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Advanced Composites: Enhanced Performance and...
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Forest Products LaboratoryForest Products LaboratoryUSDA Forest Service, Madison, WI USAUSDA Forest Service, Madison, WI USA
Jerrold E. Winandy, Jerrold E. Winandy, USDA FS USDA FS Forest Products LabForest Products Labhttp://http://www.fpl.fs.fed.uswww.fpl.fs.fed.us
Advanced Composites: Advanced Composites: Enhanced Enhanced Performance and Performance and SustainabilitySustainability
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Forest Products LaboratoryForest Products LaboratoryUSDA Forest Service, Madison, WI USAUSDA Forest Service, Madison, WI USA
Driving Forces & Challenges to Driving Forces & Challenges to Achieving Sustainable EconomiesAchieving Sustainable Economies•• UrbanizationUrbanization•• Rapid Technological and Information ChangeRapid Technological and Information Change•• Climate Change and VariabilityClimate Change and Variability•• GlobalizationGlobalization•• Accountability Accountability •• EnergyEnergy•• Invasive and Exotic SpeciesInvasive and Exotic Species•• Changing Wood ResourceChanging Wood Resource
–– Small DiameterSmall Diameter–– Wood Waste Utilization & RecyclingWood Waste Utilization & Recycling–– Plantation/Short Rotation Woody CropsPlantation/Short Rotation Woody Crops–– Genetic selection/Genetically Modified SpeciesGenetic selection/Genetically Modified Species
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Forest Products LaboratoryForest Products LaboratoryUSDA Forest Service, Madison, WI USAUSDA Forest Service, Madison, WI USA
11stst Tenet of Resource Sustainability:Tenet of Resource Sustainability:To achieve true resource To achieve true resource sustainability, always choose the sustainability, always choose the material that has the maximum material that has the maximum utility and minimum longutility and minimum long--term term impact on the environment. impact on the environment.
USDA Forest ServiceForest ProductsLaboratory
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Forest Products LaboratoryForest Products LaboratoryUSDA Forest Service, Madison, WI USAUSDA Forest Service, Madison, WI USA
22ndnd Tenet of Resource Sustainability:Tenet of Resource Sustainability:When using biobased materials is When using biobased materials is appropriate, a fundamental underappropriate, a fundamental under--standing of those biomaterials, their standing of those biomaterials, their conversion processes, and their conversion processes, and their engineering potentials is a basic engineering potentials is a basic requirement for sustainable forestry. requirement for sustainable forestry.
USDA Forest ServiceForest ProductsLaboratory
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Forest Products LaboratoryForest Products LaboratoryUSDA Forest Service, Madison, WI USAUSDA Forest Service, Madison, WI USA
FPL Advanced Composites FPL Advanced Composites Research ProgramResearch Program
•• NanocrystallineNanocrystalline--Cellulose CompositesCellulose Composites•• Enhanced HyperEnhanced Hyper--performance Compositesperformance Composites•• Advanced Structures/HousingAdvanced Structures/Housing•• Resource Sustainability & Resource Sustainability &
BioBio--based Economybased Economy•• Small Diameter & Underutilized SpeciesSmall Diameter & Underutilized Species•• HazardousHazardous--fuels Timber Fuels Reductionfuels Timber Fuels Reduction•• ValueValue--added Use of Exotic/Invasive Speciesadded Use of Exotic/Invasive Species•• Integrated Biomass TechnologiesIntegrated Biomass Technologies
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Forest Products LaboratoryForest Products LaboratoryUSDA Forest Service, Madison, WI USAUSDA Forest Service, Madison, WI USA
FPL’s Strategic Plan for Composites Research
Wood composites, alone or in combinations with Wood composites, alone or in combinations with other natural fibers or alternative materials, are the other natural fibers or alternative materials, are the means to sustainable forestry. No other technology is means to sustainable forestry. No other technology is as adaptable, or as compatible with how we currently as adaptable, or as compatible with how we currently use building materials or can it add more value or use building materials or can it add more value or functionality/serviceability. Biocomposites are a critical functionality/serviceability. Biocomposites are a critical technology as we evolve to a biobased economy.technology as we evolve to a biobased economy.
