cetakan sesuai dengan bentuk komponen yang
diinginkan
bull Resin mengalir dengan penekanan atau pem-vakuman dan meng-impregnasi preform dan
mendorongmengeluarkan udara yang ada dalam preform
1) Preform Manufacture
2) Preform Compression
5) De-molding3) Resin Injection
4) Resin Cure
bull Curing terjadi cetakan dibuka setelah terjadi pengerasan yang mencukupi
Liquid Molding (RTM VARI VARTM)
Pultrusion
bull Dry roving or fabrics ditarik melalui bak berisi
campuran resin dan katalis
bull Campuran yang basah ditarik melalui cetakan
bull Sisa resin keluar cetakan
bull Pemanasan dilakukan untuk proses curing
bull Pendinginan dilakukan untuk mempercepat siklus
produksi
Cut-off
Cooling
Die sections
Resin bath
Fibre creel
Filament Winding
bull Dry roving ditarik melalui bak berisi campuran resin dan katalis
bull Wet roving digulungkan dalam keadaan tegang kepada mandrel
bull Kontrol mekanik dari pembawa serat mengatur orientasi peletakan serat pada
mandrel
INDUSTRI COMPOSITES
AEROSPACE
HISTORY
1950 ndash Boeing
1960 ndash F14 Tomcat
1981 ndash AV-8B Harrier
Source
Low-Cost Composite Materials and Structures for Aircraft Applications
httpwwwreinforcedplasticscom
httpwwwcentennialofflightgovessayEvolution_of_TechnologycompositesTech40htm
Automotive
Composite material is used in a number of applications in the automotive
industry due to its temperature resistance rigidity and fatigue strength
The benefits of using composites include greater fuel efficiency
corrosion resistance light weight and strength Composites also provide
a low-cost way to help keep designs looking fresh
Composites are used in
- interior parts (cockpit trimming seats instrument panels)
- exterior structure (body panels openings underbody frontrear
modules)
- engine compartment and fuelmechanical area parts (axles and
suspensions fuel and exhaust systems)
- electrical and electronic components
Lamborghinis Sesto Element carbon fiber
ldquoFat men cannot run as fast as thin men but we build most of our vehicles as though dead-weight fat increased speedhellip I cannot
imagine where the delusion that weight means strength
came fromhelliprdquo mdashHenry Ford
The mix of automotive materials is changing showing a boost for FRP in helping original
equipment manufacturers meet fuel economy and emissions challenges
(Source 2011 DuPont AutomotiveSAE survey of design engineers performed by Signet Research Inc)
Source
httpwwwtoraycomcsrhighlight2009hig_001_01html
The MonoCell tub for the McLaren MP4-12C supercar is moulded as a single
piece and weighs less than 80 kg (176 lbs)
COMPOSITES IN MARINE
TRIMARAN BOAT
AMERICA NAVYINDONESIAN NAVY
Visby Class corvette
Total length is 72 meters
The beam is 1040 meters
The displacement is 600 metric tones
fully equipped the worlds largest CRP
construction
The design of the Visby aims to minimize
the optical and infrared signature above
water acoustic and hydroa coustic
signature underwater electrical potential
and magnetic signature pressure signature
radar cross section and actively emitted
signals
A stealth corvette of the YS 2000 design
has a detection range of 13km in rough
seas and 22km in calm sea without
jamming In a jammed environment the
Visby would be detected at a range of 8km
in rough sea and 11km in calm sea
The material provides high strength and
rigidity low weight good shock resistance
low radar and magnetic signature
1996
Visby is a class of stealth corvettes for the Swedish Navy
ldquoReduced 50 of a Conventional Steelrdquo
Source
Hull Construction with composite materials for ships over 100m in length 2002
Massachusetts Institute of Technology
httpwwwnaval-technologycomprojectsvisby
YACHTS
KAL YUDISTIRAMARATHON 100 ADMIRAL YACHT
LOA 3050 MWidth 6 MFuel Tank 8000 LWater Tank 3000 LIce Box 500 LAccommodation Max 35 Personnel
2 x CATERPILLAR 3412E 1200 HPMARINE DIESEL ENGINE
PC 40 ndash KRI Krait 827Department of Indonesian Navy
LOA 40 MWidth 73 MPower 190Weapon Twin Cannon Barrels
127 mm Heavy Machine GunSpeed Knot 25 KnotDisplacement 105 tonAccommodation 23 personnel
PATROL BOAT
Rigid Inflatable BoatPATROL BOAT
Yachts
36m Luxury Yacht Moonraker
36m Luxury Yacht GoldenEye
50m Luxury Yacht Casino
Royale
45m Luxury Yacht Seashaw
Boat Parts
Barovans for Seismic Sweep
Centrifugal Liftfan House for Surface Effect
Ships
Composite Boat PropellersRTM
Deckhouses for Pilot Boats
Fairing Parts for Submarines
Flybridges for Motor yachts
Light Weight Gangway
MTB Launcher Mock-up
Pleasure Boats
12m Sailboat
12m Sail-Catamaranone-off
Canoes
Dragonfly 1000Catamaran Sailboat
Fantasy 37Sailboat
Farr 60Luxury Sailboat
EurodingyOlympic Dingy Class for
Woman
Hydrolift F23 Racing Boats
Kajacs
Najad 42Sailboat
Najad 520Sailboat
Najad 441Sailboat
Najad 391Sailboat
Nordwest 900Motorboat
Nordwest 1100Motorboat
Quatro 44Motorboat
Racemaster Competition Boats
Storebro 420
Storebro 345
Sweden Yacht 370Sailboat
Sweden Yacht 69Sailboat
Windy 41Motorboat
X-632Sailboat
X-362Sailboat
Commercial Boats
175m High Speed AmbulancePassenger Boat
19m High Speed Passenger Boat
20m High Speed Passenger Boat
364m Surface Effect Passenger Ship
45m Surface Effect Passenger Ship
120m Hull Structural Parts HSSS Catamaran Ferry
APPENDIX
Marine Vessel
1188m Fast Attack Vessel FMV 90 E
20m SAV-Surface Auxiliary Vessels
34m Personnel TransportCoast Guard Vessel
40ft Experimental SES
40m Landsort-Class Mine Hunters
54m Mine Counter Measure Vehicles SES
74m Coastal Patrol Boats
Fishing Boats
30 GT
12 GT
10 GT
5 GT
WISEWings In Surface Effect
HOVERCRAFT
Designed specifically for the tourist and transport industries the
Pioneer Mk3 hovercraft is amphibious and comfortably seats 25
passengers plus 1-crew The air-conditioned cabin allows for
maximum visibility for all aboard The Pioneer Mk3 is robust and
dynamic in its performance
Commercial hovercraft
Mk3 AirLift Hovercraft - 1215m
Power is economicaly provided by one Deutz diesel engine of
330kW (442hp) to cruise easily at 40 knots with much higher
speeds available according to the surface conditions The hull is
manufactured from fibreglassPVC foam composite sandwich
the windows are glass and the skirt is urethane coated nylon A
Military version is available with increased payload and systems
redundancy Power for the Military version comes from two Steyr
diesel engines with a total installed power of 320kW (429hp) All
transmission electrical hydraulic and air systems are duplicated
for maximum redundancy The increased performance of the
Military version comes from the reduced engine weight of the twin
Steyr installation cf the Deutz installation
Source
httpwwwnauticexpocomprodairlift-hovercraftcommercial-hovercrafts-25251-142868html
HOVERFLIGHT
BALLISTIC amp UNIT DEFENCED
Triaxis Composites Collaboration with Institute of Aeronautics and Space in the development of Missile Nose Cone
Polymer composites is the evolution of the military defence
Thin steel was the helmet material of
WWII and remained the principal material until around the 1980rsquos
The advantages of using steel
included a simple technology for manufacture of the helmets low cost and reasonably good
impact protection However these helmets were found to provide only marginal protection
against fragments
During the Vietnam War the US Army experimented with fiber-reinforced inserts in the
helmets These inserts improved ballistic protection but at the same time added weight and
reduced the air space between the head and the helmet
By the early part of the 1980rsquos the US military had developed the first all-composite
100 fiber-reinforced helmet This development resulted in even better ballistic protection
without altering the weight of the helmet Other improvements included better head coverage and
more space for ventilation
Source
Composites Armor - A difficult but huge market
by A Brent Strong Brigham Young University
MILITARY VEHICLES
HIGH SPEED TRAIN SHINKANSEN
Advanced Composites provide lightweight solutions for railway vehicles
saving as much as 50-80 of the weight compared with traditional
components
A lower overall weight translates into less stress faster acceleration and
higher speeds as well as reduced starting and stopping inertia Today
these are important criteria in global high-speed and metropolitan
railway projects
Fire smoke and toxic fumes are key safety criteria for interior
components of railway carriages Any material selected for an interior
component must meet international fire retardant standards
for Rail Interiors and Exteriors
Ceiling Panels Stairs
Seating Vestibules
Window Panels Door Pillars
Partition WallsDiffusers
Gangway and Cabinet Panels Cabin and
Desk panels
Door Pillars Lavatory Modules (standard and
Front and Rear EndsRoof Panels
Nose Cones Under Fairings
Source
httpwwwpctaerail_compositesphp
101
SKY BUS
2009
Europe is the world leader in offshore wind with
828 wind turbines and a cumulative capacity of 2056 MW spread across 38 offshore wind farms in 9
European countries
The UK and Denmark are the current leaders with a 44 and 30 share respectively In 2009
five countries built new offshore wind farms
UK (284 MW)
Demark (230 MW)
Sweden (30 MW)
Germany (30 MW)
Norway (23 MW)
2010
Asia leads the growth in global wind power which grew 358 GW in 2010 bringing
total global capacity to 1944 GW ndash up 225 from 2009
the Global Wind Energy Council (GWEC)
Asia accounted for 19 GW of new global wind power installations driven by China which installed 165
GW
ldquoChina now has 423 GW of wind powerrdquo
ldquoThis puts China firmly on a path to reach 200 GW of installed wind power by 2020 At the same
time China has become the worldrsquos largest producer of wind energy equipmentrdquo
Source
httpwwwreinforcedplasticscomview15655asia-leads-global-wind-power-growth
httpimgdeusmcomdesignnews288288605-Sandia_Sizes_up_Wind_Turbine_Blade_Design_C_largegif
WIND ENERGY
Marine Current Turbines
Source
httpwwwsiemenscompressenpressreleasepress=enpressrelease2011solar-hydroex201111005htm
httpwwwmarineturbinescom
A commercial marine current turbine consists of
two rotors which are fixed on a structure within the
sea current The twin rotors rotate with the
movement of the tidal flow and the blades pitch
through 180 degrees to optimally track tidal current
(Press picture Marine Current Turbines)
Wave Star Energys Multi-point Absorber
CFRP COLUMN REINFORCEMENT
INDUSTRIAL TANKS
107
INDUSTRIAL PIPES
PRESSURE TANKS
109
ldquoLetrsquos Make with Compositesrdquo
Wet hand lay-up
Manufaktur komponen dapat dikerjakan dengan menggunakan beberapa lapis komposit
dengan memperhatikan kompatibilitas material dan tahapan curing Modifikasi proses dapat
dilakukan seperti
Vacuum bagging
setelah lay-up
Glass Roving
Bulk Resin
Catalyst
3) De-molding
2) Resin Cure
bull Curing dimulai dan komponen dilepaskan setelah pengerasan selesai
bull Serat gelas resin dan katalis dimasukkan kedalam spray gun
1) Spray-up
bull Campuran disemprotkan pada permukaan cetakan
Spray-up
69
Penyemprotan bakal komponen
Komponen
dilepaskan
dari cetakan
Full dispensing
system Chopper Roving
Atomised resin
and catalyst
Spray-up
Prepreg
1) LaminateAssembly 5) De-molding
3) Resin Melts Layup Consolidates
bull Prepreg serat yang sudah diimpregnasi oleh resin+katalis dalam kondisi padat
bull Lapisan prepreg digunting sesuai bentuk yang diinginkan kemudian diletakkan pada permukaan cetakan
sesuai bentuk komponen yang diinginkan Lay-up mudah dilakukan karena sifat ldquotackynessrdquo dari prepreg
2) Applied Vacuum Pressure and Heat
bull Tekanan dan panas diberikan resin mencair terjadi konsolidasi pada komponen
4) Resin Cures
bull Temperatur dinaikkan untuk memulai curing
Prepreg
Variasi proses Autoclave
Komponen dalam
vacuum-bag
bull Campuran resin (+katalis) dan chopped glass strands diperoleh dalam bentuk premixed compound Bulk molding
Compound (BMC) dalam bentuk adonan atau Sheet molding Compound (SMC) dalam bentuk lembaran
bull Ketika panas dan tekanan diberikan oleh cetakan compound mengalir sesuai bentuk komponen yang diinginkan
1) Placement of Charge
5) De-molding3) Squeeze to final dimensions
2) Mould Closure4) Resin Cure
bull Curing dimulai komponen dilepaskan setelah terjadi pengerasan yang cukup
Compression Molding
bull Preform atau dry reinforcement dimasukkan kedalam cetakan sesuai dengan bentuk komponen yang
diinginkan
bull Resin mengalir dengan penekanan atau pem-vakuman dan meng-impregnasi preform dan
mendorongmengeluarkan udara yang ada dalam preform
1) Preform Manufacture
2) Preform Compression
5) De-molding3) Resin Injection
4) Resin Cure
bull Curing terjadi cetakan dibuka setelah terjadi pengerasan yang mencukupi
Liquid Molding (RTM VARI VARTM)
Pultrusion
bull Dry roving or fabrics ditarik melalui bak berisi
campuran resin dan katalis
bull Campuran yang basah ditarik melalui cetakan
bull Sisa resin keluar cetakan
bull Pemanasan dilakukan untuk proses curing
bull Pendinginan dilakukan untuk mempercepat siklus
produksi
Cut-off
Cooling
Die sections
Resin bath
Fibre creel
Filament Winding
bull Dry roving ditarik melalui bak berisi campuran resin dan katalis
bull Wet roving digulungkan dalam keadaan tegang kepada mandrel
bull Kontrol mekanik dari pembawa serat mengatur orientasi peletakan serat pada
mandrel
INDUSTRI COMPOSITES
AEROSPACE
HISTORY
1950 ndash Boeing
1960 ndash F14 Tomcat
1981 ndash AV-8B Harrier
Source
Low-Cost Composite Materials and Structures for Aircraft Applications
httpwwwreinforcedplasticscom
httpwwwcentennialofflightgovessayEvolution_of_TechnologycompositesTech40htm
Automotive
Composite material is used in a number of applications in the automotive
industry due to its temperature resistance rigidity and fatigue strength
The benefits of using composites include greater fuel efficiency
corrosion resistance light weight and strength Composites also provide
a low-cost way to help keep designs looking fresh
Composites are used in
- interior parts (cockpit trimming seats instrument panels)
- exterior structure (body panels openings underbody frontrear
modules)
- engine compartment and fuelmechanical area parts (axles and
suspensions fuel and exhaust systems)
- electrical and electronic components
Lamborghinis Sesto Element carbon fiber
ldquoFat men cannot run as fast as thin men but we build most of our vehicles as though dead-weight fat increased speedhellip I cannot
imagine where the delusion that weight means strength
came fromhelliprdquo mdashHenry Ford
The mix of automotive materials is changing showing a boost for FRP in helping original
equipment manufacturers meet fuel economy and emissions challenges
(Source 2011 DuPont AutomotiveSAE survey of design engineers performed by Signet Research Inc)
Source
httpwwwtoraycomcsrhighlight2009hig_001_01html
The MonoCell tub for the McLaren MP4-12C supercar is moulded as a single
piece and weighs less than 80 kg (176 lbs)
COMPOSITES IN MARINE
TRIMARAN BOAT
AMERICA NAVYINDONESIAN NAVY
Visby Class corvette
Total length is 72 meters
The beam is 1040 meters
The displacement is 600 metric tones
fully equipped the worlds largest CRP
construction
The design of the Visby aims to minimize
the optical and infrared signature above
water acoustic and hydroa coustic
signature underwater electrical potential
and magnetic signature pressure signature
radar cross section and actively emitted
signals
A stealth corvette of the YS 2000 design
has a detection range of 13km in rough
seas and 22km in calm sea without
jamming In a jammed environment the
Visby would be detected at a range of 8km
in rough sea and 11km in calm sea
The material provides high strength and
rigidity low weight good shock resistance
low radar and magnetic signature
1996
Visby is a class of stealth corvettes for the Swedish Navy
ldquoReduced 50 of a Conventional Steelrdquo
Source
Hull Construction with composite materials for ships over 100m in length 2002
Massachusetts Institute of Technology
httpwwwnaval-technologycomprojectsvisby
YACHTS
KAL YUDISTIRAMARATHON 100 ADMIRAL YACHT
LOA 3050 MWidth 6 MFuel Tank 8000 LWater Tank 3000 LIce Box 500 LAccommodation Max 35 Personnel
2 x CATERPILLAR 3412E 1200 HPMARINE DIESEL ENGINE
PC 40 ndash KRI Krait 827Department of Indonesian Navy
LOA 40 MWidth 73 MPower 190Weapon Twin Cannon Barrels
127 mm Heavy Machine GunSpeed Knot 25 KnotDisplacement 105 tonAccommodation 23 personnel
PATROL BOAT
Rigid Inflatable BoatPATROL BOAT
Yachts
36m Luxury Yacht Moonraker
36m Luxury Yacht GoldenEye
50m Luxury Yacht Casino
Royale
45m Luxury Yacht Seashaw
Boat Parts
Barovans for Seismic Sweep
Centrifugal Liftfan House for Surface Effect
Ships
Composite Boat PropellersRTM
Deckhouses for Pilot Boats
Fairing Parts for Submarines
Flybridges for Motor yachts
Light Weight Gangway
MTB Launcher Mock-up
Pleasure Boats
12m Sailboat
12m Sail-Catamaranone-off
Canoes
Dragonfly 1000Catamaran Sailboat
Fantasy 37Sailboat
Farr 60Luxury Sailboat
EurodingyOlympic Dingy Class for
Woman
Hydrolift F23 Racing Boats
Kajacs
Najad 42Sailboat
Najad 520Sailboat
Najad 441Sailboat
Najad 391Sailboat
Nordwest 900Motorboat
Nordwest 1100Motorboat
Quatro 44Motorboat
Racemaster Competition Boats
Storebro 420
Storebro 345
Sweden Yacht 370Sailboat
Sweden Yacht 69Sailboat
Windy 41Motorboat
X-632Sailboat
X-362Sailboat
Commercial Boats
175m High Speed AmbulancePassenger Boat
19m High Speed Passenger Boat
20m High Speed Passenger Boat
364m Surface Effect Passenger Ship
45m Surface Effect Passenger Ship
120m Hull Structural Parts HSSS Catamaran Ferry
APPENDIX
Marine Vessel
1188m Fast Attack Vessel FMV 90 E
20m SAV-Surface Auxiliary Vessels
34m Personnel TransportCoast Guard Vessel
40ft Experimental SES
40m Landsort-Class Mine Hunters
54m Mine Counter Measure Vehicles SES
74m Coastal Patrol Boats
Fishing Boats
30 GT
12 GT
10 GT
5 GT
WISEWings In Surface Effect
HOVERCRAFT
Designed specifically for the tourist and transport industries the
Pioneer Mk3 hovercraft is amphibious and comfortably seats 25
passengers plus 1-crew The air-conditioned cabin allows for
maximum visibility for all aboard The Pioneer Mk3 is robust and
dynamic in its performance
Commercial hovercraft
Mk3 AirLift Hovercraft - 1215m
Power is economicaly provided by one Deutz diesel engine of
330kW (442hp) to cruise easily at 40 knots with much higher
speeds available according to the surface conditions The hull is
manufactured from fibreglassPVC foam composite sandwich
the windows are glass and the skirt is urethane coated nylon A
Military version is available with increased payload and systems
redundancy Power for the Military version comes from two Steyr
diesel engines with a total installed power of 320kW (429hp) All
transmission electrical hydraulic and air systems are duplicated
for maximum redundancy The increased performance of the
Military version comes from the reduced engine weight of the twin
Steyr installation cf the Deutz installation
Source
httpwwwnauticexpocomprodairlift-hovercraftcommercial-hovercrafts-25251-142868html
HOVERFLIGHT
BALLISTIC amp UNIT DEFENCED
Triaxis Composites Collaboration with Institute of Aeronautics and Space in the development of Missile Nose Cone
Polymer composites is the evolution of the military defence
Thin steel was the helmet material of
WWII and remained the principal material until around the 1980rsquos
The advantages of using steel
included a simple technology for manufacture of the helmets low cost and reasonably good
impact protection However these helmets were found to provide only marginal protection
against fragments
During the Vietnam War the US Army experimented with fiber-reinforced inserts in the
helmets These inserts improved ballistic protection but at the same time added weight and
reduced the air space between the head and the helmet
By the early part of the 1980rsquos the US military had developed the first all-composite
100 fiber-reinforced helmet This development resulted in even better ballistic protection
without altering the weight of the helmet Other improvements included better head coverage and
more space for ventilation
Source
Composites Armor - A difficult but huge market
by A Brent Strong Brigham Young University
MILITARY VEHICLES
HIGH SPEED TRAIN SHINKANSEN
Advanced Composites provide lightweight solutions for railway vehicles
saving as much as 50-80 of the weight compared with traditional
components
A lower overall weight translates into less stress faster acceleration and
higher speeds as well as reduced starting and stopping inertia Today
these are important criteria in global high-speed and metropolitan
railway projects
Fire smoke and toxic fumes are key safety criteria for interior
components of railway carriages Any material selected for an interior
component must meet international fire retardant standards
for Rail Interiors and Exteriors
Ceiling Panels Stairs
Seating Vestibules
Window Panels Door Pillars
Partition WallsDiffusers
Gangway and Cabinet Panels Cabin and
Desk panels
Door Pillars Lavatory Modules (standard and
Front and Rear EndsRoof Panels
Nose Cones Under Fairings
Source
httpwwwpctaerail_compositesphp
101
SKY BUS
2009
Europe is the world leader in offshore wind with
828 wind turbines and a cumulative capacity of 2056 MW spread across 38 offshore wind farms in 9
European countries
The UK and Denmark are the current leaders with a 44 and 30 share respectively In 2009
five countries built new offshore wind farms
UK (284 MW)
Demark (230 MW)
Sweden (30 MW)
Germany (30 MW)
Norway (23 MW)
2010
Asia leads the growth in global wind power which grew 358 GW in 2010 bringing
total global capacity to 1944 GW ndash up 225 from 2009
the Global Wind Energy Council (GWEC)
Asia accounted for 19 GW of new global wind power installations driven by China which installed 165
GW
ldquoChina now has 423 GW of wind powerrdquo
ldquoThis puts China firmly on a path to reach 200 GW of installed wind power by 2020 At the same
time China has become the worldrsquos largest producer of wind energy equipmentrdquo
Source
httpwwwreinforcedplasticscomview15655asia-leads-global-wind-power-growth
httpimgdeusmcomdesignnews288288605-Sandia_Sizes_up_Wind_Turbine_Blade_Design_C_largegif
WIND ENERGY
Marine Current Turbines
Source
httpwwwsiemenscompressenpressreleasepress=enpressrelease2011solar-hydroex201111005htm
httpwwwmarineturbinescom
A commercial marine current turbine consists of
two rotors which are fixed on a structure within the
sea current The twin rotors rotate with the
movement of the tidal flow and the blades pitch
through 180 degrees to optimally track tidal current
(Press picture Marine Current Turbines)
Wave Star Energys Multi-point Absorber
CFRP COLUMN REINFORCEMENT
INDUSTRIAL TANKS
107
INDUSTRIAL PIPES
PRESSURE TANKS
109
ldquoLetrsquos Make with Compositesrdquo
Glass Roving
Bulk Resin
Catalyst
3) De-molding
2) Resin Cure
bull Curing dimulai dan komponen dilepaskan setelah pengerasan selesai
bull Serat gelas resin dan katalis dimasukkan kedalam spray gun
1) Spray-up
bull Campuran disemprotkan pada permukaan cetakan
Spray-up
69
Penyemprotan bakal komponen
Komponen
dilepaskan
dari cetakan
Full dispensing
system Chopper Roving
Atomised resin
and catalyst
Spray-up
Prepreg
1) LaminateAssembly 5) De-molding
3) Resin Melts Layup Consolidates
bull Prepreg serat yang sudah diimpregnasi oleh resin+katalis dalam kondisi padat
bull Lapisan prepreg digunting sesuai bentuk yang diinginkan kemudian diletakkan pada permukaan cetakan
sesuai bentuk komponen yang diinginkan Lay-up mudah dilakukan karena sifat ldquotackynessrdquo dari prepreg
2) Applied Vacuum Pressure and Heat
bull Tekanan dan panas diberikan resin mencair terjadi konsolidasi pada komponen
4) Resin Cures
bull Temperatur dinaikkan untuk memulai curing
Prepreg
Variasi proses Autoclave
Komponen dalam
vacuum-bag
bull Campuran resin (+katalis) dan chopped glass strands diperoleh dalam bentuk premixed compound Bulk molding
Compound (BMC) dalam bentuk adonan atau Sheet molding Compound (SMC) dalam bentuk lembaran
bull Ketika panas dan tekanan diberikan oleh cetakan compound mengalir sesuai bentuk komponen yang diinginkan
1) Placement of Charge
5) De-molding3) Squeeze to final dimensions
2) Mould Closure4) Resin Cure
bull Curing dimulai komponen dilepaskan setelah terjadi pengerasan yang cukup
Compression Molding
bull Preform atau dry reinforcement dimasukkan kedalam cetakan sesuai dengan bentuk komponen yang
diinginkan
bull Resin mengalir dengan penekanan atau pem-vakuman dan meng-impregnasi preform dan
mendorongmengeluarkan udara yang ada dalam preform
1) Preform Manufacture
2) Preform Compression
5) De-molding3) Resin Injection
4) Resin Cure
bull Curing terjadi cetakan dibuka setelah terjadi pengerasan yang mencukupi
Liquid Molding (RTM VARI VARTM)
Pultrusion
bull Dry roving or fabrics ditarik melalui bak berisi
campuran resin dan katalis
bull Campuran yang basah ditarik melalui cetakan
bull Sisa resin keluar cetakan
bull Pemanasan dilakukan untuk proses curing
bull Pendinginan dilakukan untuk mempercepat siklus
produksi
Cut-off
Cooling
Die sections
Resin bath
Fibre creel
Filament Winding
bull Dry roving ditarik melalui bak berisi campuran resin dan katalis
bull Wet roving digulungkan dalam keadaan tegang kepada mandrel
bull Kontrol mekanik dari pembawa serat mengatur orientasi peletakan serat pada
mandrel
INDUSTRI COMPOSITES
AEROSPACE
HISTORY
1950 ndash Boeing
1960 ndash F14 Tomcat
1981 ndash AV-8B Harrier
Source
Low-Cost Composite Materials and Structures for Aircraft Applications
httpwwwreinforcedplasticscom
httpwwwcentennialofflightgovessayEvolution_of_TechnologycompositesTech40htm
Automotive
Composite material is used in a number of applications in the automotive
industry due to its temperature resistance rigidity and fatigue strength
The benefits of using composites include greater fuel efficiency
corrosion resistance light weight and strength Composites also provide
a low-cost way to help keep designs looking fresh
Composites are used in
- interior parts (cockpit trimming seats instrument panels)
- exterior structure (body panels openings underbody frontrear
modules)
- engine compartment and fuelmechanical area parts (axles and
suspensions fuel and exhaust systems)
- electrical and electronic components
Lamborghinis Sesto Element carbon fiber
ldquoFat men cannot run as fast as thin men but we build most of our vehicles as though dead-weight fat increased speedhellip I cannot
imagine where the delusion that weight means strength
came fromhelliprdquo mdashHenry Ford
The mix of automotive materials is changing showing a boost for FRP in helping original
equipment manufacturers meet fuel economy and emissions challenges
(Source 2011 DuPont AutomotiveSAE survey of design engineers performed by Signet Research Inc)
Source
httpwwwtoraycomcsrhighlight2009hig_001_01html
The MonoCell tub for the McLaren MP4-12C supercar is moulded as a single
piece and weighs less than 80 kg (176 lbs)
COMPOSITES IN MARINE
TRIMARAN BOAT
AMERICA NAVYINDONESIAN NAVY
Visby Class corvette
Total length is 72 meters
The beam is 1040 meters
The displacement is 600 metric tones
fully equipped the worlds largest CRP
construction
The design of the Visby aims to minimize
the optical and infrared signature above
water acoustic and hydroa coustic
signature underwater electrical potential
and magnetic signature pressure signature
radar cross section and actively emitted
signals
A stealth corvette of the YS 2000 design
has a detection range of 13km in rough
seas and 22km in calm sea without
jamming In a jammed environment the
Visby would be detected at a range of 8km
in rough sea and 11km in calm sea
The material provides high strength and
rigidity low weight good shock resistance
low radar and magnetic signature
1996
Visby is a class of stealth corvettes for the Swedish Navy
ldquoReduced 50 of a Conventional Steelrdquo
Source
Hull Construction with composite materials for ships over 100m in length 2002
Massachusetts Institute of Technology
httpwwwnaval-technologycomprojectsvisby
YACHTS
KAL YUDISTIRAMARATHON 100 ADMIRAL YACHT
LOA 3050 MWidth 6 MFuel Tank 8000 LWater Tank 3000 LIce Box 500 LAccommodation Max 35 Personnel
2 x CATERPILLAR 3412E 1200 HPMARINE DIESEL ENGINE
PC 40 ndash KRI Krait 827Department of Indonesian Navy
LOA 40 MWidth 73 MPower 190Weapon Twin Cannon Barrels
127 mm Heavy Machine GunSpeed Knot 25 KnotDisplacement 105 tonAccommodation 23 personnel
PATROL BOAT
Rigid Inflatable BoatPATROL BOAT
Yachts
36m Luxury Yacht Moonraker
36m Luxury Yacht GoldenEye
50m Luxury Yacht Casino
Royale
45m Luxury Yacht Seashaw
Boat Parts
Barovans for Seismic Sweep
Centrifugal Liftfan House for Surface Effect
Ships
Composite Boat PropellersRTM
Deckhouses for Pilot Boats
Fairing Parts for Submarines
Flybridges for Motor yachts
Light Weight Gangway
MTB Launcher Mock-up
Pleasure Boats
12m Sailboat
12m Sail-Catamaranone-off
Canoes
Dragonfly 1000Catamaran Sailboat
Fantasy 37Sailboat
Farr 60Luxury Sailboat
EurodingyOlympic Dingy Class for
Woman
Hydrolift F23 Racing Boats
Kajacs
Najad 42Sailboat
Najad 520Sailboat
Najad 441Sailboat
Najad 391Sailboat
Nordwest 900Motorboat
Nordwest 1100Motorboat
Quatro 44Motorboat
Racemaster Competition Boats
Storebro 420
Storebro 345
Sweden Yacht 370Sailboat
Sweden Yacht 69Sailboat
Windy 41Motorboat
X-632Sailboat
X-362Sailboat
Commercial Boats
175m High Speed AmbulancePassenger Boat
19m High Speed Passenger Boat
20m High Speed Passenger Boat
364m Surface Effect Passenger Ship
45m Surface Effect Passenger Ship
120m Hull Structural Parts HSSS Catamaran Ferry
APPENDIX
Marine Vessel
1188m Fast Attack Vessel FMV 90 E
20m SAV-Surface Auxiliary Vessels
34m Personnel TransportCoast Guard Vessel
40ft Experimental SES
40m Landsort-Class Mine Hunters
54m Mine Counter Measure Vehicles SES
74m Coastal Patrol Boats
Fishing Boats
30 GT
12 GT
10 GT
5 GT
WISEWings In Surface Effect
HOVERCRAFT
Designed specifically for the tourist and transport industries the
Pioneer Mk3 hovercraft is amphibious and comfortably seats 25
passengers plus 1-crew The air-conditioned cabin allows for
maximum visibility for all aboard The Pioneer Mk3 is robust and
dynamic in its performance
Commercial hovercraft
Mk3 AirLift Hovercraft - 1215m
Power is economicaly provided by one Deutz diesel engine of
330kW (442hp) to cruise easily at 40 knots with much higher
speeds available according to the surface conditions The hull is
manufactured from fibreglassPVC foam composite sandwich
the windows are glass and the skirt is urethane coated nylon A
Military version is available with increased payload and systems
redundancy Power for the Military version comes from two Steyr
diesel engines with a total installed power of 320kW (429hp) All
transmission electrical hydraulic and air systems are duplicated
for maximum redundancy The increased performance of the
Military version comes from the reduced engine weight of the twin
Steyr installation cf the Deutz installation
Source
httpwwwnauticexpocomprodairlift-hovercraftcommercial-hovercrafts-25251-142868html
HOVERFLIGHT
BALLISTIC amp UNIT DEFENCED
Triaxis Composites Collaboration with Institute of Aeronautics and Space in the development of Missile Nose Cone
Polymer composites is the evolution of the military defence
Thin steel was the helmet material of
WWII and remained the principal material until around the 1980rsquos
The advantages of using steel
included a simple technology for manufacture of the helmets low cost and reasonably good
impact protection However these helmets were found to provide only marginal protection
against fragments
During the Vietnam War the US Army experimented with fiber-reinforced inserts in the
helmets These inserts improved ballistic protection but at the same time added weight and
reduced the air space between the head and the helmet
By the early part of the 1980rsquos the US military had developed the first all-composite
100 fiber-reinforced helmet This development resulted in even better ballistic protection
without altering the weight of the helmet Other improvements included better head coverage and
more space for ventilation
Source
Composites Armor - A difficult but huge market
by A Brent Strong Brigham Young University
MILITARY VEHICLES
HIGH SPEED TRAIN SHINKANSEN
Advanced Composites provide lightweight solutions for railway vehicles
saving as much as 50-80 of the weight compared with traditional
components
