New Lightweight Hybrid Metal & Polymer-matrix Composites for Automotive & Aerospace

In the EU research project “ComMUnion”, the two Aachen-based Fraunhofer Institutes for Production Technology IPT and for Laser Technology ILT, in collaboration with 14 partners from industry, research and academia, are developing industrial processes and solutions for hybrid lightweight design by combining metal and polymer-matrix composites for automotive and aerospace applications. Hybrid components made of steel, locally functionalized with fiber-reinforced plastics combine high mechanical performance with low weight.

The project partners are presenting the component made using this method to the professional visitors at the lightweight construction trade fair JEC World in Paris on the “Composites in Action Area” at Booth 5D17.

Combined Process, Suitable for Mass Production

The new hybrid manufacturing process is based on a combination of laser texturing and laser-assisted tape placement: 

• For this purpose, components are first pre-processed using the laser to provide a specially developed, defined, rough surface structure.
• The textured surface allows the continuous fiber-reinforced thermoplastic lightweight materials, which will later be used for stiffening, to be bonded directly to the steel component.
• The bond is then mechanical, eliminating any need for additional pre-treatment measures or additional adhesion promoters, such as adhesives or bonding agents.

The stiffenings made of thermoplastic fiber-reinforced plastics, which are especially adapted to the expected loads, are joined to the component using a tape placement process. 

• The laser heats the thermoplastic tapes locally in the joining zone to the steel.
• The matrix material melts and flows into the laser textured cavities.
• After solidification of the melt material, the tape with the embedded unidirectional fibers adheres to the roughened surface of the steel part.

Optimized Mechanical Strength

The advantage of combining these two laser processes comes to the fore precisely when the mechanical properties of the component need to be improved locally without increasing the component’s weight significantly. The process is particularly suitable for mass production, as no further post-processing steps, such as curing operations, are required to consolidate the material after tape placement. 

Additionally, precision localized heating reduces distortion and residual stresses while joining the two materials. The laser texturing process, which has been developed at the Fraunhofer ILT, can also be applied in a reproducible way to the metal surface, precisely at the locations where the textures are needed. Additionally, the laser is not subject to any tool wear.

Presentation of the First Hybrid Car Body Part at JEC World 2019 in Paris

The research partners have now finished a first demonstrator component made of high-strength steel and unidirectional fiber-reinforced thermoplastic tape in order to validate the applicability of the process in the form of a proof-of-concept. The two Fraunhofer researchers Kira van der Straeten from the Fraunhofer ILT and Tido Peters from the Fraunhofer IPT manufactured a hybrid lightweight rocker panel, a body component for the automotive industry, to test and prove the functionality of the process combination as part of the ComMUnion project.

The project partners are presenting the component to the professional visitors at the lightweight construction trade fair JEC World from 12 to 14 March 2019 in Paris on the “Composites in Action Area” at Booth 5D17. The “ComMUnion” project is funded by the Horizon 2020 Research and Innovation Program of the European Union under Grant Agreement No. 680567.

Source: Fraunhofer Institutes for Production Technology IPT

New Recyclable Self-reinforced PLA Composites for Auto & Medical Applications

Driven by the wish to tackle environmental issues and work towards the EC Plastics Strategy, the composite materials developed in the Bio4self project are fully bio-based, easily recyclable, reshapable and even industrially biodegradable. The composites are produced using one type of material: Poly(lactic acid) or PLA, a thermoplastic bio-polyester derived from renewable resources such as agricultural waste, non-food crops or sugar cane. 


Apart from some medical applications (e.g. tissue scaffolds), PLA use is currently very limited, e.g. low-demanding packaging or agrotextiles. Bio4self brought PLA to the next level of application, such as parts for automotive and home appliances, by combining two types of PLA to form so called self- reinforced PLA composites (PLA SRPC).

The associated partners in this project are Centexbel, Comfil, Fraunhofer-Gesellschaft.

Overcoming PLA SRPC Production Challenges

Two different PLA grades are required to produce SRPCs: a low melting temperature PLA grade to form the matrix and an ultra-high stiffness and high melting temperature PLA grade to form the reinforcing fibers. 

