IACMI / Wind Technology Area

Derek BerryIACMI Wind TA Director

Sandia Blade WorkshopAugust 31, 2016

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Presentation Overview

• NNMI / IACMI• Wind Technology Area

• Manufacturing facility• Project topics

• Thermoplastic project• Engaging with IACMI• Wrap-up

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Additive Manufacturing 3D Printing

Youngstown, OH - 2012

National Network for Manufacturing Innovation(NNMI)

Digital ManufacturingChicago, IL - 2014

WBG SemiconductorsNCSU - Raleigh, NC - 2014

Lightweight MetalsDetroit, MI - 2014

CompositesKnoxville, TN - 2015

President Obama’s 2013 and 2014 State of the Union Addresses

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Existing Institutes in the Network

Department of Defense (DOD)

National Institute of Standards and

Technology (NIST)

Department of Energy (DOE)

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Expected New Institutes in the Network

National Institute of Standards and

Technology (NIST)

Department of Energy (DOE)

Department of Defense (DOD)

1. Robotics in Manufacturing Environments

1. Modular Chemical Process Intensification

2. Reducing Embodied Energy and Decreasing Emissions (REMADE)

1. Open Topic - two awarded by the end of the year

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January9,2015:PresidentObamaAnnouncesNewCompositeInstitute

“…and today, we’re proud to announce our latest manufacturing hub, and it is right here in Tennessee. Led by the University of Tennessee–Knoxville, the hub will be home to 122 public and private partners who are teaming up to develop materials that are lighter and stronger than steel. ”

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Shared RD&D facilities will support industry

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Core Partners are Capable and Strategically Located

>70% of automotive production occurs in IACMI states

Colorado has more blade facilities (factories plus technical centers) than any other state

>60% of manufacturers of compressed gas–fueled vehicles with in half-day drive from IACMI focus areas

>70% of US auto R&D in Michigan alone

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• Carbon fibers

• Lab-scale intermediates and composites prototyping

• Recycling

• Nondestructive evaluation (NDE)

• Materials characterization

Materials and Process Technology Area Snapshot

Wide area flaw detection

Carbon Fiber Technology Facility

Polymer AM Cell

Robotic preformer

Nonwovens Research

Lab

ORNL: US leading neutron characterization and

computing power

-Thermo-plastic-glass-carbon

recycling -Factory floor NDE-Full-scale molding

with LCCF -Pultruded spar caps

-Product lifecycle modeling-Process modeling

for lab-scale validation

-Largest open access

solution spinning lab in US

-Closed loop recycling

-Factory floor NDE -Full-scale preforming-Molding

processes with LCCF

-Factory floor NDE -Full-scale

preforming and winding processes

with LCCF

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IACMI is a Goal-Focused Institute

Five Year Technical Goals• 25% lower carbon fiber–reinforced polymer

(CFRP) cost• 50% reduction in CFRP embodied energy • 80% composite recyclability into useful

products

Impact Goals• Enhanced energy productivity• Reduced life cycle energy consumption• Increased domestic production capacity• Job growth and economic development

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An Integrated Approach to meet our Goals and Metrics

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IACMI has 140 Members and GrowingNational Labs

2%

SMEs45%

Industry Large32%

Academic12%

Industry Assoc.4%

Economic Development1% States

4%

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Members• The members are public and private and represent 32 states.

• IACMI- The Composites Institute has partnered with ACMA, the premiere composites industry association and Composites One for workforce training capabilities.

