New innovations in carbon fibre research

Carbon Nexus
Innovations in Carbon Fibre Research
Sanctuary Cove
22 April 2015
Carbon Nexus
Introduction & Capabilities
Innovations in Carbon Fibre Research
Industry Engagement & Applications
Introduction & Capabilities
The Carbon Nexus leadership team
Derek Buckmaster, Executive Director
Derek recently joined Carbon Nexus from SABIC where he was leading the technical aspects of their carbon fibre manufacturing project. Prior to joining SABIC Derek spent 19 years with GE Plastics where he worked in composites and engineering thermoplastics. With a background in technology management, strategy and product development, marketing, Six Sigma and design, Derek oversees the strategic development and marketing of Carbon Nexus. Professor Bronwyn Fox, Research Director
Bronwyn leads the carbon fibre and composite research team. She has been researching more than 10 years of experience in composites research, in fields as diverse as fibre manufacture, surface treatment, 3D preforms for complex components, out‐of‐autoclave cure of composites, and structure‐property relationships. She has published more than 100 papers and has built up a team of approximately 30 researchers to establish one of the world’s leading carbon fibre composites research facilities. Steve Atkiss, General Manager
Steve offers a skill base to the carbon fibre industry combining engineering and operational experience from research and development to full commercial scale carbon fibre processing. Steve has over 10 years of CF mufacturing experience with SGL Carbon Group. Key positions held during this period included Maintenance Manager, Engineering Manager, Production Manager and Commissioning Manager. Prior to joining Carbon Nexus he was the chief design expert for carbon fibre production line equipment and processing techniques with Despatch Industries. Adjunct Professor Brad Dunstan, Business Development (CEO, VCAMM)
Brad’s background is a unique mix of defence, automotive industry and technology commercialisation experience. His qualifications in Science, Engineering and Management provide industry focus and leadership in the Business Development role of Carbon Nexus.
Open‐access research on carbon fibre & composites
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Carbon Nexus is an open‐access •
research facility focused on carbon fibre & composite materials
Owned and operated by Deakin University, on the Waurn Ponds campus in Geelong, Australia
Developed in collaboration with the Victorian Centre for Advanced Materials Manufacturing (VCAMM)
A nexus between industry, academia, research and training
Vision: A world‐class facility to attract global companies to research and invest in Victoria
The centre was established with A$34M of funding from Deakin University, Australian Federal Government and Victorian State Government
Deakin Waurn Ponds Campus ‐ Materials Research
Deakin University – Waurn Ponds Campus
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CSIRO 3
Institute For Frontier Materials 1
Carbon Nexus 2
Waurn Ponds
Lightweight Metals
Bio‐materials
Innovative Manufacturing Technologies
Micro & Nano‐Systems
Fibres & Textiles
Polymers
Composites
Molecular Modelling
Plasma
Energy Efficiency, Resource & Infrastructure Sustainability
Energy & Electromaterials
Nanotechnology
Surface Engineering
Corrosion
A growing carbon fibre precinct
Carbon Revolution
Quickstep
A growing carbon fibre precinct
Within 50km a range of existing companies are involved in carbon fibre and composites manufacturing:
• Sykes Racing (high performance rowing boats)
• Marand (aerospace – JSF vertical stabiliser)
• RPC Technologies (pipes, tanks, rail, defence)
• Geelong Carbon Craft (motorcycle parts)
• 36T (bicycle wheels)
• Boeing Aerostructures Australia
Carbon Nexus – Where are we?
Carbon Nexus
Melbourne
Geelong
What is unique about Carbon Nexus?
