Today's KNOWLEDGE Share : Understanding Autoclaves

Today's KNOWLEDGE Share

Understanding Autoclaves: Essential for Carbon Pre-Preg Production:

An autoclave is a high-pressure, high-temperature vessel used in various industrial processes, including the production of carbon fiber pre-preg composites. In this context, it is essential for several reasons:

1. Uniform Pressure and Temperature: Autoclaves provide a controlled environment where both pressure and temperature can be uniformly distributed. This is crucial for ensuring the even curing of carbon fiber pre-pregs, leading to consistent and high-quality composite materials.

2. Enhanced Mechanical Properties: The high pressure in an autoclave helps to eliminate voids and imperfections within the laminate. This leads to improved mechanical properties such as strength, stiffness, and durability, which are critical for aerospace, automotive, and other high-performance applications.

3. Optimal Resin Flow and Distribution: The combination of heat and pressure helps the resin to flow properly and fully impregnate the carbon fibers. This ensures that the fibers are well-bonded and the final composite has the desired structural characteristics.

4. Void Reduction: Voids or air pockets can significantly weaken composite materials. The high pressure in an autoclave compresses the laminate and helps to expel trapped air and volatiles, reducing the void content and increasing the integrity of the composite.

5. Consistent Quality: Using an autoclave ensures that the entire batch of carbon pre-preg materials is processed under the same conditions, leading to consistent quality across production runs.

In summary, the use of an autoclave in carbon pre-preg production is essential to achieve high-quality, reliable, and high-performance composite materials by providing uniform pressure and temperature, enhancing mechanical properties, ensuring optimal resin flow, reducing voids, and ensuring consistent quality.

source:Michal Harasymowicz

Trinseo Opens Next-Gen Depolymerization Facility in Italy

Trinseo, a specialty material solutions provider, announced today the opening of its polymethyl methacrylate (PMMA) depolymerization facility in Rho, Italy, on June 25. The pilot facility represents a significant step forward in the Company’s commitment to sustainability, as the next-generation recycling technology helps advance a circular infrastructure for acrylic solutions and is aligned with Trinseo’s 2030 Sustainable Product Portfolio Goals.

We are thrilled about the opening of our depolymerization facility, which will help advance our goal to support a circular economy,” said Francesca Reverberi, Senior Vice President of Engineered Materials and Chief Sustainability Officer at Trinseo. “Our company remains committed to our sustainability goals, including investing in new recycling technologies that can support our customers in reaching their sustainability goals as well.”

Depolymerization is a chemical recycling process that returns acrylic solutions to the constituent monomer, methyl methacrylate (MMA). Complementary to other recycling technologies, depolymerization helps close the loop for acrylic recycling with several advantages over traditional processes. By utilizing this technology, acrylic solutions can be recycled—including PMMA sheets, which previously could not be mechanically recycled. Additionally, returning the material to its monomer form allows additives and contaminants to be removed from pre- and post-consumer acrylic products. This enables more PMMA to be recycled.

Trinseo’s PMMA depolymerization facility delivers a next-generation technology, utilizing an advanced continuous process to produce high-purity regenerated MMA from pre- and post-consumer acrylic solutions. Trinseo’s depolymerization technology leverages findings from the MMAtwo Consortium, a collaborative initiative funded by the European Union’s Horizon 2020 research and innovation program, to develop a new value chain for pre- and post-consumer PMMA and a versatile recycling process for converting this waste into high-quality regenerated monomer with carbon footprint reduction versus virgin MMA.

“Today is a critical milestone in our sustainability journey,” said Han Hendriks, Chief Technology Officer at Trinseo. “Depolymerization expands our recycled feedstock capabilities, which in turn, will help us innovate new solutions. With this new capability, we can build a more robust recycled acrylics portfolio to better meet the evolving needs of our customers.”

The recycled MMA (rMMA) generated by Trinseo’s depolymerization facility is utilized in the Company’s ALTUGLAS™ and PLEXIGLAS® R-Life product portfolios. Through this new facility, Trinseo can produce rMMA that is comparable to virgin raw materials. This enables use in high-demand applications, such as vehicle taillights or caravan windows that require high optical quality.

source:Trinseo

Today's KNOWLEDGE Share : WINGCOPTER

Today's KNOWLEDGE Share

A composite delivery drone for healthcare logistics!