The two PLA grades selected for Bio4self have a melting temperature difference of about 20°C, leaving a sufficient temperature processing window. Bio4self innovations overcome several challenges related to the production of PLA SRPC: 

• Formulation of a moisture/humidity-resistant PLA grade
• Melt extrusion of ultra-high stiffness PLA reinforcement fibers
• Development of (consolidation and thermoforming) manufacturing procedures to produce the highest performance SRPC material; and
• Industrial scale-up of production

Key Benefits of Self-Reinforced Composite

• Biobased: composites made from two PLA grades with different melting temperatures
• Performance: high mechanical strength, temperature and hydrolytic stability
• Cost: far below carbon fibre composites, comparable to or even below SR-PP
• Upscalable: using commercially-available materials and industrial equipment
• EoL: re-usable, recyclable or industrially compostable as the composite is made of PLA

As a result, the PLA SRPC developed in Bio4self matches the requirements of current commercial self-reinforced polypropylene (PP) composites. Self-reinforced PLA composites made of 0/90 fabric have a stiffness of 4 GPa, which is comparable to the stiffness achieved by self-reinforced PP, but the PLA SRPC has the advantage of using renewable materials with a better end-of-life perspective.

This innovation has been selected as a finalist for the JEC Innovation Awards 2019 in the Sustainability category.

Source: JEC Group

Researchers Develop Self-healing Composite; Prototype on Display at JEC World 2019

Researchers from EPFL's Laboratory for Processing of Advanced Composites have developed a material that can easily heal after being damaged. This cutting-edge composite could be used in aircraft, wind turbines, cars and sports equipment. 

When a wind turbine blade or an airplane is hit by something, the damaged part has to be either replaced or patched with resin. Replacing the part is expensive, while repairing it with resin can make it heavier and change its properties. But now, with this new, patented technology, researchers at EPFL have found a way to quickly and easily repair cracks in composite structures.

Heat-based Self-healing System

"With our technology, a repair agent is incorporated in the composite material," says Amaël Cohades, a researcher at EPFL School of Engineering's Laboratory for Processing of Advanced Composites (LPAC). 

Cracks in the resin can be repaired on site in little time by simply heating the material to 150°C. The heating process activates the repair agent, and the damaged part quickly heals, without any change to the original properties. This new-to-the-market technology can be applied to all sorts of structures, extending their lifespan at least threefold. 

The material’s properties and initial crack resistance are the same as those of traditional composites. What’s more, the technology is compatible with current manufacturing processes, so production facilities do not need to be retooled.

This technology could be particularly useful for wind turbines and storage tanks. "The cost of maintaining the world's wind turbines alone is estimated at 13 billion Swiss francs in 2020," says Cohades. He says the technology could also be applied to "many parts that we don't bother to repair at present, like bikes and car bumpers." 

One limitation is that the material doesn't heal if the impact breaks the fibers. But since the resin is always damaged first, this heat-based self-healing system would still work in the majority of cases.

A Prototype on Display at the World Composites Show

Thanks to an EPFL enable grant, designed to help EPFL scientists move their ideas out of the lab, the researchers were able to create a standard aerospace prototype. This part, made from fiberglass-reinforced resin, demonstrates how the healing process works. It is presented at the JEC World Composites Show in Paris from 12 to 14 March 2019. In addition, the researchers are now setting up a startup to market the new materials.

Source: EPFL

Braskem Announces Studies Focused on Transforming Post-Consumer Plastics

Seeking solutions that contribute to the circular economy and to sustainable development, Braskem announces new partnerships for the development of chemical recycling. It will be focused on transforming post-consumer plastics, such as grocery bags and packaging films for snacks and cookies, once again into chemical products that can be used by various different value chains and will benefit the general public. Braskem has applied its knowledge and commitment once again to move the industry towards the circular economy.