A lower overall weight translates into less stress faster acceleration and
higher speeds as well as reduced starting and stopping inertia Today
these are important criteria in global high-speed and metropolitan
railway projects
Fire smoke and toxic fumes are key safety criteria for interior
components of railway carriages Any material selected for an interior
component must meet international fire retardant standards
for Rail Interiors and Exteriors
Ceiling Panels Stairs
Seating Vestibules
Window Panels Door Pillars
Partition WallsDiffusers
Gangway and Cabinet Panels Cabin and
Desk panels
Door Pillars Lavatory Modules (standard and
Front and Rear EndsRoof Panels
Nose Cones Under Fairings
Source
httpwwwpctaerail_compositesphp
101
SKY BUS
2009
Europe is the world leader in offshore wind with
828 wind turbines and a cumulative capacity of 2056 MW spread across 38 offshore wind farms in 9
European countries
The UK and Denmark are the current leaders with a 44 and 30 share respectively In 2009
five countries built new offshore wind farms
UK (284 MW)
Demark (230 MW)
Sweden (30 MW)
Germany (30 MW)
Norway (23 MW)
2010
Asia leads the growth in global wind power which grew 358 GW in 2010 bringing
total global capacity to 1944 GW ndash up 225 from 2009
the Global Wind Energy Council (GWEC)
Asia accounted for 19 GW of new global wind power installations driven by China which installed 165
GW
ldquoChina now has 423 GW of wind powerrdquo
ldquoThis puts China firmly on a path to reach 200 GW of installed wind power by 2020 At the same
time China has become the worldrsquos largest producer of wind energy equipmentrdquo
Source
httpwwwreinforcedplasticscomview15655asia-leads-global-wind-power-growth
httpimgdeusmcomdesignnews288288605-Sandia_Sizes_up_Wind_Turbine_Blade_Design_C_largegif
WIND ENERGY
Marine Current Turbines
Source
httpwwwsiemenscompressenpressreleasepress=enpressrelease2011solar-hydroex201111005htm
httpwwwmarineturbinescom
A commercial marine current turbine consists of
two rotors which are fixed on a structure within the
sea current The twin rotors rotate with the
movement of the tidal flow and the blades pitch
through 180 degrees to optimally track tidal current
(Press picture Marine Current Turbines)
Wave Star Energys Multi-point Absorber
CFRP COLUMN REINFORCEMENT
INDUSTRIAL TANKS
107
INDUSTRIAL PIPES
PRESSURE TANKS
109
ldquoLetrsquos Make with Compositesrdquo
69
Penyemprotan bakal komponen
Komponen
dilepaskan
dari cetakan
Full dispensing
system Chopper Roving
Atomised resin
and catalyst
Spray-up
Prepreg
1) LaminateAssembly 5) De-molding
3) Resin Melts Layup Consolidates
bull Prepreg serat yang sudah diimpregnasi oleh resin+katalis dalam kondisi padat
bull Lapisan prepreg digunting sesuai bentuk yang diinginkan kemudian diletakkan pada permukaan cetakan
sesuai bentuk komponen yang diinginkan Lay-up mudah dilakukan karena sifat ldquotackynessrdquo dari prepreg
2) Applied Vacuum Pressure and Heat
bull Tekanan dan panas diberikan resin mencair terjadi konsolidasi pada komponen
4) Resin Cures
bull Temperatur dinaikkan untuk memulai curing
Prepreg
Variasi proses Autoclave
Komponen dalam
vacuum-bag
bull Campuran resin (+katalis) dan chopped glass strands diperoleh dalam bentuk premixed compound Bulk molding
Compound (BMC) dalam bentuk adonan atau Sheet molding Compound (SMC) dalam bentuk lembaran
bull Ketika panas dan tekanan diberikan oleh cetakan compound mengalir sesuai bentuk komponen yang diinginkan
1) Placement of Charge
5) De-molding3) Squeeze to final dimensions
2) Mould Closure4) Resin Cure
bull Curing dimulai komponen dilepaskan setelah terjadi pengerasan yang cukup
Compression Molding
bull Preform atau dry reinforcement dimasukkan kedalam cetakan sesuai dengan bentuk komponen yang
diinginkan
bull Resin mengalir dengan penekanan atau pem-vakuman dan meng-impregnasi preform dan
mendorongmengeluarkan udara yang ada dalam preform
1) Preform Manufacture
2) Preform Compression
5) De-molding3) Resin Injection
4) Resin Cure
bull Curing terjadi cetakan dibuka setelah terjadi pengerasan yang mencukupi
Liquid Molding (RTM VARI VARTM)
Pultrusion
bull Dry roving or fabrics ditarik melalui bak berisi
campuran resin dan katalis
bull Campuran yang basah ditarik melalui cetakan
bull Sisa resin keluar cetakan
bull Pemanasan dilakukan untuk proses curing
bull Pendinginan dilakukan untuk mempercepat siklus
produksi
Cut-off
Cooling
Die sections
Resin bath
Fibre creel
Filament Winding
bull Dry roving ditarik melalui bak berisi campuran resin dan katalis
bull Wet roving digulungkan dalam keadaan tegang kepada mandrel
bull Kontrol mekanik dari pembawa serat mengatur orientasi peletakan serat pada
mandrel
INDUSTRI COMPOSITES
AEROSPACE
HISTORY
1950 ndash Boeing
1960 ndash F14 Tomcat
1981 ndash AV-8B Harrier
Source
Low-Cost Composite Materials and Structures for Aircraft Applications
httpwwwreinforcedplasticscom
httpwwwcentennialofflightgovessayEvolution_of_TechnologycompositesTech40htm
Automotive
Composite material is used in a number of applications in the automotive
industry due to its temperature resistance rigidity and fatigue strength
The benefits of using composites include greater fuel efficiency
corrosion resistance light weight and strength Composites also provide
a low-cost way to help keep designs looking fresh
Composites are used in
- interior parts (cockpit trimming seats instrument panels)
- exterior structure (body panels openings underbody frontrear
modules)
- engine compartment and fuelmechanical area parts (axles and
suspensions fuel and exhaust systems)
- electrical and electronic components
Lamborghinis Sesto Element carbon fiber
ldquoFat men cannot run as fast as thin men but we build most of our vehicles as though dead-weight fat increased speedhellip I cannot
imagine where the delusion that weight means strength
came fromhelliprdquo mdashHenry Ford
The mix of automotive materials is changing showing a boost for FRP in helping original
equipment manufacturers meet fuel economy and emissions challenges
(Source 2011 DuPont AutomotiveSAE survey of design engineers performed by Signet Research Inc)
Source
httpwwwtoraycomcsrhighlight2009hig_001_01html
The MonoCell tub for the McLaren MP4-12C supercar is moulded as a single
piece and weighs less than 80 kg (176 lbs)
COMPOSITES IN MARINE
TRIMARAN BOAT
AMERICA NAVYINDONESIAN NAVY
Visby Class corvette
Total length is 72 meters
The beam is 1040 meters
The displacement is 600 metric tones
fully equipped the worlds largest CRP
construction
The design of the Visby aims to minimize
the optical and infrared signature above
water acoustic and hydroa coustic
signature underwater electrical potential
and magnetic signature pressure signature
radar cross section and actively emitted
signals
A stealth corvette of the YS 2000 design
has a detection range of 13km in rough
seas and 22km in calm sea without
jamming In a jammed environment the
Visby would be detected at a range of 8km
in rough sea and 11km in calm sea
The material provides high strength and
rigidity low weight good shock resistance
low radar and magnetic signature
1996
Visby is a class of stealth corvettes for the Swedish Navy
ldquoReduced 50 of a Conventional Steelrdquo
Source
Hull Construction with composite materials for ships over 100m in length 2002
Massachusetts Institute of Technology
httpwwwnaval-technologycomprojectsvisby
YACHTS
KAL YUDISTIRAMARATHON 100 ADMIRAL YACHT
LOA 3050 MWidth 6 MFuel Tank 8000 LWater Tank 3000 LIce Box 500 LAccommodation Max 35 Personnel
2 x CATERPILLAR 3412E 1200 HPMARINE DIESEL ENGINE
PC 40 ndash KRI Krait 827Department of Indonesian Navy
LOA 40 MWidth 73 MPower 190Weapon Twin Cannon Barrels
127 mm Heavy Machine GunSpeed Knot 25 KnotDisplacement 105 tonAccommodation 23 personnel
PATROL BOAT
Rigid Inflatable BoatPATROL BOAT
Yachts
36m Luxury Yacht Moonraker
36m Luxury Yacht GoldenEye
50m Luxury Yacht Casino
Royale
45m Luxury Yacht Seashaw
Boat Parts
Barovans for Seismic Sweep
Centrifugal Liftfan House for Surface Effect
Ships
Composite Boat PropellersRTM
Deckhouses for Pilot Boats
Fairing Parts for Submarines
Flybridges for Motor yachts
Light Weight Gangway
MTB Launcher Mock-up
Pleasure Boats
12m Sailboat
12m Sail-Catamaranone-off
Canoes
Dragonfly 1000Catamaran Sailboat
Fantasy 37Sailboat
Farr 60Luxury Sailboat
EurodingyOlympic Dingy Class for
Woman
Hydrolift F23 Racing Boats
Kajacs
Najad 42Sailboat
Najad 520Sailboat
Najad 441Sailboat
Najad 391Sailboat
Nordwest 900Motorboat
Nordwest 1100Motorboat
Quatro 44Motorboat
Racemaster Competition Boats
Storebro 420
Storebro 345
Sweden Yacht 370Sailboat
Sweden Yacht 69Sailboat
Windy 41Motorboat
X-632Sailboat
X-362Sailboat
Commercial Boats
175m High Speed AmbulancePassenger Boat
19m High Speed Passenger Boat
20m High Speed Passenger Boat
364m Surface Effect Passenger Ship
45m Surface Effect Passenger Ship
120m Hull Structural Parts HSSS Catamaran Ferry
APPENDIX
Marine Vessel
1188m Fast Attack Vessel FMV 90 E
20m SAV-Surface Auxiliary Vessels
34m Personnel TransportCoast Guard Vessel
40ft Experimental SES
40m Landsort-Class Mine Hunters
54m Mine Counter Measure Vehicles SES
74m Coastal Patrol Boats
Fishing Boats
30 GT
12 GT
10 GT
5 GT
WISEWings In Surface Effect
HOVERCRAFT
Designed specifically for the tourist and transport industries the
Pioneer Mk3 hovercraft is amphibious and comfortably seats 25
passengers plus 1-crew The air-conditioned cabin allows for
maximum visibility for all aboard The Pioneer Mk3 is robust and
dynamic in its performance
Commercial hovercraft
Mk3 AirLift Hovercraft - 1215m
Power is economicaly provided by one Deutz diesel engine of
330kW (442hp) to cruise easily at 40 knots with much higher
speeds available according to the surface conditions The hull is
manufactured from fibreglassPVC foam composite sandwich
the windows are glass and the skirt is urethane coated nylon A
Military version is available with increased payload and systems
redundancy Power for the Military version comes from two Steyr
diesel engines with a total installed power of 320kW (429hp) All
transmission electrical hydraulic and air systems are duplicated
for maximum redundancy The increased performance of the
Military version comes from the reduced engine weight of the twin
Steyr installation cf the Deutz installation
Source
httpwwwnauticexpocomprodairlift-hovercraftcommercial-hovercrafts-25251-142868html
HOVERFLIGHT
BALLISTIC amp UNIT DEFENCED
Triaxis Composites Collaboration with Institute of Aeronautics and Space in the development of Missile Nose Cone
Polymer composites is the evolution of the military defence
Thin steel was the helmet material of
WWII and remained the principal material until around the 1980rsquos
The advantages of using steel
included a simple technology for manufacture of the helmets low cost and reasonably good
impact protection However these helmets were found to provide only marginal protection
against fragments
During the Vietnam War the US Army experimented with fiber-reinforced inserts in the
helmets These inserts improved ballistic protection but at the same time added weight and
reduced the air space between the head and the helmet
By the early part of the 1980rsquos the US military had developed the first all-composite
100 fiber-reinforced helmet This development resulted in even better ballistic protection
without altering the weight of the helmet Other improvements included better head coverage and
more space for ventilation
Source
Composites Armor - A difficult but huge market
by A Brent Strong Brigham Young University
MILITARY VEHICLES
HIGH SPEED TRAIN SHINKANSEN
Advanced Composites provide lightweight solutions for railway vehicles
saving as much as 50-80 of the weight compared with traditional
components
A lower overall weight translates into less stress faster acceleration and
higher speeds as well as reduced starting and stopping inertia Today
these are important criteria in global high-speed and metropolitan
railway projects
Fire smoke and toxic fumes are key safety criteria for interior
components of railway carriages Any material selected for an interior
component must meet international fire retardant standards
for Rail Interiors and Exteriors
Ceiling Panels Stairs
Seating Vestibules
Window Panels Door Pillars
Partition WallsDiffusers
Gangway and Cabinet Panels Cabin and
Desk panels
Door Pillars Lavatory Modules (standard and
Front and Rear EndsRoof Panels
Nose Cones Under Fairings
Source
httpwwwpctaerail_compositesphp
101
SKY BUS
2009
Europe is the world leader in offshore wind with
828 wind turbines and a cumulative capacity of 2056 MW spread across 38 offshore wind farms in 9
European countries
The UK and Denmark are the current leaders with a 44 and 30 share respectively In 2009
five countries built new offshore wind farms
UK (284 MW)
Demark (230 MW)
Sweden (30 MW)
Germany (30 MW)
Norway (23 MW)
2010
Asia leads the growth in global wind power which grew 358 GW in 2010 bringing
total global capacity to 1944 GW ndash up 225 from 2009
the Global Wind Energy Council (GWEC)
Asia accounted for 19 GW of new global wind power installations driven by China which installed 165
GW
ldquoChina now has 423 GW of wind powerrdquo
ldquoThis puts China firmly on a path to reach 200 GW of installed wind power by 2020 At the same
time China has become the worldrsquos largest producer of wind energy equipmentrdquo
Source
httpwwwreinforcedplasticscomview15655asia-leads-global-wind-power-growth
httpimgdeusmcomdesignnews288288605-Sandia_Sizes_up_Wind_Turbine_Blade_Design_C_largegif
WIND ENERGY
Marine Current Turbines
Source
httpwwwsiemenscompressenpressreleasepress=enpressrelease2011solar-hydroex201111005htm
httpwwwmarineturbinescom
A commercial marine current turbine consists of
two rotors which are fixed on a structure within the
sea current The twin rotors rotate with the
movement of the tidal flow and the blades pitch
through 180 degrees to optimally track tidal current
(Press picture Marine Current Turbines)
Wave Star Energys Multi-point Absorber
CFRP COLUMN REINFORCEMENT
INDUSTRIAL TANKS
107
INDUSTRIAL PIPES
PRESSURE TANKS
109
ldquoLetrsquos Make with Compositesrdquo
Prepreg
1) LaminateAssembly 5) De-molding
3) Resin Melts Layup Consolidates
bull Prepreg serat yang sudah diimpregnasi oleh resin+katalis dalam kondisi padat
bull Lapisan prepreg digunting sesuai bentuk yang diinginkan kemudian diletakkan pada permukaan cetakan
sesuai bentuk komponen yang diinginkan Lay-up mudah dilakukan karena sifat ldquotackynessrdquo dari prepreg
2) Applied Vacuum Pressure and Heat
bull Tekanan dan panas diberikan resin mencair terjadi konsolidasi pada komponen
4) Resin Cures
bull Temperatur dinaikkan untuk memulai curing
Prepreg
Variasi proses Autoclave
Komponen dalam
vacuum-bag
bull Campuran resin (+katalis) dan chopped glass strands diperoleh dalam bentuk premixed compound Bulk molding
Compound (BMC) dalam bentuk adonan atau Sheet molding Compound (SMC) dalam bentuk lembaran
bull Ketika panas dan tekanan diberikan oleh cetakan compound mengalir sesuai bentuk komponen yang diinginkan
1) Placement of Charge
5) De-molding3) Squeeze to final dimensions
2) Mould Closure4) Resin Cure
bull Curing dimulai komponen dilepaskan setelah terjadi pengerasan yang cukup
Compression Molding
bull Preform atau dry reinforcement dimasukkan kedalam cetakan sesuai dengan bentuk komponen yang
diinginkan
bull Resin mengalir dengan penekanan atau pem-vakuman dan meng-impregnasi preform dan
mendorongmengeluarkan udara yang ada dalam preform
1) Preform Manufacture
2) Preform Compression
5) De-molding3) Resin Injection
4) Resin Cure
bull Curing terjadi cetakan dibuka setelah terjadi pengerasan yang mencukupi
Liquid Molding (RTM VARI VARTM)
Pultrusion
bull Dry roving or fabrics ditarik melalui bak berisi
campuran resin dan katalis
bull Campuran yang basah ditarik melalui cetakan
bull Sisa resin keluar cetakan
bull Pemanasan dilakukan untuk proses curing
bull Pendinginan dilakukan untuk mempercepat siklus
produksi
Cut-off
Cooling
Die sections
Resin bath
Fibre creel
Filament Winding
bull Dry roving ditarik melalui bak berisi campuran resin dan katalis
bull Wet roving digulungkan dalam keadaan tegang kepada mandrel
bull Kontrol mekanik dari pembawa serat mengatur orientasi peletakan serat pada
mandrel
INDUSTRI COMPOSITES
AEROSPACE
HISTORY
1950 ndash Boeing
1960 ndash F14 Tomcat
1981 ndash AV-8B Harrier
Source
Low-Cost Composite Materials and Structures for Aircraft Applications
httpwwwreinforcedplasticscom
httpwwwcentennialofflightgovessayEvolution_of_TechnologycompositesTech40htm
Automotive
Composite material is used in a number of applications in the automotive
industry due to its temperature resistance rigidity and fatigue strength
The benefits of using composites include greater fuel efficiency
corrosion resistance light weight and strength Composites also provide
a low-cost way to help keep designs looking fresh
Composites are used in
- interior parts (cockpit trimming seats instrument panels)
- exterior structure (body panels openings underbody frontrear
modules)
- engine compartment and fuelmechanical area parts (axles and
suspensions fuel and exhaust systems)
- electrical and electronic components
Lamborghinis Sesto Element carbon fiber
ldquoFat men cannot run as fast as thin men but we build most of our vehicles as though dead-weight fat increased speedhellip I cannot
imagine where the delusion that weight means strength
came fromhelliprdquo mdashHenry Ford
The mix of automotive materials is changing showing a boost for FRP in helping original
equipment manufacturers meet fuel economy and emissions challenges
(Source 2011 DuPont AutomotiveSAE survey of design engineers performed by Signet Research Inc)
Source
httpwwwtoraycomcsrhighlight2009hig_001_01html
The MonoCell tub for the McLaren MP4-12C supercar is moulded as a single
piece and weighs less than 80 kg (176 lbs)
COMPOSITES IN MARINE
TRIMARAN BOAT
AMERICA NAVYINDONESIAN NAVY
Visby Class corvette
Total length is 72 meters
The beam is 1040 meters
The displacement is 600 metric tones
fully equipped the worlds largest CRP
construction
The design of the Visby aims to minimize
the optical and infrared signature above
water acoustic and hydroa coustic
signature underwater electrical potential
and magnetic signature pressure signature
radar cross section and actively emitted
signals
A stealth corvette of the YS 2000 design
has a detection range of 13km in rough
seas and 22km in calm sea without
jamming In a jammed environment the
Visby would be detected at a range of 8km
in rough sea and 11km in calm sea
The material provides high strength and
rigidity low weight good shock resistance
low radar and magnetic signature
1996
Visby is a class of stealth corvettes for the Swedish Navy
ldquoReduced 50 of a Conventional Steelrdquo
Source
Hull Construction with composite materials for ships over 100m in length 2002
Massachusetts Institute of Technology
httpwwwnaval-technologycomprojectsvisby
YACHTS
KAL YUDISTIRAMARATHON 100 ADMIRAL YACHT
LOA 3050 MWidth 6 MFuel Tank 8000 LWater Tank 3000 LIce Box 500 LAccommodation Max 35 Personnel
2 x CATERPILLAR 3412E 1200 HPMARINE DIESEL ENGINE
PC 40 ndash KRI Krait 827Department of Indonesian Navy
LOA 40 MWidth 73 MPower 190Weapon Twin Cannon Barrels
127 mm Heavy Machine GunSpeed Knot 25 KnotDisplacement 105 tonAccommodation 23 personnel
PATROL BOAT
Rigid Inflatable BoatPATROL BOAT
Yachts
36m Luxury Yacht Moonraker
36m Luxury Yacht GoldenEye
50m Luxury Yacht Casino
Royale
45m Luxury Yacht Seashaw
Boat Parts
Barovans for Seismic Sweep
Centrifugal Liftfan House for Surface Effect
Ships
Composite Boat PropellersRTM
Deckhouses for Pilot Boats
Fairing Parts for Submarines
Flybridges for Motor yachts
Light Weight Gangway
MTB Launcher Mock-up
Pleasure Boats
12m Sailboat
12m Sail-Catamaranone-off
Canoes
Dragonfly 1000Catamaran Sailboat
Fantasy 37Sailboat
Farr 60Luxury Sailboat
EurodingyOlympic Dingy Class for
Woman
Hydrolift F23 Racing Boats
Kajacs
Najad 42Sailboat
Najad 520Sailboat
Najad 441Sailboat
Najad 391Sailboat
Nordwest 900Motorboat
Nordwest 1100Motorboat
Quatro 44Motorboat
Racemaster Competition Boats
Storebro 420
Storebro 345
Sweden Yacht 370Sailboat
Sweden Yacht 69Sailboat
Windy 41Motorboat
X-632Sailboat
X-362Sailboat
Commercial Boats
175m High Speed AmbulancePassenger Boat
19m High Speed Passenger Boat
20m High Speed Passenger Boat
364m Surface Effect Passenger Ship
45m Surface Effect Passenger Ship
120m Hull Structural Parts HSSS Catamaran Ferry
APPENDIX
Marine Vessel
1188m Fast Attack Vessel FMV 90 E
20m SAV-Surface Auxiliary Vessels
34m Personnel TransportCoast Guard Vessel
40ft Experimental SES
40m Landsort-Class Mine Hunters
54m Mine Counter Measure Vehicles SES
74m Coastal Patrol Boats
Fishing Boats
30 GT
12 GT
10 GT
5 GT
WISEWings In Surface Effect
HOVERCRAFT
Designed specifically for the tourist and transport industries the
Pioneer Mk3 hovercraft is amphibious and comfortably seats 25
passengers plus 1-crew The air-conditioned cabin allows for
maximum visibility for all aboard The Pioneer Mk3 is robust and
dynamic in its performance
Commercial hovercraft
Mk3 AirLift Hovercraft - 1215m
Power is economicaly provided by one Deutz diesel engine of
330kW (442hp) to cruise easily at 40 knots with much higher
speeds available according to the surface conditions The hull is
manufactured from fibreglassPVC foam composite sandwich
the windows are glass and the skirt is urethane coated nylon A
Military version is available with increased payload and systems
redundancy Power for the Military version comes from two Steyr
diesel engines with a total installed power of 320kW (429hp) All
transmission electrical hydraulic and air systems are duplicated
for maximum redundancy The increased performance of the
Military version comes from the reduced engine weight of the twin
Steyr installation cf the Deutz installation
Source
httpwwwnauticexpocomprodairlift-hovercraftcommercial-hovercrafts-25251-142868html
HOVERFLIGHT
BALLISTIC amp UNIT DEFENCED
Triaxis Composites Collaboration with Institute of Aeronautics and Space in the development of Missile Nose Cone
Polymer composites is the evolution of the military defence
Thin steel was the helmet material of
WWII and remained the principal material until around the 1980rsquos
The advantages of using steel
included a simple technology for manufacture of the helmets low cost and reasonably good
impact protection However these helmets were found to provide only marginal protection
against fragments
During the Vietnam War the US Army experimented with fiber-reinforced inserts in the
helmets These inserts improved ballistic protection but at the same time added weight and
reduced the air space between the head and the helmet
By the early part of the 1980rsquos the US military had developed the first all-composite
100 fiber-reinforced helmet This development resulted in even better ballistic protection
without altering the weight of the helmet Other improvements included better head coverage and
more space for ventilation
Source
Composites Armor - A difficult but huge market
by A Brent Strong Brigham Young University
MILITARY VEHICLES
HIGH SPEED TRAIN SHINKANSEN
Advanced Composites provide lightweight solutions for railway vehicles
saving as much as 50-80 of the weight compared with traditional
components
A lower overall weight translates into less stress faster acceleration and
higher speeds as well as reduced starting and stopping inertia Today
these are important criteria in global high-speed and metropolitan
railway projects
Fire smoke and toxic fumes are key safety criteria for interior
components of railway carriages Any material selected for an interior
component must meet international fire retardant standards
for Rail Interiors and Exteriors
Ceiling Panels Stairs
Seating Vestibules
Window Panels Door Pillars
Partition WallsDiffusers
Gangway and Cabinet Panels Cabin and
Desk panels
Door Pillars Lavatory Modules (standard and
Front and Rear EndsRoof Panels
Nose Cones Under Fairings
Source
httpwwwpctaerail_compositesphp
101
SKY BUS
2009
Europe is the world leader in offshore wind with
828 wind turbines and a cumulative capacity of 2056 MW spread across 38 offshore wind farms in 9
European countries
The UK and Denmark are the current leaders with a 44 and 30 share respectively In 2009
five countries built new offshore wind farms
UK (284 MW)
Demark (230 MW)
Sweden (30 MW)
Germany (30 MW)
Norway (23 MW)
2010
Asia leads the growth in global wind power which grew 358 GW in 2010 bringing
total global capacity to 1944 GW ndash up 225 from 2009
the Global Wind Energy Council (GWEC)
Asia accounted for 19 GW of new global wind power installations driven by China which installed 165
GW
ldquoChina now has 423 GW of wind powerrdquo
ldquoThis puts China firmly on a path to reach 200 GW of installed wind power by 2020 At the same
time China has become the worldrsquos largest producer of wind energy equipmentrdquo
Source
httpwwwreinforcedplasticscomview15655asia-leads-global-wind-power-growth
httpimgdeusmcomdesignnews288288605-Sandia_Sizes_up_Wind_Turbine_Blade_Design_C_largegif
WIND ENERGY
Marine Current Turbines
Source
httpwwwsiemenscompressenpressreleasepress=enpressrelease2011solar-hydroex201111005htm
httpwwwmarineturbinescom
A commercial marine current turbine consists of
two rotors which are fixed on a structure within the
sea current The twin rotors rotate with the
movement of the tidal flow and the blades pitch
through 180 degrees to optimally track tidal current
(Press picture Marine Current Turbines)
Wave Star Energys Multi-point Absorber
CFRP COLUMN REINFORCEMENT
INDUSTRIAL TANKS
107
INDUSTRIAL PIPES
PRESSURE TANKS
109
ldquoLetrsquos Make with Compositesrdquo
Prepreg
Variasi proses Autoclave
Komponen dalam
vacuum-bag
bull Campuran resin (+katalis) dan chopped glass strands diperoleh dalam bentuk premixed compound Bulk molding
Compound (BMC) dalam bentuk adonan atau Sheet molding Compound (SMC) dalam bentuk lembaran
bull Ketika panas dan tekanan diberikan oleh cetakan compound mengalir sesuai bentuk komponen yang diinginkan
1) Placement of Charge
5) De-molding3) Squeeze to final dimensions
2) Mould Closure4) Resin Cure
bull Curing dimulai komponen dilepaskan setelah terjadi pengerasan yang cukup
Compression Molding
bull Preform atau dry reinforcement dimasukkan kedalam cetakan sesuai dengan bentuk komponen yang
diinginkan
bull Resin mengalir dengan penekanan atau pem-vakuman dan meng-impregnasi preform dan
mendorongmengeluarkan udara yang ada dalam preform
1) Preform Manufacture
2) Preform Compression
5) De-molding3) Resin Injection
4) Resin Cure
bull Curing terjadi cetakan dibuka setelah terjadi pengerasan yang mencukupi
Liquid Molding (RTM VARI VARTM)
Pultrusion
bull Dry roving or fabrics ditarik melalui bak berisi
campuran resin dan katalis
bull Campuran yang basah ditarik melalui cetakan
bull Sisa resin keluar cetakan
bull Pemanasan dilakukan untuk proses curing
bull Pendinginan dilakukan untuk mempercepat siklus
produksi
Cut-off
Cooling
Die sections
Resin bath
Fibre creel
Filament Winding
bull Dry roving ditarik melalui bak berisi campuran resin dan katalis
bull Wet roving digulungkan dalam keadaan tegang kepada mandrel
bull Kontrol mekanik dari pembawa serat mengatur orientasi peletakan serat pada
mandrel
INDUSTRI COMPOSITES
AEROSPACE
HISTORY
1950 ndash Boeing
1960 ndash F14 Tomcat
1981 ndash AV-8B Harrier
Source
Low-Cost Composite Materials and Structures for Aircraft Applications
httpwwwreinforcedplasticscom
httpwwwcentennialofflightgovessayEvolution_of_TechnologycompositesTech40htm
Automotive
Composite material is used in a number of applications in the automotive
industry due to its temperature resistance rigidity and fatigue strength
The benefits of using composites include greater fuel efficiency
corrosion resistance light weight and strength Composites also provide
a low-cost way to help keep designs looking fresh
Composites are used in
- interior parts (cockpit trimming seats instrument panels)
- exterior structure (body panels openings underbody frontrear
modules)
- engine compartment and fuelmechanical area parts (axles and
suspensions fuel and exhaust systems)
- electrical and electronic components
Lamborghinis Sesto Element carbon fiber
ldquoFat men cannot run as fast as thin men but we build most of our vehicles as though dead-weight fat increased speedhellip I cannot
imagine where the delusion that weight means strength
came fromhelliprdquo mdashHenry Ford
The mix of automotive materials is changing showing a boost for FRP in helping original
equipment manufacturers meet fuel economy and emissions challenges
(Source 2011 DuPont AutomotiveSAE survey of design engineers performed by Signet Research Inc)
Source
httpwwwtoraycomcsrhighlight2009hig_001_01html
The MonoCell tub for the McLaren MP4-12C supercar is moulded as a single
piece and weighs less than 80 kg (176 lbs)
COMPOSITES IN MARINE
TRIMARAN BOAT
AMERICA NAVYINDONESIAN NAVY
Visby Class corvette
Total length is 72 meters
The beam is 1040 meters
The displacement is 600 metric tones
fully equipped the worlds largest CRP
construction
The design of the Visby aims to minimize
the optical and infrared signature above
water acoustic and hydroa coustic
signature underwater electrical potential
and magnetic signature pressure signature
radar cross section and actively emitted
signals
A stealth corvette of the YS 2000 design
has a detection range of 13km in rough
seas and 22km in calm sea without
jamming In a jammed environment the
Visby would be detected at a range of 8km
in rough sea and 11km in calm sea
The material provides high strength and
rigidity low weight good shock resistance
low radar and magnetic signature
1996
Visby is a class of stealth corvettes for the Swedish Navy
ldquoReduced 50 of a Conventional Steelrdquo
Source
Hull Construction with composite materials for ships over 100m in length 2002
Massachusetts Institute of Technology
httpwwwnaval-technologycomprojectsvisby
YACHTS
KAL YUDISTIRAMARATHON 100 ADMIRAL YACHT
LOA 3050 MWidth 6 MFuel Tank 8000 LWater Tank 3000 LIce Box 500 LAccommodation Max 35 Personnel
2 x CATERPILLAR 3412E 1200 HPMARINE DIESEL ENGINE
PC 40 ndash KRI Krait 827Department of Indonesian Navy
LOA 40 MWidth 73 MPower 190Weapon Twin Cannon Barrels
127 mm Heavy Machine GunSpeed Knot 25 KnotDisplacement 105 tonAccommodation 23 personnel
PATROL BOAT
Rigid Inflatable BoatPATROL BOAT
Yachts
36m Luxury Yacht Moonraker
36m Luxury Yacht GoldenEye
50m Luxury Yacht Casino
Royale
45m Luxury Yacht Seashaw
Boat Parts
Barovans for Seismic Sweep
Centrifugal Liftfan House for Surface Effect
Ships
Composite Boat PropellersRTM
Deckhouses for Pilot Boats
Fairing Parts for Submarines
Flybridges for Motor yachts
Light Weight Gangway
MTB Launcher Mock-up
Pleasure Boats
12m Sailboat
12m Sail-Catamaranone-off
Canoes
Dragonfly 1000Catamaran Sailboat
Fantasy 37Sailboat
Farr 60Luxury Sailboat
EurodingyOlympic Dingy Class for
Woman
Hydrolift F23 Racing Boats
Kajacs
Najad 42Sailboat
Najad 520Sailboat
Najad 441Sailboat
Najad 391Sailboat
Nordwest 900Motorboat
Nordwest 1100Motorboat
Quatro 44Motorboat
Racemaster Competition Boats
Storebro 420
Storebro 345
Sweden Yacht 370Sailboat
Sweden Yacht 69Sailboat
Windy 41Motorboat
X-632Sailboat
X-362Sailboat
Commercial Boats
175m High Speed AmbulancePassenger Boat
19m High Speed Passenger Boat
20m High Speed Passenger Boat
364m Surface Effect Passenger Ship
45m Surface Effect Passenger Ship
120m Hull Structural Parts HSSS Catamaran Ferry
APPENDIX
Marine Vessel
1188m Fast Attack Vessel FMV 90 E
20m SAV-Surface Auxiliary Vessels
34m Personnel TransportCoast Guard Vessel
40ft Experimental SES
40m Landsort-Class Mine Hunters
54m Mine Counter Measure Vehicles SES
74m Coastal Patrol Boats
Fishing Boats
30 GT
12 GT
10 GT
5 GT
WISEWings In Surface Effect
HOVERCRAFT
Designed specifically for the tourist and transport industries the
Pioneer Mk3 hovercraft is amphibious and comfortably seats 25
passengers plus 1-crew The air-conditioned cabin allows for
maximum visibility for all aboard The Pioneer Mk3 is robust and
dynamic in its performance
Commercial hovercraft
Mk3 AirLift Hovercraft - 1215m
Power is economicaly provided by one Deutz diesel engine of