WINGCOPTER's W198 is a universal, all-electric composite (carbon and fiberglass) tiltrotor aircraft capable of carrying and operating a wide range of payloads, making it ideal for search and rescue, monitoring, inspection, survey, mapping, and delivery operations!

Check out some of the highlights of their new drone architecture:

1) OPTIMIZED FOR CARGO FLIGHTS: The unique aerodynamic design enables an efficient forward flight with a wide center of gravity, making it an optimal drone for cargo delivery.

2) ENHANCED FLIGHT CHARACTERISTICS: The winglets extend the surface of the wing making it more efficient in fixed-wing mode without compromising the compact size of the drone.

3) ADVANCED MANEUVERABILITY: The Wingcopter 198 can withstand strong winds and fly in harsh weather conditions thanks to its patented tilt-rotor technology.

source:#managingcomposites #thenativelab

Today's KNOWLEDGE Share : Core defects leads to catastrophic results

Today's KNOWLEDGE Share

Based on consulting requests, I realize that a lot of people forget that huge forces are developed during the molding process, as a result of pressure levels exceeding often 1000 bar/100MPa.

That amounts to 1 metric Ton of equivalent force applied to each square cm of tool surface.That is why clamp tonnage numbers are what they are of course.

But, no matter how good your steel or tool design is, metal will bend significantly when subjected to huge unbalanced forces.

And, even more surprisingly, for balanced forces, the cavity will expand by "compressing" the steel by quite a few microns !

You can run a quick FEA to check that, by applying 1000-2000 bar on a piece of steel.

Of course tubular shaped parts will readily see significant core shift problems as soon as flow is slightly unbalanced, since a differential of a few Tons-force can quickly appear if flow is not perfectly balanced. The problem here is, of course, that the more the core deflects, the more the unbalance grows. So it is a bad case of positive feedback leading to catastrophic results (unexpected weldlines in the thinned side towards which the core has been bent/pushed).

Don't underestimate the importance of these effects in molding.

While coupling Flow Analysis with stress analysis on the steel structure can supposedly model this, it is very challenging to describe the complex tool assembly. And such coupled approaches can be very challenging numerically. So, while core-shifting predictions are now quite standard, full tool deflections are usually neglected in simulations. And the clear tendency of steel compressibility to lead to overpack is never accounted for.

source:Vito leo

Today's KNOWLEDGE Share : Cupra Born VZ driving sustainability with Bcomp’s natural fibre materials

Today's KNOWLEDGE Share

Cupra announces the use of Bcomp’s innovative natural fibre composite solutions for the new CUP Bucket seats in the Cupra Born VZ electric vehicles, the latest addition to the Spanish brand’s vehicle line-up.  

Cupra focuses on innovation and sustainability to redefine the automotive industry. This approach is exemplified by the Cupra Born VZ, which combines powerful performance with eco-friendly design, aiming to inspire a new generation of drivers with its progressive and responsible engineering.

For the car’s interior design, Cupra’s collaboration with Bcomp and Sabelt, renowned for their expertise in high-performance automotive seats, has resulted in the creation of the first full natural fibre CUP Bucket seats in the Cupra vehicle line-up. By replacing the seatbacks currently made from carbon and glass fibres, the new all-natural fibre seatbacks offer significant reductions in emissions. Indeed, the use of Bcomp’s proprietary ampliTex™ technical material reduces CO2 emissions by 49% compared to the hybrid version, while also offering end-of-life options. The incorporation of natural fibres offers other significant benefits including enhanced vibration damping and increased safety, providing an optimal blend of sustainability and high performance.

The close collaboration between Cupra and Bcomp also reflects the ability to rapidly integrate these natural materials into the production car manufacturing process. With a shared commitment to improving environmental responsibility without compromising performance, the transition from traditional materials to innovative sustainable materials has been remarkably swift. The ampliTex™ natural fibre provides both the structural layer and a visual surface that introduces an elegant natural appearance and higher level of comfort for drivers and occupants.

The resulting fully natural fibre-based CUP Bucket seats are available exclusively for the most powerful electric Cupra. The Cupra Born VZ delivers impressive performance with 322 horsepower and a massive instant torque of 545 Newton-meters, allowing the vehicle to accelerate from 0 to 100km/h in just 5.7 seconds and reach a top speed of 200km/h while offering a thrilling and dynamic driving experience for anyone seated comfortably in the supportive bucket seat.