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Forest Products LaboratoryForest Products LaboratoryUSDA Forest Service, Madison, WI USAUSDA Forest Service, Madison, WI USA
USDA, Forest ServiceForest Products Laboratory
Mission: Engineered Composites ScienceMission: Engineered Composites ScienceDevelop a fundamental understanding of wood and biocomposite materials and then use that knowledge to enhance existing and develop new technologies and products that meet user needs, promote forest resource sustainability, and empower the conversion to a bio-based economy.
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Forest Products LaboratoryForest Products LaboratoryUSDA Forest Service, Madison, WI USAUSDA Forest Service, Madison, WI USA
Wood & Biocomposites: the science of taking biomaterials apart & reconstructing
them for specific engineering uses.• Chips/Flakes/Strands/Fibers• Nanoscience
– Fiber surface activation– NCC-reinforced Composites
• Resins – Hot:UF/PF/pMDI– Cold:PR, Urethane– Thermo-plastic– Ceramic/Inorganic
• Processing– Dry- or Wet-formed and
Hot/Cold Pressed – Melt-blended and
Extruded/Molded
Performance of BioPerformance of Bio--Composites = f (Composites = f (materials & processmaterials & process))
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Forest Products LaboratoryForest Products LaboratoryUSDA Forest Service, Madison, WI USAUSDA Forest Service, Madison, WI USA
WoodWood--based Composite based Composite Technologies: AdvantagesTechnologies: Advantages
•• Generally accepted worldwideGenerally accepted worldwide•• Add value to diverse species and Add value to diverse species and
materials:materials:•• SmallSmall--diameter timberdiameter timber•• FastFast--grown plantation timbergrown plantation timber•• AgAg-- & Lignocellulosic& Lignocellulosic--residuesresidues•• Exotic/Invasive speciesExotic/Invasive species•• Recycled lumber and EWCRecycled lumber and EWC--panelspanels•• Timber removed as HazardousTimber removed as Hazardous--fuelfuel
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Forest Products LaboratoryForest Products LaboratoryUSDA Forest Service, Madison, WI USAUSDA Forest Service, Madison, WI USA
WoodWood--based Composite based Composite Technologies: AdvantagesTechnologies: Advantages
•• LightLight•• StrongStrong•• Easily workedEasily worked•• Cost effectiveCost effective
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Forest Products LaboratoryForest Products LaboratoryUSDA Forest Service, Madison, WI USAUSDA Forest Service, Madison, WI USA
Wood & Competitive Materials in Residential Buildings
5%
5%
11%
39%
40%
Solid WoodOthersEngineered WoodMetalsPlastics
[estimate by Freedonia Group, 2002]
~9.3 billion M~9.3 billion M33, 2002, 2002
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Forest Products LaboratoryForest Products LaboratoryUSDA Forest Service, Madison, WI USAUSDA Forest Service, Madison, WI USA
WoodWood--based Composite based Composite Technologies: LimitationsTechnologies: Limitations
•• Current performance limits broader Current performance limits broader applications in Commercial/Nonapplications in Commercial/Non--Residential Residential construction and Advanced Materials marketsconstruction and Advanced Materials markets
•• Public and Engineering communities perceive Public and Engineering communities perceive problems with:problems with:
•• FireFire•• Structural performance/creepStructural performance/creep•• Durability & waterDurability & water--related issuesrelated issues•• ServiceService--lifelife
•• Timber harvesting is not seen as “Green”Timber harvesting is not seen as “Green”
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Forest Products LaboratoryForest Products LaboratoryUSDA Forest Service, Madison, WI USAUSDA Forest Service, Madison, WI USA
Four Problems in Developing the Next-generation of Engineered
BioComposites (EBC)•• Identify and exceed user needsIdentify and exceed user needs•• Develop more robust Develop more robust EBC’sEBC’s•• Develop advanced Develop advanced EBC’sEBC’s with high with high
performance and reliability for performance and reliability for commercial /noncommercial /non--residential constructionresidential construction
•• Develop new ecoDevelop new eco--friendly, costfriendly, cost--competitive technologies for harvesting, competitive technologies for harvesting, processing, and endprocessing, and end--ofof--life reuse.life reuse.