Research into Technologies Transforming Plastics

The partnerships seek to further research into technologies that can transform plastics that are more difficult to be recycled mechanically into new chemical products. The research is being conducted in partnership with:

• Polymer Engineering Laboratory (EngePol) at the Alberto Luiz Coimbra Institute of Graduate Studies
• Research in Engineering of the Federal University of Rio de Janeiro (COPPE/UFRJ)
• SENAI Institute for Innovation in Biosynthetics (SENAI CETIQT)
• Cetrel (an environmental service company that started its activities in 1978 jointly with manufacturers located in the Camaçari Petrochemical Complex)

"As we strive to reach a true circular economy, we recognize the challenges and limitations posed by traditional recycling technologies. Braskem is committed to developing, implementing and offering sustainable solutions. Chemical recycling and its potential to overcome all these challenges and limitations will enable us to achieve this goal. We are accelerating these efforts through partnerships and collaboration with other companies that think like we do in order to reach these targets as soon as possible," explained Gus Hutras, head of Process Technology at Braskem.

Technological Route Complementing Braskem’s Initiatives

This new technological route complements the initiatives that Braskem has recently undertaken to contribute to the Circular Economy, which is a production concept that involves reducing, reusing, recuperating and recycling materials to create a sustainable cycle from the production phase to the reintegration of materials in a new production process.

"These studies in chemical recycling uphold the principles of Braskem, which drives innovation to develop sustainable solutions. Every day, we want to create businesses and initiatives that increase the value of plastic waste," said Fabiana Quiroga, head of Recycling. "The advantage of chemical recycling lies in its capacity to process and transform plastic waste back into a raw material that can be used to make new plastics," she added.

To add value to materials made from recycled resins, Braskem has maintained, since 2015, the Wecycle platform, which combines the need for proper disposal with the market's demand for sustainable raw materials. The platform works to develop businesses and initiatives that add value to plastic waste through partnerships, which enhances the development of products, solutions and processes that involve all links of the plastics recycling chain by supporting businesses and actions involving recycling.

Braskem's Initiatives to Promote the Circular Economy

Braskem, the Americas' largest resin producer and the world's leading biopolymer producer, has defined a series of global initiatives to boost the Circular Economy in the production chain of manufactured plastic goods. Entitled "Braskem's Positioning for the Circular Economy," the document establishes:

• Initiatives for forging partnerships with clients to conceive new products that will extend and facilitate the recycling and reuse of plastic packaging, especially single-use packaging
• It also establishes higher investments in new resins derived from renewable resources, such as Green Plastic made from sugar cane, and support for new technologies, business models and systems for collecting, picking, recycling and recovering materials

Braskem invites its clients and other stakeholders to join forces. The initiatives also include encouraging consumers to get involved in recycling programs through educational actions focusing on conscientious consumerism, the use of life cycle assessment tools and support for actions that improve solid waste management to prevent the disposal of debris in marine environments.


Source: Braskem

SANITIZED AG Offers Non-biocidal Technology with Bluesign® Sustainability Label

Polyester sport and functional textiles treated with Sanitized® Odoractiv 10 are protected against “permastink”. Already a holder of the Swiss Technology Award, the Sanitized® Odoractiv 10 odor-management technology can now carry the bluesign® sustainability label, the Skin Friendly certification from the Hohenstein Institute and the ECO PASSPORT by OEKO-TEX® label. SANITIZED AG has been a bluesign® system partner for over 10 years.

Odor-free Polyester Functional Clothing

 An unwelcome odor can quickly develop in polyester sport and functional clothing, even if freshly washed. This is “permastink”. It’s a challenge to the textile industry as it generally reduces the attractiveness and market opportunities of sport and functional clothing made from polyester.

The patented, non-biocidal Sanitized® Odoractiv 10 technology provides specific solutions and sales arguments for the end products. It works in two ways: The odor-causing bacteria can’t stick to the textile surface and are washed out completely in a normal wash cycle. This is due to the anti-adhesive “coating” applied in the padding process. This effect has been proven in a test procedure developed in cooperation with EMPA (Swiss Federal Laboratories for Material Science and Technology). Secondly, the treatment has an adsorbing effect. The odors are “trapped” and repeatedly expelled during a normal wash cycle.

No Binder, No Nano

Another characteristic: The treatment with Sanitized® Odoractiv 10 doesn’t apply an additional binder system. As with all of our products, SANITZED AG uses no nano technology. The safety and tolerability have been confirmed by the Skin Friendly certification from the Hohenstein Institute and ECO PASSPORT by OEKO-TEX® label. These have now been joined by the bluesign® accreditation.