The Carbon Fibre Pilot Line facility
• A state‐of‐the‐art Carbon Fibre 50‐100 tonne pilot‐scale production facility in a university environment with world class research infrastructure
• The only facility of its type, globally
The People
• A dynamic team of multi‐disciplined researchers with a focus on delivering industrially relevant outcomes
The Partnerships
• Strong partnerships with global carbon fibre manufacturers and users
• Global collaborations of strategic importance
Carbon Fibre Processing – Single Tow Line
• Single‐tow continuous carbonisation line
• Installed in a secure facility
• Flexible configuration to meet customer requirements
• Capable of processing tows from 0.5K to 320K
Ideal for:
• Fundamental research
• Initial assessment of new
precursors
• Assessment of new sizing recipes
• Process condition experiments
• Initial process training
Carbon Fibre Processing – Single Tow Line
Typical operating parameters at 30 m/h:
• Creel to winder duration:
• Oxidation time:
• LT Furnace duration:
• HT Furnace duration:
212 minutes
88 minutes in heat
2.4 minutes in heat
1.8 minutes in heat
Typical Carbon Fibre output at 30 m/h:
• 3k (single tow)
• 12k (single tow)
• 24k (single tow)
• 50k (single tow)
• 320k (single tow)
0.144 kg/24 hours
0.576 kg/24 hours
1.150 kg/24 hours
2.300 kg/24 hours
14.84 kg/24 hours
Carbon Fibre Processing – Pilot Line
• Installed in a secure facility
• Up to 30 tows, 3K to 320K
• Industrial‐scale equipment
• Fibre length 396m, creel to winders
• 86m line length, 92m building length
Ideal for:
• Precursor commercialisation trials
• Assessment of new sizing recipes
• Process condition experiments
• Production of small quantities of customised carbon fibre
• Industrial operator training
Carbon Fibre Processing – Pilot Line
Typical operating parameters at 120 m/h:
• Creel to winder duration:
198 minutes
• Oxidation time:
128 minutes (creel to LT)
• LT & HT Furnace duration:
2.0 minutes in heat
Typical Carbon Fibre output at 120 m/h:
• 3k (30 tows)
17.2 kg/24 hours
• 12k (30 tows)
69.1 kg/24 hours
• 24k (30 tows)
138 kg/24 hours
• 50k (18 tows)
276 kg/24 hours
• 320k (single tow)
331 kg/24 hours
Carbon Fibre Processing – Training Packages Offered
Carbon Nexus offers a range of training:
Standard package
• Two weeks intensive training offered for Grade One Operators
• Participants are equipped to be production‐ready and able to safely operate commercial‐scale Carbon Fibre production equipment
Tailored training courses
• To meet the specific requirements of current and future carbon fibre manufacturers
• Training is provided at all levels, from operator, process engineer, in‐house trainer, researcher and management.
Carbon Fibre Processing – Typical Training Topics Covered
Carbon Fibre Theory Line Maintenance
Administration
Health and Safety Protocols
Emergency Protocols
Process Explained
Practical Fibre Skills Start‐Up & Shut‐Down Operations
Process Line Operations
HAZOP (Hazardous Operations)
Sample Extraction
Quality Assurance and Procedure Creation
• Environmental Protocols
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Carbon Fibre Characterisation
Many specialised fibre analyses including
• Scanning electron microscopy
• Atomic Force Microscopy
• Small and Wide Angle X‐ray Scattering (SAX/WAX) • Raman spectroscopy
• Surface Energy Analysis
• Differential Scanning Calorimetry
• Fourier Transform IR Spectroscopy • Fibre Diameter Analysis
• X‐Ray Diffraction Spectroscopy
• X‐ray Photoelectron Spectroscopy
Composites Processing
Carbon Nexus offers a range of composites processing methods including:
• Dry lay‐up
• Vacuum‐assisted resin infusion
• Programmable curing ovens (capable of N2 atmosphere)
• Out‐of‐autoclave curing
– Compression molding
– Quickstep
Innovation in Carbon Fibre Research Research across the entire carbon fibre supply chain
Carbon Nexus offers research, development, training and consulting capabilities across the entire carbon fibre supply chain
Acrylonitrile (monomer)
Polymer chemistry
Precursor Fibre
Fibre science
Carbon Fibre
Composites
Carbon fibre processing
Textiles
Preforms
Surface Treatment
Sizing
Rapid manufacturing
Structures
Structural design,
analysis & monitoring
Strategic research themes driven by industry needs
LOW COST FIBRE
HIGH PERFORMANCE FIBRE
IMPROVED SURFACE TREATMENT
RAPID CURE
Low Cost Carbon Fibre – Energy Optimisation
Power Consumption
Prior to Optimisation (%)
Optimised Power Consumption
(kW)
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Drives 3.2%
Winders 1.7%
200
300
Oxidation
Abatement
5.6%
Pre‐
Carbonisation
6.7%
LT Furnace
HT Furnace