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Forest Products LaboratoryForest Products LaboratoryUSDA Forest Service, Madison, WI USAUSDA Forest Service, Madison, WI USA
The Future of Advanced Wood-and Lignocellulosic-Composites
I.I. Nanotechnology Nanotechnology II.II. Biorefinery: Biorefinery: BiofuelsBiofuels & & BioenergyBioenergyIII.III. Advanced BioAdvanced Bio--based Compositesbased CompositesIV.IV. Advanced StructuresAdvanced StructuresV.V. Sustainability and Enhancing Sustainability and Enhancing
Transition to a Biobased EconomyTransition to a Biobased Economy
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Forest Products LaboratoryForest Products LaboratoryUSDA Forest Service, Madison, WI USAUSDA Forest Service, Madison, WI USA
I.I.Nanotechnology and Nanotechnology and WoodWood-- & Bio& Bio--compositescomposites
With engineered biocomposites, With engineered biocomposites, nanotechnology will not be a science in itself. nanotechnology will not be a science in itself. It will become the fundamental scale for It will become the fundamental scale for approaching a problem, similar to how we now approaching a problem, similar to how we now think of using a “material sciencethink of using a “material science--type” approach. type” approach.
Nanotechnology will become a standard for Nanotechnology will become a standard for a basic type of approach to science. It will provide a basic type of approach to science. It will provide a tool by which we quantify or model the relationa tool by which we quantify or model the relation--ship between “Materialsship between “Materials--ProcessProcess--Performance”.Performance”.
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Forest Products LaboratoryForest Products LaboratoryUSDA Forest Service, Madison, WI USAUSDA Forest Service, Madison, WI USA
NanocrystallineNanocrystalline Cellulose, Cellulose, NanoNano--activated Fiber Surfaces, & activated Fiber Surfaces, &
NanoNano--reinforced Compositesreinforced Composites
TEM image of cellulose nanocrystals
• Using commercial wood pulp
• H2S04 hydrolysis
• Dispersed In PP-polymer matrix
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Forest Products LaboratoryForest Products LaboratoryUSDA Forest Service, Madison, WI USAUSDA Forest Service, Madison, WI USA
Major Technology shifts require Strategic ReinventionMajor Technology shifts require Strategic Reinvention
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Forest Products LaboratoryForest Products LaboratoryUSDA Forest Service, Madison, WI USAUSDA Forest Service, Madison, WI USA
Trus-joist/Weyerhaeuser, Inc
Major Product advances require Major Product advances require continual refocusing of Strategic Visioncontinual refocusing of Strategic Vision
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Forest Products LaboratoryForest Products LaboratoryUSDA Forest Service, Madison, WI USAUSDA Forest Service, Madison, WI USA
II.II.Likely Scenarios for the Likely Scenarios for the Forest Biomass BiorefineryForest Biomass Biorefinery
•• Stand Alone BiorefineryStand Alone Biorefinery(without fiber production)
•• Integrated Biomass TechnologiesIntegrated Biomass Technologies
(EtOH Composites Paper Energy)
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Forest Products LaboratoryForest Products LaboratoryUSDA Forest Service, Madison, WI USAUSDA Forest Service, Madison, WI USA
Integrated Biomass Utilization1a. Biofuels: EtOH from Hemicellulose
EtOH
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Forest Products LaboratoryForest Products LaboratoryUSDA Forest Service, Madison, WI USAUSDA Forest Service, Madison, WI USA
Integrated Biomass UtilizationIntegrated Biomass Utilization1b. Value1b. Value--added Biobased Adhesivesadded Biobased AdhesivesPharmaceuticals, and Biochemicals.Pharmaceuticals, and Biochemicals.
