Latest Manufacturing Technologies for Low-cost, Energy- …€¦ · Derek Berry Wind Turbines...
Transcript of Latest Manufacturing Technologies for Low-cost, Energy- …€¦ · Derek Berry Wind Turbines...
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Latest Manufacturing Technologies for Low-cost, Energy-efficient Manufacturing of Advanced Polymer Composites
Uday VaidyaChief Technology Officer
8th Annual American Manufacturing
Strategies Summit 2017
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Manufacturing USA Integration
UT Lab:
precursor, digital
fiber
Automation
Workforce collaborationWorkforce collaboration,
Colocation
Workforce collaboration,
Modeling & Simulation
Recycling initiatives
Resins & AdhesivesFacility & Equipment
Networking; Testbeds
Composite AM,
Tooling
Confidential information-Do Not Distribute 2
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Operated by Collaborative Composite Solutions Corp, an independent not-for-profit
Governed by a board of directors
A wholly owned subsidiary of the University of Tennessee Research Foundation
Headquartered in Knoxville, Tennessee
Over 155 member consortium, including more than 125 industrial entities across supply chain
$250M in funding with $70M from DOE and $180M from partners
What is IACMI?
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Research and Development Partner for Industry
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IACMI – A National Institute for Advanced Composites
OhioCompressedGas Storage
IndianaInnovativeDesign,
Predictive Modeling &Simulation
TennesseeComposite Materials & Process Technology
New YorkComposite Prototyping Center
MichiganVehicles
WashingtonComposite Recycling Technology Center & Peninsula College
ColoradoWind Turbines
Technical Goals:• Lower carbon fiber–reinforced polymer (CFRP) cost• Reduce CFRP embodied energy • Improve composite recyclability into useful products
150 partners
All 50 states
IACMI- The Composites Institute has partnered with ACMA, the premiere composites industry association and Composites One for workforce training capabilities.
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IACMI-The Composites Institute Senior Leadership Team
Dale BrosiusChief Commercialization Officer
Cliff EberleMaterials and
Processing Technology Area
Director
R. Byron PipesModeling & Simulation
Technology AreaDirector
Lawrence DrzalVehicles Technology
Area Director
Derek BerryWind Turbines
Technology Area Director
Brian RiceCompressed Gas
StorageTechnology Area
Director
Uday VaidyaChief Technology OfficerRenae Speck
Chief Operations Officer
John HopkinsChief Executive Officer
Interim
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IACMI-The Composites Institute Facilities
ColoradoIndiana
Michigan
Tennessee
Ohio
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IACMI Focus Areas and Metrics
+ 500M Capital Investment
Confidential information-Do Not Distribute 8
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Solutionspinning
line Carbon Fiber Technology
Facility Pre-preg
productionpilot/full
scale Pilot-scale
PCM 750 ton press
Full ScalePCM
4,000 ton press
Scale-up Across IACMI Core Partners
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Materials
Production
Intermediates
Processing
Composites
Manufacturing
(Sub) System
Assembly
Composites
Recycling
Pro
du
ct
Fo
rms
Pro
cess T
ech
no
log
ies
Crosscutting Technologies and Shared Services
•Commercial PAN-CF
•Low Cost PAN-CF
•Low Cost PO-CF
•Low Cost Pitch-CF
•Low Cost Lignin-CF
•Biomass PAN-CF
•Glass Fiber
•Thermoplastic Resins
•Thermoset Resins
•Additives
•Woven Fabric
•Non-woven Fabric
•Braids
•Prepregs
•Towpreg
•Molding Compounds
•Tapes
•Pultruded Forms
(rods, beams)
•3D Parts/Preforms
•Sheet Products
•Tooling (molds, dies)
•Pultruded Forms
•Pressure Vessels
•Pipes
•Shafts
•Rollers
•Tubes
•Automotive
Assemblies
Bodies, Chassis,
Chassis
Interiors
•Gas Storage
Systems
CNG
Hydrogen
•Wind Turbines
Spars (Caps,
Shear
Webs)
Blade Skins
Blades
•Offal/Trim Scrap
•Chopped Fiber
•Roll Goods
•Preforms
•Fiber Spinning
Solution Spinning
Melt Spinning
Gel Spinning
Electro Spinning
•Fiber Conversion
Thermal
Plasma
Microwave
Ultraviolet
•Fabric Weaving
•Fiber Braiding
•Prepregging
•Compounding
SMC
BMC
•Extrusion
•Stitching
•Auto Tape
Placement
•Preforming
•Thermoforming
•Compression
Molding
•Injection Molding
•Transfer Molding
HP-RTM
VA-RTM
Other Variants
•Additive
Manufacturing
•Filament Winding
•Pultrusion
•Infusion/Compressio
n
•Resin spraying
•Infusion/Cure/Set
Cooling (TP systems)
Thermal
Plasma
Microwave
Ultraviolet
Induction
Infrared
Magnetic Field
Electron Beam
•Pyrolysis
•Solvolysis
•Modeling & Simulation
Supercomputing
Process modeling
Microstructure properties
Probabilistic failure
Analysis
Multiscale modeling
Rheokinetics modeling
Crash modeling
•NDE/NDI
Thermography
Fiber optics
Spectroscopy
Flurorescence
Attenuation/Reflection
High resolution
microscopy
Scanning lasers
•Materials
Characterization
Microscopy
X-Rays
Neutrons
Mechanical
Physical
Thermal
Chemical
•Joining
Adhesives
(Reversible, Curie
Limited Curing)
Mechanical
fastening
(For Multi-
Material
Systems)
•Innovative Design Concepts
Composite Tube Super-Light-
weight auto. body structure
Composite vehicle snap fit joints
Conformable auto CGS tanks
Segmented adhesive-bonded
wind blades
Key IACMI Capabilities (300,000 sq.ft, $200 million in replacement value investment)
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Ways to Partner with IACMI
1. RD&D Research Project
A. Enterprise
B. Technology Collaboration
C. Topic-Specific
2. Membership
A. Charter
B. Premium
C. Resource
D. Consortium
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Roadmapping Strategy
Integrated R&D efforts across IACMI Technology Areas toward 5-/10-year targets
Industry-led projects draw upon resources from one or more IACMI Technology Areas
Eight cross-cutting subtopics help address full range of enabling technologies
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Global vehicle production is growing
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Why Lightweighting?