State PartnerGeographic ExtensionsMembersInterested Parties

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Successful integration means IACMI becomes the Industry’s Institute

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$70M - DOE

$189M - Other

122 - Member Consortium

6 States

Strong Leadership

5 Focus AreasProduction

Capacity

Jobs

- 75%CFRP Embodied Energy Savings

- 50%CFRPProduction Cost

GHG 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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IACMI Wind Technology Area (Wind TA)• NRELleadstheWindTA– buildingona30yearhistoryof

collaborationwitheverymajorwindturbineOEMandUSblademanufacturer

• Teamofindustryanduniversitypartners,including:JohnsManville,TPIComposites,Vestas,SiemensWind,GEWind,ColoradoStateUniversity,ColoradoSchoolofMines,UniversityofColoradoBoulderandIowaStateUniversity

• Windturbinecompositesmanufacturinginnovationprojectsinsuchareasas:

• Thermoplasticresinsystems• Pultrudedsparcaps(FRP/CF)• Manufacturingautomation• Additivemanufacturing– toolingandcomponents• Segmentedbladedesignandmanufacturing• Recyclingofwindturbinebladesandcomponents• In-processnon-destructive evaluation(NDE) IACMIWindTechnologyAreaObjectives:

• ProvidecomprehensiveexpertiseandcapabilitiestoenableachievementofDOEandIACMIgoalsandmetrics

• DrivedownCOEforwindpower• CoordinatewithDOEEEREWWPTOto

leverageinvestments

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Materials & Intermediates

Low Cost CF

Resins, Fillers, & Adhesives

Fiber to Fabric Conversion

Material Testing & Data Sharing

Advanced Continuous Fiber

Recycling and Material Reuse

Standardization & Qualification

Reference Parts

Decision Tool Database

High Confidence Predicted Properties

Part Qualification Standards

Modeling & Simulation

Techno-Economic

Models

Manufacturing Process

Simulation

Standardized Data Transfer

Crash Performance Predication

User Friendly Model

CGS

Fiber & Fiber Architecture

Resin Development;

Thermoplastics

Standards for non-conventional composite tanks

Fiber Deposition & Layup

Testing and Validation of Performance

Vehicles

NDE for Process Control

Pre/Post Mold Processes & Automation

Rapid Preforms

Low-Cost Short-Lead Tooling

Simulation: Design through Manufacture &

Life Cycle

Wind

In-field SHM/NDE

In-factory Joints

Rapid Low Cost Tooling

Scale CF and Hybrid CF

Demonstration

Tailored Forms

ATP/AFP

Wind TA Roadmap Alignment

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• Composites Manufacturing and Education Technology Facility

• Manufacturing space will focus on composite manufacturing innovation

• 55’ x 200’ – 11,000 sq. ft.

• Adjacent to blade test facility

• Full-scale blade component manufacturing

Facilities: Wind TA CoMET Facility

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FOR 60m BLADES

IACMI Wind TA CoMET Facility

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IACMI Wind TA CoMET Facility Wind Tooling

In Kind Cost Share Donation of wind turbine component tooling• DowAksa, GE and others

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IACMI Wind in Composites Demonstration• NREL/NWTC hosted the IACMI ‘Composites in Wind’

Demonstration at the newly renovated CoMET facility on June 14 and 15, 2016

• Over 150 attendees from industry, academia and government participated in interactive composite manufacturing demonstrations

• The event successfully opened the new NREL manufacturing space that will focus on composite manufacturing innovation and workforce development

• Attendees enjoyed a tour of the NWTC field and structural testing facilities

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IACMI Wind TA CoMET Facility Capabilities• Rapid prototyping of new blade materials and production methods

• Full scale blade component tooling and fixtures (root, spar cap, tip, shear web)

• Infusion (VARTM), pultrusion, pre-preg, RTM, hand lay-up (small parts)

• Polyester, vinyl-Esther, epoxy, thermoplastic / fiberglass, carbon fiber

• Comprehensive composite production equipment (mixers, vacuum, dispensers)• Molding, assembly, bonding, finishing

• Segmented 3D printed tooling (13m SWiFTblades)