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Forest Products LaboratoryForest Products LaboratoryUSDA Forest Service, Madison, WI USAUSDA Forest Service, Madison, WI USA
Integrated Biomass UtilizationIntegrated Biomass Utilization2. Value2. Value--added Composites & Paperadded Composites & Paper
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Forest Products LaboratoryForest Products LaboratoryUSDA Forest Service, Madison, WI USAUSDA Forest Service, Madison, WI USA
Integrated Biomass UtilizationIntegrated Biomass Utilization3. Energy from Biomass3. Energy from Biomass
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Forest Products LaboratoryForest Products LaboratoryUSDA Forest Service, Madison, WI USAUSDA Forest Service, Madison, WI USA
III.III.Problem Areas for Advanced Problem Areas for Advanced CompositesComposites ResearchResearch
••Understand base materials and theUnderstand base materials and therelationship between materials, relationship between materials, their processing and propertiestheir processing and properties
••Define performance requirements forDefine performance requirements forexisting and develop the next existing and develop the next generation of compositesgeneration of composites
••Address resource sustainability and Address resource sustainability and educate users that wood and educate users that wood and woodwood--based composites are the based composites are the means to sustainable forestrymeans to sustainable forestry
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Forest Products LaboratoryForest Products LaboratoryUSDA Forest Service, Madison, WI USAUSDA Forest Service, Madison, WI USA
•• EW C & M DF: Enhance structural EW C & M DF: Enhance structural strength & enhance durabilitystrength & enhance durability
••M DF: Define the effects of therm al M DF: Define the effects of therm al treatm ents strength and utilitytreatm ents strength and utility
••EW C: Developing FireEW C: Developing Fire--and Decayand Decay--Resistant Engineered W ood Resistant Engineered W ood Com posites Com posites
••EW C: Define cardinal thresholds of EW C: Define cardinal thresholds of tem p. and M C for decay tem p. and M C for decay
Enhance Perform ance and Durability Enhance Perform ance and Durability for the existing “for the existing “statestate--ofof--art”art”in EW C:in EW C:
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Forest Products LaboratoryForest Products LaboratoryUSDA Forest Service, Madison, WI USAUSDA Forest Service, Madison, WI USA
Advanced Bio-Composites:
•• Corrugated Fiberboard Corrugated Fiberboard (1940’s)(1940’s)
•• FPL Spaceboard FPL Spaceboard (1970’s(1970’s--80’s)80’s)
•• 3D Engineered Fiberboard3D Engineered Fiberboard•• Lightweight Systems Lightweight Systems
–– FurnitureFurniture–– PackagingPackaging–– Engineered PalletsEngineered Pallets–– Emergency StructuresEmergency Structures
•• Biomemetic/Smart SystemsBiomemetic/Smart Systems•• Bamboo CompositesBamboo Composites
Corrugated Paperboard vs. Corrugated Paperboard vs. 3D3D--Engineered FiberboardEngineered Fiberboard
Bamboo HiBamboo Hi--Shock BoardShock Board
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Forest Products LaboratoryForest Products LaboratoryUSDA Forest Service, Madison, WI USAUSDA Forest Service, Madison, WI USA
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Forest Products LaboratoryForest Products LaboratoryUSDA Forest Service, Madison, WI USAUSDA Forest Service, Madison, WI USA
Three-dimensional Engineered Fiberboard (3DEF)
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Forest Products LaboratoryForest Products LaboratoryUSDA Forest Service, Madison, WI USAUSDA Forest Service, Madison, WI USA
Use of 3DEF for Emergency Structures
(Post hurricane/tornado/tsunami)3DEF panels as floor panels 3DEF panels as roof panels
3DEF panels as wall panels WallsFloors
Roofs
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Forest Products LaboratoryForest Products LaboratoryUSDA Forest Service, Madison, WI USAUSDA Forest Service, Madison, WI USA
InorganicInorganic--bound bound WoodWood--fiber Compositesfiber Composites
•• CementCement
•• NonNon--sinteredsinteredCeramicsCeramics
•• SilicatesSilicates
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Forest Products LaboratoryForest Products LaboratoryUSDA Forest Service, Madison, WI USAUSDA Forest Service, Madison, WI USA
Wood Thermoplastic CompositesBasic research on WTPC Basic research on WTPC
over the last 15over the last 15--20 years has 20 years has formed the basis for formed the basis for phenomenal recent and phenomenal recent and future growth for WTPC in future growth for WTPC in Building & ConstructionBuilding & Construction
0
5
10
15
20
1990 1995 2000 2005 2010
Year
Mar
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hare
(%)
WTPC Decking
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Forest Products LaboratoryForest Products LaboratoryUSDA Forest Service, Madison, WI USAUSDA Forest Service, Madison, WI USA