330kW (442hp) to cruise easily at 40 knots with much higher
speeds available according to the surface conditions The hull is
manufactured from fibreglassPVC foam composite sandwich
the windows are glass and the skirt is urethane coated nylon A
Military version is available with increased payload and systems
redundancy Power for the Military version comes from two Steyr
diesel engines with a total installed power of 320kW (429hp) All
transmission electrical hydraulic and air systems are duplicated
for maximum redundancy The increased performance of the
Military version comes from the reduced engine weight of the twin
Steyr installation cf the Deutz installation
Source
httpwwwnauticexpocomprodairlift-hovercraftcommercial-hovercrafts-25251-142868html
HOVERFLIGHT
BALLISTIC amp UNIT DEFENCED
Triaxis Composites Collaboration with Institute of Aeronautics and Space in the development of Missile Nose Cone
Polymer composites is the evolution of the military defence
Thin steel was the helmet material of
WWII and remained the principal material until around the 1980rsquos
The advantages of using steel
included a simple technology for manufacture of the helmets low cost and reasonably good
impact protection However these helmets were found to provide only marginal protection
against fragments
During the Vietnam War the US Army experimented with fiber-reinforced inserts in the
helmets These inserts improved ballistic protection but at the same time added weight and
reduced the air space between the head and the helmet
By the early part of the 1980rsquos the US military had developed the first all-composite
100 fiber-reinforced helmet This development resulted in even better ballistic protection
without altering the weight of the helmet Other improvements included better head coverage and
more space for ventilation
Source
Composites Armor - A difficult but huge market
by A Brent Strong Brigham Young University
MILITARY VEHICLES
HIGH SPEED TRAIN SHINKANSEN
Advanced Composites provide lightweight solutions for railway vehicles
saving as much as 50-80 of the weight compared with traditional
components
A lower overall weight translates into less stress faster acceleration and
higher speeds as well as reduced starting and stopping inertia Today
these are important criteria in global high-speed and metropolitan
railway projects
Fire smoke and toxic fumes are key safety criteria for interior
components of railway carriages Any material selected for an interior
component must meet international fire retardant standards
for Rail Interiors and Exteriors
Ceiling Panels Stairs
Seating Vestibules
Window Panels Door Pillars
Partition WallsDiffusers
Gangway and Cabinet Panels Cabin and
Desk panels
Door Pillars Lavatory Modules (standard and
Front and Rear EndsRoof Panels
Nose Cones Under Fairings
Source
httpwwwpctaerail_compositesphp
101
SKY BUS
2009
Europe is the world leader in offshore wind with
828 wind turbines and a cumulative capacity of 2056 MW spread across 38 offshore wind farms in 9
European countries
The UK and Denmark are the current leaders with a 44 and 30 share respectively In 2009
five countries built new offshore wind farms
UK (284 MW)
Demark (230 MW)
Sweden (30 MW)
Germany (30 MW)
Norway (23 MW)
2010
Asia leads the growth in global wind power which grew 358 GW in 2010 bringing
total global capacity to 1944 GW ndash up 225 from 2009
the Global Wind Energy Council (GWEC)
Asia accounted for 19 GW of new global wind power installations driven by China which installed 165
GW
ldquoChina now has 423 GW of wind powerrdquo
ldquoThis puts China firmly on a path to reach 200 GW of installed wind power by 2020 At the same
time China has become the worldrsquos largest producer of wind energy equipmentrdquo
Source
httpwwwreinforcedplasticscomview15655asia-leads-global-wind-power-growth
httpimgdeusmcomdesignnews288288605-Sandia_Sizes_up_Wind_Turbine_Blade_Design_C_largegif
WIND ENERGY
Marine Current Turbines
Source
httpwwwsiemenscompressenpressreleasepress=enpressrelease2011solar-hydroex201111005htm
httpwwwmarineturbinescom
A commercial marine current turbine consists of
two rotors which are fixed on a structure within the
sea current The twin rotors rotate with the
movement of the tidal flow and the blades pitch
through 180 degrees to optimally track tidal current
(Press picture Marine Current Turbines)
Wave Star Energys Multi-point Absorber
CFRP COLUMN REINFORCEMENT
INDUSTRIAL TANKS
107
INDUSTRIAL PIPES
PRESSURE TANKS
109
ldquoLetrsquos Make with Compositesrdquo
bull Campuran resin (+katalis) dan chopped glass strands diperoleh dalam bentuk premixed compound Bulk molding
Compound (BMC) dalam bentuk adonan atau Sheet molding Compound (SMC) dalam bentuk lembaran
bull Ketika panas dan tekanan diberikan oleh cetakan compound mengalir sesuai bentuk komponen yang diinginkan
1) Placement of Charge
5) De-molding3) Squeeze to final dimensions
2) Mould Closure4) Resin Cure
bull Curing dimulai komponen dilepaskan setelah terjadi pengerasan yang cukup
Compression Molding
bull Preform atau dry reinforcement dimasukkan kedalam cetakan sesuai dengan bentuk komponen yang
diinginkan
bull Resin mengalir dengan penekanan atau pem-vakuman dan meng-impregnasi preform dan
mendorongmengeluarkan udara yang ada dalam preform
1) Preform Manufacture
2) Preform Compression
5) De-molding3) Resin Injection
4) Resin Cure
bull Curing terjadi cetakan dibuka setelah terjadi pengerasan yang mencukupi
Liquid Molding (RTM VARI VARTM)
Pultrusion
bull Dry roving or fabrics ditarik melalui bak berisi
campuran resin dan katalis
bull Campuran yang basah ditarik melalui cetakan
bull Sisa resin keluar cetakan
bull Pemanasan dilakukan untuk proses curing
bull Pendinginan dilakukan untuk mempercepat siklus
produksi
Cut-off
Cooling
Die sections
Resin bath
Fibre creel
Filament Winding
bull Dry roving ditarik melalui bak berisi campuran resin dan katalis
bull Wet roving digulungkan dalam keadaan tegang kepada mandrel
bull Kontrol mekanik dari pembawa serat mengatur orientasi peletakan serat pada
mandrel
INDUSTRI COMPOSITES
AEROSPACE
HISTORY
1950 ndash Boeing
1960 ndash F14 Tomcat
1981 ndash AV-8B Harrier
Source
Low-Cost Composite Materials and Structures for Aircraft Applications
httpwwwreinforcedplasticscom
httpwwwcentennialofflightgovessayEvolution_of_TechnologycompositesTech40htm
Automotive
Composite material is used in a number of applications in the automotive
industry due to its temperature resistance rigidity and fatigue strength
The benefits of using composites include greater fuel efficiency
corrosion resistance light weight and strength Composites also provide
a low-cost way to help keep designs looking fresh
Composites are used in
- interior parts (cockpit trimming seats instrument panels)
- exterior structure (body panels openings underbody frontrear
modules)
- engine compartment and fuelmechanical area parts (axles and
suspensions fuel and exhaust systems)
- electrical and electronic components
Lamborghinis Sesto Element carbon fiber
ldquoFat men cannot run as fast as thin men but we build most of our vehicles as though dead-weight fat increased speedhellip I cannot
imagine where the delusion that weight means strength
came fromhelliprdquo mdashHenry Ford
The mix of automotive materials is changing showing a boost for FRP in helping original
equipment manufacturers meet fuel economy and emissions challenges
(Source 2011 DuPont AutomotiveSAE survey of design engineers performed by Signet Research Inc)
Source
httpwwwtoraycomcsrhighlight2009hig_001_01html
The MonoCell tub for the McLaren MP4-12C supercar is moulded as a single
piece and weighs less than 80 kg (176 lbs)
COMPOSITES IN MARINE
TRIMARAN BOAT
AMERICA NAVYINDONESIAN NAVY
Visby Class corvette
Total length is 72 meters
The beam is 1040 meters
The displacement is 600 metric tones
fully equipped the worlds largest CRP
construction
The design of the Visby aims to minimize
the optical and infrared signature above
water acoustic and hydroa coustic
signature underwater electrical potential
and magnetic signature pressure signature
radar cross section and actively emitted
signals
A stealth corvette of the YS 2000 design
has a detection range of 13km in rough
seas and 22km in calm sea without
jamming In a jammed environment the
Visby would be detected at a range of 8km
in rough sea and 11km in calm sea
The material provides high strength and
rigidity low weight good shock resistance
low radar and magnetic signature
1996
Visby is a class of stealth corvettes for the Swedish Navy
ldquoReduced 50 of a Conventional Steelrdquo
Source
Hull Construction with composite materials for ships over 100m in length 2002
Massachusetts Institute of Technology
httpwwwnaval-technologycomprojectsvisby
YACHTS
KAL YUDISTIRAMARATHON 100 ADMIRAL YACHT
LOA 3050 MWidth 6 MFuel Tank 8000 LWater Tank 3000 LIce Box 500 LAccommodation Max 35 Personnel
2 x CATERPILLAR 3412E 1200 HPMARINE DIESEL ENGINE
PC 40 ndash KRI Krait 827Department of Indonesian Navy
LOA 40 MWidth 73 MPower 190Weapon Twin Cannon Barrels
127 mm Heavy Machine GunSpeed Knot 25 KnotDisplacement 105 tonAccommodation 23 personnel
PATROL BOAT
Rigid Inflatable BoatPATROL BOAT
Yachts
36m Luxury Yacht Moonraker
36m Luxury Yacht GoldenEye
50m Luxury Yacht Casino
Royale
45m Luxury Yacht Seashaw
Boat Parts
Barovans for Seismic Sweep
Centrifugal Liftfan House for Surface Effect
Ships
Composite Boat PropellersRTM
Deckhouses for Pilot Boats
Fairing Parts for Submarines
Flybridges for Motor yachts
Light Weight Gangway
MTB Launcher Mock-up
Pleasure Boats
12m Sailboat
12m Sail-Catamaranone-off
Canoes
Dragonfly 1000Catamaran Sailboat
Fantasy 37Sailboat
Farr 60Luxury Sailboat
EurodingyOlympic Dingy Class for
Woman
Hydrolift F23 Racing Boats
Kajacs
Najad 42Sailboat
Najad 520Sailboat
Najad 441Sailboat
Najad 391Sailboat
Nordwest 900Motorboat
Nordwest 1100Motorboat
Quatro 44Motorboat
Racemaster Competition Boats
Storebro 420
Storebro 345
Sweden Yacht 370Sailboat
Sweden Yacht 69Sailboat
Windy 41Motorboat
X-632Sailboat
X-362Sailboat
Commercial Boats
175m High Speed AmbulancePassenger Boat
19m High Speed Passenger Boat
20m High Speed Passenger Boat
364m Surface Effect Passenger Ship
45m Surface Effect Passenger Ship
120m Hull Structural Parts HSSS Catamaran Ferry
APPENDIX
Marine Vessel
1188m Fast Attack Vessel FMV 90 E
20m SAV-Surface Auxiliary Vessels
34m Personnel TransportCoast Guard Vessel
40ft Experimental SES
40m Landsort-Class Mine Hunters
54m Mine Counter Measure Vehicles SES
74m Coastal Patrol Boats
Fishing Boats
30 GT
12 GT
10 GT
5 GT
WISEWings In Surface Effect
HOVERCRAFT
Designed specifically for the tourist and transport industries the
Pioneer Mk3 hovercraft is amphibious and comfortably seats 25
passengers plus 1-crew The air-conditioned cabin allows for
maximum visibility for all aboard The Pioneer Mk3 is robust and
dynamic in its performance
Commercial hovercraft
Mk3 AirLift Hovercraft - 1215m
Power is economicaly provided by one Deutz diesel engine of
330kW (442hp) to cruise easily at 40 knots with much higher
speeds available according to the surface conditions The hull is
manufactured from fibreglassPVC foam composite sandwich
the windows are glass and the skirt is urethane coated nylon A
Military version is available with increased payload and systems
redundancy Power for the Military version comes from two Steyr
diesel engines with a total installed power of 320kW (429hp) All
transmission electrical hydraulic and air systems are duplicated
for maximum redundancy The increased performance of the
Military version comes from the reduced engine weight of the twin
Steyr installation cf the Deutz installation
Source
httpwwwnauticexpocomprodairlift-hovercraftcommercial-hovercrafts-25251-142868html
HOVERFLIGHT
BALLISTIC amp UNIT DEFENCED
Triaxis Composites Collaboration with Institute of Aeronautics and Space in the development of Missile Nose Cone
Polymer composites is the evolution of the military defence
Thin steel was the helmet material of
WWII and remained the principal material until around the 1980rsquos
The advantages of using steel
included a simple technology for manufacture of the helmets low cost and reasonably good
impact protection However these helmets were found to provide only marginal protection
against fragments
During the Vietnam War the US Army experimented with fiber-reinforced inserts in the
helmets These inserts improved ballistic protection but at the same time added weight and
reduced the air space between the head and the helmet
By the early part of the 1980rsquos the US military had developed the first all-composite
100 fiber-reinforced helmet This development resulted in even better ballistic protection
without altering the weight of the helmet Other improvements included better head coverage and
more space for ventilation
Source
Composites Armor - A difficult but huge market
by A Brent Strong Brigham Young University
MILITARY VEHICLES
HIGH SPEED TRAIN SHINKANSEN
Advanced Composites provide lightweight solutions for railway vehicles
saving as much as 50-80 of the weight compared with traditional
components
A lower overall weight translates into less stress faster acceleration and
higher speeds as well as reduced starting and stopping inertia Today
these are important criteria in global high-speed and metropolitan
railway projects
Fire smoke and toxic fumes are key safety criteria for interior
components of railway carriages Any material selected for an interior
component must meet international fire retardant standards
for Rail Interiors and Exteriors
Ceiling Panels Stairs
Seating Vestibules
Window Panels Door Pillars
Partition WallsDiffusers
Gangway and Cabinet Panels Cabin and
Desk panels
Door Pillars Lavatory Modules (standard and
Front and Rear EndsRoof Panels
Nose Cones Under Fairings
Source
httpwwwpctaerail_compositesphp
101
SKY BUS
2009
Europe is the world leader in offshore wind with
828 wind turbines and a cumulative capacity of 2056 MW spread across 38 offshore wind farms in 9
European countries
The UK and Denmark are the current leaders with a 44 and 30 share respectively In 2009
five countries built new offshore wind farms
UK (284 MW)
Demark (230 MW)
Sweden (30 MW)
Germany (30 MW)
Norway (23 MW)
2010
Asia leads the growth in global wind power which grew 358 GW in 2010 bringing
total global capacity to 1944 GW ndash up 225 from 2009
the Global Wind Energy Council (GWEC)
Asia accounted for 19 GW of new global wind power installations driven by China which installed 165
GW
ldquoChina now has 423 GW of wind powerrdquo
ldquoThis puts China firmly on a path to reach 200 GW of installed wind power by 2020 At the same
time China has become the worldrsquos largest producer of wind energy equipmentrdquo
Source
httpwwwreinforcedplasticscomview15655asia-leads-global-wind-power-growth
httpimgdeusmcomdesignnews288288605-Sandia_Sizes_up_Wind_Turbine_Blade_Design_C_largegif
WIND ENERGY
Marine Current Turbines
Source
httpwwwsiemenscompressenpressreleasepress=enpressrelease2011solar-hydroex201111005htm
httpwwwmarineturbinescom
A commercial marine current turbine consists of
two rotors which are fixed on a structure within the
sea current The twin rotors rotate with the
movement of the tidal flow and the blades pitch
through 180 degrees to optimally track tidal current
(Press picture Marine Current Turbines)
Wave Star Energys Multi-point Absorber
CFRP COLUMN REINFORCEMENT
INDUSTRIAL TANKS
107
INDUSTRIAL PIPES
PRESSURE TANKS
109
ldquoLetrsquos Make with Compositesrdquo
bull Preform atau dry reinforcement dimasukkan kedalam cetakan sesuai dengan bentuk komponen yang
diinginkan
bull Resin mengalir dengan penekanan atau pem-vakuman dan meng-impregnasi preform dan
mendorongmengeluarkan udara yang ada dalam preform
1) Preform Manufacture
2) Preform Compression
5) De-molding3) Resin Injection
4) Resin Cure
bull Curing terjadi cetakan dibuka setelah terjadi pengerasan yang mencukupi
Liquid Molding (RTM VARI VARTM)
Pultrusion
bull Dry roving or fabrics ditarik melalui bak berisi
campuran resin dan katalis
bull Campuran yang basah ditarik melalui cetakan
bull Sisa resin keluar cetakan
bull Pemanasan dilakukan untuk proses curing
bull Pendinginan dilakukan untuk mempercepat siklus
produksi
Cut-off
Cooling
Die sections
Resin bath
Fibre creel
Filament Winding
bull Dry roving ditarik melalui bak berisi campuran resin dan katalis
bull Wet roving digulungkan dalam keadaan tegang kepada mandrel
bull Kontrol mekanik dari pembawa serat mengatur orientasi peletakan serat pada
mandrel
INDUSTRI COMPOSITES
AEROSPACE
HISTORY
1950 ndash Boeing
1960 ndash F14 Tomcat
1981 ndash AV-8B Harrier
Source
Low-Cost Composite Materials and Structures for Aircraft Applications
httpwwwreinforcedplasticscom
httpwwwcentennialofflightgovessayEvolution_of_TechnologycompositesTech40htm
Automotive
Composite material is used in a number of applications in the automotive
industry due to its temperature resistance rigidity and fatigue strength
The benefits of using composites include greater fuel efficiency
corrosion resistance light weight and strength Composites also provide
a low-cost way to help keep designs looking fresh
Composites are used in
- interior parts (cockpit trimming seats instrument panels)
- exterior structure (body panels openings underbody frontrear
modules)
- engine compartment and fuelmechanical area parts (axles and
suspensions fuel and exhaust systems)
- electrical and electronic components
Lamborghinis Sesto Element carbon fiber
ldquoFat men cannot run as fast as thin men but we build most of our vehicles as though dead-weight fat increased speedhellip I cannot
imagine where the delusion that weight means strength
came fromhelliprdquo mdashHenry Ford
The mix of automotive materials is changing showing a boost for FRP in helping original
equipment manufacturers meet fuel economy and emissions challenges
(Source 2011 DuPont AutomotiveSAE survey of design engineers performed by Signet Research Inc)
Source
httpwwwtoraycomcsrhighlight2009hig_001_01html
The MonoCell tub for the McLaren MP4-12C supercar is moulded as a single
piece and weighs less than 80 kg (176 lbs)
COMPOSITES IN MARINE
TRIMARAN BOAT
AMERICA NAVYINDONESIAN NAVY
Visby Class corvette
Total length is 72 meters
The beam is 1040 meters
The displacement is 600 metric tones
fully equipped the worlds largest CRP
construction
The design of the Visby aims to minimize
the optical and infrared signature above
water acoustic and hydroa coustic
signature underwater electrical potential
and magnetic signature pressure signature
radar cross section and actively emitted
signals
A stealth corvette of the YS 2000 design
has a detection range of 13km in rough
seas and 22km in calm sea without
jamming In a jammed environment the
Visby would be detected at a range of 8km
in rough sea and 11km in calm sea
The material provides high strength and
rigidity low weight good shock resistance
low radar and magnetic signature
1996
Visby is a class of stealth corvettes for the Swedish Navy
ldquoReduced 50 of a Conventional Steelrdquo
Source
Hull Construction with composite materials for ships over 100m in length 2002
Massachusetts Institute of Technology
httpwwwnaval-technologycomprojectsvisby
YACHTS
KAL YUDISTIRAMARATHON 100 ADMIRAL YACHT
LOA 3050 MWidth 6 MFuel Tank 8000 LWater Tank 3000 LIce Box 500 LAccommodation Max 35 Personnel
2 x CATERPILLAR 3412E 1200 HPMARINE DIESEL ENGINE
PC 40 ndash KRI Krait 827Department of Indonesian Navy
LOA 40 MWidth 73 MPower 190Weapon Twin Cannon Barrels
127 mm Heavy Machine GunSpeed Knot 25 KnotDisplacement 105 tonAccommodation 23 personnel
PATROL BOAT
Rigid Inflatable BoatPATROL BOAT
Yachts
36m Luxury Yacht Moonraker
36m Luxury Yacht GoldenEye
50m Luxury Yacht Casino
Royale
45m Luxury Yacht Seashaw
Boat Parts
Barovans for Seismic Sweep
Centrifugal Liftfan House for Surface Effect
Ships
Composite Boat PropellersRTM
Deckhouses for Pilot Boats
Fairing Parts for Submarines
Flybridges for Motor yachts
Light Weight Gangway
MTB Launcher Mock-up
Pleasure Boats
12m Sailboat
12m Sail-Catamaranone-off
Canoes
Dragonfly 1000Catamaran Sailboat
Fantasy 37Sailboat
Farr 60Luxury Sailboat
EurodingyOlympic Dingy Class for
Woman
Hydrolift F23 Racing Boats
Kajacs
Najad 42Sailboat
Najad 520Sailboat
Najad 441Sailboat
Najad 391Sailboat
Nordwest 900Motorboat
Nordwest 1100Motorboat
Quatro 44Motorboat
Racemaster Competition Boats
Storebro 420
Storebro 345
Sweden Yacht 370Sailboat
Sweden Yacht 69Sailboat
Windy 41Motorboat
X-632Sailboat
X-362Sailboat
Commercial Boats
175m High Speed AmbulancePassenger Boat
19m High Speed Passenger Boat
20m High Speed Passenger Boat
364m Surface Effect Passenger Ship
45m Surface Effect Passenger Ship
120m Hull Structural Parts HSSS Catamaran Ferry
APPENDIX
Marine Vessel
1188m Fast Attack Vessel FMV 90 E
20m SAV-Surface Auxiliary Vessels
34m Personnel TransportCoast Guard Vessel
40ft Experimental SES
40m Landsort-Class Mine Hunters
54m Mine Counter Measure Vehicles SES
74m Coastal Patrol Boats
Fishing Boats
30 GT
12 GT
10 GT
5 GT
WISEWings In Surface Effect
HOVERCRAFT
Designed specifically for the tourist and transport industries the
Pioneer Mk3 hovercraft is amphibious and comfortably seats 25
passengers plus 1-crew The air-conditioned cabin allows for
maximum visibility for all aboard The Pioneer Mk3 is robust and
dynamic in its performance
Commercial hovercraft
Mk3 AirLift Hovercraft - 1215m
Power is economicaly provided by one Deutz diesel engine of
330kW (442hp) to cruise easily at 40 knots with much higher
speeds available according to the surface conditions The hull is
manufactured from fibreglassPVC foam composite sandwich
the windows are glass and the skirt is urethane coated nylon A
Military version is available with increased payload and systems
redundancy Power for the Military version comes from two Steyr
diesel engines with a total installed power of 320kW (429hp) All
transmission electrical hydraulic and air systems are duplicated
for maximum redundancy The increased performance of the
Military version comes from the reduced engine weight of the twin
Steyr installation cf the Deutz installation
Source
httpwwwnauticexpocomprodairlift-hovercraftcommercial-hovercrafts-25251-142868html
HOVERFLIGHT
BALLISTIC amp UNIT DEFENCED
Triaxis Composites Collaboration with Institute of Aeronautics and Space in the development of Missile Nose Cone
Polymer composites is the evolution of the military defence
Thin steel was the helmet material of
WWII and remained the principal material until around the 1980rsquos
The advantages of using steel
included a simple technology for manufacture of the helmets low cost and reasonably good
impact protection However these helmets were found to provide only marginal protection
against fragments
During the Vietnam War the US Army experimented with fiber-reinforced inserts in the
helmets These inserts improved ballistic protection but at the same time added weight and
reduced the air space between the head and the helmet
By the early part of the 1980rsquos the US military had developed the first all-composite
100 fiber-reinforced helmet This development resulted in even better ballistic protection
without altering the weight of the helmet Other improvements included better head coverage and
more space for ventilation
Source
Composites Armor - A difficult but huge market
by A Brent Strong Brigham Young University
MILITARY VEHICLES
HIGH SPEED TRAIN SHINKANSEN
Advanced Composites provide lightweight solutions for railway vehicles
saving as much as 50-80 of the weight compared with traditional
components
A lower overall weight translates into less stress faster acceleration and
higher speeds as well as reduced starting and stopping inertia Today
these are important criteria in global high-speed and metropolitan
railway projects
Fire smoke and toxic fumes are key safety criteria for interior
components of railway carriages Any material selected for an interior
component must meet international fire retardant standards
for Rail Interiors and Exteriors
Ceiling Panels Stairs
Seating Vestibules
Window Panels Door Pillars
Partition WallsDiffusers
Gangway and Cabinet Panels Cabin and
Desk panels
Door Pillars Lavatory Modules (standard and
Front and Rear EndsRoof Panels
Nose Cones Under Fairings
Source
httpwwwpctaerail_compositesphp
101
SKY BUS
2009
Europe is the world leader in offshore wind with
828 wind turbines and a cumulative capacity of 2056 MW spread across 38 offshore wind farms in 9
European countries
The UK and Denmark are the current leaders with a 44 and 30 share respectively In 2009
five countries built new offshore wind farms
UK (284 MW)
Demark (230 MW)
Sweden (30 MW)
Germany (30 MW)
Norway (23 MW)
2010
Asia leads the growth in global wind power which grew 358 GW in 2010 bringing
total global capacity to 1944 GW ndash up 225 from 2009
the Global Wind Energy Council (GWEC)
Asia accounted for 19 GW of new global wind power installations driven by China which installed 165
GW
ldquoChina now has 423 GW of wind powerrdquo
ldquoThis puts China firmly on a path to reach 200 GW of installed wind power by 2020 At the same
time China has become the worldrsquos largest producer of wind energy equipmentrdquo
Source
httpwwwreinforcedplasticscomview15655asia-leads-global-wind-power-growth
httpimgdeusmcomdesignnews288288605-Sandia_Sizes_up_Wind_Turbine_Blade_Design_C_largegif
WIND ENERGY
Marine Current Turbines
Source
httpwwwsiemenscompressenpressreleasepress=enpressrelease2011solar-hydroex201111005htm
httpwwwmarineturbinescom
A commercial marine current turbine consists of
two rotors which are fixed on a structure within the
sea current The twin rotors rotate with the
movement of the tidal flow and the blades pitch
through 180 degrees to optimally track tidal current
(Press picture Marine Current Turbines)
Wave Star Energys Multi-point Absorber
CFRP COLUMN REINFORCEMENT
INDUSTRIAL TANKS
107
INDUSTRIAL PIPES
PRESSURE TANKS
109
ldquoLetrsquos Make with Compositesrdquo
Pultrusion
bull Dry roving or fabrics ditarik melalui bak berisi
campuran resin dan katalis
bull Campuran yang basah ditarik melalui cetakan
bull Sisa resin keluar cetakan
bull Pemanasan dilakukan untuk proses curing
bull Pendinginan dilakukan untuk mempercepat siklus
produksi
Cut-off
Cooling
Die sections
Resin bath
Fibre creel
Filament Winding
bull Dry roving ditarik melalui bak berisi campuran resin dan katalis
bull Wet roving digulungkan dalam keadaan tegang kepada mandrel
bull Kontrol mekanik dari pembawa serat mengatur orientasi peletakan serat pada
mandrel
INDUSTRI COMPOSITES
AEROSPACE
HISTORY
1950 ndash Boeing
1960 ndash F14 Tomcat
1981 ndash AV-8B Harrier
Source
Low-Cost Composite Materials and Structures for Aircraft Applications
httpwwwreinforcedplasticscom
httpwwwcentennialofflightgovessayEvolution_of_TechnologycompositesTech40htm
Automotive
Composite material is used in a number of applications in the automotive
industry due to its temperature resistance rigidity and fatigue strength
The benefits of using composites include greater fuel efficiency
corrosion resistance light weight and strength Composites also provide
a low-cost way to help keep designs looking fresh
Composites are used in
- interior parts (cockpit trimming seats instrument panels)
- exterior structure (body panels openings underbody frontrear
modules)
- engine compartment and fuelmechanical area parts (axles and
suspensions fuel and exhaust systems)
- electrical and electronic components
Lamborghinis Sesto Element carbon fiber
ldquoFat men cannot run as fast as thin men but we build most of our vehicles as though dead-weight fat increased speedhellip I cannot
imagine where the delusion that weight means strength
came fromhelliprdquo mdashHenry Ford
The mix of automotive materials is changing showing a boost for FRP in helping original
equipment manufacturers meet fuel economy and emissions challenges
(Source 2011 DuPont AutomotiveSAE survey of design engineers performed by Signet Research Inc)
Source
httpwwwtoraycomcsrhighlight2009hig_001_01html
The MonoCell tub for the McLaren MP4-12C supercar is moulded as a single
piece and weighs less than 80 kg (176 lbs)
COMPOSITES IN MARINE
TRIMARAN BOAT
AMERICA NAVYINDONESIAN NAVY
Visby Class corvette
Total length is 72 meters
The beam is 1040 meters
The displacement is 600 metric tones
fully equipped the worlds largest CRP
construction
The design of the Visby aims to minimize
the optical and infrared signature above
water acoustic and hydroa coustic
signature underwater electrical potential
and magnetic signature pressure signature
radar cross section and actively emitted
signals
A stealth corvette of the YS 2000 design
has a detection range of 13km in rough
seas and 22km in calm sea without
jamming In a jammed environment the
Visby would be detected at a range of 8km
in rough sea and 11km in calm sea
The material provides high strength and
rigidity low weight good shock resistance
low radar and magnetic signature
1996
Visby is a class of stealth corvettes for the Swedish Navy
ldquoReduced 50 of a Conventional Steelrdquo
Source
Hull Construction with composite materials for ships over 100m in length 2002
Massachusetts Institute of Technology
httpwwwnaval-technologycomprojectsvisby
YACHTS
KAL YUDISTIRAMARATHON 100 ADMIRAL YACHT
LOA 3050 MWidth 6 MFuel Tank 8000 LWater Tank 3000 LIce Box 500 LAccommodation Max 35 Personnel
2 x CATERPILLAR 3412E 1200 HPMARINE DIESEL ENGINE
PC 40 ndash KRI Krait 827Department of Indonesian Navy
LOA 40 MWidth 73 MPower 190Weapon Twin Cannon Barrels
127 mm Heavy Machine GunSpeed Knot 25 KnotDisplacement 105 tonAccommodation 23 personnel
PATROL BOAT
Rigid Inflatable BoatPATROL BOAT
Yachts
36m Luxury Yacht Moonraker
36m Luxury Yacht GoldenEye
50m Luxury Yacht Casino
Royale
45m Luxury Yacht Seashaw
Boat Parts
Barovans for Seismic Sweep
Centrifugal Liftfan House for Surface Effect
Ships
Composite Boat PropellersRTM
Deckhouses for Pilot Boats
Fairing Parts for Submarines
Flybridges for Motor yachts
Light Weight Gangway
MTB Launcher Mock-up
Pleasure Boats
12m Sailboat
12m Sail-Catamaranone-off
Canoes
Dragonfly 1000Catamaran Sailboat
Fantasy 37Sailboat
Farr 60Luxury Sailboat
EurodingyOlympic Dingy Class for
Woman
Hydrolift F23 Racing Boats
Kajacs
Najad 42Sailboat
Najad 520Sailboat
Najad 441Sailboat
Najad 391Sailboat
Nordwest 900Motorboat
Nordwest 1100Motorboat
Quatro 44Motorboat
Racemaster Competition Boats
Storebro 420
Storebro 345
Sweden Yacht 370Sailboat
Sweden Yacht 69Sailboat
Windy 41Motorboat
X-632Sailboat
X-362Sailboat
Commercial Boats
175m High Speed AmbulancePassenger Boat
19m High Speed Passenger Boat
20m High Speed Passenger Boat
364m Surface Effect Passenger Ship
45m Surface Effect Passenger Ship
120m Hull Structural Parts HSSS Catamaran Ferry
APPENDIX
Marine Vessel
1188m Fast Attack Vessel FMV 90 E
20m SAV-Surface Auxiliary Vessels
34m Personnel TransportCoast Guard Vessel
40ft Experimental SES
40m Landsort-Class Mine Hunters
54m Mine Counter Measure Vehicles SES
74m Coastal Patrol Boats
Fishing Boats
30 GT
12 GT
10 GT
5 GT
WISEWings In Surface Effect
HOVERCRAFT
Designed specifically for the tourist and transport industries the
Pioneer Mk3 hovercraft is amphibious and comfortably seats 25
passengers plus 1-crew The air-conditioned cabin allows for
maximum visibility for all aboard The Pioneer Mk3 is robust and
dynamic in its performance
Commercial hovercraft
Mk3 AirLift Hovercraft - 1215m
Power is economicaly provided by one Deutz diesel engine of
330kW (442hp) to cruise easily at 40 knots with much higher
speeds available according to the surface conditions The hull is
manufactured from fibreglassPVC foam composite sandwich
the windows are glass and the skirt is urethane coated nylon A
Military version is available with increased payload and systems
redundancy Power for the Military version comes from two Steyr
diesel engines with a total installed power of 320kW (429hp) All
transmission electrical hydraulic and air systems are duplicated
for maximum redundancy The increased performance of the
Military version comes from the reduced engine weight of the twin
Steyr installation cf the Deutz installation
Source
httpwwwnauticexpocomprodairlift-hovercraftcommercial-hovercrafts-25251-142868html
