Natural fibre composites made solely from the Castor plant for aircraft cabin interior materials

Michael T. Heitzmann, Ching-Tai Ng, Benjamin Lindenberger, Martin Veidt, MengHou, Rowan Paton

15/12/2009 Michael Heitzmann 1

Presented by Michael Heitzmann

PPC11 6-10 December, Cairns

7.Decemeber 2009

Test title

• Test … Level1– Test Level 2

• Test Level 3

– Test level 4

» Test Level 5

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5 planets needed to cover resources if all humans would use as much as the Americans

With the current world wide consumption, 1.4 planets are needed to provide the resources we use and to absorb our waste

Source: Global footprint networkhttp://www.footprintnetwork.org

Test title

• Test … Level1– Test Level 2

• Test Level 3

– Test level 4

» Test Level 5

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More efficient use of resources

Test title

• Test … Level1– Test Level 2

• Test Level 3

– Test level 4

» Test Level 5

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Single plant composite for applications in the transport industry

Outline

• Introduction of the castor plant

• Polyamide 11 from the castor oil

• Castor plant fibre

• Single plant composite

• Mechanical properties of the composite

• Future research

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Castor seeds producing countries~1.2 million tonnes per year

Castor Plant (Ricinus Communis L.)

• Grows 2-3m per season

• Very high stalk yield

• Robust:

• Often cultivated on inferior soilnot fit for food crop

• Only the seeds are used

• Not competing with crop

Facts from: Christopher Brickell. The Royal Horticultural Society A-Z Encyclopedia of Garden Plants. London: Dorling Kindersley, Dorling Kindersley, 1996.

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Nylon 11 from Castor Oil

• 40% reduction of CO2 emission

• 50% lower global warming potential than epoxy resin

• Thermoplastic resin material Recycling

• Nylon 11 grade FR-106 meets the Fire, Smoke and Toxicity requirements according FAR 25.853

Source: N. Arkema. PA11 & PA12 Comprehensive Brochure. Arkema Inc. 2004

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Castor fibre - Introduction

• First published research of castor fibre as a natural fibre for composites

• Bast fibre– Elementary fibres

• 3-7mm length

• 10-35 µm diameter

– Technical fibre (fibre bundle)

• 5-15 elementary fibres

• 75-200 µm diameter

• 150-500 mm length

• 30% < 300mm

• Fibre production– Cold water retting

• 2 Week

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Castor fibre - Properties

• Low density (1.232 g/ccm) – ASTM D3800 using the buoyancy method

• Excellent mechanical properties – Large spread typical for natural fibres

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Castor fibre - Properties

• Low density (1.232 g/ccm) – ASTM D3800 using the buoyancy method

• Excellent mechanical properties – Large spread typical for natural fibres

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Castor Products:Nylon 11 + Castor

Fibre

single-plant-based

compositematerial

The Concept

The Castor Plant = 100% Bio-basedComposite

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Castor composite - manufacturing

• Compression moulding– PA 11 Rilsan ES Naturelle (Powder)

– Two samples:

• Orientated (UD) fibres

• Random orientated fibres (MD)

– Good impregnation

– Fibre volume content

• UD ~ 30-35%

• MD ~ 30%

– Density 1.16-1.220 g/ccm

– Thermal degradation of the fibre at 230°C

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Castor composite – Mechanical performance

• Good mechanical properties– Significant increase in flexural module

– Indication of a good interface

• No sizing of fibres

Room for improvement

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Castor composite – Mechanical performance

• Good mechanical properties– Significant increase in flexural module

– Indication of a good interface

• No sizing of fibres

Room for improvement

• Excellent weight specific properties

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CAF/P

A11

UD (3

0%)

GF/

PF

AL 6

013

T6

0

100

200

300

Fle

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Future research

• Fire, smoke and toxicity

• Life cycle cost analysis

• Further study of fibres – Influence of growth condition on fibre quality

– Influence of moisture content

– Investigation on different castor species

– Improved retting and sizing processes

• Manufacturing process– Sparing impregnation

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Conclusion

• New natural fibre for composites

• Fibres produced from agricultural wast product

• Fibre properties comparable with other natural fibres

• Composite with excellent weight specific properties

• Indication of good compatibility between PA11 and castor fibre

• No sizing of fibre and “rustic” retting process

• No long-term study of effects like degeneration

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Acknowledgements

• A/Prof. Martin Veidt and Dr. Meng Hou

(The University of Queensland)

• My colleagues: Ching-Tai Ng and Benjamin Lindenberger

• Composite CRC

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"If we knew what it was we were doing, it would not be called research, would it?" -Albert Einstein-

Questions?