Advanced BiocompositesAdvanced BiocompositesLowLow--cost, Rapidlycost, Rapidly--built, ADAbuilt, ADA--accessible, accessible,
Biocomposite SurfacesBiocomposite Surfaces
Four Field Trials: CA, WI, MD, NYCommercialized in 2005
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Forest Products LaboratoryForest Products LaboratoryUSDA Forest Service, Madison, WI USAUSDA Forest Service, Madison, WI USA
IV.IV.Advanced Structures will require Advanced Structures will require Advanced Engineered Materials:Advanced Engineered Materials:
FPL is developing the bioFPL is developing the bio--based based technologies to pioneer these technologies to pioneer these
future materialsfuture materials
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Forest Products LaboratoryForest Products LaboratoryUSDA Forest Service, Madison, WI USAUSDA Forest Service, Madison, WI USA
Engineering and MaterialsEngineering and MaterialsEnhanced Wood MaterialsEnhanced Wood Materials
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Forest Products LaboratoryForest Products LaboratoryUSDA Forest Service, Madison, WI USAUSDA Forest Service, Madison, WI USA
Engineering and MaterialsEngineering and MaterialsDeconstruction & ReuseDeconstruction & Reuse
3 Trillion (1012) Bd.Ft. = 23.5 Billion (109) m3
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Forest Products LaboratoryForest Products LaboratoryUSDA Forest Service, Madison, WI USAUSDA Forest Service, Madison, WI USA
V.V. To develop a sustainable bioTo develop a sustainable bio--based, rather than a based, rather than a petropetro--centric centric economy, we must develop valueeconomy, we must develop value--added bioadded bio--composites to promote composites to promote longlong--term resource sustainabilityterm resource sustainability and and economic developmenteconomic development
•• HazardousHazardous--fuels reductionfuels reduction•• Forest & Range residuesForest & Range residues•• PostPost--industrial wood waste industrial wood waste •• PostPost--consumer wood wasteconsumer wood waste•• Exotic/Invasive remediationExotic/Invasive remediation•• Recycling WPC lumberRecycling WPC lumber•• Biocomposites: Biocomposites:
Juniper/SaltJuniper/Salt--cedar, Fibers from Chickencedar, Fibers from Chicken--feathers, feathers, Corn Stalks, Guayule, Corn Stalks, Guayule, AgaveAgave, & Sterile Digested , & Sterile Digested Bovine BiomassBovine Biomass
MDF-CFF
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Forest Products LaboratoryForest Products LaboratoryUSDA Forest Service, Madison, WI USAUSDA Forest Service, Madison, WI USA
To develop a sustainable bioTo develop a sustainable bio--based based economy, rather than a economy, rather than a petropetro--centric society, centric society,
we need to develop valuewe need to develop value--added bioadded bio--composites to promote longcomposites to promote long--term resource term resource sustainabilitysustainability and economic developmentand economic development
OSB from Burnt Pine WPC from Invasive Juniper and Salt-cedar
Chicken-feather MDFAg-residue Biocomposites
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Forest Products LaboratoryForest Products LaboratoryUSDA Forest Service, Madison, WI USAUSDA Forest Service, Madison, WI USA
Value-added Uses for Exotic-Invasive Species
Sustainable Forestry and Resource Management
FPL’s Advance Composites Science Research Program
fpl.fs.fed.us/rwu4706
Hazardous Forest Fuels Utilization
Playground Safety and ADA-accessibility
Leadership in Development of New WTPC Building Products
Define Field (Solar, biological, Thermal) Performance of WTPC Building Products
Jerrold E. Winandy, USDA FS Forest Products Lab�http://www.fpl.fs.fed.usDriving Forces & Challenges to Achieving Sustainable EconomiesFPL Advanced Composites Research ProgramFPL’s Strategic Plan for Composites Research�USDA, �Forest Service�Forest Products �Laboratory�Wood & Biocomposites: the science of taking biomaterials apart & reconstructing them for specific engineering uses.Wood-based Composite Technologies: AdvantagesWood-based Composite Technologies: AdvantagesWood & Competitive Materials in Residential BuildingsWood-based Composite Technologies: LimitationsFour Problems in Developing the Next-generation of Engineered BioComposites (EBC)The Future of Advanced Wood-and Lignocellulosic-CompositesI. Nanotechnology and Wood- & Bio-compositesNanocrystalline Cellulose, �Nano-activated Fiber Surfaces, & �Nano-reinforced CompositesII. Likely Scenarios for the �Forest Biomass BiorefineryAdvanced Bio-Composites: �Three-dimensional Engineered Fiberboard (3DEF)Use of 3DEF for Emergency Structures�(Post hurricane/tornado/tsunami)Inorganic-bound �Wood-fiber CompositesWood Thermoplastic CompositesAdvanced BiocompositesV. To develop a sustainable bio-based, rather than a petro-centric economy, we must develop value-added bio-composites to prom