HOVERFLIGHT
BALLISTIC amp UNIT DEFENCED
Triaxis Composites Collaboration with Institute of Aeronautics and Space in the development of Missile Nose Cone
Polymer composites is the evolution of the military defence
Thin steel was the helmet material of
WWII and remained the principal material until around the 1980rsquos
The advantages of using steel
included a simple technology for manufacture of the helmets low cost and reasonably good
impact protection However these helmets were found to provide only marginal protection
against fragments
During the Vietnam War the US Army experimented with fiber-reinforced inserts in the
helmets These inserts improved ballistic protection but at the same time added weight and
reduced the air space between the head and the helmet
By the early part of the 1980rsquos the US military had developed the first all-composite
100 fiber-reinforced helmet This development resulted in even better ballistic protection
without altering the weight of the helmet Other improvements included better head coverage and
more space for ventilation
Source
Composites Armor - A difficult but huge market
by A Brent Strong Brigham Young University
MILITARY VEHICLES
HIGH SPEED TRAIN SHINKANSEN
Advanced Composites provide lightweight solutions for railway vehicles
saving as much as 50-80 of the weight compared with traditional
components
A lower overall weight translates into less stress faster acceleration and
higher speeds as well as reduced starting and stopping inertia Today
these are important criteria in global high-speed and metropolitan
railway projects
Fire smoke and toxic fumes are key safety criteria for interior
components of railway carriages Any material selected for an interior
component must meet international fire retardant standards
for Rail Interiors and Exteriors
Ceiling Panels Stairs
Seating Vestibules
Window Panels Door Pillars
Partition WallsDiffusers
Gangway and Cabinet Panels Cabin and
Desk panels
Door Pillars Lavatory Modules (standard and
Front and Rear EndsRoof Panels
Nose Cones Under Fairings
Source
httpwwwpctaerail_compositesphp
101
SKY BUS
2009
Europe is the world leader in offshore wind with
828 wind turbines and a cumulative capacity of 2056 MW spread across 38 offshore wind farms in 9
European countries
The UK and Denmark are the current leaders with a 44 and 30 share respectively In 2009
five countries built new offshore wind farms
UK (284 MW)
Demark (230 MW)
Sweden (30 MW)
Germany (30 MW)
Norway (23 MW)
2010
Asia leads the growth in global wind power which grew 358 GW in 2010 bringing
total global capacity to 1944 GW ndash up 225 from 2009
the Global Wind Energy Council (GWEC)
Asia accounted for 19 GW of new global wind power installations driven by China which installed 165
GW
ldquoChina now has 423 GW of wind powerrdquo
ldquoThis puts China firmly on a path to reach 200 GW of installed wind power by 2020 At the same
time China has become the worldrsquos largest producer of wind energy equipmentrdquo
Source
httpwwwreinforcedplasticscomview15655asia-leads-global-wind-power-growth
httpimgdeusmcomdesignnews288288605-Sandia_Sizes_up_Wind_Turbine_Blade_Design_C_largegif
WIND ENERGY
Marine Current Turbines
Source
httpwwwsiemenscompressenpressreleasepress=enpressrelease2011solar-hydroex201111005htm
httpwwwmarineturbinescom
A commercial marine current turbine consists of
two rotors which are fixed on a structure within the
sea current The twin rotors rotate with the
movement of the tidal flow and the blades pitch
through 180 degrees to optimally track tidal current
(Press picture Marine Current Turbines)
Wave Star Energys Multi-point Absorber
CFRP COLUMN REINFORCEMENT
INDUSTRIAL TANKS
107
INDUSTRIAL PIPES
PRESSURE TANKS
109
ldquoLetrsquos Make with Compositesrdquo
Filament Winding
bull Dry roving ditarik melalui bak berisi campuran resin dan katalis
bull Wet roving digulungkan dalam keadaan tegang kepada mandrel
bull Kontrol mekanik dari pembawa serat mengatur orientasi peletakan serat pada
mandrel
INDUSTRI COMPOSITES
AEROSPACE
HISTORY
1950 ndash Boeing
1960 ndash F14 Tomcat
1981 ndash AV-8B Harrier
Source
Low-Cost Composite Materials and Structures for Aircraft Applications
httpwwwreinforcedplasticscom
httpwwwcentennialofflightgovessayEvolution_of_TechnologycompositesTech40htm
Automotive
Composite material is used in a number of applications in the automotive
industry due to its temperature resistance rigidity and fatigue strength
The benefits of using composites include greater fuel efficiency
corrosion resistance light weight and strength Composites also provide
a low-cost way to help keep designs looking fresh
Composites are used in
- interior parts (cockpit trimming seats instrument panels)
- exterior structure (body panels openings underbody frontrear
modules)
- engine compartment and fuelmechanical area parts (axles and
suspensions fuel and exhaust systems)
- electrical and electronic components
Lamborghinis Sesto Element carbon fiber
ldquoFat men cannot run as fast as thin men but we build most of our vehicles as though dead-weight fat increased speedhellip I cannot
imagine where the delusion that weight means strength
came fromhelliprdquo mdashHenry Ford
The mix of automotive materials is changing showing a boost for FRP in helping original
equipment manufacturers meet fuel economy and emissions challenges
(Source 2011 DuPont AutomotiveSAE survey of design engineers performed by Signet Research Inc)
Source
httpwwwtoraycomcsrhighlight2009hig_001_01html
The MonoCell tub for the McLaren MP4-12C supercar is moulded as a single
piece and weighs less than 80 kg (176 lbs)
COMPOSITES IN MARINE
TRIMARAN BOAT
AMERICA NAVYINDONESIAN NAVY
Visby Class corvette
Total length is 72 meters
The beam is 1040 meters
The displacement is 600 metric tones
fully equipped the worlds largest CRP
construction
The design of the Visby aims to minimize
the optical and infrared signature above
water acoustic and hydroa coustic
signature underwater electrical potential
and magnetic signature pressure signature
radar cross section and actively emitted
signals
A stealth corvette of the YS 2000 design
has a detection range of 13km in rough
seas and 22km in calm sea without
jamming In a jammed environment the
Visby would be detected at a range of 8km
in rough sea and 11km in calm sea
The material provides high strength and
rigidity low weight good shock resistance
low radar and magnetic signature
1996
Visby is a class of stealth corvettes for the Swedish Navy
ldquoReduced 50 of a Conventional Steelrdquo
Source
Hull Construction with composite materials for ships over 100m in length 2002
Massachusetts Institute of Technology
httpwwwnaval-technologycomprojectsvisby
YACHTS
KAL YUDISTIRAMARATHON 100 ADMIRAL YACHT
LOA 3050 MWidth 6 MFuel Tank 8000 LWater Tank 3000 LIce Box 500 LAccommodation Max 35 Personnel
2 x CATERPILLAR 3412E 1200 HPMARINE DIESEL ENGINE
PC 40 ndash KRI Krait 827Department of Indonesian Navy
LOA 40 MWidth 73 MPower 190Weapon Twin Cannon Barrels
127 mm Heavy Machine GunSpeed Knot 25 KnotDisplacement 105 tonAccommodation 23 personnel
PATROL BOAT
Rigid Inflatable BoatPATROL BOAT
Yachts
36m Luxury Yacht Moonraker
36m Luxury Yacht GoldenEye
50m Luxury Yacht Casino
Royale
45m Luxury Yacht Seashaw
Boat Parts
Barovans for Seismic Sweep
Centrifugal Liftfan House for Surface Effect
Ships
Composite Boat PropellersRTM
Deckhouses for Pilot Boats
Fairing Parts for Submarines
Flybridges for Motor yachts
Light Weight Gangway
MTB Launcher Mock-up
Pleasure Boats
12m Sailboat
12m Sail-Catamaranone-off
Canoes
Dragonfly 1000Catamaran Sailboat
Fantasy 37Sailboat
Farr 60Luxury Sailboat
EurodingyOlympic Dingy Class for
Woman
Hydrolift F23 Racing Boats
Kajacs
Najad 42Sailboat
Najad 520Sailboat
Najad 441Sailboat
Najad 391Sailboat
Nordwest 900Motorboat
Nordwest 1100Motorboat
Quatro 44Motorboat
Racemaster Competition Boats
Storebro 420
Storebro 345
Sweden Yacht 370Sailboat
Sweden Yacht 69Sailboat
Windy 41Motorboat
X-632Sailboat
X-362Sailboat
Commercial Boats
175m High Speed AmbulancePassenger Boat
19m High Speed Passenger Boat
20m High Speed Passenger Boat
364m Surface Effect Passenger Ship
45m Surface Effect Passenger Ship
120m Hull Structural Parts HSSS Catamaran Ferry
APPENDIX
Marine Vessel
1188m Fast Attack Vessel FMV 90 E
20m SAV-Surface Auxiliary Vessels
34m Personnel TransportCoast Guard Vessel
40ft Experimental SES
40m Landsort-Class Mine Hunters
54m Mine Counter Measure Vehicles SES
74m Coastal Patrol Boats
Fishing Boats
30 GT
12 GT
10 GT
5 GT
WISEWings In Surface Effect
HOVERCRAFT
Designed specifically for the tourist and transport industries the
Pioneer Mk3 hovercraft is amphibious and comfortably seats 25
passengers plus 1-crew The air-conditioned cabin allows for
maximum visibility for all aboard The Pioneer Mk3 is robust and
dynamic in its performance
Commercial hovercraft
Mk3 AirLift Hovercraft - 1215m
Power is economicaly provided by one Deutz diesel engine of
330kW (442hp) to cruise easily at 40 knots with much higher
speeds available according to the surface conditions The hull is
manufactured from fibreglassPVC foam composite sandwich
the windows are glass and the skirt is urethane coated nylon A
Military version is available with increased payload and systems
redundancy Power for the Military version comes from two Steyr
diesel engines with a total installed power of 320kW (429hp) All
transmission electrical hydraulic and air systems are duplicated
for maximum redundancy The increased performance of the
Military version comes from the reduced engine weight of the twin
Steyr installation cf the Deutz installation
Source
httpwwwnauticexpocomprodairlift-hovercraftcommercial-hovercrafts-25251-142868html
HOVERFLIGHT
BALLISTIC amp UNIT DEFENCED
Triaxis Composites Collaboration with Institute of Aeronautics and Space in the development of Missile Nose Cone
Polymer composites is the evolution of the military defence
Thin steel was the helmet material of
WWII and remained the principal material until around the 1980rsquos
The advantages of using steel
included a simple technology for manufacture of the helmets low cost and reasonably good
impact protection However these helmets were found to provide only marginal protection
against fragments
During the Vietnam War the US Army experimented with fiber-reinforced inserts in the
helmets These inserts improved ballistic protection but at the same time added weight and
reduced the air space between the head and the helmet
By the early part of the 1980rsquos the US military had developed the first all-composite
100 fiber-reinforced helmet This development resulted in even better ballistic protection
without altering the weight of the helmet Other improvements included better head coverage and
more space for ventilation
Source
Composites Armor - A difficult but huge market
by A Brent Strong Brigham Young University
MILITARY VEHICLES
HIGH SPEED TRAIN SHINKANSEN
Advanced Composites provide lightweight solutions for railway vehicles
saving as much as 50-80 of the weight compared with traditional
components
A lower overall weight translates into less stress faster acceleration and
higher speeds as well as reduced starting and stopping inertia Today
these are important criteria in global high-speed and metropolitan
railway projects
Fire smoke and toxic fumes are key safety criteria for interior
components of railway carriages Any material selected for an interior
component must meet international fire retardant standards
for Rail Interiors and Exteriors
Ceiling Panels Stairs
Seating Vestibules
Window Panels Door Pillars
Partition WallsDiffusers
Gangway and Cabinet Panels Cabin and
Desk panels
Door Pillars Lavatory Modules (standard and
Front and Rear EndsRoof Panels
Nose Cones Under Fairings
Source
httpwwwpctaerail_compositesphp
101
SKY BUS
2009
Europe is the world leader in offshore wind with
828 wind turbines and a cumulative capacity of 2056 MW spread across 38 offshore wind farms in 9
European countries
The UK and Denmark are the current leaders with a 44 and 30 share respectively In 2009
five countries built new offshore wind farms
UK (284 MW)
Demark (230 MW)
Sweden (30 MW)
Germany (30 MW)
Norway (23 MW)
2010
Asia leads the growth in global wind power which grew 358 GW in 2010 bringing
total global capacity to 1944 GW ndash up 225 from 2009
the Global Wind Energy Council (GWEC)
Asia accounted for 19 GW of new global wind power installations driven by China which installed 165
GW
ldquoChina now has 423 GW of wind powerrdquo
ldquoThis puts China firmly on a path to reach 200 GW of installed wind power by 2020 At the same
time China has become the worldrsquos largest producer of wind energy equipmentrdquo
Source
httpwwwreinforcedplasticscomview15655asia-leads-global-wind-power-growth
httpimgdeusmcomdesignnews288288605-Sandia_Sizes_up_Wind_Turbine_Blade_Design_C_largegif
WIND ENERGY
Marine Current Turbines
Source
httpwwwsiemenscompressenpressreleasepress=enpressrelease2011solar-hydroex201111005htm
httpwwwmarineturbinescom
A commercial marine current turbine consists of
two rotors which are fixed on a structure within the
sea current The twin rotors rotate with the
movement of the tidal flow and the blades pitch
through 180 degrees to optimally track tidal current
(Press picture Marine Current Turbines)
Wave Star Energys Multi-point Absorber
CFRP COLUMN REINFORCEMENT
INDUSTRIAL TANKS
107
INDUSTRIAL PIPES
PRESSURE TANKS
109
ldquoLetrsquos Make with Compositesrdquo
INDUSTRI COMPOSITES
AEROSPACE
HISTORY
1950 ndash Boeing
1960 ndash F14 Tomcat
1981 ndash AV-8B Harrier
Source
Low-Cost Composite Materials and Structures for Aircraft Applications
httpwwwreinforcedplasticscom
httpwwwcentennialofflightgovessayEvolution_of_TechnologycompositesTech40htm
Automotive
Composite material is used in a number of applications in the automotive
industry due to its temperature resistance rigidity and fatigue strength
The benefits of using composites include greater fuel efficiency
corrosion resistance light weight and strength Composites also provide
a low-cost way to help keep designs looking fresh
Composites are used in
- interior parts (cockpit trimming seats instrument panels)
- exterior structure (body panels openings underbody frontrear
modules)
- engine compartment and fuelmechanical area parts (axles and
suspensions fuel and exhaust systems)
- electrical and electronic components
Lamborghinis Sesto Element carbon fiber
ldquoFat men cannot run as fast as thin men but we build most of our vehicles as though dead-weight fat increased speedhellip I cannot
imagine where the delusion that weight means strength
came fromhelliprdquo mdashHenry Ford
The mix of automotive materials is changing showing a boost for FRP in helping original
equipment manufacturers meet fuel economy and emissions challenges
(Source 2011 DuPont AutomotiveSAE survey of design engineers performed by Signet Research Inc)
Source
httpwwwtoraycomcsrhighlight2009hig_001_01html
The MonoCell tub for the McLaren MP4-12C supercar is moulded as a single
piece and weighs less than 80 kg (176 lbs)
COMPOSITES IN MARINE
TRIMARAN BOAT
AMERICA NAVYINDONESIAN NAVY
Visby Class corvette
Total length is 72 meters
The beam is 1040 meters
The displacement is 600 metric tones
fully equipped the worlds largest CRP
construction
The design of the Visby aims to minimize
the optical and infrared signature above
water acoustic and hydroa coustic
signature underwater electrical potential
and magnetic signature pressure signature
radar cross section and actively emitted
signals
A stealth corvette of the YS 2000 design
has a detection range of 13km in rough
seas and 22km in calm sea without
jamming In a jammed environment the
Visby would be detected at a range of 8km
in rough sea and 11km in calm sea
The material provides high strength and
rigidity low weight good shock resistance
low radar and magnetic signature
1996
Visby is a class of stealth corvettes for the Swedish Navy
ldquoReduced 50 of a Conventional Steelrdquo
Source
Hull Construction with composite materials for ships over 100m in length 2002
Massachusetts Institute of Technology
httpwwwnaval-technologycomprojectsvisby
YACHTS
KAL YUDISTIRAMARATHON 100 ADMIRAL YACHT
LOA 3050 MWidth 6 MFuel Tank 8000 LWater Tank 3000 LIce Box 500 LAccommodation Max 35 Personnel
2 x CATERPILLAR 3412E 1200 HPMARINE DIESEL ENGINE
PC 40 ndash KRI Krait 827Department of Indonesian Navy
LOA 40 MWidth 73 MPower 190Weapon Twin Cannon Barrels
127 mm Heavy Machine GunSpeed Knot 25 KnotDisplacement 105 tonAccommodation 23 personnel
PATROL BOAT
Rigid Inflatable BoatPATROL BOAT
Yachts
36m Luxury Yacht Moonraker
36m Luxury Yacht GoldenEye
50m Luxury Yacht Casino
Royale
45m Luxury Yacht Seashaw
Boat Parts
Barovans for Seismic Sweep
Centrifugal Liftfan House for Surface Effect
Ships
Composite Boat PropellersRTM
Deckhouses for Pilot Boats
Fairing Parts for Submarines
Flybridges for Motor yachts
Light Weight Gangway
MTB Launcher Mock-up
Pleasure Boats
12m Sailboat
12m Sail-Catamaranone-off
Canoes
Dragonfly 1000Catamaran Sailboat
Fantasy 37Sailboat
Farr 60Luxury Sailboat
EurodingyOlympic Dingy Class for
Woman
Hydrolift F23 Racing Boats
Kajacs
Najad 42Sailboat
Najad 520Sailboat
Najad 441Sailboat
Najad 391Sailboat
Nordwest 900Motorboat
Nordwest 1100Motorboat
Quatro 44Motorboat
Racemaster Competition Boats
Storebro 420
Storebro 345
Sweden Yacht 370Sailboat
Sweden Yacht 69Sailboat
Windy 41Motorboat
X-632Sailboat
X-362Sailboat
Commercial Boats
175m High Speed AmbulancePassenger Boat
19m High Speed Passenger Boat
20m High Speed Passenger Boat
364m Surface Effect Passenger Ship
45m Surface Effect Passenger Ship
120m Hull Structural Parts HSSS Catamaran Ferry
APPENDIX
Marine Vessel
1188m Fast Attack Vessel FMV 90 E
20m SAV-Surface Auxiliary Vessels
34m Personnel TransportCoast Guard Vessel
40ft Experimental SES
40m Landsort-Class Mine Hunters
54m Mine Counter Measure Vehicles SES
74m Coastal Patrol Boats
Fishing Boats
30 GT
12 GT
10 GT
5 GT
WISEWings In Surface Effect
HOVERCRAFT
Designed specifically for the tourist and transport industries the
Pioneer Mk3 hovercraft is amphibious and comfortably seats 25
passengers plus 1-crew The air-conditioned cabin allows for
maximum visibility for all aboard The Pioneer Mk3 is robust and
dynamic in its performance
Commercial hovercraft
Mk3 AirLift Hovercraft - 1215m
Power is economicaly provided by one Deutz diesel engine of
330kW (442hp) to cruise easily at 40 knots with much higher
speeds available according to the surface conditions The hull is
manufactured from fibreglassPVC foam composite sandwich
the windows are glass and the skirt is urethane coated nylon A
Military version is available with increased payload and systems
redundancy Power for the Military version comes from two Steyr
diesel engines with a total installed power of 320kW (429hp) All
transmission electrical hydraulic and air systems are duplicated
for maximum redundancy The increased performance of the
Military version comes from the reduced engine weight of the twin
Steyr installation cf the Deutz installation
Source
httpwwwnauticexpocomprodairlift-hovercraftcommercial-hovercrafts-25251-142868html
HOVERFLIGHT
BALLISTIC amp UNIT DEFENCED
Triaxis Composites Collaboration with Institute of Aeronautics and Space in the development of Missile Nose Cone
Polymer composites is the evolution of the military defence
Thin steel was the helmet material of
WWII and remained the principal material until around the 1980rsquos
The advantages of using steel
included a simple technology for manufacture of the helmets low cost and reasonably good
impact protection However these helmets were found to provide only marginal protection
against fragments
During the Vietnam War the US Army experimented with fiber-reinforced inserts in the
helmets These inserts improved ballistic protection but at the same time added weight and
reduced the air space between the head and the helmet
By the early part of the 1980rsquos the US military had developed the first all-composite
100 fiber-reinforced helmet This development resulted in even better ballistic protection
without altering the weight of the helmet Other improvements included better head coverage and
more space for ventilation
Source
Composites Armor - A difficult but huge market
by A Brent Strong Brigham Young University
MILITARY VEHICLES
HIGH SPEED TRAIN SHINKANSEN
Advanced Composites provide lightweight solutions for railway vehicles
saving as much as 50-80 of the weight compared with traditional
components
A lower overall weight translates into less stress faster acceleration and
higher speeds as well as reduced starting and stopping inertia Today
these are important criteria in global high-speed and metropolitan
railway projects
Fire smoke and toxic fumes are key safety criteria for interior
components of railway carriages Any material selected for an interior
component must meet international fire retardant standards
for Rail Interiors and Exteriors
Ceiling Panels Stairs
Seating Vestibules
Window Panels Door Pillars
Partition WallsDiffusers
Gangway and Cabinet Panels Cabin and
Desk panels
Door Pillars Lavatory Modules (standard and
Front and Rear EndsRoof Panels
Nose Cones Under Fairings
Source
httpwwwpctaerail_compositesphp
101
SKY BUS
2009
Europe is the world leader in offshore wind with
828 wind turbines and a cumulative capacity of 2056 MW spread across 38 offshore wind farms in 9
European countries
The UK and Denmark are the current leaders with a 44 and 30 share respectively In 2009
five countries built new offshore wind farms
UK (284 MW)
Demark (230 MW)
Sweden (30 MW)
Germany (30 MW)
Norway (23 MW)
2010
Asia leads the growth in global wind power which grew 358 GW in 2010 bringing
total global capacity to 1944 GW ndash up 225 from 2009
the Global Wind Energy Council (GWEC)
Asia accounted for 19 GW of new global wind power installations driven by China which installed 165
GW
ldquoChina now has 423 GW of wind powerrdquo
ldquoThis puts China firmly on a path to reach 200 GW of installed wind power by 2020 At the same
time China has become the worldrsquos largest producer of wind energy equipmentrdquo
Source
httpwwwreinforcedplasticscomview15655asia-leads-global-wind-power-growth
httpimgdeusmcomdesignnews288288605-Sandia_Sizes_up_Wind_Turbine_Blade_Design_C_largegif
WIND ENERGY
Marine Current Turbines
Source
httpwwwsiemenscompressenpressreleasepress=enpressrelease2011solar-hydroex201111005htm
httpwwwmarineturbinescom
A commercial marine current turbine consists of
two rotors which are fixed on a structure within the
sea current The twin rotors rotate with the
movement of the tidal flow and the blades pitch
through 180 degrees to optimally track tidal current
(Press picture Marine Current Turbines)
Wave Star Energys Multi-point Absorber
CFRP COLUMN REINFORCEMENT
INDUSTRIAL TANKS
107
INDUSTRIAL PIPES
PRESSURE TANKS
109
ldquoLetrsquos Make with Compositesrdquo
AEROSPACE
HISTORY
1950 ndash Boeing
1960 ndash F14 Tomcat
1981 ndash AV-8B Harrier
Source
Low-Cost Composite Materials and Structures for Aircraft Applications
httpwwwreinforcedplasticscom
httpwwwcentennialofflightgovessayEvolution_of_TechnologycompositesTech40htm
Automotive
Composite material is used in a number of applications in the automotive
industry due to its temperature resistance rigidity and fatigue strength
The benefits of using composites include greater fuel efficiency
corrosion resistance light weight and strength Composites also provide
a low-cost way to help keep designs looking fresh
Composites are used in
- interior parts (cockpit trimming seats instrument panels)
- exterior structure (body panels openings underbody frontrear
modules)
- engine compartment and fuelmechanical area parts (axles and
suspensions fuel and exhaust systems)
- electrical and electronic components
Lamborghinis Sesto Element carbon fiber
ldquoFat men cannot run as fast as thin men but we build most of our vehicles as though dead-weight fat increased speedhellip I cannot
imagine where the delusion that weight means strength
came fromhelliprdquo mdashHenry Ford
The mix of automotive materials is changing showing a boost for FRP in helping original
equipment manufacturers meet fuel economy and emissions challenges
(Source 2011 DuPont AutomotiveSAE survey of design engineers performed by Signet Research Inc)
Source
httpwwwtoraycomcsrhighlight2009hig_001_01html
The MonoCell tub for the McLaren MP4-12C supercar is moulded as a single
piece and weighs less than 80 kg (176 lbs)
COMPOSITES IN MARINE
TRIMARAN BOAT
AMERICA NAVYINDONESIAN NAVY
Visby Class corvette
Total length is 72 meters
The beam is 1040 meters
The displacement is 600 metric tones
fully equipped the worlds largest CRP
construction
The design of the Visby aims to minimize
the optical and infrared signature above
water acoustic and hydroa coustic
signature underwater electrical potential
and magnetic signature pressure signature
radar cross section and actively emitted
signals
A stealth corvette of the YS 2000 design
has a detection range of 13km in rough
seas and 22km in calm sea without
jamming In a jammed environment the
Visby would be detected at a range of 8km
in rough sea and 11km in calm sea
The material provides high strength and
rigidity low weight good shock resistance
low radar and magnetic signature
1996
Visby is a class of stealth corvettes for the Swedish Navy
ldquoReduced 50 of a Conventional Steelrdquo
Source
Hull Construction with composite materials for ships over 100m in length 2002
Massachusetts Institute of Technology
httpwwwnaval-technologycomprojectsvisby
YACHTS
KAL YUDISTIRAMARATHON 100 ADMIRAL YACHT
LOA 3050 MWidth 6 MFuel Tank 8000 LWater Tank 3000 LIce Box 500 LAccommodation Max 35 Personnel
2 x CATERPILLAR 3412E 1200 HPMARINE DIESEL ENGINE
PC 40 ndash KRI Krait 827Department of Indonesian Navy
LOA 40 MWidth 73 MPower 190Weapon Twin Cannon Barrels
127 mm Heavy Machine GunSpeed Knot 25 KnotDisplacement 105 tonAccommodation 23 personnel
PATROL BOAT
Rigid Inflatable BoatPATROL BOAT
Yachts
36m Luxury Yacht Moonraker
36m Luxury Yacht GoldenEye
50m Luxury Yacht Casino
Royale
45m Luxury Yacht Seashaw
Boat Parts
Barovans for Seismic Sweep
Centrifugal Liftfan House for Surface Effect
Ships
Composite Boat PropellersRTM
Deckhouses for Pilot Boats
Fairing Parts for Submarines
Flybridges for Motor yachts
Light Weight Gangway
MTB Launcher Mock-up
Pleasure Boats
12m Sailboat
12m Sail-Catamaranone-off
Canoes
Dragonfly 1000Catamaran Sailboat
Fantasy 37Sailboat
Farr 60Luxury Sailboat
EurodingyOlympic Dingy Class for
Woman
Hydrolift F23 Racing Boats
Kajacs
Najad 42Sailboat
Najad 520Sailboat
Najad 441Sailboat
Najad 391Sailboat
Nordwest 900Motorboat
Nordwest 1100Motorboat
Quatro 44Motorboat
Racemaster Competition Boats
Storebro 420
Storebro 345
Sweden Yacht 370Sailboat
Sweden Yacht 69Sailboat
Windy 41Motorboat
X-632Sailboat
X-362Sailboat
Commercial Boats
175m High Speed AmbulancePassenger Boat
19m High Speed Passenger Boat
20m High Speed Passenger Boat
364m Surface Effect Passenger Ship
45m Surface Effect Passenger Ship
120m Hull Structural Parts HSSS Catamaran Ferry
APPENDIX
Marine Vessel
1188m Fast Attack Vessel FMV 90 E
20m SAV-Surface Auxiliary Vessels
34m Personnel TransportCoast Guard Vessel
40ft Experimental SES
40m Landsort-Class Mine Hunters
54m Mine Counter Measure Vehicles SES
74m Coastal Patrol Boats
Fishing Boats
30 GT
12 GT
10 GT
5 GT
WISEWings In Surface Effect
HOVERCRAFT
Designed specifically for the tourist and transport industries the
Pioneer Mk3 hovercraft is amphibious and comfortably seats 25
passengers plus 1-crew The air-conditioned cabin allows for
maximum visibility for all aboard The Pioneer Mk3 is robust and
dynamic in its performance
Commercial hovercraft
Mk3 AirLift Hovercraft - 1215m
Power is economicaly provided by one Deutz diesel engine of
330kW (442hp) to cruise easily at 40 knots with much higher
speeds available according to the surface conditions The hull is
manufactured from fibreglassPVC foam composite sandwich
the windows are glass and the skirt is urethane coated nylon A
Military version is available with increased payload and systems
redundancy Power for the Military version comes from two Steyr
diesel engines with a total installed power of 320kW (429hp) All
transmission electrical hydraulic and air systems are duplicated
for maximum redundancy The increased performance of the
Military version comes from the reduced engine weight of the twin
Steyr installation cf the Deutz installation
Source
httpwwwnauticexpocomprodairlift-hovercraftcommercial-hovercrafts-25251-142868html
HOVERFLIGHT
BALLISTIC amp UNIT DEFENCED
Triaxis Composites Collaboration with Institute of Aeronautics and Space in the development of Missile Nose Cone
Polymer composites is the evolution of the military defence
Thin steel was the helmet material of
WWII and remained the principal material until around the 1980rsquos
The advantages of using steel
included a simple technology for manufacture of the helmets low cost and reasonably good
impact protection However these helmets were found to provide only marginal protection
against fragments
During the Vietnam War the US Army experimented with fiber-reinforced inserts in the
helmets These inserts improved ballistic protection but at the same time added weight and
reduced the air space between the head and the helmet
By the early part of the 1980rsquos the US military had developed the first all-composite
100 fiber-reinforced helmet This development resulted in even better ballistic protection
without altering the weight of the helmet Other improvements included better head coverage and
more space for ventilation
Source
Composites Armor - A difficult but huge market
by A Brent Strong Brigham Young University
MILITARY VEHICLES
HIGH SPEED TRAIN SHINKANSEN
Advanced Composites provide lightweight solutions for railway vehicles
saving as much as 50-80 of the weight compared with traditional
components
A lower overall weight translates into less stress faster acceleration and
higher speeds as well as reduced starting and stopping inertia Today
these are important criteria in global high-speed and metropolitan
railway projects
Fire smoke and toxic fumes are key safety criteria for interior
components of railway carriages Any material selected for an interior
component must meet international fire retardant standards
for Rail Interiors and Exteriors
Ceiling Panels Stairs
Seating Vestibules
Window Panels Door Pillars
Partition WallsDiffusers
Gangway and Cabinet Panels Cabin and
Desk panels
Door Pillars Lavatory Modules (standard and
Front and Rear EndsRoof Panels
Nose Cones Under Fairings
Source
httpwwwpctaerail_compositesphp
101
SKY BUS
2009
Europe is the world leader in offshore wind with
828 wind turbines and a cumulative capacity of 2056 MW spread across 38 offshore wind farms in 9
European countries
The UK and Denmark are the current leaders with a 44 and 30 share respectively In 2009
five countries built new offshore wind farms
UK (284 MW)
Demark (230 MW)
Sweden (30 MW)
Germany (30 MW)
Norway (23 MW)
2010
Asia leads the growth in global wind power which grew 358 GW in 2010 bringing
total global capacity to 1944 GW ndash up 225 from 2009
the Global Wind Energy Council (GWEC)
Asia accounted for 19 GW of new global wind power installations driven by China which installed 165
GW
ldquoChina now has 423 GW of wind powerrdquo
ldquoThis puts China firmly on a path to reach 200 GW of installed wind power by 2020 At the same
time China has become the worldrsquos largest producer of wind energy equipmentrdquo
Source
httpwwwreinforcedplasticscomview15655asia-leads-global-wind-power-growth
httpimgdeusmcomdesignnews288288605-Sandia_Sizes_up_Wind_Turbine_Blade_Design_C_largegif
WIND ENERGY
Marine Current Turbines
Source
httpwwwsiemenscompressenpressreleasepress=enpressrelease2011solar-hydroex201111005htm
httpwwwmarineturbinescom
A commercial marine current turbine consists of
two rotors which are fixed on a structure within the
sea current The twin rotors rotate with the
movement of the tidal flow and the blades pitch
through 180 degrees to optimally track tidal current
(Press picture Marine Current Turbines)
Wave Star Energys Multi-point Absorber