• Large area rapid NDE

• Modeling and manufacturing Simulation

• Panels, material test coupons and components

• Structural testing: coupons, component, joints

• Workforce development / training

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Project 4.2: Thermoplastic Resin Systems• This project develops new thermoplastic process technology and materials for wind

turbine blade manufacturing. This project addresses the challenges of using thermoplastics in blades, such as: cost (through techno-economic modeling), processing temperature(through process modeling & thermal NDE), and material properties (through panel production & testing). The ultimate project outcome is a structurally verified thermoplastic blade component, which will demonstrate commercial feasibility of integrating thermoplastics in wind turbine blade production

• Length of Project:– BP1: July 1, 2015, through January, 31, 2016– BP2: February 1, 2016, through January 31, 2017– BP3: February 1, 2017, through January 31, 2018

• Partners: NREL, ORNL, Johns Manville, Colorado School of Mines, TPI Composites, Arkema, Purdue University, Vanderbilt University

• Expected TRL level progression:– TRL start: 3– TRL finish: 7

TRL 3-4 (BP1)

Glass sizingResin process modeling

TRL 5-6 (BP2)

Panel productionCoupon testingTechno-economic modeling

TRL 7 (BP3)

Full-scale blade root componentComponent testing

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Thermoplastic Project Team

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Work Underway: BP1 Work Completed• Constructed backbone of techno-economic

model

• Defined baseline structural properties for wind blade spar caps

• Evaluated thermoplastic matrix choices:§ Caprolactam-based nylon-6§ Acrylic (Arkema Elium)

• Evaluated manufacturing methods:§ Infusion, pultrusion, pre-preg and RTM

• Detailed potential tooling challenges for thermoplastic resin processing

• Manufactured four thermoplastic panels§ Panel 1,2: Nylon-6 using RTM§ Panel 3,4: Arkema Elium using infusion

Nylon-6 Panel Fabrication at Johns Manville

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• Definition of baseline tooling specifications

• Master plug

• Standard production tooling• Design• Laminate• Heating system• Vacuum system• Mold framework• Bonding operation equipment• Staging

• Mold qualification

• Design tolerances

• Mold maintenance

Work Underway: BP1 Work Completed

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Work Underway: BP2 Work CompletedID

Number BP2 Milestones

4.2.3.3

Commission laboratory scale VARTM facility at a university partner. The university partner will collaborate with industry partners to ensure the laboratory scale is representative of full-scale production. The subsequent work at this laboratory will expand our knowledge and experience in thermoplastic matrix processing. The deliverable of this commissioning will be an infused composite panel using VARTM equipment at the laboratory. The panel will be constructed with uni-directional stitched fabric made of Johns Manville StarRov® RXN 886 roving, with an a real weight of 650 g/m2, and Nylon-6 resin. The panel will have minimum geometric specifications of 500 mm x 500 mm x 2 mm. This panel will provide coupon samples to be tested for structural properties - such as static and fatigue tensile strength, tensile modulus, compression strength and compression modulus - in order to inform the thermoplastic database for this project.

4.2.3.5 Develop a comprehensive test panel (coupon level) test plan for all thermoplastic panels fabricated during BP2.

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Engaging with IACMI: Project Types

Project Type Project Budget

Cost Share Duration Other

Requirements Intent

Enterprise >$600K

Minimum 1:1 with

50% being cash

Up to 5 years

• A small number of value-chain members can jointly submit

• Must involve team collaboration & potential large economic and commercial impact

Bigger projects with multiple partners that significantly contributes to achieving IACMI goals.

TechnicalCollaborations

$20K—$600K

Minimum1:1 (large entities:

50% being cash)

Up to 2 years

• Phase 1 is <6months and $150 K total costs

• Optional Phase 2 is <18 months and $450 K total costs

Smaller investigatory efforts that can be started up quickly.

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Project Proposal and Review Process

§ Evaluation criteria is in RFPs

§ Responsive to roadmap needs

§ Evaluators include Directors, TAB, BOD, and/or DOE

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USDepartment of Energy

PartnerStates

CorePartners

Charter, premium,

and resource members

Consortium members

Supporters

ThankYou

Thank You & Questions