Stabilisation
48.4%
ST & Sizing
15.7%
100
ST & Sizing
Winders
Drives
Abatement
Carbonisation
18.7%
Following optimisation (277 kW)
Prior to Optimisatin (822 kW)
400
500
Effect of tension
D/G Ratio
D (1378 cm‐1) / G (1588 cm‐1) UQ/Deakin Low Cost Carbon Fibre from Australian Spinifex grass
• Highest aspect ratio, toughest nanocellulose ever reported
• Mild, low energy (low cost) processing
• Unusually high hemicellulose content engenders flexibility
Prof Darren Martin, Prof Eric McFarland, Prof Bronwyn Fox, Dr Pratheep Kumar Annamalai, Dr Bronwyn Laycock
Electro‐spun fibres
Ionic Liquids
New approaches towards lowering the cost and environmental impact of carbon fibre production 70°C decrease in exothermic event for PAN: Enables oxidizing at lower temperatures High performance carbon fibre
1. Advanced characterisation techniques
2. Nanostructured precursors
3. RAFT PAN precursors
Nanostructured precursors:
• Collaboration with the University of Wollongong
• More than 250% improvement in tensile strength and 270% improvement in Young’s modulus of PAN‐based precursor, with addition of 1 wt. % of nano‐additive
High Performance Carbon Fibre
Novel advanced characterisation techniques
TEM image of high‐modulus fibre
(Scale = 5nm)
Comparison of compressive strength in longitudinal (top) and transverse (bottom) directions
Precursor Chemistry
Partners:
CSIRO
University of Southern Mississippi
Fibre Characterisation
Australian Synchrotron
Clayton, Victoria
High brilliance photon source:
• Single fibre/monofilament studies
• Fibre‐composite studies
SAXS‐WAXS content:
SAXS: nm length scales
• Lamellar structure
• Pore size
WAXS: atomic ordering
• Graphitic lattice spacing
• Orientation
• Elastic strain Dr. Peter Lynch
Bio‐inspired interfaces for surface treatment & sizing
• Bio‐inspired design of interfaces
• Ability to tailor plasma polymer coatings
Abalone shell inner surface
Prof Tiffany Walsh, Prof Sally MacArthur (Swinburne)
Dr Luke O’Dell
Dr Luke Henderson
Sugawara‐Narutaki, Polym. J. 2012, doi: 10.1038/pj.2012.171
Fibre surface treatment and sizing
Precursor Manufacturers
Post spinning modification
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handling
strength
reduce stabilisation time
increase oxidation rate
Carbon Fibre Manufacturers
Intermediate product Manufacturers
Composite Manufacturers
Surface treatment and sizing
• handling
• handling
• fibre wet‐out (prepreg)
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handling
fibre wet‐out
interphase
performance in composite
How does sizing affect the performance of carbon fibres
and their composites?
Effect of sizing on fibre handling
Single Fibre Friction Test
Favimat Jaw Arrangement
0.15
0.14
Test direction
0.13
Force [cN]
0.12
0.11
0.10
0.09
Metal bars
Sized
0.08
Oxidised
0.07
Unoxidised
Pretension weight
0.06
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20
30
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50
60
70
80
Time [s]
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Fibre‐metal friction measured by FAVIMAT single fibre tester
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Important parameter for processing fibres into textiles
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Electrolytic oxidation process roughens the surface resulting in increased fibre friction •
Epoxy treated samples show most resistance with force peaks due to the tacky epoxy sizing
Single fibre fragmentation test
Unsized CF
Sized CF
Oxidized CF
Unsized CF
Sized CF
Oxidised CF
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0.040
0.035
15
IFSS (N/tex)
Percentage (%)
0.030
10
0.025
0.020
0.015
0.010
5
0.005
0.000
Unsized CF
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200
400
600
800
Fragment Length (um)
1000
1200
Sized CF
Quanxiang Li, PhD candidate, AFFRIC
Oxidised CF
Effect of sizing on the performance of composites
Inter‐Laminar Shear Strength (ILSS)
Unidirectional laminate [0]8
Short beam shear strength (ASTM 2344‐00)
Electrolytic oxidation removes contamination and weak layers from the fibre surface which increases the bond strength Significantly higher ILSS for epoxy sized fibres, stronger interface Treatment
ILSS
(MPa)
Unoxidised
34±4.4
Oxidised
40±3.0
Sized
58±2.5
Fracture Morphology
unoxidised
Smooth resin surface
oxidised
epoxy sized
Resin failure
Completed Projects: QUICKSTEP™ vs Autoclave
“Green” process: 30 to 50% less energy consumption than autoclave curing
Rapid heating and cooling, with control of exotherm up to 75% reduction in overall cycle time
First research projects were to prove the process by comparison to autoclave components.