CFRP COLUMN REINFORCEMENT
INDUSTRIAL TANKS
107
INDUSTRIAL PIPES
PRESSURE TANKS
109
ldquoLetrsquos Make with Compositesrdquo
HISTORY
1950 ndash Boeing
1960 ndash F14 Tomcat
1981 ndash AV-8B Harrier
Source
Low-Cost Composite Materials and Structures for Aircraft Applications
httpwwwreinforcedplasticscom
httpwwwcentennialofflightgovessayEvolution_of_TechnologycompositesTech40htm
Automotive
Composite material is used in a number of applications in the automotive
industry due to its temperature resistance rigidity and fatigue strength
The benefits of using composites include greater fuel efficiency
corrosion resistance light weight and strength Composites also provide
a low-cost way to help keep designs looking fresh
Composites are used in
- interior parts (cockpit trimming seats instrument panels)
- exterior structure (body panels openings underbody frontrear
modules)
- engine compartment and fuelmechanical area parts (axles and
suspensions fuel and exhaust systems)
- electrical and electronic components
Lamborghinis Sesto Element carbon fiber
ldquoFat men cannot run as fast as thin men but we build most of our vehicles as though dead-weight fat increased speedhellip I cannot
imagine where the delusion that weight means strength
came fromhelliprdquo mdashHenry Ford
The mix of automotive materials is changing showing a boost for FRP in helping original
equipment manufacturers meet fuel economy and emissions challenges
(Source 2011 DuPont AutomotiveSAE survey of design engineers performed by Signet Research Inc)
Source
httpwwwtoraycomcsrhighlight2009hig_001_01html
The MonoCell tub for the McLaren MP4-12C supercar is moulded as a single
piece and weighs less than 80 kg (176 lbs)
COMPOSITES IN MARINE
TRIMARAN BOAT
AMERICA NAVYINDONESIAN NAVY
Visby Class corvette
Total length is 72 meters
The beam is 1040 meters
The displacement is 600 metric tones
fully equipped the worlds largest CRP
construction
The design of the Visby aims to minimize
the optical and infrared signature above
water acoustic and hydroa coustic
signature underwater electrical potential
and magnetic signature pressure signature
radar cross section and actively emitted
signals
A stealth corvette of the YS 2000 design
has a detection range of 13km in rough
seas and 22km in calm sea without
jamming In a jammed environment the
Visby would be detected at a range of 8km
in rough sea and 11km in calm sea
The material provides high strength and
rigidity low weight good shock resistance
low radar and magnetic signature
1996
Visby is a class of stealth corvettes for the Swedish Navy
ldquoReduced 50 of a Conventional Steelrdquo
Source
Hull Construction with composite materials for ships over 100m in length 2002
Massachusetts Institute of Technology
httpwwwnaval-technologycomprojectsvisby
YACHTS
KAL YUDISTIRAMARATHON 100 ADMIRAL YACHT
LOA 3050 MWidth 6 MFuel Tank 8000 LWater Tank 3000 LIce Box 500 LAccommodation Max 35 Personnel
2 x CATERPILLAR 3412E 1200 HPMARINE DIESEL ENGINE
PC 40 ndash KRI Krait 827Department of Indonesian Navy
LOA 40 MWidth 73 MPower 190Weapon Twin Cannon Barrels
127 mm Heavy Machine GunSpeed Knot 25 KnotDisplacement 105 tonAccommodation 23 personnel
PATROL BOAT
Rigid Inflatable BoatPATROL BOAT
Yachts
36m Luxury Yacht Moonraker
36m Luxury Yacht GoldenEye
50m Luxury Yacht Casino
Royale
45m Luxury Yacht Seashaw
Boat Parts
Barovans for Seismic Sweep
Centrifugal Liftfan House for Surface Effect
Ships
Composite Boat PropellersRTM
Deckhouses for Pilot Boats
Fairing Parts for Submarines
Flybridges for Motor yachts
Light Weight Gangway
MTB Launcher Mock-up
Pleasure Boats
12m Sailboat
12m Sail-Catamaranone-off
Canoes
Dragonfly 1000Catamaran Sailboat
Fantasy 37Sailboat
Farr 60Luxury Sailboat
EurodingyOlympic Dingy Class for
Woman
Hydrolift F23 Racing Boats
Kajacs
Najad 42Sailboat
Najad 520Sailboat
Najad 441Sailboat
Najad 391Sailboat
Nordwest 900Motorboat
Nordwest 1100Motorboat
Quatro 44Motorboat
Racemaster Competition Boats
Storebro 420
Storebro 345
Sweden Yacht 370Sailboat
Sweden Yacht 69Sailboat
Windy 41Motorboat
X-632Sailboat
X-362Sailboat
Commercial Boats
175m High Speed AmbulancePassenger Boat
19m High Speed Passenger Boat
20m High Speed Passenger Boat
364m Surface Effect Passenger Ship
45m Surface Effect Passenger Ship
120m Hull Structural Parts HSSS Catamaran Ferry
APPENDIX
Marine Vessel
1188m Fast Attack Vessel FMV 90 E
20m SAV-Surface Auxiliary Vessels
34m Personnel TransportCoast Guard Vessel
40ft Experimental SES
40m Landsort-Class Mine Hunters
54m Mine Counter Measure Vehicles SES
74m Coastal Patrol Boats
Fishing Boats
30 GT
12 GT
10 GT
5 GT
WISEWings In Surface Effect
HOVERCRAFT
Designed specifically for the tourist and transport industries the
Pioneer Mk3 hovercraft is amphibious and comfortably seats 25
passengers plus 1-crew The air-conditioned cabin allows for
maximum visibility for all aboard The Pioneer Mk3 is robust and
dynamic in its performance
Commercial hovercraft
Mk3 AirLift Hovercraft - 1215m
Power is economicaly provided by one Deutz diesel engine of
330kW (442hp) to cruise easily at 40 knots with much higher
speeds available according to the surface conditions The hull is
manufactured from fibreglassPVC foam composite sandwich
the windows are glass and the skirt is urethane coated nylon A
Military version is available with increased payload and systems
redundancy Power for the Military version comes from two Steyr
diesel engines with a total installed power of 320kW (429hp) All
transmission electrical hydraulic and air systems are duplicated
for maximum redundancy The increased performance of the
Military version comes from the reduced engine weight of the twin
Steyr installation cf the Deutz installation
Source
httpwwwnauticexpocomprodairlift-hovercraftcommercial-hovercrafts-25251-142868html
HOVERFLIGHT
BALLISTIC amp UNIT DEFENCED
Triaxis Composites Collaboration with Institute of Aeronautics and Space in the development of Missile Nose Cone
Polymer composites is the evolution of the military defence
Thin steel was the helmet material of
WWII and remained the principal material until around the 1980rsquos
The advantages of using steel
included a simple technology for manufacture of the helmets low cost and reasonably good
impact protection However these helmets were found to provide only marginal protection
against fragments
During the Vietnam War the US Army experimented with fiber-reinforced inserts in the
helmets These inserts improved ballistic protection but at the same time added weight and
reduced the air space between the head and the helmet
By the early part of the 1980rsquos the US military had developed the first all-composite
100 fiber-reinforced helmet This development resulted in even better ballistic protection
without altering the weight of the helmet Other improvements included better head coverage and
more space for ventilation
Source
Composites Armor - A difficult but huge market
by A Brent Strong Brigham Young University
MILITARY VEHICLES
HIGH SPEED TRAIN SHINKANSEN
Advanced Composites provide lightweight solutions for railway vehicles
saving as much as 50-80 of the weight compared with traditional
components
A lower overall weight translates into less stress faster acceleration and
higher speeds as well as reduced starting and stopping inertia Today
these are important criteria in global high-speed and metropolitan
railway projects
Fire smoke and toxic fumes are key safety criteria for interior
components of railway carriages Any material selected for an interior
component must meet international fire retardant standards
for Rail Interiors and Exteriors
Ceiling Panels Stairs
Seating Vestibules
Window Panels Door Pillars
Partition WallsDiffusers
Gangway and Cabinet Panels Cabin and
Desk panels
Door Pillars Lavatory Modules (standard and
Front and Rear EndsRoof Panels
Nose Cones Under Fairings
Source
httpwwwpctaerail_compositesphp
101
SKY BUS
2009
Europe is the world leader in offshore wind with
828 wind turbines and a cumulative capacity of 2056 MW spread across 38 offshore wind farms in 9
European countries
The UK and Denmark are the current leaders with a 44 and 30 share respectively In 2009
five countries built new offshore wind farms
UK (284 MW)
Demark (230 MW)
Sweden (30 MW)
Germany (30 MW)
Norway (23 MW)
2010
Asia leads the growth in global wind power which grew 358 GW in 2010 bringing
total global capacity to 1944 GW ndash up 225 from 2009
the Global Wind Energy Council (GWEC)
Asia accounted for 19 GW of new global wind power installations driven by China which installed 165
GW
ldquoChina now has 423 GW of wind powerrdquo
ldquoThis puts China firmly on a path to reach 200 GW of installed wind power by 2020 At the same
time China has become the worldrsquos largest producer of wind energy equipmentrdquo
Source
httpwwwreinforcedplasticscomview15655asia-leads-global-wind-power-growth
httpimgdeusmcomdesignnews288288605-Sandia_Sizes_up_Wind_Turbine_Blade_Design_C_largegif
WIND ENERGY
Marine Current Turbines
Source
httpwwwsiemenscompressenpressreleasepress=enpressrelease2011solar-hydroex201111005htm
httpwwwmarineturbinescom
A commercial marine current turbine consists of
two rotors which are fixed on a structure within the
sea current The twin rotors rotate with the
movement of the tidal flow and the blades pitch
through 180 degrees to optimally track tidal current
(Press picture Marine Current Turbines)
Wave Star Energys Multi-point Absorber
CFRP COLUMN REINFORCEMENT
INDUSTRIAL TANKS
107
INDUSTRIAL PIPES
PRESSURE TANKS
109
ldquoLetrsquos Make with Compositesrdquo
Automotive
Composite material is used in a number of applications in the automotive
industry due to its temperature resistance rigidity and fatigue strength
The benefits of using composites include greater fuel efficiency
corrosion resistance light weight and strength Composites also provide
a low-cost way to help keep designs looking fresh
Composites are used in
- interior parts (cockpit trimming seats instrument panels)
- exterior structure (body panels openings underbody frontrear
modules)
- engine compartment and fuelmechanical area parts (axles and
suspensions fuel and exhaust systems)
- electrical and electronic components
Lamborghinis Sesto Element carbon fiber
ldquoFat men cannot run as fast as thin men but we build most of our vehicles as though dead-weight fat increased speedhellip I cannot
imagine where the delusion that weight means strength
came fromhelliprdquo mdashHenry Ford
The mix of automotive materials is changing showing a boost for FRP in helping original
equipment manufacturers meet fuel economy and emissions challenges
(Source 2011 DuPont AutomotiveSAE survey of design engineers performed by Signet Research Inc)
Source
httpwwwtoraycomcsrhighlight2009hig_001_01html
The MonoCell tub for the McLaren MP4-12C supercar is moulded as a single
piece and weighs less than 80 kg (176 lbs)
COMPOSITES IN MARINE
TRIMARAN BOAT
AMERICA NAVYINDONESIAN NAVY
Visby Class corvette
Total length is 72 meters
The beam is 1040 meters
The displacement is 600 metric tones
fully equipped the worlds largest CRP
construction
The design of the Visby aims to minimize
the optical and infrared signature above
water acoustic and hydroa coustic
signature underwater electrical potential
and magnetic signature pressure signature
radar cross section and actively emitted
signals
A stealth corvette of the YS 2000 design
has a detection range of 13km in rough
seas and 22km in calm sea without
jamming In a jammed environment the
Visby would be detected at a range of 8km
in rough sea and 11km in calm sea
The material provides high strength and
rigidity low weight good shock resistance
low radar and magnetic signature
1996
Visby is a class of stealth corvettes for the Swedish Navy
ldquoReduced 50 of a Conventional Steelrdquo
Source
Hull Construction with composite materials for ships over 100m in length 2002
Massachusetts Institute of Technology
httpwwwnaval-technologycomprojectsvisby
YACHTS
KAL YUDISTIRAMARATHON 100 ADMIRAL YACHT
LOA 3050 MWidth 6 MFuel Tank 8000 LWater Tank 3000 LIce Box 500 LAccommodation Max 35 Personnel
2 x CATERPILLAR 3412E 1200 HPMARINE DIESEL ENGINE
PC 40 ndash KRI Krait 827Department of Indonesian Navy
LOA 40 MWidth 73 MPower 190Weapon Twin Cannon Barrels
127 mm Heavy Machine GunSpeed Knot 25 KnotDisplacement 105 tonAccommodation 23 personnel
PATROL BOAT
Rigid Inflatable BoatPATROL BOAT
Yachts
36m Luxury Yacht Moonraker
36m Luxury Yacht GoldenEye
50m Luxury Yacht Casino
Royale
45m Luxury Yacht Seashaw
Boat Parts
Barovans for Seismic Sweep
Centrifugal Liftfan House for Surface Effect
Ships
Composite Boat PropellersRTM
Deckhouses for Pilot Boats
Fairing Parts for Submarines
Flybridges for Motor yachts
Light Weight Gangway
MTB Launcher Mock-up
Pleasure Boats
12m Sailboat
12m Sail-Catamaranone-off
Canoes
Dragonfly 1000Catamaran Sailboat
Fantasy 37Sailboat
Farr 60Luxury Sailboat
EurodingyOlympic Dingy Class for
Woman
Hydrolift F23 Racing Boats
Kajacs
Najad 42Sailboat
Najad 520Sailboat
Najad 441Sailboat
Najad 391Sailboat
Nordwest 900Motorboat
Nordwest 1100Motorboat
Quatro 44Motorboat
Racemaster Competition Boats
Storebro 420
Storebro 345
Sweden Yacht 370Sailboat
Sweden Yacht 69Sailboat
Windy 41Motorboat
X-632Sailboat
X-362Sailboat
Commercial Boats
175m High Speed AmbulancePassenger Boat
19m High Speed Passenger Boat
20m High Speed Passenger Boat
364m Surface Effect Passenger Ship
45m Surface Effect Passenger Ship
120m Hull Structural Parts HSSS Catamaran Ferry
APPENDIX
Marine Vessel
1188m Fast Attack Vessel FMV 90 E
20m SAV-Surface Auxiliary Vessels
34m Personnel TransportCoast Guard Vessel
40ft Experimental SES
40m Landsort-Class Mine Hunters
54m Mine Counter Measure Vehicles SES
74m Coastal Patrol Boats
Fishing Boats
30 GT
12 GT
10 GT
5 GT
WISEWings In Surface Effect
HOVERCRAFT
Designed specifically for the tourist and transport industries the
Pioneer Mk3 hovercraft is amphibious and comfortably seats 25
passengers plus 1-crew The air-conditioned cabin allows for
maximum visibility for all aboard The Pioneer Mk3 is robust and
dynamic in its performance
Commercial hovercraft
Mk3 AirLift Hovercraft - 1215m
Power is economicaly provided by one Deutz diesel engine of
330kW (442hp) to cruise easily at 40 knots with much higher
speeds available according to the surface conditions The hull is
manufactured from fibreglassPVC foam composite sandwich
the windows are glass and the skirt is urethane coated nylon A
Military version is available with increased payload and systems
redundancy Power for the Military version comes from two Steyr
diesel engines with a total installed power of 320kW (429hp) All
transmission electrical hydraulic and air systems are duplicated
for maximum redundancy The increased performance of the
Military version comes from the reduced engine weight of the twin
Steyr installation cf the Deutz installation
Source
httpwwwnauticexpocomprodairlift-hovercraftcommercial-hovercrafts-25251-142868html
HOVERFLIGHT
BALLISTIC amp UNIT DEFENCED
Triaxis Composites Collaboration with Institute of Aeronautics and Space in the development of Missile Nose Cone
Polymer composites is the evolution of the military defence
Thin steel was the helmet material of
WWII and remained the principal material until around the 1980rsquos
The advantages of using steel
included a simple technology for manufacture of the helmets low cost and reasonably good
impact protection However these helmets were found to provide only marginal protection
against fragments
During the Vietnam War the US Army experimented with fiber-reinforced inserts in the
helmets These inserts improved ballistic protection but at the same time added weight and
reduced the air space between the head and the helmet
By the early part of the 1980rsquos the US military had developed the first all-composite
100 fiber-reinforced helmet This development resulted in even better ballistic protection
without altering the weight of the helmet Other improvements included better head coverage and
more space for ventilation
Source
Composites Armor - A difficult but huge market
by A Brent Strong Brigham Young University
MILITARY VEHICLES
HIGH SPEED TRAIN SHINKANSEN
Advanced Composites provide lightweight solutions for railway vehicles
saving as much as 50-80 of the weight compared with traditional
components
A lower overall weight translates into less stress faster acceleration and
higher speeds as well as reduced starting and stopping inertia Today
these are important criteria in global high-speed and metropolitan
railway projects
Fire smoke and toxic fumes are key safety criteria for interior
components of railway carriages Any material selected for an interior
component must meet international fire retardant standards
for Rail Interiors and Exteriors
Ceiling Panels Stairs
Seating Vestibules
Window Panels Door Pillars
Partition WallsDiffusers
Gangway and Cabinet Panels Cabin and
Desk panels
Door Pillars Lavatory Modules (standard and
Front and Rear EndsRoof Panels
Nose Cones Under Fairings
Source
httpwwwpctaerail_compositesphp
101
SKY BUS
2009
Europe is the world leader in offshore wind with
828 wind turbines and a cumulative capacity of 2056 MW spread across 38 offshore wind farms in 9
European countries
The UK and Denmark are the current leaders with a 44 and 30 share respectively In 2009
five countries built new offshore wind farms
UK (284 MW)
Demark (230 MW)
Sweden (30 MW)
Germany (30 MW)
Norway (23 MW)
2010
Asia leads the growth in global wind power which grew 358 GW in 2010 bringing
total global capacity to 1944 GW ndash up 225 from 2009
the Global Wind Energy Council (GWEC)
Asia accounted for 19 GW of new global wind power installations driven by China which installed 165
GW
ldquoChina now has 423 GW of wind powerrdquo
ldquoThis puts China firmly on a path to reach 200 GW of installed wind power by 2020 At the same
time China has become the worldrsquos largest producer of wind energy equipmentrdquo
Source
httpwwwreinforcedplasticscomview15655asia-leads-global-wind-power-growth
httpimgdeusmcomdesignnews288288605-Sandia_Sizes_up_Wind_Turbine_Blade_Design_C_largegif
WIND ENERGY
Marine Current Turbines
Source
httpwwwsiemenscompressenpressreleasepress=enpressrelease2011solar-hydroex201111005htm
httpwwwmarineturbinescom
A commercial marine current turbine consists of
two rotors which are fixed on a structure within the
sea current The twin rotors rotate with the
movement of the tidal flow and the blades pitch
through 180 degrees to optimally track tidal current
(Press picture Marine Current Turbines)
Wave Star Energys Multi-point Absorber
CFRP COLUMN REINFORCEMENT
INDUSTRIAL TANKS
107
INDUSTRIAL PIPES
PRESSURE TANKS
109
ldquoLetrsquos Make with Compositesrdquo
Lamborghinis Sesto Element carbon fiber
ldquoFat men cannot run as fast as thin men but we build most of our vehicles as though dead-weight fat increased speedhellip I cannot
imagine where the delusion that weight means strength
came fromhelliprdquo mdashHenry Ford
The mix of automotive materials is changing showing a boost for FRP in helping original
equipment manufacturers meet fuel economy and emissions challenges
(Source 2011 DuPont AutomotiveSAE survey of design engineers performed by Signet Research Inc)
Source
httpwwwtoraycomcsrhighlight2009hig_001_01html
The MonoCell tub for the McLaren MP4-12C supercar is moulded as a single
piece and weighs less than 80 kg (176 lbs)
COMPOSITES IN MARINE
TRIMARAN BOAT
AMERICA NAVYINDONESIAN NAVY
Visby Class corvette
Total length is 72 meters
The beam is 1040 meters
The displacement is 600 metric tones
fully equipped the worlds largest CRP
construction
The design of the Visby aims to minimize
the optical and infrared signature above
water acoustic and hydroa coustic
signature underwater electrical potential
and magnetic signature pressure signature
radar cross section and actively emitted
signals
A stealth corvette of the YS 2000 design
has a detection range of 13km in rough
seas and 22km in calm sea without
jamming In a jammed environment the
Visby would be detected at a range of 8km
in rough sea and 11km in calm sea
The material provides high strength and
rigidity low weight good shock resistance
low radar and magnetic signature
1996
Visby is a class of stealth corvettes for the Swedish Navy
ldquoReduced 50 of a Conventional Steelrdquo
Source
Hull Construction with composite materials for ships over 100m in length 2002
Massachusetts Institute of Technology
httpwwwnaval-technologycomprojectsvisby
YACHTS
KAL YUDISTIRAMARATHON 100 ADMIRAL YACHT
LOA 3050 MWidth 6 MFuel Tank 8000 LWater Tank 3000 LIce Box 500 LAccommodation Max 35 Personnel
2 x CATERPILLAR 3412E 1200 HPMARINE DIESEL ENGINE
PC 40 ndash KRI Krait 827Department of Indonesian Navy
LOA 40 MWidth 73 MPower 190Weapon Twin Cannon Barrels
127 mm Heavy Machine GunSpeed Knot 25 KnotDisplacement 105 tonAccommodation 23 personnel
PATROL BOAT
Rigid Inflatable BoatPATROL BOAT
Yachts
36m Luxury Yacht Moonraker
36m Luxury Yacht GoldenEye
50m Luxury Yacht Casino
Royale
45m Luxury Yacht Seashaw
Boat Parts
Barovans for Seismic Sweep
Centrifugal Liftfan House for Surface Effect
Ships
Composite Boat PropellersRTM
Deckhouses for Pilot Boats
Fairing Parts for Submarines
Flybridges for Motor yachts
Light Weight Gangway
MTB Launcher Mock-up
Pleasure Boats
12m Sailboat
12m Sail-Catamaranone-off
Canoes
Dragonfly 1000Catamaran Sailboat
Fantasy 37Sailboat
Farr 60Luxury Sailboat
EurodingyOlympic Dingy Class for
Woman
Hydrolift F23 Racing Boats
Kajacs
Najad 42Sailboat
Najad 520Sailboat
Najad 441Sailboat
Najad 391Sailboat
Nordwest 900Motorboat
Nordwest 1100Motorboat
Quatro 44Motorboat
Racemaster Competition Boats
Storebro 420
Storebro 345
Sweden Yacht 370Sailboat
Sweden Yacht 69Sailboat
Windy 41Motorboat
X-632Sailboat
X-362Sailboat
Commercial Boats
175m High Speed AmbulancePassenger Boat
19m High Speed Passenger Boat
20m High Speed Passenger Boat
364m Surface Effect Passenger Ship
45m Surface Effect Passenger Ship
120m Hull Structural Parts HSSS Catamaran Ferry
APPENDIX
Marine Vessel
1188m Fast Attack Vessel FMV 90 E
20m SAV-Surface Auxiliary Vessels
34m Personnel TransportCoast Guard Vessel
40ft Experimental SES
40m Landsort-Class Mine Hunters
54m Mine Counter Measure Vehicles SES
74m Coastal Patrol Boats
Fishing Boats
30 GT
12 GT
10 GT
5 GT
WISEWings In Surface Effect
HOVERCRAFT
Designed specifically for the tourist and transport industries the
Pioneer Mk3 hovercraft is amphibious and comfortably seats 25
passengers plus 1-crew The air-conditioned cabin allows for
maximum visibility for all aboard The Pioneer Mk3 is robust and
dynamic in its performance
Commercial hovercraft
Mk3 AirLift Hovercraft - 1215m
Power is economicaly provided by one Deutz diesel engine of
330kW (442hp) to cruise easily at 40 knots with much higher
speeds available according to the surface conditions The hull is
manufactured from fibreglassPVC foam composite sandwich
the windows are glass and the skirt is urethane coated nylon A
Military version is available with increased payload and systems
redundancy Power for the Military version comes from two Steyr
diesel engines with a total installed power of 320kW (429hp) All
transmission electrical hydraulic and air systems are duplicated
for maximum redundancy The increased performance of the
Military version comes from the reduced engine weight of the twin
Steyr installation cf the Deutz installation
Source
httpwwwnauticexpocomprodairlift-hovercraftcommercial-hovercrafts-25251-142868html
HOVERFLIGHT
BALLISTIC amp UNIT DEFENCED
Triaxis Composites Collaboration with Institute of Aeronautics and Space in the development of Missile Nose Cone
Polymer composites is the evolution of the military defence
Thin steel was the helmet material of
WWII and remained the principal material until around the 1980rsquos
The advantages of using steel
included a simple technology for manufacture of the helmets low cost and reasonably good
impact protection However these helmets were found to provide only marginal protection
against fragments
During the Vietnam War the US Army experimented with fiber-reinforced inserts in the
helmets These inserts improved ballistic protection but at the same time added weight and
reduced the air space between the head and the helmet
By the early part of the 1980rsquos the US military had developed the first all-composite
100 fiber-reinforced helmet This development resulted in even better ballistic protection
without altering the weight of the helmet Other improvements included better head coverage and
more space for ventilation
Source
Composites Armor - A difficult but huge market
by A Brent Strong Brigham Young University
MILITARY VEHICLES
HIGH SPEED TRAIN SHINKANSEN
Advanced Composites provide lightweight solutions for railway vehicles
saving as much as 50-80 of the weight compared with traditional
components
A lower overall weight translates into less stress faster acceleration and
higher speeds as well as reduced starting and stopping inertia Today
these are important criteria in global high-speed and metropolitan
railway projects
Fire smoke and toxic fumes are key safety criteria for interior
components of railway carriages Any material selected for an interior
component must meet international fire retardant standards
for Rail Interiors and Exteriors
Ceiling Panels Stairs
Seating Vestibules
Window Panels Door Pillars
Partition WallsDiffusers
Gangway and Cabinet Panels Cabin and
Desk panels
Door Pillars Lavatory Modules (standard and
Front and Rear EndsRoof Panels
Nose Cones Under Fairings
Source
httpwwwpctaerail_compositesphp
101
SKY BUS
2009
Europe is the world leader in offshore wind with
828 wind turbines and a cumulative capacity of 2056 MW spread across 38 offshore wind farms in 9
European countries
The UK and Denmark are the current leaders with a 44 and 30 share respectively In 2009
five countries built new offshore wind farms
UK (284 MW)
Demark (230 MW)
Sweden (30 MW)
Germany (30 MW)
Norway (23 MW)
2010
Asia leads the growth in global wind power which grew 358 GW in 2010 bringing
total global capacity to 1944 GW ndash up 225 from 2009
the Global Wind Energy Council (GWEC)
Asia accounted for 19 GW of new global wind power installations driven by China which installed 165
GW
ldquoChina now has 423 GW of wind powerrdquo
ldquoThis puts China firmly on a path to reach 200 GW of installed wind power by 2020 At the same
time China has become the worldrsquos largest producer of wind energy equipmentrdquo
Source
httpwwwreinforcedplasticscomview15655asia-leads-global-wind-power-growth
httpimgdeusmcomdesignnews288288605-Sandia_Sizes_up_Wind_Turbine_Blade_Design_C_largegif
WIND ENERGY
Marine Current Turbines
Source
httpwwwsiemenscompressenpressreleasepress=enpressrelease2011solar-hydroex201111005htm
httpwwwmarineturbinescom
A commercial marine current turbine consists of
two rotors which are fixed on a structure within the
sea current The twin rotors rotate with the
movement of the tidal flow and the blades pitch
through 180 degrees to optimally track tidal current
(Press picture Marine Current Turbines)
Wave Star Energys Multi-point Absorber
CFRP COLUMN REINFORCEMENT
INDUSTRIAL TANKS
107
INDUSTRIAL PIPES
PRESSURE TANKS
109
ldquoLetrsquos Make with Compositesrdquo
The mix of automotive materials is changing showing a boost for FRP in helping original
equipment manufacturers meet fuel economy and emissions challenges
(Source 2011 DuPont AutomotiveSAE survey of design engineers performed by Signet Research Inc)
Source
httpwwwtoraycomcsrhighlight2009hig_001_01html
The MonoCell tub for the McLaren MP4-12C supercar is moulded as a single
piece and weighs less than 80 kg (176 lbs)
COMPOSITES IN MARINE
TRIMARAN BOAT
AMERICA NAVYINDONESIAN NAVY
Visby Class corvette
Total length is 72 meters
The beam is 1040 meters
The displacement is 600 metric tones
fully equipped the worlds largest CRP
construction
The design of the Visby aims to minimize
the optical and infrared signature above
water acoustic and hydroa coustic
signature underwater electrical potential
and magnetic signature pressure signature
radar cross section and actively emitted
signals
A stealth corvette of the YS 2000 design
has a detection range of 13km in rough
seas and 22km in calm sea without
jamming In a jammed environment the
Visby would be detected at a range of 8km
in rough sea and 11km in calm sea
The material provides high strength and
rigidity low weight good shock resistance
low radar and magnetic signature
1996
Visby is a class of stealth corvettes for the Swedish Navy
ldquoReduced 50 of a Conventional Steelrdquo
Source
Hull Construction with composite materials for ships over 100m in length 2002
Massachusetts Institute of Technology
httpwwwnaval-technologycomprojectsvisby
YACHTS
KAL YUDISTIRAMARATHON 100 ADMIRAL YACHT
LOA 3050 MWidth 6 MFuel Tank 8000 LWater Tank 3000 LIce Box 500 LAccommodation Max 35 Personnel
2 x CATERPILLAR 3412E 1200 HPMARINE DIESEL ENGINE
PC 40 ndash KRI Krait 827Department of Indonesian Navy
LOA 40 MWidth 73 MPower 190Weapon Twin Cannon Barrels
127 mm Heavy Machine GunSpeed Knot 25 KnotDisplacement 105 tonAccommodation 23 personnel
PATROL BOAT
Rigid Inflatable BoatPATROL BOAT
Yachts
36m Luxury Yacht Moonraker
36m Luxury Yacht GoldenEye
50m Luxury Yacht Casino
Royale
45m Luxury Yacht Seashaw
Boat Parts
Barovans for Seismic Sweep
Centrifugal Liftfan House for Surface Effect
Ships
Composite Boat PropellersRTM
Deckhouses for Pilot Boats
Fairing Parts for Submarines
Flybridges for Motor yachts
Light Weight Gangway
MTB Launcher Mock-up
Pleasure Boats
12m Sailboat
12m Sail-Catamaranone-off
Canoes
Dragonfly 1000Catamaran Sailboat
Fantasy 37Sailboat
Farr 60Luxury Sailboat
EurodingyOlympic Dingy Class for
Woman
Hydrolift F23 Racing Boats
Kajacs
Najad 42Sailboat
Najad 520Sailboat
Najad 441Sailboat
Najad 391Sailboat
Nordwest 900Motorboat
Nordwest 1100Motorboat
Quatro 44Motorboat
Racemaster Competition Boats
Storebro 420
Storebro 345
Sweden Yacht 370Sailboat
Sweden Yacht 69Sailboat
Windy 41Motorboat
X-632Sailboat
X-362Sailboat
Commercial Boats
175m High Speed AmbulancePassenger Boat
19m High Speed Passenger Boat
20m High Speed Passenger Boat
364m Surface Effect Passenger Ship
45m Surface Effect Passenger Ship
120m Hull Structural Parts HSSS Catamaran Ferry
APPENDIX
Marine Vessel
1188m Fast Attack Vessel FMV 90 E
20m SAV-Surface Auxiliary Vessels
34m Personnel TransportCoast Guard Vessel
40ft Experimental SES
40m Landsort-Class Mine Hunters
54m Mine Counter Measure Vehicles SES
74m Coastal Patrol Boats
Fishing Boats
30 GT
12 GT
10 GT
5 GT
WISEWings In Surface Effect
HOVERCRAFT
Designed specifically for the tourist and transport industries the
Pioneer Mk3 hovercraft is amphibious and comfortably seats 25
passengers plus 1-crew The air-conditioned cabin allows for
maximum visibility for all aboard The Pioneer Mk3 is robust and
dynamic in its performance
Commercial hovercraft
Mk3 AirLift Hovercraft - 1215m
Power is economicaly provided by one Deutz diesel engine of
330kW (442hp) to cruise easily at 40 knots with much higher
speeds available according to the surface conditions The hull is
manufactured from fibreglassPVC foam composite sandwich
the windows are glass and the skirt is urethane coated nylon A
Military version is available with increased payload and systems
redundancy Power for the Military version comes from two Steyr
diesel engines with a total installed power of 320kW (429hp) All
transmission electrical hydraulic and air systems are duplicated
for maximum redundancy The increased performance of the
Military version comes from the reduced engine weight of the twin
Steyr installation cf the Deutz installation
Source
httpwwwnauticexpocomprodairlift-hovercraftcommercial-hovercrafts-25251-142868html
HOVERFLIGHT
BALLISTIC amp UNIT DEFENCED
Triaxis Composites Collaboration with Institute of Aeronautics and Space in the development of Missile Nose Cone
Polymer composites is the evolution of the military defence
Thin steel was the helmet material of
WWII and remained the principal material until around the 1980rsquos
The advantages of using steel
included a simple technology for manufacture of the helmets low cost and reasonably good