Source: SANITIZED AG

 

Nestlé & Danimer Scientific to Produce Biodegradable Water Bottles Made from PHA

Nestlé and Danimer Scientific has announced a global partnership to develop biodegradable bottles. Nestlé and Danimer Scientific will collaborate to design and manufacture bio-based resins for Nestlé’s water business using Danimer Scientific’s PHA polymer Nodax™.
In 2018, the University of Georgia (U.S.A.) confirmed in a study that Nodax™ is an effective biodegradable alternative to petrochemical plastics. PepsiCo, an existing partner of Danimer, may also gain access to the resins developed under this collaboration.

Nodax™ PHA-based Eco-friendly Packaging

Stephen Croskrey, CEO of Danimer Scientific said: "Researchers have shown that PHA biodegrades in a wide range of environments, including industrial and home compost, soil, fresh and sea water,"
"As a material that is reliably biodegradable across both aerobic and anaerobic conditions, our Nodax™ PHA is an ideal fit to drive the creation of eco-friendly packaging for Nestlé’s products. Nodax™ PHA is suitable feedstock for industrial compost, home compost, and anaerobic digester facilities as well as reuse through recycling. We look forward to supporting Nestlé in the years to come.”

Addressing the Growing Global Plastic Waste Packaging Issue

In 2018, Nestlé announced its commitment to make 100% of its packaging recyclable or reusable by 2025. To achieve this goal, the company has already undertaken several initiatives including the creation of the Nestlé Institute of Packaging Sciences. This institute is dedicated to the discovery and development of functional, safe and environmentally friendly packaging solutions including functional paper and biodegradable materials.

Stefan Palzer, Chief Technology Officer for Nestlé said, "Strategic innovation partnerships play a key role for Nestlé as we make progress in improving the sustainability of our packaging. In order to effectively address the plastic issue in various markets, we need a wide range of technological solutions, including new paper materials and biodegradable polymers which can also be recycled."

Maurizio Patarnello, CEO of Nestlé Waters said, "Nestlé Waters is committed to addressing the growing global plastic waste packaging issue. A biodegradable bottle, which is also recyclable, can help improve the environmental impact of our business in countries without collection and recycling systems."

Source: Nestlé

New Catalytic Process to Develop Renewable Isoprene - Gevo

Gevo has announced that it has developed a proprietary, breakthrough catalytic process that transforms low-cost commercially available, or even waste by-product, renewable alcohols into renewable isoprene that would be expected to compete head-to-head on price with natural and petroleum-based chemical equivalents while reducing CO₂ emissions.

Key Chemical Building Block for Producing Rubber

Isoprene is predominantly used in the production of synthetic-based rubber. The market for isoprene is estimated to be approximately $4 Billion USD by 2025, growing at a compound annual growth rate of 7% or greater driven by growth in the automotive sector.

Chemical-based Catalytic Process

Gevo recently developed a chemical-based catalytic process to convert low-value “fusel oils,” a mixture of alcohols that are byproducts from fermentation processes such as ethanol production, into renewable isoprene. Fusel oils from the ethanol industry alone equate to about 2.5 million tons of potential bio-based waste feedstock.
“Renewable, low-carbon, low-cost isoprene has been pursued by a lot of companies over the years without commercial success. Fermentation processes were always deemed to be too expensive to make isoprene directly. As it turns out, our catalytic chemistry team and engineers figured out how to make low-cost, renewable isoprene suitable for the market using a chemical catalyst that we apply to fusel oils, a mixed, renewable alcohol stream that is produced as a by-product or even as a waste during large industrial fermentations such as those in the ethanol industry."

"Our team was able to translate what we learned while developing renewable, sustainable jet fuel and isooctane, to enable other viable alcoholic feedstocks. I give credit to our catalytic chemistry team, led by Jonathan Smith, for this breakthrough. We expect to pursue a licensing strategy with this technology. Potential licensees could be ethanol producers that want to improve the profitability of their facilities, chemical plants that simply want cost competitive low-carbon isoprene, or even standalone businesses. This is the first time in my 30 years in this industry where I have seen what I believe to be a viable route to fully renewable, low-cost isoprene. I look forward to seeing this one get commercially developed. It looks as if this technology could address a large current unmet need in the marketplace and make money,” said Dr. Patrick Gruber, Chief Executive Officer of Gevo.
Source: Gevo