“Excess weight kills any self-propelled vehicle. There are a lot of fool ideas about weight . . . Whenever anyone suggests to me that I might increase weight or add a part, I look into decreasing weight and eliminating a part!” – Henry Ford, 1922
Every automotive manufacturer is pursuing
lightweighting as a key strategy to reduce fuel
consumption—irrespective of the powertrain technology
pathway.
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Weight reduction – Automotive, Mass Transit & Truck
Performance
Increased ‘customer value’ while staying within Corporate Average Fuel Economy (CAFÉ) limits
Long term increase in fuel prices
6-8% (with mass compounding) increase in fuel economy for every 10% reduction in weight, everything else being the same
DOE, Carpenter, 2008
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Big Area Additive Manufacturing for producing large scale
composites – ground vehicle components, cars, bridges,
wind mill blades etc..
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Leverage Computing Power to Enhance Design Confidence
Create Composites Virtual Factory HUB (cvfHUB)
Develop platform for hosting and integration of commercial software tools for composites
Provide end-to-end simulation for composites
Correlate at multiple scales prediction and reality
Make tools and knowledge available to entire value chain to enhance confidence and reduce cost
Implementation is underway, rollout commences mid-2017
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• Facility is shared by IACMI-The Composites Institute and LIFT Innovation Institute
IACMI-The Composites Institute Facilities, Vehicle Scale Up Facility in Corktown Area of Detroit, Michigan
• Co-located with LIFT, 9300 m2 total
• Capitalization >$15M
Compression Press
Schuler Press: 4000T, 3.7m x 2.4m platen
Thermosets & Thermoplastic
Infusion, compression
Injection Molding Cell
Milacron Press: 3000T, 3m x 2.4m platen
1-10kg shot size, 3 – 275kg dryers
Robotic handling
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*Courtesy of Xperion
CGS Manufacture State of the Art
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Braid Offers Potential for Enhanced Safety and Reduced Mass
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• High-performance simulation tools
• Wind resource assessment
• Wind forecasting
• Utility grid connectivity
• Economic analysis of turbine technology
• Full-scale structural testing
− Blades
− Dynamometer
− Field testing
National Wind Technology Center (NWTC)
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Wind Blade Challenges and Opportunities
• Reduction in hands-on labor− Automated fabric laying− Automated tape laying
• Transportation logistics
− Segmented blades
• Recyclability
− Thermoplastics?
• Field reliability of blades
− In-process nondestructiveevaluation
− Structural testing
• Blade structural properties
− Pultruded spar caps
• Time to market
− Additive manufacturing―molds
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• Manufacturing space focused on composite manufacturing innovation
• 55’ x 200’ – 10,000 sq. ft.
• Adjacent to blade test facility
• Full-scale blade component manufacturing
IACMI Wind TA Composites Manufacturing and Education Technology (CoMET) Facility
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Full Scale Wind Blade Tooling
48.5m blade tip mold
Courtesy GE
Large shear web mold
Courtesy GE
Portion of 60m spar cap infusion mold
Courtesy DowAksa
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Workforce Training
STEM Events
Hands-On Events
Intern Program
Online Training (CCT)
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$70M - DOE
$189M - Other
123 - Member Consortium
6 Core Partner States
Strong Leadership
5 Technology Areas
Production capacity
Jobs
- 75%CFRP embodied energy savings
- 50%CFRPproduction cost
Greenhouse gas avoidance
- 25%
- 50%
- 50%- 75%
95%FRP recycled
and/or reused
80%
Federal Investment Will Catalyze a Composites Ecosystem
in the Heart of US Manufacturing
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10/30/2017 Confidential information statement (go to INSERT>>HEADER & FOOTER) 27
Contact info:
Uday Vaidya
Chief Technology Officer
IACMI-The Composites Institute, managed by Collaborative Composite
Solutions Corporation
Email: [email protected]