By adopting advanced eco-friendly materials, Cupra not only enhances the sustainability of its vehicles but also sets a new benchmark for the automotive industry. We are changing the sporty aesthetics to incorporate a functional part made of flax fibre in the interior of a car”.

source: Bcomp/jeccomposites.com

New Energy Blue and ARCO/Murray partner to build biomass refineries to produce sustainable fuels and chemicals

New Energy Blue, the clean-energy developer whose technology converts agricultural waste into lowest-carbon biofuels and biochemicals, and ARCO/Murray, one of America's largest, most experienced, and fastest-growing construction firms, today announce a partnership to build out the New Energy Biomass Refinery designed platform across the American Midwest. 

ARCO/Murray will construct the flagship New Energy Freedom biomass refinery in Mason City, Iowa, to sustainably process corn stalks into second-generation fuel ethanol and clean lignin at large commercial capacity. The partners have agreed to a $650 million construction contract. In 2023, New Energy Blue completed the design engineering, obtained local permits to proceed, and conducted field trials of new harvesting methods and machinery; in 2024, the project entered the final investment decision (FID) phase. The partners plan to break ground later this year and start up the refinery in 2026.  

The significant economic impact anticipated is comparable to that typically seen with first-generation ethanol facilities. In Iowa, the state responsible for approximately one-quarter of U.S. production, the industry contributes about $8 billion to household incomes annually and 100,000 indirect and induced jobs. The construction of the Freedom refinery in Mason City is projected to generate between 400 and 500 high-paying construction positions over a 20-month period. Refinery operators and feedstock suppliers from New Energy Farmers aggregation team will hold about 70 permanent jobs carrying an annual payroll of $7 million. The economic ripple effects will likely support another 5,000 jobs. Local corn growers stand to benefit by not only selling their excess corn stalks to the refinery but also participating in profit-sharing through the New Energy Farmers business unit. 

Patrick Hidder, Executive Vice President of ARCO/Murray's Green Infrastructure team, says, "We are excited to partner with New Energy Blue on this groundbreaking biomass refining project, reflecting our shared commitment to sustainability and innovation in the renewable energy sector. We welcome the opportunity to help launch a nascent industry dedicated to decarbonizing this country's fuel and chemicals." 

James Foster, Vice President of Construction for New Energy Blue, says the selection of ARCO/Murray as engineering, procurement, and construction (EPC) contractor "has paid off immediately. Their involvement is letting us accelerate the project schedule, manage costs, and provide the necessary bonding capacity needed to satisfy finance. ARCO/Murray's expertise in process piping, water treatment, anaerobic digestion, and power solutions has already added significant value."  

source:New Energy Blue/ prnewswire.com

Today's KNOWLEDGE Share :Microplastic fibres released from cleaning sponge

Today's KNOWLEDGE Share

Commonly used cleaning product releases millions of microplastic fibres

A study has demonstrated that one single sponge can release millions of microplastic fibres that could end up inside the body.

Researchers from the School of Energy and Environment at Southeast University, China, have analysed how much microplastic a specific and common type of cleaning product releases. The result was 1.5+ trillion particles a month on a global scale.

Researchers: trillions of fibres released from cleaning sponge

The popular melamine sponge was the subject of the researchers' study.

They examined sponges from different brands and rubbed them against the same surface.

In doing so, they determined that one single sponge released approximately 6.5 million fibres for every g they were worn down.

To calculate how many microplastic fibres are shed globally every month, the researchers estimated that all sponges wear down by an average of 10 %.

This data, combined with sales figures from global online retailer Amazon, prompted the researchers to conclude that 1.55 trillion fibres could potentially be released from melamine sponges every month.

Why it can be harmful to your health

Science Illustrated has previously described how microplastics find their way into the human body - either through the air or via what we eat and drink.

When a melamine sponge is used or rubbed against a surface, it eventually breaks down into smaller pieces that release microplastics.

The microplastics can then be flushed into the sewage system and eventually ingested by fish or other animals, which is how the fibres enter the food chain. This could ultimately affect humans who eat fish or other foods, absorbing the microplastics.

However, the researchers' results also indicated that dense sponges both decomposed more slowly and released fewer fibres than sponges whose foam was less dense.

Their advice is to use dense sponges or natural cleaning products, of which there are many on the market, to avoid too much microplastic ending up in nature.

The study has been published in ACS Journals.

source:scienceillustrated.com