impact protection However these helmets were found to provide only marginal protection
against fragments
During the Vietnam War the US Army experimented with fiber-reinforced inserts in the
helmets These inserts improved ballistic protection but at the same time added weight and
reduced the air space between the head and the helmet
By the early part of the 1980rsquos the US military had developed the first all-composite
100 fiber-reinforced helmet This development resulted in even better ballistic protection
without altering the weight of the helmet Other improvements included better head coverage and
more space for ventilation
Source
Composites Armor - A difficult but huge market
by A Brent Strong Brigham Young University
MILITARY VEHICLES
HIGH SPEED TRAIN SHINKANSEN
Advanced Composites provide lightweight solutions for railway vehicles
saving as much as 50-80 of the weight compared with traditional
components
A lower overall weight translates into less stress faster acceleration and
higher speeds as well as reduced starting and stopping inertia Today
these are important criteria in global high-speed and metropolitan
railway projects
Fire smoke and toxic fumes are key safety criteria for interior
components of railway carriages Any material selected for an interior
component must meet international fire retardant standards
for Rail Interiors and Exteriors
Ceiling Panels Stairs
Seating Vestibules
Window Panels Door Pillars
Partition WallsDiffusers
Gangway and Cabinet Panels Cabin and
Desk panels
Door Pillars Lavatory Modules (standard and
Front and Rear EndsRoof Panels
Nose Cones Under Fairings
Source
httpwwwpctaerail_compositesphp
101
SKY BUS
2009
Europe is the world leader in offshore wind with
828 wind turbines and a cumulative capacity of 2056 MW spread across 38 offshore wind farms in 9
European countries
The UK and Denmark are the current leaders with a 44 and 30 share respectively In 2009
five countries built new offshore wind farms
UK (284 MW)
Demark (230 MW)
Sweden (30 MW)
Germany (30 MW)
Norway (23 MW)
2010
Asia leads the growth in global wind power which grew 358 GW in 2010 bringing
total global capacity to 1944 GW ndash up 225 from 2009
the Global Wind Energy Council (GWEC)
Asia accounted for 19 GW of new global wind power installations driven by China which installed 165
GW
ldquoChina now has 423 GW of wind powerrdquo
ldquoThis puts China firmly on a path to reach 200 GW of installed wind power by 2020 At the same
time China has become the worldrsquos largest producer of wind energy equipmentrdquo
Source
httpwwwreinforcedplasticscomview15655asia-leads-global-wind-power-growth
httpimgdeusmcomdesignnews288288605-Sandia_Sizes_up_Wind_Turbine_Blade_Design_C_largegif
WIND ENERGY
Marine Current Turbines
Source
httpwwwsiemenscompressenpressreleasepress=enpressrelease2011solar-hydroex201111005htm
httpwwwmarineturbinescom
A commercial marine current turbine consists of
two rotors which are fixed on a structure within the
sea current The twin rotors rotate with the
movement of the tidal flow and the blades pitch
through 180 degrees to optimally track tidal current
(Press picture Marine Current Turbines)
Wave Star Energys Multi-point Absorber
CFRP COLUMN REINFORCEMENT
INDUSTRIAL TANKS
107
INDUSTRIAL PIPES
PRESSURE TANKS
109
ldquoLetrsquos Make with Compositesrdquo
Source
httpwwwtoraycomcsrhighlight2009hig_001_01html
The MonoCell tub for the McLaren MP4-12C supercar is moulded as a single
piece and weighs less than 80 kg (176 lbs)
COMPOSITES IN MARINE
TRIMARAN BOAT
AMERICA NAVYINDONESIAN NAVY
Visby Class corvette
Total length is 72 meters
The beam is 1040 meters
The displacement is 600 metric tones
fully equipped the worlds largest CRP
construction
The design of the Visby aims to minimize
the optical and infrared signature above
water acoustic and hydroa coustic
signature underwater electrical potential
and magnetic signature pressure signature
radar cross section and actively emitted
signals
A stealth corvette of the YS 2000 design
has a detection range of 13km in rough
seas and 22km in calm sea without
jamming In a jammed environment the
Visby would be detected at a range of 8km
in rough sea and 11km in calm sea
The material provides high strength and
rigidity low weight good shock resistance
low radar and magnetic signature
1996
Visby is a class of stealth corvettes for the Swedish Navy
ldquoReduced 50 of a Conventional Steelrdquo
Source
Hull Construction with composite materials for ships over 100m in length 2002
Massachusetts Institute of Technology
httpwwwnaval-technologycomprojectsvisby
YACHTS
KAL YUDISTIRAMARATHON 100 ADMIRAL YACHT
LOA 3050 MWidth 6 MFuel Tank 8000 LWater Tank 3000 LIce Box 500 LAccommodation Max 35 Personnel
2 x CATERPILLAR 3412E 1200 HPMARINE DIESEL ENGINE
PC 40 ndash KRI Krait 827Department of Indonesian Navy
LOA 40 MWidth 73 MPower 190Weapon Twin Cannon Barrels
127 mm Heavy Machine GunSpeed Knot 25 KnotDisplacement 105 tonAccommodation 23 personnel
PATROL BOAT
Rigid Inflatable BoatPATROL BOAT
Yachts
36m Luxury Yacht Moonraker
36m Luxury Yacht GoldenEye
50m Luxury Yacht Casino
Royale
45m Luxury Yacht Seashaw
Boat Parts
Barovans for Seismic Sweep
Centrifugal Liftfan House for Surface Effect
Ships
Composite Boat PropellersRTM
Deckhouses for Pilot Boats
Fairing Parts for Submarines
Flybridges for Motor yachts
Light Weight Gangway
MTB Launcher Mock-up
Pleasure Boats
12m Sailboat
12m Sail-Catamaranone-off
Canoes
Dragonfly 1000Catamaran Sailboat
Fantasy 37Sailboat
Farr 60Luxury Sailboat
EurodingyOlympic Dingy Class for
Woman
Hydrolift F23 Racing Boats
Kajacs
Najad 42Sailboat
Najad 520Sailboat
Najad 441Sailboat
Najad 391Sailboat
Nordwest 900Motorboat
Nordwest 1100Motorboat
Quatro 44Motorboat
Racemaster Competition Boats
Storebro 420
Storebro 345
Sweden Yacht 370Sailboat
Sweden Yacht 69Sailboat
Windy 41Motorboat
X-632Sailboat
X-362Sailboat
Commercial Boats
175m High Speed AmbulancePassenger Boat
19m High Speed Passenger Boat
20m High Speed Passenger Boat
364m Surface Effect Passenger Ship
45m Surface Effect Passenger Ship
120m Hull Structural Parts HSSS Catamaran Ferry
APPENDIX
Marine Vessel
1188m Fast Attack Vessel FMV 90 E
20m SAV-Surface Auxiliary Vessels
34m Personnel TransportCoast Guard Vessel
40ft Experimental SES
40m Landsort-Class Mine Hunters
54m Mine Counter Measure Vehicles SES
74m Coastal Patrol Boats
Fishing Boats
30 GT
12 GT
10 GT
5 GT
WISEWings In Surface Effect
HOVERCRAFT
Designed specifically for the tourist and transport industries the
Pioneer Mk3 hovercraft is amphibious and comfortably seats 25
passengers plus 1-crew The air-conditioned cabin allows for
maximum visibility for all aboard The Pioneer Mk3 is robust and
dynamic in its performance
Commercial hovercraft
Mk3 AirLift Hovercraft - 1215m
Power is economicaly provided by one Deutz diesel engine of
330kW (442hp) to cruise easily at 40 knots with much higher
speeds available according to the surface conditions The hull is
manufactured from fibreglassPVC foam composite sandwich
the windows are glass and the skirt is urethane coated nylon A
Military version is available with increased payload and systems
redundancy Power for the Military version comes from two Steyr
diesel engines with a total installed power of 320kW (429hp) All
transmission electrical hydraulic and air systems are duplicated
for maximum redundancy The increased performance of the
Military version comes from the reduced engine weight of the twin
Steyr installation cf the Deutz installation
Source
httpwwwnauticexpocomprodairlift-hovercraftcommercial-hovercrafts-25251-142868html
HOVERFLIGHT
BALLISTIC amp UNIT DEFENCED
Triaxis Composites Collaboration with Institute of Aeronautics and Space in the development of Missile Nose Cone
Polymer composites is the evolution of the military defence
Thin steel was the helmet material of
WWII and remained the principal material until around the 1980rsquos
The advantages of using steel
included a simple technology for manufacture of the helmets low cost and reasonably good
impact protection However these helmets were found to provide only marginal protection
against fragments
During the Vietnam War the US Army experimented with fiber-reinforced inserts in the
helmets These inserts improved ballistic protection but at the same time added weight and
reduced the air space between the head and the helmet
By the early part of the 1980rsquos the US military had developed the first all-composite
100 fiber-reinforced helmet This development resulted in even better ballistic protection
without altering the weight of the helmet Other improvements included better head coverage and
more space for ventilation
Source
Composites Armor - A difficult but huge market
by A Brent Strong Brigham Young University
MILITARY VEHICLES
HIGH SPEED TRAIN SHINKANSEN
Advanced Composites provide lightweight solutions for railway vehicles
saving as much as 50-80 of the weight compared with traditional
components
A lower overall weight translates into less stress faster acceleration and
higher speeds as well as reduced starting and stopping inertia Today
these are important criteria in global high-speed and metropolitan
railway projects
Fire smoke and toxic fumes are key safety criteria for interior
components of railway carriages Any material selected for an interior
component must meet international fire retardant standards
for Rail Interiors and Exteriors
Ceiling Panels Stairs
Seating Vestibules
Window Panels Door Pillars
Partition WallsDiffusers
Gangway and Cabinet Panels Cabin and
Desk panels
Door Pillars Lavatory Modules (standard and
Front and Rear EndsRoof Panels
Nose Cones Under Fairings
Source
httpwwwpctaerail_compositesphp
101
SKY BUS
2009
Europe is the world leader in offshore wind with
828 wind turbines and a cumulative capacity of 2056 MW spread across 38 offshore wind farms in 9
European countries
The UK and Denmark are the current leaders with a 44 and 30 share respectively In 2009
five countries built new offshore wind farms
UK (284 MW)
Demark (230 MW)
Sweden (30 MW)
Germany (30 MW)
Norway (23 MW)
2010
Asia leads the growth in global wind power which grew 358 GW in 2010 bringing
total global capacity to 1944 GW ndash up 225 from 2009
the Global Wind Energy Council (GWEC)
Asia accounted for 19 GW of new global wind power installations driven by China which installed 165
GW
ldquoChina now has 423 GW of wind powerrdquo
ldquoThis puts China firmly on a path to reach 200 GW of installed wind power by 2020 At the same
time China has become the worldrsquos largest producer of wind energy equipmentrdquo
Source
httpwwwreinforcedplasticscomview15655asia-leads-global-wind-power-growth
httpimgdeusmcomdesignnews288288605-Sandia_Sizes_up_Wind_Turbine_Blade_Design_C_largegif
WIND ENERGY
Marine Current Turbines
Source
httpwwwsiemenscompressenpressreleasepress=enpressrelease2011solar-hydroex201111005htm
httpwwwmarineturbinescom
A commercial marine current turbine consists of
two rotors which are fixed on a structure within the
sea current The twin rotors rotate with the
movement of the tidal flow and the blades pitch
through 180 degrees to optimally track tidal current
(Press picture Marine Current Turbines)
Wave Star Energys Multi-point Absorber
CFRP COLUMN REINFORCEMENT
INDUSTRIAL TANKS
107
INDUSTRIAL PIPES
PRESSURE TANKS
109
ldquoLetrsquos Make with Compositesrdquo
The MonoCell tub for the McLaren MP4-12C supercar is moulded as a single
piece and weighs less than 80 kg (176 lbs)
COMPOSITES IN MARINE
TRIMARAN BOAT
AMERICA NAVYINDONESIAN NAVY
Visby Class corvette
Total length is 72 meters
The beam is 1040 meters
The displacement is 600 metric tones
fully equipped the worlds largest CRP
construction
The design of the Visby aims to minimize
the optical and infrared signature above
water acoustic and hydroa coustic
signature underwater electrical potential
and magnetic signature pressure signature
radar cross section and actively emitted
signals
A stealth corvette of the YS 2000 design
has a detection range of 13km in rough
seas and 22km in calm sea without
jamming In a jammed environment the
Visby would be detected at a range of 8km
in rough sea and 11km in calm sea
The material provides high strength and
rigidity low weight good shock resistance
low radar and magnetic signature
1996
Visby is a class of stealth corvettes for the Swedish Navy
ldquoReduced 50 of a Conventional Steelrdquo
Source
Hull Construction with composite materials for ships over 100m in length 2002
Massachusetts Institute of Technology
httpwwwnaval-technologycomprojectsvisby
YACHTS
KAL YUDISTIRAMARATHON 100 ADMIRAL YACHT
LOA 3050 MWidth 6 MFuel Tank 8000 LWater Tank 3000 LIce Box 500 LAccommodation Max 35 Personnel
2 x CATERPILLAR 3412E 1200 HPMARINE DIESEL ENGINE
PC 40 ndash KRI Krait 827Department of Indonesian Navy
LOA 40 MWidth 73 MPower 190Weapon Twin Cannon Barrels
127 mm Heavy Machine GunSpeed Knot 25 KnotDisplacement 105 tonAccommodation 23 personnel
PATROL BOAT
Rigid Inflatable BoatPATROL BOAT
Yachts
36m Luxury Yacht Moonraker
36m Luxury Yacht GoldenEye
50m Luxury Yacht Casino
Royale
45m Luxury Yacht Seashaw
Boat Parts
Barovans for Seismic Sweep
Centrifugal Liftfan House for Surface Effect
Ships
Composite Boat PropellersRTM
Deckhouses for Pilot Boats
Fairing Parts for Submarines
Flybridges for Motor yachts
Light Weight Gangway
MTB Launcher Mock-up
Pleasure Boats
12m Sailboat
12m Sail-Catamaranone-off
Canoes
Dragonfly 1000Catamaran Sailboat
Fantasy 37Sailboat
Farr 60Luxury Sailboat
EurodingyOlympic Dingy Class for
Woman
Hydrolift F23 Racing Boats
Kajacs
Najad 42Sailboat
Najad 520Sailboat
Najad 441Sailboat
Najad 391Sailboat
Nordwest 900Motorboat
Nordwest 1100Motorboat
Quatro 44Motorboat
Racemaster Competition Boats
Storebro 420
Storebro 345
Sweden Yacht 370Sailboat
Sweden Yacht 69Sailboat
Windy 41Motorboat
X-632Sailboat
X-362Sailboat
Commercial Boats
175m High Speed AmbulancePassenger Boat
19m High Speed Passenger Boat
20m High Speed Passenger Boat
364m Surface Effect Passenger Ship
45m Surface Effect Passenger Ship
120m Hull Structural Parts HSSS Catamaran Ferry
APPENDIX
Marine Vessel
1188m Fast Attack Vessel FMV 90 E
20m SAV-Surface Auxiliary Vessels
34m Personnel TransportCoast Guard Vessel
40ft Experimental SES
40m Landsort-Class Mine Hunters
54m Mine Counter Measure Vehicles SES
74m Coastal Patrol Boats
Fishing Boats
30 GT
12 GT
10 GT
5 GT
WISEWings In Surface Effect
HOVERCRAFT
Designed specifically for the tourist and transport industries the
Pioneer Mk3 hovercraft is amphibious and comfortably seats 25
passengers plus 1-crew The air-conditioned cabin allows for
maximum visibility for all aboard The Pioneer Mk3 is robust and
dynamic in its performance
Commercial hovercraft
Mk3 AirLift Hovercraft - 1215m
Power is economicaly provided by one Deutz diesel engine of
330kW (442hp) to cruise easily at 40 knots with much higher
speeds available according to the surface conditions The hull is
manufactured from fibreglassPVC foam composite sandwich
the windows are glass and the skirt is urethane coated nylon A
Military version is available with increased payload and systems
redundancy Power for the Military version comes from two Steyr
diesel engines with a total installed power of 320kW (429hp) All
transmission electrical hydraulic and air systems are duplicated
for maximum redundancy The increased performance of the
Military version comes from the reduced engine weight of the twin
Steyr installation cf the Deutz installation
Source
httpwwwnauticexpocomprodairlift-hovercraftcommercial-hovercrafts-25251-142868html
HOVERFLIGHT
BALLISTIC amp UNIT DEFENCED
Triaxis Composites Collaboration with Institute of Aeronautics and Space in the development of Missile Nose Cone
Polymer composites is the evolution of the military defence
Thin steel was the helmet material of
WWII and remained the principal material until around the 1980rsquos
The advantages of using steel
included a simple technology for manufacture of the helmets low cost and reasonably good
impact protection However these helmets were found to provide only marginal protection
against fragments
During the Vietnam War the US Army experimented with fiber-reinforced inserts in the
helmets These inserts improved ballistic protection but at the same time added weight and
reduced the air space between the head and the helmet
By the early part of the 1980rsquos the US military had developed the first all-composite
100 fiber-reinforced helmet This development resulted in even better ballistic protection
without altering the weight of the helmet Other improvements included better head coverage and
more space for ventilation
Source
Composites Armor - A difficult but huge market
by A Brent Strong Brigham Young University
MILITARY VEHICLES
HIGH SPEED TRAIN SHINKANSEN
Advanced Composites provide lightweight solutions for railway vehicles
saving as much as 50-80 of the weight compared with traditional
components
A lower overall weight translates into less stress faster acceleration and
higher speeds as well as reduced starting and stopping inertia Today
these are important criteria in global high-speed and metropolitan
railway projects
Fire smoke and toxic fumes are key safety criteria for interior
components of railway carriages Any material selected for an interior
component must meet international fire retardant standards
for Rail Interiors and Exteriors
Ceiling Panels Stairs
Seating Vestibules
Window Panels Door Pillars
Partition WallsDiffusers
Gangway and Cabinet Panels Cabin and
Desk panels
Door Pillars Lavatory Modules (standard and
Front and Rear EndsRoof Panels
Nose Cones Under Fairings
Source
httpwwwpctaerail_compositesphp
101
SKY BUS
2009
Europe is the world leader in offshore wind with
828 wind turbines and a cumulative capacity of 2056 MW spread across 38 offshore wind farms in 9
European countries
The UK and Denmark are the current leaders with a 44 and 30 share respectively In 2009
five countries built new offshore wind farms
UK (284 MW)
Demark (230 MW)
Sweden (30 MW)
Germany (30 MW)
Norway (23 MW)
2010
Asia leads the growth in global wind power which grew 358 GW in 2010 bringing
total global capacity to 1944 GW ndash up 225 from 2009
the Global Wind Energy Council (GWEC)
Asia accounted for 19 GW of new global wind power installations driven by China which installed 165
GW
ldquoChina now has 423 GW of wind powerrdquo
ldquoThis puts China firmly on a path to reach 200 GW of installed wind power by 2020 At the same
time China has become the worldrsquos largest producer of wind energy equipmentrdquo
Source
httpwwwreinforcedplasticscomview15655asia-leads-global-wind-power-growth
httpimgdeusmcomdesignnews288288605-Sandia_Sizes_up_Wind_Turbine_Blade_Design_C_largegif
WIND ENERGY
Marine Current Turbines
Source
httpwwwsiemenscompressenpressreleasepress=enpressrelease2011solar-hydroex201111005htm
httpwwwmarineturbinescom
A commercial marine current turbine consists of
two rotors which are fixed on a structure within the
sea current The twin rotors rotate with the
movement of the tidal flow and the blades pitch
through 180 degrees to optimally track tidal current
(Press picture Marine Current Turbines)
Wave Star Energys Multi-point Absorber
CFRP COLUMN REINFORCEMENT
INDUSTRIAL TANKS
107
INDUSTRIAL PIPES
PRESSURE TANKS
109
ldquoLetrsquos Make with Compositesrdquo
COMPOSITES IN MARINE
TRIMARAN BOAT
AMERICA NAVYINDONESIAN NAVY
Visby Class corvette
Total length is 72 meters
The beam is 1040 meters
The displacement is 600 metric tones
fully equipped the worlds largest CRP
construction
The design of the Visby aims to minimize
the optical and infrared signature above
water acoustic and hydroa coustic
signature underwater electrical potential
and magnetic signature pressure signature
radar cross section and actively emitted
signals
A stealth corvette of the YS 2000 design
has a detection range of 13km in rough
seas and 22km in calm sea without
jamming In a jammed environment the
Visby would be detected at a range of 8km
in rough sea and 11km in calm sea
The material provides high strength and
rigidity low weight good shock resistance
low radar and magnetic signature
1996
Visby is a class of stealth corvettes for the Swedish Navy
ldquoReduced 50 of a Conventional Steelrdquo
Source
Hull Construction with composite materials for ships over 100m in length 2002
Massachusetts Institute of Technology
httpwwwnaval-technologycomprojectsvisby
YACHTS
KAL YUDISTIRAMARATHON 100 ADMIRAL YACHT
LOA 3050 MWidth 6 MFuel Tank 8000 LWater Tank 3000 LIce Box 500 LAccommodation Max 35 Personnel
2 x CATERPILLAR 3412E 1200 HPMARINE DIESEL ENGINE
PC 40 ndash KRI Krait 827Department of Indonesian Navy
LOA 40 MWidth 73 MPower 190Weapon Twin Cannon Barrels
127 mm Heavy Machine GunSpeed Knot 25 KnotDisplacement 105 tonAccommodation 23 personnel
PATROL BOAT
Rigid Inflatable BoatPATROL BOAT
Yachts
36m Luxury Yacht Moonraker
36m Luxury Yacht GoldenEye
50m Luxury Yacht Casino
Royale
45m Luxury Yacht Seashaw
Boat Parts
Barovans for Seismic Sweep
Centrifugal Liftfan House for Surface Effect
Ships
Composite Boat PropellersRTM
Deckhouses for Pilot Boats
Fairing Parts for Submarines
Flybridges for Motor yachts
Light Weight Gangway
MTB Launcher Mock-up
Pleasure Boats
12m Sailboat
12m Sail-Catamaranone-off
Canoes
Dragonfly 1000Catamaran Sailboat
Fantasy 37Sailboat
Farr 60Luxury Sailboat
EurodingyOlympic Dingy Class for
Woman
Hydrolift F23 Racing Boats
Kajacs
Najad 42Sailboat
Najad 520Sailboat
Najad 441Sailboat
Najad 391Sailboat
Nordwest 900Motorboat
Nordwest 1100Motorboat
Quatro 44Motorboat
Racemaster Competition Boats
Storebro 420
Storebro 345
Sweden Yacht 370Sailboat
Sweden Yacht 69Sailboat
Windy 41Motorboat
X-632Sailboat
X-362Sailboat
Commercial Boats
175m High Speed AmbulancePassenger Boat
19m High Speed Passenger Boat
20m High Speed Passenger Boat
364m Surface Effect Passenger Ship
45m Surface Effect Passenger Ship
120m Hull Structural Parts HSSS Catamaran Ferry
APPENDIX
Marine Vessel
1188m Fast Attack Vessel FMV 90 E
20m SAV-Surface Auxiliary Vessels
34m Personnel TransportCoast Guard Vessel
40ft Experimental SES
40m Landsort-Class Mine Hunters
54m Mine Counter Measure Vehicles SES
74m Coastal Patrol Boats
Fishing Boats
30 GT
12 GT
10 GT
5 GT
WISEWings In Surface Effect
HOVERCRAFT
Designed specifically for the tourist and transport industries the
Pioneer Mk3 hovercraft is amphibious and comfortably seats 25
passengers plus 1-crew The air-conditioned cabin allows for
maximum visibility for all aboard The Pioneer Mk3 is robust and
dynamic in its performance
Commercial hovercraft
Mk3 AirLift Hovercraft - 1215m
Power is economicaly provided by one Deutz diesel engine of
330kW (442hp) to cruise easily at 40 knots with much higher
speeds available according to the surface conditions The hull is
manufactured from fibreglassPVC foam composite sandwich
the windows are glass and the skirt is urethane coated nylon A
Military version is available with increased payload and systems
redundancy Power for the Military version comes from two Steyr
diesel engines with a total installed power of 320kW (429hp) All
transmission electrical hydraulic and air systems are duplicated
for maximum redundancy The increased performance of the
Military version comes from the reduced engine weight of the twin
Steyr installation cf the Deutz installation
Source
httpwwwnauticexpocomprodairlift-hovercraftcommercial-hovercrafts-25251-142868html
HOVERFLIGHT
BALLISTIC amp UNIT DEFENCED
Triaxis Composites Collaboration with Institute of Aeronautics and Space in the development of Missile Nose Cone
Polymer composites is the evolution of the military defence
Thin steel was the helmet material of
WWII and remained the principal material until around the 1980rsquos
The advantages of using steel
included a simple technology for manufacture of the helmets low cost and reasonably good
impact protection However these helmets were found to provide only marginal protection
against fragments
During the Vietnam War the US Army experimented with fiber-reinforced inserts in the
helmets These inserts improved ballistic protection but at the same time added weight and
reduced the air space between the head and the helmet
By the early part of the 1980rsquos the US military had developed the first all-composite
100 fiber-reinforced helmet This development resulted in even better ballistic protection
without altering the weight of the helmet Other improvements included better head coverage and
more space for ventilation
Source
Composites Armor - A difficult but huge market
by A Brent Strong Brigham Young University
MILITARY VEHICLES
HIGH SPEED TRAIN SHINKANSEN
Advanced Composites provide lightweight solutions for railway vehicles
saving as much as 50-80 of the weight compared with traditional
components
A lower overall weight translates into less stress faster acceleration and
higher speeds as well as reduced starting and stopping inertia Today
these are important criteria in global high-speed and metropolitan
railway projects
Fire smoke and toxic fumes are key safety criteria for interior
components of railway carriages Any material selected for an interior
component must meet international fire retardant standards
for Rail Interiors and Exteriors
Ceiling Panels Stairs
Seating Vestibules
Window Panels Door Pillars
Partition WallsDiffusers
Gangway and Cabinet Panels Cabin and
Desk panels
Door Pillars Lavatory Modules (standard and
Front and Rear EndsRoof Panels
Nose Cones Under Fairings
Source
httpwwwpctaerail_compositesphp
101
SKY BUS
2009
Europe is the world leader in offshore wind with
828 wind turbines and a cumulative capacity of 2056 MW spread across 38 offshore wind farms in 9
European countries
The UK and Denmark are the current leaders with a 44 and 30 share respectively In 2009
five countries built new offshore wind farms
UK (284 MW)
Demark (230 MW)
Sweden (30 MW)
Germany (30 MW)
Norway (23 MW)
2010
Asia leads the growth in global wind power which grew 358 GW in 2010 bringing
total global capacity to 1944 GW ndash up 225 from 2009
the Global Wind Energy Council (GWEC)
Asia accounted for 19 GW of new global wind power installations driven by China which installed 165
GW
ldquoChina now has 423 GW of wind powerrdquo
ldquoThis puts China firmly on a path to reach 200 GW of installed wind power by 2020 At the same
time China has become the worldrsquos largest producer of wind energy equipmentrdquo
Source
httpwwwreinforcedplasticscomview15655asia-leads-global-wind-power-growth
httpimgdeusmcomdesignnews288288605-Sandia_Sizes_up_Wind_Turbine_Blade_Design_C_largegif
WIND ENERGY
Marine Current Turbines
Source
httpwwwsiemenscompressenpressreleasepress=enpressrelease2011solar-hydroex201111005htm
httpwwwmarineturbinescom
A commercial marine current turbine consists of
two rotors which are fixed on a structure within the
sea current The twin rotors rotate with the
movement of the tidal flow and the blades pitch
through 180 degrees to optimally track tidal current
(Press picture Marine Current Turbines)
Wave Star Energys Multi-point Absorber
CFRP COLUMN REINFORCEMENT
INDUSTRIAL TANKS
107
INDUSTRIAL PIPES
PRESSURE TANKS
109
ldquoLetrsquos Make with Compositesrdquo
TRIMARAN BOAT
AMERICA NAVYINDONESIAN NAVY
Visby Class corvette
Total length is 72 meters
The beam is 1040 meters
The displacement is 600 metric tones
fully equipped the worlds largest CRP
construction
The design of the Visby aims to minimize
the optical and infrared signature above
water acoustic and hydroa coustic
signature underwater electrical potential
and magnetic signature pressure signature
radar cross section and actively emitted
signals
A stealth corvette of the YS 2000 design
has a detection range of 13km in rough
seas and 22km in calm sea without
jamming In a jammed environment the
Visby would be detected at a range of 8km
in rough sea and 11km in calm sea
The material provides high strength and
rigidity low weight good shock resistance
low radar and magnetic signature
1996
Visby is a class of stealth corvettes for the Swedish Navy
ldquoReduced 50 of a Conventional Steelrdquo
Source
Hull Construction with composite materials for ships over 100m in length 2002
Massachusetts Institute of Technology
httpwwwnaval-technologycomprojectsvisby
YACHTS
KAL YUDISTIRAMARATHON 100 ADMIRAL YACHT
LOA 3050 MWidth 6 MFuel Tank 8000 LWater Tank 3000 LIce Box 500 LAccommodation Max 35 Personnel
2 x CATERPILLAR 3412E 1200 HPMARINE DIESEL ENGINE
PC 40 ndash KRI Krait 827Department of Indonesian Navy
LOA 40 MWidth 73 MPower 190Weapon Twin Cannon Barrels
127 mm Heavy Machine GunSpeed Knot 25 KnotDisplacement 105 tonAccommodation 23 personnel
PATROL BOAT
Rigid Inflatable BoatPATROL BOAT
Yachts
36m Luxury Yacht Moonraker
36m Luxury Yacht GoldenEye
50m Luxury Yacht Casino
Royale
45m Luxury Yacht Seashaw
Boat Parts
Barovans for Seismic Sweep
Centrifugal Liftfan House for Surface Effect
Ships
Composite Boat PropellersRTM
Deckhouses for Pilot Boats
Fairing Parts for Submarines
Flybridges for Motor yachts
Light Weight Gangway
MTB Launcher Mock-up
Pleasure Boats
12m Sailboat
12m Sail-Catamaranone-off
Canoes
Dragonfly 1000Catamaran Sailboat
Fantasy 37Sailboat
Farr 60Luxury Sailboat
EurodingyOlympic Dingy Class for
Woman
Hydrolift F23 Racing Boats
Kajacs
Najad 42Sailboat
Najad 520Sailboat
Najad 441Sailboat
Najad 391Sailboat
Nordwest 900Motorboat
Nordwest 1100Motorboat
Quatro 44Motorboat
Racemaster Competition Boats
Storebro 420
Storebro 345
Sweden Yacht 370Sailboat
Sweden Yacht 69Sailboat
Windy 41Motorboat
X-632Sailboat
X-362Sailboat
Commercial Boats
175m High Speed AmbulancePassenger Boat
19m High Speed Passenger Boat
20m High Speed Passenger Boat
364m Surface Effect Passenger Ship
45m Surface Effect Passenger Ship
120m Hull Structural Parts HSSS Catamaran Ferry
APPENDIX
Marine Vessel
1188m Fast Attack Vessel FMV 90 E
20m SAV-Surface Auxiliary Vessels
34m Personnel TransportCoast Guard Vessel
40ft Experimental SES
40m Landsort-Class Mine Hunters
54m Mine Counter Measure Vehicles SES
74m Coastal Patrol Boats
Fishing Boats
30 GT
12 GT
10 GT
5 GT
WISEWings In Surface Effect
HOVERCRAFT
Designed specifically for the tourist and transport industries the
Pioneer Mk3 hovercraft is amphibious and comfortably seats 25
passengers plus 1-crew The air-conditioned cabin allows for
maximum visibility for all aboard The Pioneer Mk3 is robust and
dynamic in its performance
Commercial hovercraft
Mk3 AirLift Hovercraft - 1215m
Power is economicaly provided by one Deutz diesel engine of
330kW (442hp) to cruise easily at 40 knots with much higher
speeds available according to the surface conditions The hull is
manufactured from fibreglassPVC foam composite sandwich
the windows are glass and the skirt is urethane coated nylon A
Military version is available with increased payload and systems
redundancy Power for the Military version comes from two Steyr
diesel engines with a total installed power of 320kW (429hp) All
transmission electrical hydraulic and air systems are duplicated
for maximum redundancy The increased performance of the
Military version comes from the reduced engine weight of the twin
Steyr installation cf the Deutz installation
Source
httpwwwnauticexpocomprodairlift-hovercraftcommercial-hovercrafts-25251-142868html
HOVERFLIGHT
BALLISTIC amp UNIT DEFENCED
Triaxis Composites Collaboration with Institute of Aeronautics and Space in the development of Missile Nose Cone
Polymer composites is the evolution of the military defence
Thin steel was the helmet material of
WWII and remained the principal material until around the 1980rsquos
The advantages of using steel
included a simple technology for manufacture of the helmets low cost and reasonably good
impact protection However these helmets were found to provide only marginal protection
against fragments
During the Vietnam War the US Army experimented with fiber-reinforced inserts in the
helmets These inserts improved ballistic protection but at the same time added weight and
reduced the air space between the head and the helmet
By the early part of the 1980rsquos the US military had developed the first all-composite
100 fiber-reinforced helmet This development resulted in even better ballistic protection
without altering the weight of the helmet Other improvements included better head coverage and
