Materials and Processing Technology Area - IACMI · Materials and Process ... Technology Facility...
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Materials and Processing Technology Area Cliff Eberle June 17, 2015
Transcript of Materials and Processing Technology Area - IACMI · Materials and Process ... Technology Facility...
Materials and Processing
Technology Area
Cliff Eberle
June 17, 2015
2 Presentation name
• 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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Recycling
US leaders in CF
recycling
Fibers World’s largest
PAN fiber source
and leading US
furnace
manufacturer for
CF; top 3 US
glass fiber
producers
Resins
World Leading Thermoplastic & Thermoset Resin
Providers
M&P Technology Area engages
market leading members
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IACMI Goals as stated in the Funding
Opportunity Announcement
Focus Areas
• Vehicles • Wind Turbine Blades • Compressed Gas Storage (CNG, Hydrogen)
Five Year Technical Goals
• 25% lower 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
TRL 4 - 7
These goals depend on materials and processing technology developments
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25% lower CFRP cost demands lower
CF cost!
CFRP cost build-up for a van door inner with intrusion beam. Source: Rocky Mountain Institute
Cost breakdown for 700-bar CFRP H2 storage tank. Source: Strategic Analysis
59%
8%
10%
5%
18%
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50% reduction in CFRP embodied
energy requires attention to CF
0
200
400
600
800
1000
1200
Baseline, 30%scrap rate
Baseline, 5%scrap rate
50% Less CFEnergy
75% Less CFEnergy
Co
mp
osi
te E
mb
od
ied
En
erg
y, M
J/kg
Energy Embodied in HP-RTM Composite with 61 wt% CF
Intermediate & Composite Fab
Resin
Carbon Fiber Scrap
Net Carbon Fiber
Source: ORNL
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Current ROM estimated recycling rates (all “downcycling”):
• ~ 100k tpy CFRP production; > 10k tpy scrap & < 1k tpy recycled; negligible EOL
• ~ 9M tpy GFRP production; ~ 500k tpy scrap; ~1M tpy EOL, 10 - 80% recycled
Near-term focus on recycling waste from CFRP production scrap
Mid-term we will add end-of-life composite structures
Achieving 80% composites recyclability
Key challenges: 1. Strong value proposition for GFRP recycling
2. Collection, sorting, classification, separation
End of life materials often lack a known pedigree and include
metals, electronics, etc.
3. Fiber reclamation
Current technologies at TRL 5 – 8 based on: mechanical
recycling, chemical recycling, solvolysis, and pyrolysis
4. Delivering many life cycles of high value intermediates and
components in high volume manufacturing
Scientific Research
Technology
Development
Recyclers and
end users;
Regulations
and policies
IACMI
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IACMI has unique precursor and carbon
fiber processing capabilities
Melt spinning
World’s largest university-based
solution spinning lab
Bench and pilot
scale heat treatment
equipment
World’s most flexible carbon fiber
semi-production facility
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Highlighted M&P Composites Fabrication
• Lab scale
– Compounding
– Weaving
– Prepregging
– Injection molding
– Compression molding
– Thermoforming
• Full scale
– Robotic preforming
– 3D printing
– Filament winding
– Pultrusion
Robotic preforming
Big area additive manufacturing cell
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IACMI recycling capabilities
Adherent Technologies wet chemical composite recycling pilot reactor
MIT-RCF’s slurry preforming (top) and roll goods (bottom) production in its commercial carbon fiber recycling facility
Photos courtesy of Adherent Technologies and MIT-RCF
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Title: Three Dimensional Microstructure of Polymeric Composite Materials Used
in Sandwich Structures Using Dual Modality from Combined High Resolution
X-ray and Neutron TomographyDr. Dayakar Penumadu, University of Tennessee, Knoxville, USA
18th International conference on Composite Materials (ICCM 18), Jeju, S. Korea
Navy Relevance: Understanding the failure mechanism at multi-length scales non-destructively of the wet and dry CFRP specimen will benefit
with safer application of CFRP use in Navy vessels.
Current Research: X-ray and neutron tomography techniques provide non-destructive method to visualize the interior of the CFRP facings for
failure mechanism investigation. The technique revealed the non-uniform density distribution of resin in the sample. The wet sample failed with
the delamination of the outer layer concentrating in the failure zone while the entire dry sample took part in the failure process during cyclic
loading.
Objective: Overview of X-ray and neutron tomography performed on the CFRP facing used for sandwich structures is given. The capabilities and limitations of the techniques are presented. Three-dimensional Image registration of X-ray and neutron tomography data is performed, and the contrasts of X-ray and neutron images are compared. The imaging technique will be applied to study the failure mechanism of wet and dry CFRP under loading.
X-ray Tomography SetupNeutron Tomography Setup
Peak Energy: 7.30x10-6 keV
Parallel Beam
Resolution: 29.8 m/voxel
FOV: 61 x 61 mm2
Peak Energy: 100 keV
Cone Beam
Resolution: 13.2 m/voxel
FOV: 30.5 x 30.5 mm2
Neutron Tomography Slice X-ray Tomography Slice
Dry Wet
Failure
ZoneAway Failure
ZoneAway
Failure Mechanism Comparison of Wet and
Dry CFRP after Cyclic Loading
1.70
cm-1
0.98
0.27
Resin
Fiber Bundle
Non-Uniform Resin
Density Distribution
NDE Overview
• We apply NDE data to help meet IACMI metrics for speed and yield by closing the loop around process design and control.
• We deploy our NDE capabilities where and when needed across the supply chain and product lifecycle.
Process Quality Control Property Quality Assurance Product Lifecycle Support
Flaw imaging
Precursors
Fibers
Composites
Components
Assemblies
Rapid inspection
Process monitoring
of material state
Products
Health
monitoring
Microstructure
imaging
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IACMI
Characterization
• Mechanical and physical properties, stress-life testing, fatigue behavior, durability, environmental conditioning
• Multi-Scale and high resolution microscopy, spectroscopy, diffraction/scattering, residual stress and imaging
• Premier polymer characterization facilities for molecular weight and distribution, conformation, size, and thermal properties
• Advance fiber characterization using FTIR, NMR, XPS
Multi-Scale, Multi-Modal
Process-Property Relationship & Durability
Automotive Crashworthiness
Precursors
Carbon Fibers
Composites
Components
Assemblies
Products
Structural
monitoring
Multi-axial static &
fatigue behavior Single Carbon Fiber
Nano-Tensile Testing
Interface/interphase
shear with resin
Material Joining
Characterization
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M&P Workforce Development Partners
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Materials and Processing POC’s
Doug Adams (NDE)
615-322.-2697
Cliff Eberle (M&P)
865-574-0302
Soydan Ozcan (Recycling)
865-241-2158
Dayakar Penumadu
Materials characterization
865-974-2503
Matt Weisenberger
Solution Spinning
859-257-0322
