Post on 26-May-2020
Composites Innovation from Europe
Dr. Gunnar Merz, March 27, 2019
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Agenda
Market for Carbon Fiber Reinforced Plastics (CFRP)
Access to CFRP Market
Support by a network CFK Valley e.V. as one example
Composites Innovations by CFK Valley members Aerospace Application: Airbus A350
Construction Industry
One Family House
Spectacular Buildings
Trailer Technology
Recycling of CFRP
Outlook
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0
20
40
60
80
100
120
140
160
2006 2007 2008 2009 2010 2011 2012 2013 2014 2015 2016 2017 2018 2019 2020
Industrial
Sport
Aerospace
CFRP Market until 2020
Source: JEC Magazine
M m
t C
arb
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Fib
ers
/ ye
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Airbus A350 Sports
Construction
Automotive
Transportation and Trains
Ship Building
Wind Energy
Components for Offshore Technology
Importance of diversification into industrial applications
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Challenge: Automation as Key to Mass Production
Source: dpa/Ford
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Network participation shortens the innovation process and reduces risk
Science
- Create Knowledge - Transfer Knowledge
Universities/National Labs
Industry
- Accept risks - Investments
Companies/Start-Ups/Investors
Politics
- Funding - Regulation/Laws
Regional/National governments
Involvement
Stepwise Innovation Process
Entrepreneurial experimentation
Risk involved
Knowledge development
Key role of e.g. Universities
Knowledge diffusion
Transfer of Knowledge by e.g. institutes
Resource Mobilization
Work Force E.g. Crowdsourcing
Capital
Crowdfunding, -lending, -investment
Legitimation
Society Acceptance
Guidance of Search
Subsidies
Regulations
Market Formation
Based on customer needs
Business Success
Infrastructure in Stade – Broad View
Deep Sea Harbor
Autobahn partly to
Hamburg
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Infrastructure in Stade – Close View
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Airbus Stade / CTC
Composites Technology Center (CTC) Stade – a subsidiary of Airbus
Germany‘s leading center for research and development of complex, large scale CFRP parts
Developer of multiple CFRP components and technologies for the A350
Airbus facility Stade – The company‘s CFRP competence center
Production of vertical stabilizers from
CFRP since the early 1980‘s
Production of A350‘s upper wing cover –
world‘s largest CFRP part (32m length)
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DLR - German Aerospace Center
Research focus on production of large scale CFRP structures
Equipment BALU – Largest research autoclave in the world (length: 20 m, diameter: 5,8 m, 𝑝𝑚𝑎𝑥 = 150 psi, 𝑇𝑚𝑎𝑥 = 400°C)
GroFi – CNC controlled multi-robot facility for AFP and ATL
Fully automated RTM process chain for an automated production of parts up to 1,5 m length
Wind blade production capabilities
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Fraunhofer Institute - IFAM
Research focus on automated assembly of large scale aircraft structures
Equipment Development platform for automated form- and position control
Test stand for automated fuselage assembly using adhesive bonding
High accuracy mobile robot assembly/machining units
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Education R&D
Design
Production Operation Recycling
Reuse of recycled materials
EH&S
Our Members Competencies along the entire composites value chain
BOLLE & CORDS
Elektrotechnik GmbH
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CFK Valley – a global network Countries with members
CFK VALLEY INDIA
2004
2014
2015
2017
2017
2018
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Innovations: Only one of many examples in aerospace application
Collaboration of our members to develop CFRP parts of the Airbus A350:
Upper Wing Cover
Fuselage
Vertical Stabilizer
Upper wing cover: Largest CFRP part (length: 32m) at Airbus produced in Stade
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© CTC GmbH. All rights reserved. Confidential and proprietary document.
A350 Wing Cover Manufacturing
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© CTC GmbH. All rights reserved. Confidential and proprietary document.
Overview – A350 XWB Wing Upper Cover
Largest monolithic CFRP component within Airbus
Length of approx. 32m
Approx. 2t weight
Prepreg based technology
Stringers integrated in co-bonding process
Approx. 300m of stringer per cover
Harmonized process with transnational collaboration
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© CTC GmbH. All rights reserved. Confidential and proprietary document.
Wing Skin Manufacturing
• Technology change in skin lay-up from
automatic tape laying machines to
automatic fibre placement machines
• 12.5 mm wide tows
• Increase of overall process productivity
• Significant reduction of material scrap
• Copper mesh as first layer to protect against
lightning strinkes
© Werner Bartsch
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© CTC GmbH. All rights reserved. Confidential and proprietary document.
Manufacturing and Industrial Implementation
The process has been implemented in a production line with the following main features:
• Fiber placement with high productivity and just in time production
• High quality forming with dedicated machines
• Lay out defined by the process & single movement direction of product
• External referenced automated stringer integration
• No manual transportation or movement of product
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A Carbon mast at the beginning in 2010
The construction engineer Dr. Amer Affan bought a sailing boat with a CFRP mast
He was fascinated by the material and wanted to know if he can use it for construction
2010 he visited the CFK Valley booth at JEC Paris and became a member
Dr. Amer Affan made use of the knowledge of CFK Valley
Today he is a world market leader for CFRP in construction
Source: JEC
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Composites in Construction Vision Award 2014
2014 CFK Valley Vision Award: Dr. Amer Affan (Dubai) Yas Mall Abu-Dhabi
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Composites in Construction More Spectacular Projects
Abu Dhabi Cruise Terminal
Sidra Hospital Qatar
Status March 2019
Museum of the Future in Dubai
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Fire Test
Use of non combustable epoxy matrix
Vision for Composites One Family House
CANNES - PROJECT SITE
INSTALLATION
INSTALLATION
INSTALLATION
INSTALLATION
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Composites in Transportation Cooling truck for food home delivery
CFRP structure allows additional 500 kg load (50 % increase)
Sensors implemented to check integrity of the carbon composites structure
Logistics Innovation Award Winner 2014
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Composites in Transportation CFRP Reefer Trailer
CFRP monocoque structure (13.6 x 2.6 x 0.75 m)
Integration of functions
Pallet carrier
Side protection
Weight reduction
Savings: 3 mt
Reduction of Fuel Consumption up to 25%
Increased load volume
Improved insulation
Reduction of life cycle costs
Source: TTT – The Team Technology
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Composites in Automation Modular Lightweight Gripper System
Development of a lightweight gripper system made from CFRP for robots
Up to 40 – 60 % weight reduction possible
Allows the usage of a smaller, more affordable standard industry robot
Or: Higher accelerations
Currently in implementation phase at Audi
Winner of the CFK Valley Innovation Award 2018
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Composites Recycling Reuse of fibers in new applications
Efficient Waste Collection
CFRP Production Waste and “End of Life”
High Quality CFRP Powder
Pyrolysis Process developed with Dow
CFRP Recycling Center in
Wischhafen
New applications in other plastic materials
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