more space for ventilation
Source
Composites Armor - A difficult but huge market
by A Brent Strong Brigham Young University
MILITARY VEHICLES
HIGH SPEED TRAIN SHINKANSEN
Advanced Composites provide lightweight solutions for railway vehicles
saving as much as 50-80 of the weight compared with traditional
components
A lower overall weight translates into less stress faster acceleration and
higher speeds as well as reduced starting and stopping inertia Today
these are important criteria in global high-speed and metropolitan
railway projects
Fire smoke and toxic fumes are key safety criteria for interior
components of railway carriages Any material selected for an interior
component must meet international fire retardant standards
for Rail Interiors and Exteriors
Ceiling Panels Stairs
Seating Vestibules
Window Panels Door Pillars
Partition WallsDiffusers
Gangway and Cabinet Panels Cabin and
Desk panels
Door Pillars Lavatory Modules (standard and
Front and Rear EndsRoof Panels
Nose Cones Under Fairings
Source
httpwwwpctaerail_compositesphp
101
SKY BUS
2009
Europe is the world leader in offshore wind with
828 wind turbines and a cumulative capacity of 2056 MW spread across 38 offshore wind farms in 9
European countries
The UK and Denmark are the current leaders with a 44 and 30 share respectively In 2009
five countries built new offshore wind farms
UK (284 MW)
Demark (230 MW)
Sweden (30 MW)
Germany (30 MW)
Norway (23 MW)
2010
Asia leads the growth in global wind power which grew 358 GW in 2010 bringing
total global capacity to 1944 GW ndash up 225 from 2009
the Global Wind Energy Council (GWEC)
Asia accounted for 19 GW of new global wind power installations driven by China which installed 165
GW
ldquoChina now has 423 GW of wind powerrdquo
ldquoThis puts China firmly on a path to reach 200 GW of installed wind power by 2020 At the same
time China has become the worldrsquos largest producer of wind energy equipmentrdquo
Source
httpwwwreinforcedplasticscomview15655asia-leads-global-wind-power-growth
httpimgdeusmcomdesignnews288288605-Sandia_Sizes_up_Wind_Turbine_Blade_Design_C_largegif
WIND ENERGY
Marine Current Turbines
Source
httpwwwsiemenscompressenpressreleasepress=enpressrelease2011solar-hydroex201111005htm
httpwwwmarineturbinescom
A commercial marine current turbine consists of
two rotors which are fixed on a structure within the
sea current The twin rotors rotate with the
movement of the tidal flow and the blades pitch
through 180 degrees to optimally track tidal current
(Press picture Marine Current Turbines)
Wave Star Energys Multi-point Absorber
CFRP COLUMN REINFORCEMENT
INDUSTRIAL TANKS
107
INDUSTRIAL PIPES
PRESSURE TANKS
109
ldquoLetrsquos Make with Compositesrdquo
Visby Class corvette
Total length is 72 meters
The beam is 1040 meters
The displacement is 600 metric tones
fully equipped the worlds largest CRP
construction
The design of the Visby aims to minimize
the optical and infrared signature above
water acoustic and hydroa coustic
signature underwater electrical potential
and magnetic signature pressure signature
radar cross section and actively emitted
signals
A stealth corvette of the YS 2000 design
has a detection range of 13km in rough
seas and 22km in calm sea without
jamming In a jammed environment the
Visby would be detected at a range of 8km
in rough sea and 11km in calm sea
The material provides high strength and
rigidity low weight good shock resistance
low radar and magnetic signature
1996
Visby is a class of stealth corvettes for the Swedish Navy
ldquoReduced 50 of a Conventional Steelrdquo
Source
Hull Construction with composite materials for ships over 100m in length 2002
Massachusetts Institute of Technology
httpwwwnaval-technologycomprojectsvisby
YACHTS
KAL YUDISTIRAMARATHON 100 ADMIRAL YACHT
LOA 3050 MWidth 6 MFuel Tank 8000 LWater Tank 3000 LIce Box 500 LAccommodation Max 35 Personnel
2 x CATERPILLAR 3412E 1200 HPMARINE DIESEL ENGINE
PC 40 ndash KRI Krait 827Department of Indonesian Navy
LOA 40 MWidth 73 MPower 190Weapon Twin Cannon Barrels
127 mm Heavy Machine GunSpeed Knot 25 KnotDisplacement 105 tonAccommodation 23 personnel
PATROL BOAT
Rigid Inflatable BoatPATROL BOAT
Yachts
36m Luxury Yacht Moonraker
36m Luxury Yacht GoldenEye
50m Luxury Yacht Casino
Royale
45m Luxury Yacht Seashaw
Boat Parts
Barovans for Seismic Sweep
Centrifugal Liftfan House for Surface Effect
Ships
Composite Boat PropellersRTM
Deckhouses for Pilot Boats
Fairing Parts for Submarines
Flybridges for Motor yachts
Light Weight Gangway
MTB Launcher Mock-up
Pleasure Boats
12m Sailboat
12m Sail-Catamaranone-off
Canoes
Dragonfly 1000Catamaran Sailboat
Fantasy 37Sailboat
Farr 60Luxury Sailboat
EurodingyOlympic Dingy Class for
Woman
Hydrolift F23 Racing Boats
Kajacs
Najad 42Sailboat
Najad 520Sailboat
Najad 441Sailboat
Najad 391Sailboat
Nordwest 900Motorboat
Nordwest 1100Motorboat
Quatro 44Motorboat
Racemaster Competition Boats
Storebro 420
Storebro 345
Sweden Yacht 370Sailboat
Sweden Yacht 69Sailboat
Windy 41Motorboat
X-632Sailboat
X-362Sailboat
Commercial Boats
175m High Speed AmbulancePassenger Boat
19m High Speed Passenger Boat
20m High Speed Passenger Boat
364m Surface Effect Passenger Ship
45m Surface Effect Passenger Ship
120m Hull Structural Parts HSSS Catamaran Ferry
APPENDIX
Marine Vessel
1188m Fast Attack Vessel FMV 90 E
20m SAV-Surface Auxiliary Vessels
34m Personnel TransportCoast Guard Vessel
40ft Experimental SES
40m Landsort-Class Mine Hunters
54m Mine Counter Measure Vehicles SES
74m Coastal Patrol Boats
Fishing Boats
30 GT
12 GT
10 GT
5 GT
WISEWings In Surface Effect
HOVERCRAFT
Designed specifically for the tourist and transport industries the
Pioneer Mk3 hovercraft is amphibious and comfortably seats 25
passengers plus 1-crew The air-conditioned cabin allows for
maximum visibility for all aboard The Pioneer Mk3 is robust and
dynamic in its performance
Commercial hovercraft
Mk3 AirLift Hovercraft - 1215m
Power is economicaly provided by one Deutz diesel engine of
330kW (442hp) to cruise easily at 40 knots with much higher
speeds available according to the surface conditions The hull is
manufactured from fibreglassPVC foam composite sandwich
the windows are glass and the skirt is urethane coated nylon A
Military version is available with increased payload and systems
redundancy Power for the Military version comes from two Steyr
diesel engines with a total installed power of 320kW (429hp) All
transmission electrical hydraulic and air systems are duplicated
for maximum redundancy The increased performance of the
Military version comes from the reduced engine weight of the twin
Steyr installation cf the Deutz installation
Source
httpwwwnauticexpocomprodairlift-hovercraftcommercial-hovercrafts-25251-142868html
HOVERFLIGHT
BALLISTIC amp UNIT DEFENCED
Triaxis Composites Collaboration with Institute of Aeronautics and Space in the development of Missile Nose Cone
Polymer composites is the evolution of the military defence
Thin steel was the helmet material of
WWII and remained the principal material until around the 1980rsquos
The advantages of using steel
included a simple technology for manufacture of the helmets low cost and reasonably good
impact protection However these helmets were found to provide only marginal protection
against fragments
During the Vietnam War the US Army experimented with fiber-reinforced inserts in the
helmets These inserts improved ballistic protection but at the same time added weight and
reduced the air space between the head and the helmet
By the early part of the 1980rsquos the US military had developed the first all-composite
100 fiber-reinforced helmet This development resulted in even better ballistic protection
without altering the weight of the helmet Other improvements included better head coverage and
more space for ventilation
Source
Composites Armor - A difficult but huge market
by A Brent Strong Brigham Young University
MILITARY VEHICLES
HIGH SPEED TRAIN SHINKANSEN
Advanced Composites provide lightweight solutions for railway vehicles
saving as much as 50-80 of the weight compared with traditional
components
A lower overall weight translates into less stress faster acceleration and
higher speeds as well as reduced starting and stopping inertia Today
these are important criteria in global high-speed and metropolitan
railway projects
Fire smoke and toxic fumes are key safety criteria for interior
components of railway carriages Any material selected for an interior
component must meet international fire retardant standards
for Rail Interiors and Exteriors
Ceiling Panels Stairs
Seating Vestibules
Window Panels Door Pillars
Partition WallsDiffusers
Gangway and Cabinet Panels Cabin and
Desk panels
Door Pillars Lavatory Modules (standard and
Front and Rear EndsRoof Panels
Nose Cones Under Fairings
Source
httpwwwpctaerail_compositesphp
101
SKY BUS
2009
Europe is the world leader in offshore wind with
828 wind turbines and a cumulative capacity of 2056 MW spread across 38 offshore wind farms in 9
European countries
The UK and Denmark are the current leaders with a 44 and 30 share respectively In 2009
five countries built new offshore wind farms
UK (284 MW)
Demark (230 MW)
Sweden (30 MW)
Germany (30 MW)
Norway (23 MW)
2010
Asia leads the growth in global wind power which grew 358 GW in 2010 bringing
total global capacity to 1944 GW ndash up 225 from 2009
the Global Wind Energy Council (GWEC)
Asia accounted for 19 GW of new global wind power installations driven by China which installed 165
GW
ldquoChina now has 423 GW of wind powerrdquo
ldquoThis puts China firmly on a path to reach 200 GW of installed wind power by 2020 At the same
time China has become the worldrsquos largest producer of wind energy equipmentrdquo
Source
httpwwwreinforcedplasticscomview15655asia-leads-global-wind-power-growth
httpimgdeusmcomdesignnews288288605-Sandia_Sizes_up_Wind_Turbine_Blade_Design_C_largegif
WIND ENERGY
Marine Current Turbines
Source
httpwwwsiemenscompressenpressreleasepress=enpressrelease2011solar-hydroex201111005htm
httpwwwmarineturbinescom
A commercial marine current turbine consists of
two rotors which are fixed on a structure within the
sea current The twin rotors rotate with the
movement of the tidal flow and the blades pitch
through 180 degrees to optimally track tidal current
(Press picture Marine Current Turbines)
Wave Star Energys Multi-point Absorber
CFRP COLUMN REINFORCEMENT
INDUSTRIAL TANKS
107
INDUSTRIAL PIPES
PRESSURE TANKS
109
ldquoLetrsquos Make with Compositesrdquo
YACHTS
KAL YUDISTIRAMARATHON 100 ADMIRAL YACHT
LOA 3050 MWidth 6 MFuel Tank 8000 LWater Tank 3000 LIce Box 500 LAccommodation Max 35 Personnel
2 x CATERPILLAR 3412E 1200 HPMARINE DIESEL ENGINE
PC 40 ndash KRI Krait 827Department of Indonesian Navy
LOA 40 MWidth 73 MPower 190Weapon Twin Cannon Barrels
127 mm Heavy Machine GunSpeed Knot 25 KnotDisplacement 105 tonAccommodation 23 personnel
PATROL BOAT
Rigid Inflatable BoatPATROL BOAT
Yachts
36m Luxury Yacht Moonraker
36m Luxury Yacht GoldenEye
50m Luxury Yacht Casino
Royale
45m Luxury Yacht Seashaw
Boat Parts
Barovans for Seismic Sweep
Centrifugal Liftfan House for Surface Effect
Ships
Composite Boat PropellersRTM
Deckhouses for Pilot Boats
Fairing Parts for Submarines
Flybridges for Motor yachts
Light Weight Gangway
MTB Launcher Mock-up
Pleasure Boats
12m Sailboat
12m Sail-Catamaranone-off
Canoes
Dragonfly 1000Catamaran Sailboat
Fantasy 37Sailboat
Farr 60Luxury Sailboat
EurodingyOlympic Dingy Class for
Woman
Hydrolift F23 Racing Boats
Kajacs
Najad 42Sailboat
Najad 520Sailboat
Najad 441Sailboat
Najad 391Sailboat
Nordwest 900Motorboat
Nordwest 1100Motorboat
Quatro 44Motorboat
Racemaster Competition Boats
Storebro 420
Storebro 345
Sweden Yacht 370Sailboat
Sweden Yacht 69Sailboat
Windy 41Motorboat
X-632Sailboat
X-362Sailboat
Commercial Boats
175m High Speed AmbulancePassenger Boat
19m High Speed Passenger Boat
20m High Speed Passenger Boat
364m Surface Effect Passenger Ship
45m Surface Effect Passenger Ship
120m Hull Structural Parts HSSS Catamaran Ferry
APPENDIX
Marine Vessel
1188m Fast Attack Vessel FMV 90 E
20m SAV-Surface Auxiliary Vessels
34m Personnel TransportCoast Guard Vessel
40ft Experimental SES
40m Landsort-Class Mine Hunters
54m Mine Counter Measure Vehicles SES
74m Coastal Patrol Boats
Fishing Boats
30 GT
12 GT
10 GT
5 GT
WISEWings In Surface Effect
HOVERCRAFT
Designed specifically for the tourist and transport industries the
Pioneer Mk3 hovercraft is amphibious and comfortably seats 25
passengers plus 1-crew The air-conditioned cabin allows for
maximum visibility for all aboard The Pioneer Mk3 is robust and
dynamic in its performance
Commercial hovercraft
Mk3 AirLift Hovercraft - 1215m
Power is economicaly provided by one Deutz diesel engine of
330kW (442hp) to cruise easily at 40 knots with much higher
speeds available according to the surface conditions The hull is
manufactured from fibreglassPVC foam composite sandwich
the windows are glass and the skirt is urethane coated nylon A
Military version is available with increased payload and systems
redundancy Power for the Military version comes from two Steyr
diesel engines with a total installed power of 320kW (429hp) All
transmission electrical hydraulic and air systems are duplicated
for maximum redundancy The increased performance of the
Military version comes from the reduced engine weight of the twin
Steyr installation cf the Deutz installation
Source
httpwwwnauticexpocomprodairlift-hovercraftcommercial-hovercrafts-25251-142868html
HOVERFLIGHT
BALLISTIC amp UNIT DEFENCED
Triaxis Composites Collaboration with Institute of Aeronautics and Space in the development of Missile Nose Cone
Polymer composites is the evolution of the military defence
Thin steel was the helmet material of
WWII and remained the principal material until around the 1980rsquos
The advantages of using steel
included a simple technology for manufacture of the helmets low cost and reasonably good
impact protection However these helmets were found to provide only marginal protection
against fragments
During the Vietnam War the US Army experimented with fiber-reinforced inserts in the
helmets These inserts improved ballistic protection but at the same time added weight and
reduced the air space between the head and the helmet
By the early part of the 1980rsquos the US military had developed the first all-composite
100 fiber-reinforced helmet This development resulted in even better ballistic protection
without altering the weight of the helmet Other improvements included better head coverage and
more space for ventilation
Source
Composites Armor - A difficult but huge market
by A Brent Strong Brigham Young University
MILITARY VEHICLES
HIGH SPEED TRAIN SHINKANSEN
Advanced Composites provide lightweight solutions for railway vehicles
saving as much as 50-80 of the weight compared with traditional
components
A lower overall weight translates into less stress faster acceleration and
higher speeds as well as reduced starting and stopping inertia Today
these are important criteria in global high-speed and metropolitan
railway projects
Fire smoke and toxic fumes are key safety criteria for interior
components of railway carriages Any material selected for an interior
component must meet international fire retardant standards
for Rail Interiors and Exteriors
Ceiling Panels Stairs
Seating Vestibules
Window Panels Door Pillars
Partition WallsDiffusers
Gangway and Cabinet Panels Cabin and
Desk panels
Door Pillars Lavatory Modules (standard and
Front and Rear EndsRoof Panels
Nose Cones Under Fairings
Source
httpwwwpctaerail_compositesphp
101
SKY BUS
2009
Europe is the world leader in offshore wind with
828 wind turbines and a cumulative capacity of 2056 MW spread across 38 offshore wind farms in 9
European countries
The UK and Denmark are the current leaders with a 44 and 30 share respectively In 2009
five countries built new offshore wind farms
UK (284 MW)
Demark (230 MW)
Sweden (30 MW)
Germany (30 MW)
Norway (23 MW)
2010
Asia leads the growth in global wind power which grew 358 GW in 2010 bringing
total global capacity to 1944 GW ndash up 225 from 2009
the Global Wind Energy Council (GWEC)
Asia accounted for 19 GW of new global wind power installations driven by China which installed 165
GW
ldquoChina now has 423 GW of wind powerrdquo
ldquoThis puts China firmly on a path to reach 200 GW of installed wind power by 2020 At the same
time China has become the worldrsquos largest producer of wind energy equipmentrdquo
Source
httpwwwreinforcedplasticscomview15655asia-leads-global-wind-power-growth
httpimgdeusmcomdesignnews288288605-Sandia_Sizes_up_Wind_Turbine_Blade_Design_C_largegif
WIND ENERGY
Marine Current Turbines
Source
httpwwwsiemenscompressenpressreleasepress=enpressrelease2011solar-hydroex201111005htm
httpwwwmarineturbinescom
A commercial marine current turbine consists of
two rotors which are fixed on a structure within the
sea current The twin rotors rotate with the
movement of the tidal flow and the blades pitch
through 180 degrees to optimally track tidal current
(Press picture Marine Current Turbines)
Wave Star Energys Multi-point Absorber
CFRP COLUMN REINFORCEMENT
INDUSTRIAL TANKS
107
INDUSTRIAL PIPES
PRESSURE TANKS
109
ldquoLetrsquos Make with Compositesrdquo
PC 40 ndash KRI Krait 827Department of Indonesian Navy
LOA 40 MWidth 73 MPower 190Weapon Twin Cannon Barrels
127 mm Heavy Machine GunSpeed Knot 25 KnotDisplacement 105 tonAccommodation 23 personnel
PATROL BOAT
Rigid Inflatable BoatPATROL BOAT
Yachts
36m Luxury Yacht Moonraker
36m Luxury Yacht GoldenEye
50m Luxury Yacht Casino
Royale
45m Luxury Yacht Seashaw
Boat Parts
Barovans for Seismic Sweep
Centrifugal Liftfan House for Surface Effect
Ships
Composite Boat PropellersRTM
Deckhouses for Pilot Boats
Fairing Parts for Submarines
Flybridges for Motor yachts
Light Weight Gangway
MTB Launcher Mock-up
Pleasure Boats
12m Sailboat
12m Sail-Catamaranone-off
Canoes
Dragonfly 1000Catamaran Sailboat
Fantasy 37Sailboat
Farr 60Luxury Sailboat
EurodingyOlympic Dingy Class for
Woman
Hydrolift F23 Racing Boats
Kajacs
Najad 42Sailboat
Najad 520Sailboat
Najad 441Sailboat
Najad 391Sailboat
Nordwest 900Motorboat
Nordwest 1100Motorboat
Quatro 44Motorboat
Racemaster Competition Boats
Storebro 420
Storebro 345
Sweden Yacht 370Sailboat
Sweden Yacht 69Sailboat
Windy 41Motorboat
X-632Sailboat
X-362Sailboat
Commercial Boats
175m High Speed AmbulancePassenger Boat
19m High Speed Passenger Boat
20m High Speed Passenger Boat
364m Surface Effect Passenger Ship
45m Surface Effect Passenger Ship
120m Hull Structural Parts HSSS Catamaran Ferry
APPENDIX
Marine Vessel
1188m Fast Attack Vessel FMV 90 E
20m SAV-Surface Auxiliary Vessels
34m Personnel TransportCoast Guard Vessel
40ft Experimental SES
40m Landsort-Class Mine Hunters
54m Mine Counter Measure Vehicles SES
74m Coastal Patrol Boats
Fishing Boats
30 GT
12 GT
10 GT
5 GT
WISEWings In Surface Effect
HOVERCRAFT
Designed specifically for the tourist and transport industries the
Pioneer Mk3 hovercraft is amphibious and comfortably seats 25
passengers plus 1-crew The air-conditioned cabin allows for
maximum visibility for all aboard The Pioneer Mk3 is robust and
dynamic in its performance
Commercial hovercraft
Mk3 AirLift Hovercraft - 1215m
Power is economicaly provided by one Deutz diesel engine of
330kW (442hp) to cruise easily at 40 knots with much higher
speeds available according to the surface conditions The hull is
manufactured from fibreglassPVC foam composite sandwich
the windows are glass and the skirt is urethane coated nylon A
Military version is available with increased payload and systems
redundancy Power for the Military version comes from two Steyr
diesel engines with a total installed power of 320kW (429hp) All
transmission electrical hydraulic and air systems are duplicated
for maximum redundancy The increased performance of the
Military version comes from the reduced engine weight of the twin
Steyr installation cf the Deutz installation
Source
httpwwwnauticexpocomprodairlift-hovercraftcommercial-hovercrafts-25251-142868html
HOVERFLIGHT
BALLISTIC amp UNIT DEFENCED
Triaxis Composites Collaboration with Institute of Aeronautics and Space in the development of Missile Nose Cone
Polymer composites is the evolution of the military defence
Thin steel was the helmet material of
WWII and remained the principal material until around the 1980rsquos
The advantages of using steel
included a simple technology for manufacture of the helmets low cost and reasonably good
impact protection However these helmets were found to provide only marginal protection
against fragments
During the Vietnam War the US Army experimented with fiber-reinforced inserts in the
helmets These inserts improved ballistic protection but at the same time added weight and
reduced the air space between the head and the helmet
By the early part of the 1980rsquos the US military had developed the first all-composite
100 fiber-reinforced helmet This development resulted in even better ballistic protection
without altering the weight of the helmet Other improvements included better head coverage and
more space for ventilation
Source
Composites Armor - A difficult but huge market
by A Brent Strong Brigham Young University
MILITARY VEHICLES
HIGH SPEED TRAIN SHINKANSEN
Advanced Composites provide lightweight solutions for railway vehicles
saving as much as 50-80 of the weight compared with traditional
components
A lower overall weight translates into less stress faster acceleration and
higher speeds as well as reduced starting and stopping inertia Today
these are important criteria in global high-speed and metropolitan
railway projects
Fire smoke and toxic fumes are key safety criteria for interior
components of railway carriages Any material selected for an interior
component must meet international fire retardant standards
for Rail Interiors and Exteriors
Ceiling Panels Stairs
Seating Vestibules
Window Panels Door Pillars
Partition WallsDiffusers
Gangway and Cabinet Panels Cabin and
Desk panels
Door Pillars Lavatory Modules (standard and
Front and Rear EndsRoof Panels
Nose Cones Under Fairings
Source
httpwwwpctaerail_compositesphp
101
SKY BUS
2009
Europe is the world leader in offshore wind with
828 wind turbines and a cumulative capacity of 2056 MW spread across 38 offshore wind farms in 9
European countries
The UK and Denmark are the current leaders with a 44 and 30 share respectively In 2009
five countries built new offshore wind farms
UK (284 MW)
Demark (230 MW)
Sweden (30 MW)
Germany (30 MW)
Norway (23 MW)
2010
Asia leads the growth in global wind power which grew 358 GW in 2010 bringing
total global capacity to 1944 GW ndash up 225 from 2009
the Global Wind Energy Council (GWEC)
Asia accounted for 19 GW of new global wind power installations driven by China which installed 165
GW
ldquoChina now has 423 GW of wind powerrdquo
ldquoThis puts China firmly on a path to reach 200 GW of installed wind power by 2020 At the same
time China has become the worldrsquos largest producer of wind energy equipmentrdquo
Source
httpwwwreinforcedplasticscomview15655asia-leads-global-wind-power-growth
httpimgdeusmcomdesignnews288288605-Sandia_Sizes_up_Wind_Turbine_Blade_Design_C_largegif
WIND ENERGY
Marine Current Turbines
Source
httpwwwsiemenscompressenpressreleasepress=enpressrelease2011solar-hydroex201111005htm
httpwwwmarineturbinescom
A commercial marine current turbine consists of
two rotors which are fixed on a structure within the
sea current The twin rotors rotate with the
movement of the tidal flow and the blades pitch
through 180 degrees to optimally track tidal current
(Press picture Marine Current Turbines)
Wave Star Energys Multi-point Absorber
CFRP COLUMN REINFORCEMENT
INDUSTRIAL TANKS
107
INDUSTRIAL PIPES
PRESSURE TANKS
109
ldquoLetrsquos Make with Compositesrdquo
Rigid Inflatable BoatPATROL BOAT
Yachts
36m Luxury Yacht Moonraker
36m Luxury Yacht GoldenEye
50m Luxury Yacht Casino
Royale
45m Luxury Yacht Seashaw
Boat Parts
Barovans for Seismic Sweep
Centrifugal Liftfan House for Surface Effect
Ships
Composite Boat PropellersRTM
Deckhouses for Pilot Boats
Fairing Parts for Submarines
Flybridges for Motor yachts
Light Weight Gangway
MTB Launcher Mock-up
Pleasure Boats
12m Sailboat
12m Sail-Catamaranone-off
Canoes
Dragonfly 1000Catamaran Sailboat
Fantasy 37Sailboat
Farr 60Luxury Sailboat
EurodingyOlympic Dingy Class for
Woman
Hydrolift F23 Racing Boats
Kajacs
Najad 42Sailboat
Najad 520Sailboat
Najad 441Sailboat
Najad 391Sailboat
Nordwest 900Motorboat
Nordwest 1100Motorboat
Quatro 44Motorboat
Racemaster Competition Boats
Storebro 420
Storebro 345
Sweden Yacht 370Sailboat
Sweden Yacht 69Sailboat
Windy 41Motorboat
X-632Sailboat
X-362Sailboat
Commercial Boats
175m High Speed AmbulancePassenger Boat
19m High Speed Passenger Boat
20m High Speed Passenger Boat
364m Surface Effect Passenger Ship
45m Surface Effect Passenger Ship
120m Hull Structural Parts HSSS Catamaran Ferry
APPENDIX
Marine Vessel
1188m Fast Attack Vessel FMV 90 E
20m SAV-Surface Auxiliary Vessels
34m Personnel TransportCoast Guard Vessel
40ft Experimental SES
40m Landsort-Class Mine Hunters
54m Mine Counter Measure Vehicles SES
74m Coastal Patrol Boats
Fishing Boats
30 GT
12 GT
10 GT
5 GT
WISEWings In Surface Effect
HOVERCRAFT
Designed specifically for the tourist and transport industries the
Pioneer Mk3 hovercraft is amphibious and comfortably seats 25
passengers plus 1-crew The air-conditioned cabin allows for
maximum visibility for all aboard The Pioneer Mk3 is robust and
dynamic in its performance
Commercial hovercraft
Mk3 AirLift Hovercraft - 1215m
Power is economicaly provided by one Deutz diesel engine of
330kW (442hp) to cruise easily at 40 knots with much higher
speeds available according to the surface conditions The hull is
manufactured from fibreglassPVC foam composite sandwich
the windows are glass and the skirt is urethane coated nylon A
Military version is available with increased payload and systems
redundancy Power for the Military version comes from two Steyr
diesel engines with a total installed power of 320kW (429hp) All
transmission electrical hydraulic and air systems are duplicated
for maximum redundancy The increased performance of the
Military version comes from the reduced engine weight of the twin
Steyr installation cf the Deutz installation
Source
httpwwwnauticexpocomprodairlift-hovercraftcommercial-hovercrafts-25251-142868html
HOVERFLIGHT
BALLISTIC amp UNIT DEFENCED
Triaxis Composites Collaboration with Institute of Aeronautics and Space in the development of Missile Nose Cone
Polymer composites is the evolution of the military defence
Thin steel was the helmet material of
WWII and remained the principal material until around the 1980rsquos
The advantages of using steel
included a simple technology for manufacture of the helmets low cost and reasonably good
impact protection However these helmets were found to provide only marginal protection
against fragments
During the Vietnam War the US Army experimented with fiber-reinforced inserts in the
helmets These inserts improved ballistic protection but at the same time added weight and
reduced the air space between the head and the helmet
By the early part of the 1980rsquos the US military had developed the first all-composite
100 fiber-reinforced helmet This development resulted in even better ballistic protection
without altering the weight of the helmet Other improvements included better head coverage and
more space for ventilation
Source
Composites Armor - A difficult but huge market
by A Brent Strong Brigham Young University
MILITARY VEHICLES
HIGH SPEED TRAIN SHINKANSEN
Advanced Composites provide lightweight solutions for railway vehicles
saving as much as 50-80 of the weight compared with traditional
components
A lower overall weight translates into less stress faster acceleration and
higher speeds as well as reduced starting and stopping inertia Today
these are important criteria in global high-speed and metropolitan
railway projects
Fire smoke and toxic fumes are key safety criteria for interior
components of railway carriages Any material selected for an interior
component must meet international fire retardant standards
for Rail Interiors and Exteriors
Ceiling Panels Stairs
Seating Vestibules
Window Panels Door Pillars
Partition WallsDiffusers
Gangway and Cabinet Panels Cabin and
Desk panels
Door Pillars Lavatory Modules (standard and
Front and Rear EndsRoof Panels
Nose Cones Under Fairings
Source
httpwwwpctaerail_compositesphp
101
SKY BUS
2009
Europe is the world leader in offshore wind with
828 wind turbines and a cumulative capacity of 2056 MW spread across 38 offshore wind farms in 9
European countries
The UK and Denmark are the current leaders with a 44 and 30 share respectively In 2009
five countries built new offshore wind farms
UK (284 MW)
Demark (230 MW)
Sweden (30 MW)
Germany (30 MW)
Norway (23 MW)
2010
Asia leads the growth in global wind power which grew 358 GW in 2010 bringing
total global capacity to 1944 GW ndash up 225 from 2009
the Global Wind Energy Council (GWEC)
Asia accounted for 19 GW of new global wind power installations driven by China which installed 165
GW
ldquoChina now has 423 GW of wind powerrdquo
ldquoThis puts China firmly on a path to reach 200 GW of installed wind power by 2020 At the same
time China has become the worldrsquos largest producer of wind energy equipmentrdquo
Source
httpwwwreinforcedplasticscomview15655asia-leads-global-wind-power-growth
httpimgdeusmcomdesignnews288288605-Sandia_Sizes_up_Wind_Turbine_Blade_Design_C_largegif
WIND ENERGY
Marine Current Turbines
Source
httpwwwsiemenscompressenpressreleasepress=enpressrelease2011solar-hydroex201111005htm
httpwwwmarineturbinescom
A commercial marine current turbine consists of
two rotors which are fixed on a structure within the
sea current The twin rotors rotate with the
movement of the tidal flow and the blades pitch
through 180 degrees to optimally track tidal current
(Press picture Marine Current Turbines)
Wave Star Energys Multi-point Absorber
CFRP COLUMN REINFORCEMENT
INDUSTRIAL TANKS
107
INDUSTRIAL PIPES
PRESSURE TANKS
109
ldquoLetrsquos Make with Compositesrdquo
Yachts
36m Luxury Yacht Moonraker
36m Luxury Yacht GoldenEye
50m Luxury Yacht Casino
Royale
45m Luxury Yacht Seashaw
Boat Parts
Barovans for Seismic Sweep
Centrifugal Liftfan House for Surface Effect
Ships
Composite Boat PropellersRTM
Deckhouses for Pilot Boats
Fairing Parts for Submarines
Flybridges for Motor yachts
Light Weight Gangway
MTB Launcher Mock-up
Pleasure Boats
12m Sailboat
12m Sail-Catamaranone-off
Canoes
Dragonfly 1000Catamaran Sailboat
Fantasy 37Sailboat
Farr 60Luxury Sailboat
EurodingyOlympic Dingy Class for
Woman
Hydrolift F23 Racing Boats
Kajacs
Najad 42Sailboat
Najad 520Sailboat
Najad 441Sailboat
Najad 391Sailboat
Nordwest 900Motorboat
Nordwest 1100Motorboat
Quatro 44Motorboat
Racemaster Competition Boats
Storebro 420
Storebro 345
Sweden Yacht 370Sailboat
Sweden Yacht 69Sailboat
Windy 41Motorboat
X-632Sailboat
X-362Sailboat
Commercial Boats
175m High Speed AmbulancePassenger Boat
19m High Speed Passenger Boat
20m High Speed Passenger Boat
364m Surface Effect Passenger Ship
45m Surface Effect Passenger Ship
120m Hull Structural Parts HSSS Catamaran Ferry
APPENDIX
Marine Vessel
1188m Fast Attack Vessel FMV 90 E
20m SAV-Surface Auxiliary Vessels
34m Personnel TransportCoast Guard Vessel
40ft Experimental SES
40m Landsort-Class Mine Hunters
54m Mine Counter Measure Vehicles SES
74m Coastal Patrol Boats
Fishing Boats
30 GT
12 GT
10 GT
5 GT
WISEWings In Surface Effect
HOVERCRAFT
Designed specifically for the tourist and transport industries the
Pioneer Mk3 hovercraft is amphibious and comfortably seats 25
passengers plus 1-crew The air-conditioned cabin allows for
maximum visibility for all aboard The Pioneer Mk3 is robust and
dynamic in its performance
Commercial hovercraft
Mk3 AirLift Hovercraft - 1215m
Power is economicaly provided by one Deutz diesel engine of
330kW (442hp) to cruise easily at 40 knots with much higher
speeds available according to the surface conditions The hull is
manufactured from fibreglassPVC foam composite sandwich