Current research aims to make the process more robust:
• Part lifetime prediction
• Leak detection
• New tooling materials Carbon Nexus is globally connected
Carbon Nexus has a wide range of international research collaborators
Industry Collaborations and the Application of Technology
Completed Projects: Rapid Cure Process Development
Multimatic project
• Multimatic: Global tier‐one automotive supplier providing components and turn‐key vehicles
• Deakin and Multimatic have had a decade long relationship
• Most recently, a joint development was undertaken between Multimatic, Deakin and an end user to develop a high volume composite manufacturing process
• Project achievements:
– One part per minute
– Unique resin system
– Cost effective process
– Targeted mechanical properties
• Project was supported by the Australian Automotive CRC
• Subsequent project: Embed Deakin researchers into Multimatic’s operations to assist in the Tech Transfer and commercialisation of the process.
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Completed Projects: 3D Pre‐forms for composite structures
Lightweight interiors for electric vehicles
Novel 3D knitting and molding process (Futuris patent)
One piece structures with integrated hard points for hardware such as latches and anchorages
3 step manufacturing process:
Knit, inflate & infuse, cure.
Reduced labour, reduced energy consumption, low capital investment
Significant weight reduction
Carbon Revolution
• Deakin technology start‐up
• Unique single‐piece carbon fibre wheels
• Providing ongoing development support
Completed Projects: Surface finish of automotive parts
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Reduction of print‐through in painted automotive carbon fibre parts
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Identified and optimised the effect of resin systems and carbon fibre material on the surface of automotive panels
Print through
NanoCarbon – Graphene developments
Pages from Carbon Fibre Future Directions conference presentation
Completed Projects: Advanced joining of composites
Melding process
• Method of joining composites
• Un‐cured material is ‘melded’ together to produce a co‐cured like part with no adhesive
Bellmont Composites
Resin infusion process development
• Victoria Police VE Divisional Van POD
Manufacture of highly shaped composites
Automated D4 Process using low cost tooling to produce composite parts
Single sided tooling
Rapid cycle times: flat stack of fabric to ‘stamped’ component in under 20 mins
Eliminates detailed material preparation (starts with flat stack of uncut fabric)
Moving towards mass production methods analogous to metal stamping.
Proven on Military materials (e.g. Kevlar, Dyneema)
Working with key players in the industry
Carbon Nexus has collaborated with and provided R&D services to a wide range of industry players
How do companies work with Carbon Nexus?
Contract research:
• This can be wholly funded by the industrial partner; or
• As a collaborative project with multiple partners Academic research engagements:
• Sponsored under‐graduate project collaborations
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Opportunities with the School of Engineering
• Research Connect: Industry‐based graduate research programs (Masters or PhD levels)
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50% of the cost of a graduate researcher sponsored by government
• Industry‐linked PhD Scholarships
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Dedicated PhD student to conduct research project for 3 years
Funding Options for Commercial Innovation Carbon Nexus leverages a range of funding options which are attractive to industrial partners:
Australian Research Council
– Grants for innovative research & development
CRC Network
– Australian‐government funded centres to bring together universities and companies to commercialise innovation
Other Government funding opportunities
– Geelong Region Innovation & Infrastructure Fund
– National Stronger Regions Fund
– Automotive New Markets Fund
– Enterprise Infrastructure Program
– Industry Growth Centres (new)
– R&D Tax incentives
What services do we offer?
Carbon Nexus offers a wide range of research and development and consulting services, based around its core competencies and the skills of its people:
• Fundamental research into carbon fibre properties, structure and synthesis
• Commercialisation of R&D related to carbon fibre and composites
• Analysis of novel or modified precursor materials
• Carbon fibre processing optimisation and research
• Training for carbon fibre processing line operators and technicians
Carbon Nexus also offers a wide range of consulting services :
• Carbonisation processing
• Carbonisation equipment selection, factory design and commissioning
• Energy optimisation
• Carbon fibre supply chain
www.carbonnexus.com.au