the windows are glass and the skirt is urethane coated nylon A
Military version is available with increased payload and systems
redundancy Power for the Military version comes from two Steyr
diesel engines with a total installed power of 320kW (429hp) All
transmission electrical hydraulic and air systems are duplicated
for maximum redundancy The increased performance of the
Military version comes from the reduced engine weight of the twin
Steyr installation cf the Deutz installation
Source
httpwwwnauticexpocomprodairlift-hovercraftcommercial-hovercrafts-25251-142868html
HOVERFLIGHT
BALLISTIC amp UNIT DEFENCED
Triaxis Composites Collaboration with Institute of Aeronautics and Space in the development of Missile Nose Cone
Polymer composites is the evolution of the military defence
Thin steel was the helmet material of
WWII and remained the principal material until around the 1980rsquos
The advantages of using steel
included a simple technology for manufacture of the helmets low cost and reasonably good
impact protection However these helmets were found to provide only marginal protection
against fragments
During the Vietnam War the US Army experimented with fiber-reinforced inserts in the
helmets These inserts improved ballistic protection but at the same time added weight and
reduced the air space between the head and the helmet
By the early part of the 1980rsquos the US military had developed the first all-composite
100 fiber-reinforced helmet This development resulted in even better ballistic protection
without altering the weight of the helmet Other improvements included better head coverage and
more space for ventilation
Source
Composites Armor - A difficult but huge market
by A Brent Strong Brigham Young University
MILITARY VEHICLES
HIGH SPEED TRAIN SHINKANSEN
Advanced Composites provide lightweight solutions for railway vehicles
saving as much as 50-80 of the weight compared with traditional
components
A lower overall weight translates into less stress faster acceleration and
higher speeds as well as reduced starting and stopping inertia Today
these are important criteria in global high-speed and metropolitan
railway projects
Fire smoke and toxic fumes are key safety criteria for interior
components of railway carriages Any material selected for an interior
component must meet international fire retardant standards
for Rail Interiors and Exteriors
Ceiling Panels Stairs
Seating Vestibules
Window Panels Door Pillars
Partition WallsDiffusers
Gangway and Cabinet Panels Cabin and
Desk panels
Door Pillars Lavatory Modules (standard and
Front and Rear EndsRoof Panels
Nose Cones Under Fairings
Source
httpwwwpctaerail_compositesphp
101
SKY BUS
2009
Europe is the world leader in offshore wind with
828 wind turbines and a cumulative capacity of 2056 MW spread across 38 offshore wind farms in 9
European countries
The UK and Denmark are the current leaders with a 44 and 30 share respectively In 2009
five countries built new offshore wind farms
UK (284 MW)
Demark (230 MW)
Sweden (30 MW)
Germany (30 MW)
Norway (23 MW)
2010
Asia leads the growth in global wind power which grew 358 GW in 2010 bringing
total global capacity to 1944 GW ndash up 225 from 2009
the Global Wind Energy Council (GWEC)
Asia accounted for 19 GW of new global wind power installations driven by China which installed 165
GW
ldquoChina now has 423 GW of wind powerrdquo
ldquoThis puts China firmly on a path to reach 200 GW of installed wind power by 2020 At the same
time China has become the worldrsquos largest producer of wind energy equipmentrdquo
Source
httpwwwreinforcedplasticscomview15655asia-leads-global-wind-power-growth
httpimgdeusmcomdesignnews288288605-Sandia_Sizes_up_Wind_Turbine_Blade_Design_C_largegif
WIND ENERGY
Marine Current Turbines
Source
httpwwwsiemenscompressenpressreleasepress=enpressrelease2011solar-hydroex201111005htm
httpwwwmarineturbinescom
A commercial marine current turbine consists of
two rotors which are fixed on a structure within the
sea current The twin rotors rotate with the
movement of the tidal flow and the blades pitch
through 180 degrees to optimally track tidal current
(Press picture Marine Current Turbines)
Wave Star Energys Multi-point Absorber
CFRP COLUMN REINFORCEMENT
INDUSTRIAL TANKS
107
INDUSTRIAL PIPES
PRESSURE TANKS
109
ldquoLetrsquos Make with Compositesrdquo
WISEWings In Surface Effect
HOVERCRAFT
Designed specifically for the tourist and transport industries the
Pioneer Mk3 hovercraft is amphibious and comfortably seats 25
passengers plus 1-crew The air-conditioned cabin allows for
maximum visibility for all aboard The Pioneer Mk3 is robust and
dynamic in its performance
Commercial hovercraft
Mk3 AirLift Hovercraft - 1215m
Power is economicaly provided by one Deutz diesel engine of
330kW (442hp) to cruise easily at 40 knots with much higher
speeds available according to the surface conditions The hull is
manufactured from fibreglassPVC foam composite sandwich
the windows are glass and the skirt is urethane coated nylon A
Military version is available with increased payload and systems
redundancy Power for the Military version comes from two Steyr
diesel engines with a total installed power of 320kW (429hp) All
transmission electrical hydraulic and air systems are duplicated
for maximum redundancy The increased performance of the
Military version comes from the reduced engine weight of the twin
Steyr installation cf the Deutz installation
Source
httpwwwnauticexpocomprodairlift-hovercraftcommercial-hovercrafts-25251-142868html
HOVERFLIGHT
BALLISTIC amp UNIT DEFENCED
Triaxis Composites Collaboration with Institute of Aeronautics and Space in the development of Missile Nose Cone
Polymer composites is the evolution of the military defence
Thin steel was the helmet material of
WWII and remained the principal material until around the 1980rsquos
The advantages of using steel
included a simple technology for manufacture of the helmets low cost and reasonably good
impact protection However these helmets were found to provide only marginal protection
against fragments
During the Vietnam War the US Army experimented with fiber-reinforced inserts in the
helmets These inserts improved ballistic protection but at the same time added weight and
reduced the air space between the head and the helmet
By the early part of the 1980rsquos the US military had developed the first all-composite
100 fiber-reinforced helmet This development resulted in even better ballistic protection
without altering the weight of the helmet Other improvements included better head coverage and
more space for ventilation
Source
Composites Armor - A difficult but huge market
by A Brent Strong Brigham Young University
MILITARY VEHICLES
HIGH SPEED TRAIN SHINKANSEN
Advanced Composites provide lightweight solutions for railway vehicles
saving as much as 50-80 of the weight compared with traditional
components
A lower overall weight translates into less stress faster acceleration and
higher speeds as well as reduced starting and stopping inertia Today
these are important criteria in global high-speed and metropolitan
railway projects
Fire smoke and toxic fumes are key safety criteria for interior
components of railway carriages Any material selected for an interior
component must meet international fire retardant standards
for Rail Interiors and Exteriors
Ceiling Panels Stairs
Seating Vestibules
Window Panels Door Pillars
Partition WallsDiffusers
Gangway and Cabinet Panels Cabin and
Desk panels
Door Pillars Lavatory Modules (standard and
Front and Rear EndsRoof Panels
Nose Cones Under Fairings
Source
httpwwwpctaerail_compositesphp
101
SKY BUS
2009
Europe is the world leader in offshore wind with
828 wind turbines and a cumulative capacity of 2056 MW spread across 38 offshore wind farms in 9
European countries
The UK and Denmark are the current leaders with a 44 and 30 share respectively In 2009
five countries built new offshore wind farms
UK (284 MW)
Demark (230 MW)
Sweden (30 MW)
Germany (30 MW)
Norway (23 MW)
2010
Asia leads the growth in global wind power which grew 358 GW in 2010 bringing
total global capacity to 1944 GW ndash up 225 from 2009
the Global Wind Energy Council (GWEC)
Asia accounted for 19 GW of new global wind power installations driven by China which installed 165
GW
ldquoChina now has 423 GW of wind powerrdquo
ldquoThis puts China firmly on a path to reach 200 GW of installed wind power by 2020 At the same
time China has become the worldrsquos largest producer of wind energy equipmentrdquo
Source
httpwwwreinforcedplasticscomview15655asia-leads-global-wind-power-growth
httpimgdeusmcomdesignnews288288605-Sandia_Sizes_up_Wind_Turbine_Blade_Design_C_largegif
WIND ENERGY
Marine Current Turbines
Source
httpwwwsiemenscompressenpressreleasepress=enpressrelease2011solar-hydroex201111005htm
httpwwwmarineturbinescom
A commercial marine current turbine consists of
two rotors which are fixed on a structure within the
sea current The twin rotors rotate with the
movement of the tidal flow and the blades pitch
through 180 degrees to optimally track tidal current
(Press picture Marine Current Turbines)
Wave Star Energys Multi-point Absorber
CFRP COLUMN REINFORCEMENT
INDUSTRIAL TANKS
107
INDUSTRIAL PIPES
PRESSURE TANKS
109
ldquoLetrsquos Make with Compositesrdquo
HOVERCRAFT
Designed specifically for the tourist and transport industries the
Pioneer Mk3 hovercraft is amphibious and comfortably seats 25
passengers plus 1-crew The air-conditioned cabin allows for
maximum visibility for all aboard The Pioneer Mk3 is robust and
dynamic in its performance
Commercial hovercraft
Mk3 AirLift Hovercraft - 1215m
Power is economicaly provided by one Deutz diesel engine of
330kW (442hp) to cruise easily at 40 knots with much higher
speeds available according to the surface conditions The hull is
manufactured from fibreglassPVC foam composite sandwich
the windows are glass and the skirt is urethane coated nylon A
Military version is available with increased payload and systems
redundancy Power for the Military version comes from two Steyr
diesel engines with a total installed power of 320kW (429hp) All
transmission electrical hydraulic and air systems are duplicated
for maximum redundancy The increased performance of the
Military version comes from the reduced engine weight of the twin
Steyr installation cf the Deutz installation
Source
httpwwwnauticexpocomprodairlift-hovercraftcommercial-hovercrafts-25251-142868html
HOVERFLIGHT
BALLISTIC amp UNIT DEFENCED
Triaxis Composites Collaboration with Institute of Aeronautics and Space in the development of Missile Nose Cone
Polymer composites is the evolution of the military defence
Thin steel was the helmet material of
WWII and remained the principal material until around the 1980rsquos
The advantages of using steel
included a simple technology for manufacture of the helmets low cost and reasonably good
impact protection However these helmets were found to provide only marginal protection
against fragments
During the Vietnam War the US Army experimented with fiber-reinforced inserts in the
helmets These inserts improved ballistic protection but at the same time added weight and
reduced the air space between the head and the helmet
By the early part of the 1980rsquos the US military had developed the first all-composite
100 fiber-reinforced helmet This development resulted in even better ballistic protection
without altering the weight of the helmet Other improvements included better head coverage and
more space for ventilation
Source
Composites Armor - A difficult but huge market
by A Brent Strong Brigham Young University
MILITARY VEHICLES
HIGH SPEED TRAIN SHINKANSEN
Advanced Composites provide lightweight solutions for railway vehicles
saving as much as 50-80 of the weight compared with traditional
components
A lower overall weight translates into less stress faster acceleration and
higher speeds as well as reduced starting and stopping inertia Today
these are important criteria in global high-speed and metropolitan
railway projects
Fire smoke and toxic fumes are key safety criteria for interior
components of railway carriages Any material selected for an interior
component must meet international fire retardant standards
for Rail Interiors and Exteriors
Ceiling Panels Stairs
Seating Vestibules
Window Panels Door Pillars
Partition WallsDiffusers
Gangway and Cabinet Panels Cabin and
Desk panels
Door Pillars Lavatory Modules (standard and
Front and Rear EndsRoof Panels
Nose Cones Under Fairings
Source
httpwwwpctaerail_compositesphp
101
SKY BUS
2009
Europe is the world leader in offshore wind with
828 wind turbines and a cumulative capacity of 2056 MW spread across 38 offshore wind farms in 9
European countries
The UK and Denmark are the current leaders with a 44 and 30 share respectively In 2009
five countries built new offshore wind farms
UK (284 MW)
Demark (230 MW)
Sweden (30 MW)
Germany (30 MW)
Norway (23 MW)
2010
Asia leads the growth in global wind power which grew 358 GW in 2010 bringing
total global capacity to 1944 GW ndash up 225 from 2009
the Global Wind Energy Council (GWEC)
Asia accounted for 19 GW of new global wind power installations driven by China which installed 165
GW
ldquoChina now has 423 GW of wind powerrdquo
ldquoThis puts China firmly on a path to reach 200 GW of installed wind power by 2020 At the same
time China has become the worldrsquos largest producer of wind energy equipmentrdquo
Source
httpwwwreinforcedplasticscomview15655asia-leads-global-wind-power-growth
httpimgdeusmcomdesignnews288288605-Sandia_Sizes_up_Wind_Turbine_Blade_Design_C_largegif
WIND ENERGY
Marine Current Turbines
Source
httpwwwsiemenscompressenpressreleasepress=enpressrelease2011solar-hydroex201111005htm
httpwwwmarineturbinescom
A commercial marine current turbine consists of
two rotors which are fixed on a structure within the
sea current The twin rotors rotate with the
movement of the tidal flow and the blades pitch
through 180 degrees to optimally track tidal current
(Press picture Marine Current Turbines)
Wave Star Energys Multi-point Absorber
CFRP COLUMN REINFORCEMENT
INDUSTRIAL TANKS
107
INDUSTRIAL PIPES
PRESSURE TANKS
109
ldquoLetrsquos Make with Compositesrdquo
HOVERFLIGHT
BALLISTIC amp UNIT DEFENCED
Triaxis Composites Collaboration with Institute of Aeronautics and Space in the development of Missile Nose Cone
Polymer composites is the evolution of the military defence
Thin steel was the helmet material of
WWII and remained the principal material until around the 1980rsquos
The advantages of using steel
included a simple technology for manufacture of the helmets low cost and reasonably good
impact protection However these helmets were found to provide only marginal protection
against fragments
During the Vietnam War the US Army experimented with fiber-reinforced inserts in the
helmets These inserts improved ballistic protection but at the same time added weight and
reduced the air space between the head and the helmet
By the early part of the 1980rsquos the US military had developed the first all-composite
100 fiber-reinforced helmet This development resulted in even better ballistic protection
without altering the weight of the helmet Other improvements included better head coverage and
more space for ventilation
Source
Composites Armor - A difficult but huge market
by A Brent Strong Brigham Young University
MILITARY VEHICLES
HIGH SPEED TRAIN SHINKANSEN
Advanced Composites provide lightweight solutions for railway vehicles
saving as much as 50-80 of the weight compared with traditional
components
A lower overall weight translates into less stress faster acceleration and
higher speeds as well as reduced starting and stopping inertia Today
these are important criteria in global high-speed and metropolitan
railway projects
Fire smoke and toxic fumes are key safety criteria for interior
components of railway carriages Any material selected for an interior
component must meet international fire retardant standards
for Rail Interiors and Exteriors
Ceiling Panels Stairs
Seating Vestibules
Window Panels Door Pillars
Partition WallsDiffusers
Gangway and Cabinet Panels Cabin and
Desk panels
Door Pillars Lavatory Modules (standard and
Front and Rear EndsRoof Panels
Nose Cones Under Fairings
Source
httpwwwpctaerail_compositesphp
101
SKY BUS
2009
Europe is the world leader in offshore wind with
828 wind turbines and a cumulative capacity of 2056 MW spread across 38 offshore wind farms in 9
European countries
The UK and Denmark are the current leaders with a 44 and 30 share respectively In 2009
five countries built new offshore wind farms
UK (284 MW)
Demark (230 MW)
Sweden (30 MW)
Germany (30 MW)
Norway (23 MW)
2010
Asia leads the growth in global wind power which grew 358 GW in 2010 bringing
total global capacity to 1944 GW ndash up 225 from 2009
the Global Wind Energy Council (GWEC)
Asia accounted for 19 GW of new global wind power installations driven by China which installed 165
GW
ldquoChina now has 423 GW of wind powerrdquo
ldquoThis puts China firmly on a path to reach 200 GW of installed wind power by 2020 At the same
time China has become the worldrsquos largest producer of wind energy equipmentrdquo
Source
httpwwwreinforcedplasticscomview15655asia-leads-global-wind-power-growth
httpimgdeusmcomdesignnews288288605-Sandia_Sizes_up_Wind_Turbine_Blade_Design_C_largegif
WIND ENERGY
Marine Current Turbines
Source
httpwwwsiemenscompressenpressreleasepress=enpressrelease2011solar-hydroex201111005htm
httpwwwmarineturbinescom
A commercial marine current turbine consists of
two rotors which are fixed on a structure within the
sea current The twin rotors rotate with the
movement of the tidal flow and the blades pitch
through 180 degrees to optimally track tidal current
(Press picture Marine Current Turbines)
Wave Star Energys Multi-point Absorber
CFRP COLUMN REINFORCEMENT
INDUSTRIAL TANKS
107
INDUSTRIAL PIPES
PRESSURE TANKS
109
ldquoLetrsquos Make with Compositesrdquo
BALLISTIC amp UNIT DEFENCED
Triaxis Composites Collaboration with Institute of Aeronautics and Space in the development of Missile Nose Cone
Polymer composites is the evolution of the military defence
Thin steel was the helmet material of
WWII and remained the principal material until around the 1980rsquos
The advantages of using steel
included a simple technology for manufacture of the helmets low cost and reasonably good
impact protection However these helmets were found to provide only marginal protection
against fragments
During the Vietnam War the US Army experimented with fiber-reinforced inserts in the
helmets These inserts improved ballistic protection but at the same time added weight and
reduced the air space between the head and the helmet
By the early part of the 1980rsquos the US military had developed the first all-composite
100 fiber-reinforced helmet This development resulted in even better ballistic protection
without altering the weight of the helmet Other improvements included better head coverage and
more space for ventilation
Source
Composites Armor - A difficult but huge market
by A Brent Strong Brigham Young University
MILITARY VEHICLES
HIGH SPEED TRAIN SHINKANSEN
Advanced Composites provide lightweight solutions for railway vehicles
saving as much as 50-80 of the weight compared with traditional
components
A lower overall weight translates into less stress faster acceleration and
higher speeds as well as reduced starting and stopping inertia Today
these are important criteria in global high-speed and metropolitan
railway projects
Fire smoke and toxic fumes are key safety criteria for interior
components of railway carriages Any material selected for an interior
component must meet international fire retardant standards
for Rail Interiors and Exteriors
Ceiling Panels Stairs
Seating Vestibules
Window Panels Door Pillars
Partition WallsDiffusers
Gangway and Cabinet Panels Cabin and
Desk panels
Door Pillars Lavatory Modules (standard and
Front and Rear EndsRoof Panels
Nose Cones Under Fairings
Source
httpwwwpctaerail_compositesphp
101
SKY BUS
2009
Europe is the world leader in offshore wind with
828 wind turbines and a cumulative capacity of 2056 MW spread across 38 offshore wind farms in 9
European countries
The UK and Denmark are the current leaders with a 44 and 30 share respectively In 2009
five countries built new offshore wind farms
UK (284 MW)
Demark (230 MW)
Sweden (30 MW)
Germany (30 MW)
Norway (23 MW)
2010
Asia leads the growth in global wind power which grew 358 GW in 2010 bringing
total global capacity to 1944 GW ndash up 225 from 2009
the Global Wind Energy Council (GWEC)
Asia accounted for 19 GW of new global wind power installations driven by China which installed 165
GW
ldquoChina now has 423 GW of wind powerrdquo
ldquoThis puts China firmly on a path to reach 200 GW of installed wind power by 2020 At the same
time China has become the worldrsquos largest producer of wind energy equipmentrdquo
Source
httpwwwreinforcedplasticscomview15655asia-leads-global-wind-power-growth
httpimgdeusmcomdesignnews288288605-Sandia_Sizes_up_Wind_Turbine_Blade_Design_C_largegif
WIND ENERGY
Marine Current Turbines
Source
httpwwwsiemenscompressenpressreleasepress=enpressrelease2011solar-hydroex201111005htm
httpwwwmarineturbinescom
A commercial marine current turbine consists of
two rotors which are fixed on a structure within the
sea current The twin rotors rotate with the
movement of the tidal flow and the blades pitch
through 180 degrees to optimally track tidal current
(Press picture Marine Current Turbines)
Wave Star Energys Multi-point Absorber
CFRP COLUMN REINFORCEMENT
INDUSTRIAL TANKS
107
INDUSTRIAL PIPES
PRESSURE TANKS
109
ldquoLetrsquos Make with Compositesrdquo
Polymer composites is the evolution of the military defence
Thin steel was the helmet material of
WWII and remained the principal material until around the 1980rsquos
The advantages of using steel
included a simple technology for manufacture of the helmets low cost and reasonably good
impact protection However these helmets were found to provide only marginal protection
against fragments
During the Vietnam War the US Army experimented with fiber-reinforced inserts in the
helmets These inserts improved ballistic protection but at the same time added weight and
reduced the air space between the head and the helmet
By the early part of the 1980rsquos the US military had developed the first all-composite
100 fiber-reinforced helmet This development resulted in even better ballistic protection
without altering the weight of the helmet Other improvements included better head coverage and
more space for ventilation
Source
Composites Armor - A difficult but huge market
by A Brent Strong Brigham Young University
MILITARY VEHICLES
HIGH SPEED TRAIN SHINKANSEN
Advanced Composites provide lightweight solutions for railway vehicles
saving as much as 50-80 of the weight compared with traditional
components
A lower overall weight translates into less stress faster acceleration and
higher speeds as well as reduced starting and stopping inertia Today
these are important criteria in global high-speed and metropolitan
railway projects
Fire smoke and toxic fumes are key safety criteria for interior
components of railway carriages Any material selected for an interior
component must meet international fire retardant standards
for Rail Interiors and Exteriors
Ceiling Panels Stairs
Seating Vestibules
Window Panels Door Pillars
Partition WallsDiffusers
Gangway and Cabinet Panels Cabin and
Desk panels
Door Pillars Lavatory Modules (standard and
Front and Rear EndsRoof Panels
Nose Cones Under Fairings
Source
httpwwwpctaerail_compositesphp
101
SKY BUS
2009
Europe is the world leader in offshore wind with
828 wind turbines and a cumulative capacity of 2056 MW spread across 38 offshore wind farms in 9
European countries
The UK and Denmark are the current leaders with a 44 and 30 share respectively In 2009
five countries built new offshore wind farms
UK (284 MW)
Demark (230 MW)
Sweden (30 MW)
Germany (30 MW)
Norway (23 MW)
2010
Asia leads the growth in global wind power which grew 358 GW in 2010 bringing
total global capacity to 1944 GW ndash up 225 from 2009
the Global Wind Energy Council (GWEC)
Asia accounted for 19 GW of new global wind power installations driven by China which installed 165
GW
ldquoChina now has 423 GW of wind powerrdquo
ldquoThis puts China firmly on a path to reach 200 GW of installed wind power by 2020 At the same
time China has become the worldrsquos largest producer of wind energy equipmentrdquo
Source
httpwwwreinforcedplasticscomview15655asia-leads-global-wind-power-growth
httpimgdeusmcomdesignnews288288605-Sandia_Sizes_up_Wind_Turbine_Blade_Design_C_largegif
WIND ENERGY
Marine Current Turbines
Source
httpwwwsiemenscompressenpressreleasepress=enpressrelease2011solar-hydroex201111005htm
httpwwwmarineturbinescom
A commercial marine current turbine consists of
two rotors which are fixed on a structure within the
sea current The twin rotors rotate with the
movement of the tidal flow and the blades pitch
through 180 degrees to optimally track tidal current
(Press picture Marine Current Turbines)
Wave Star Energys Multi-point Absorber
CFRP COLUMN REINFORCEMENT
INDUSTRIAL TANKS
107
INDUSTRIAL PIPES
PRESSURE TANKS
109
ldquoLetrsquos Make with Compositesrdquo
HIGH SPEED TRAIN SHINKANSEN
Advanced Composites provide lightweight solutions for railway vehicles
saving as much as 50-80 of the weight compared with traditional
components
A lower overall weight translates into less stress faster acceleration and
higher speeds as well as reduced starting and stopping inertia Today
these are important criteria in global high-speed and metropolitan
railway projects
Fire smoke and toxic fumes are key safety criteria for interior
components of railway carriages Any material selected for an interior
component must meet international fire retardant standards
for Rail Interiors and Exteriors
Ceiling Panels Stairs
Seating Vestibules
Window Panels Door Pillars
Partition WallsDiffusers
Gangway and Cabinet Panels Cabin and
Desk panels
Door Pillars Lavatory Modules (standard and
Front and Rear EndsRoof Panels
Nose Cones Under Fairings
Source
httpwwwpctaerail_compositesphp
101
SKY BUS
2009
Europe is the world leader in offshore wind with
828 wind turbines and a cumulative capacity of 2056 MW spread across 38 offshore wind farms in 9
European countries
The UK and Denmark are the current leaders with a 44 and 30 share respectively In 2009
five countries built new offshore wind farms
UK (284 MW)
Demark (230 MW)
Sweden (30 MW)
Germany (30 MW)
Norway (23 MW)
2010
Asia leads the growth in global wind power which grew 358 GW in 2010 bringing
total global capacity to 1944 GW ndash up 225 from 2009
the Global Wind Energy Council (GWEC)
Asia accounted for 19 GW of new global wind power installations driven by China which installed 165
GW
ldquoChina now has 423 GW of wind powerrdquo
ldquoThis puts China firmly on a path to reach 200 GW of installed wind power by 2020 At the same
time China has become the worldrsquos largest producer of wind energy equipmentrdquo
Source
httpwwwreinforcedplasticscomview15655asia-leads-global-wind-power-growth
httpimgdeusmcomdesignnews288288605-Sandia_Sizes_up_Wind_Turbine_Blade_Design_C_largegif
WIND ENERGY
Marine Current Turbines
Source
httpwwwsiemenscompressenpressreleasepress=enpressrelease2011solar-hydroex201111005htm
httpwwwmarineturbinescom
A commercial marine current turbine consists of
two rotors which are fixed on a structure within the
sea current The twin rotors rotate with the
movement of the tidal flow and the blades pitch
through 180 degrees to optimally track tidal current
(Press picture Marine Current Turbines)
Wave Star Energys Multi-point Absorber
CFRP COLUMN REINFORCEMENT
INDUSTRIAL TANKS
107
INDUSTRIAL PIPES
PRESSURE TANKS
109
ldquoLetrsquos Make with Compositesrdquo
101
SKY BUS
2009
Europe is the world leader in offshore wind with
828 wind turbines and a cumulative capacity of 2056 MW spread across 38 offshore wind farms in 9
European countries
The UK and Denmark are the current leaders with a 44 and 30 share respectively In 2009
five countries built new offshore wind farms
UK (284 MW)
Demark (230 MW)
Sweden (30 MW)
Germany (30 MW)
Norway (23 MW)
2010
Asia leads the growth in global wind power which grew 358 GW in 2010 bringing
total global capacity to 1944 GW ndash up 225 from 2009
the Global Wind Energy Council (GWEC)
Asia accounted for 19 GW of new global wind power installations driven by China which installed 165
GW
ldquoChina now has 423 GW of wind powerrdquo
ldquoThis puts China firmly on a path to reach 200 GW of installed wind power by 2020 At the same
time China has become the worldrsquos largest producer of wind energy equipmentrdquo
Source
httpwwwreinforcedplasticscomview15655asia-leads-global-wind-power-growth
httpimgdeusmcomdesignnews288288605-Sandia_Sizes_up_Wind_Turbine_Blade_Design_C_largegif
WIND ENERGY
Marine Current Turbines
Source
httpwwwsiemenscompressenpressreleasepress=enpressrelease2011solar-hydroex201111005htm
httpwwwmarineturbinescom
A commercial marine current turbine consists of
two rotors which are fixed on a structure within the
sea current The twin rotors rotate with the
movement of the tidal flow and the blades pitch
through 180 degrees to optimally track tidal current
(Press picture Marine Current Turbines)
Wave Star Energys Multi-point Absorber
CFRP COLUMN REINFORCEMENT
INDUSTRIAL TANKS
107
INDUSTRIAL PIPES
PRESSURE TANKS
109
ldquoLetrsquos Make with Compositesrdquo
2009
Europe is the world leader in offshore wind with
828 wind turbines and a cumulative capacity of 2056 MW spread across 38 offshore wind farms in 9
European countries
The UK and Denmark are the current leaders with a 44 and 30 share respectively In 2009
five countries built new offshore wind farms
UK (284 MW)
Demark (230 MW)
Sweden (30 MW)
Germany (30 MW)
Norway (23 MW)
2010
Asia leads the growth in global wind power which grew 358 GW in 2010 bringing
total global capacity to 1944 GW ndash up 225 from 2009
the Global Wind Energy Council (GWEC)
Asia accounted for 19 GW of new global wind power installations driven by China which installed 165
GW
ldquoChina now has 423 GW of wind powerrdquo
ldquoThis puts China firmly on a path to reach 200 GW of installed wind power by 2020 At the same
time China has become the worldrsquos largest producer of wind energy equipmentrdquo
Source
httpwwwreinforcedplasticscomview15655asia-leads-global-wind-power-growth
httpimgdeusmcomdesignnews288288605-Sandia_Sizes_up_Wind_Turbine_Blade_Design_C_largegif
WIND ENERGY
Marine Current Turbines
Source
httpwwwsiemenscompressenpressreleasepress=enpressrelease2011solar-hydroex201111005htm
httpwwwmarineturbinescom
A commercial marine current turbine consists of
two rotors which are fixed on a structure within the
sea current The twin rotors rotate with the
movement of the tidal flow and the blades pitch
through 180 degrees to optimally track tidal current
(Press picture Marine Current Turbines)
Wave Star Energys Multi-point Absorber
CFRP COLUMN REINFORCEMENT
INDUSTRIAL TANKS
107
INDUSTRIAL PIPES
PRESSURE TANKS
109
ldquoLetrsquos Make with Compositesrdquo
Marine Current Turbines
Source
httpwwwsiemenscompressenpressreleasepress=enpressrelease2011solar-hydroex201111005htm
httpwwwmarineturbinescom
A commercial marine current turbine consists of
two rotors which are fixed on a structure within the
sea current The twin rotors rotate with the
movement of the tidal flow and the blades pitch
through 180 degrees to optimally track tidal current
(Press picture Marine Current Turbines)
Wave Star Energys Multi-point Absorber
CFRP COLUMN REINFORCEMENT
INDUSTRIAL TANKS
107
INDUSTRIAL PIPES
PRESSURE TANKS
109
ldquoLetrsquos Make with Compositesrdquo
CFRP COLUMN REINFORCEMENT
INDUSTRIAL TANKS
107
INDUSTRIAL PIPES
PRESSURE TANKS
109
ldquoLetrsquos Make with Compositesrdquo
INDUSTRIAL TANKS
107
INDUSTRIAL PIPES
PRESSURE TANKS
109
ldquoLetrsquos Make with Compositesrdquo
107
INDUSTRIAL PIPES
PRESSURE TANKS
109
ldquoLetrsquos Make with Compositesrdquo
PRESSURE TANKS
109
ldquoLetrsquos Make with Compositesrdquo
109
ldquoLetrsquos Make with Compositesrdquo