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Carbon Composites - The Future

Conference Paper · November 2017

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 „Carbon Composites – The Future“

FIBRALSPEC Conference and Workshop

Athen
Nov. 29th 2017

Prof. Dr. rer. nat. Michael Heine

Universität Augsburg / Lehrstuhl Materials Engineering
Institut für Materials Resource Management (MRM)
 The Global CFRP-Market Forecast (09/2017)
compared with key market developments

Source: M:Kühnel, M.Sauer, The global CF and CC market 2017, International Composite Congress (ICC) Stuttgart, Sept. 18th 2017
https://www.carbon-composites.eu/media/2996/ccev-avk-marktbericht-2017.pdf

2 Carbon Composites - The Future 29.10.2017

 The Global CFRP-Market (09/2017)
by application
Total: 126,7 kt
http://www.offshorewind.biz/wp-
content/uploads/2015/05/Bureau-Veritas-
Guidelines-to-Spur-Tidal-Energy-
Total: 126,7 bn US$
Development-320x190.jpg

Airbus

Airbus

https://upload.wikimedia.org/
wikipedia/commons/0/0a/Wo
od_putter_iron.jpg

BMW

Source: M:Kühnel, M.Sauer, The global CF

and CC market 2017, International Composite
Congress (ICC) Stuttgart, Sept. 18th 2017

3 Carbon Composites - The Future 29.10.2017

 The Global CFRP-Market (09/2017)
by revenues

Revenues in US$ billion by market segment

Total: 19,3 bn US$

Source: M:Kühnel, M.Sauer, The global CF and CC market 2017, International Composite Congress (ICC) Stuttgart, Sept. 18th 2017

4 Carbon Composites - The Future 29.10.2017

The Global Carbon Composite Market
related to matrix systems (09/2017)

Revenues in US$ billion by matrix

Total: 19,3 bn US$

Source: M:Kühnel, M.Sauer, The

global CF and CC market 2017,
International Composite Congress
(ICC) Stuttgart, Sept. 18th 2017

5 Carbon Composites - The Future 29.10.2017

 Additive and Generative Processes
The key for break-through innovations

The special situation that carbon fiber reinforced composites (CFRP) as

construction material results directly within the production process offers
the potential for breakthrough innovations.
Airbus

BMW

Barth Group

http://img.xcitefun.net/users/2
009/02/28675,xcitefun-world-2-
nd-tallest-building-starting-in-
jeddah-k-s-a.jpg

6 Carbon Composites - The Future 29.10.2017

 Production Processes for CFRP
Allocation of Process Types (2015)
Total: 91 kt

http://www.carbon-
composites.eu/media/2307/cfrp-market-
report-ec-2016-kuehnel-freigabe.pdf):

7 Carbon Composites - The Future 29.10.2017

Carbon Fiber Supplier Situation (09/2017)

8 Carbon Composites - The Future 29.10.2017

 Carbon Fiber Supplier Situation
related to regions (09/2017)

Total: 136,5 kt

Source: M:Kühnel, M.Sauer, The global CF and CC

https://www.carbon-composites.eu/media/2996/ccev-avk- market 2017, International Composite Congress (ICC)
marktbericht-2017.pdf Stuttgart, Sept. 18th 2017

9 Carbon Composites - The Future 29.10.2017

 The Global Carbon Fiber Market
compared with other material groups (2016)

10 Carbon Composites - The Future 29.10.2017

 The Global Plastic Market

Polyolefines (PE, PP):

200 Mio t

European Polymer Production [Mio t]

[Mio t]

Global Polymer Production [Mio t]

Source: PlasticsEurope (PEMRG) / Consultic
http://www.plasticseurope.de/Document/plastics-the-facts-20142015.aspx?Page=DOCUMENT&FolID=2 (25.10.2015)

Global need for polymers in CFRP: 0,05 Mio t

11 Carbon Composites - The Future 29.10.2017

 High Performance Polymers
still a niche market

Historical development of the market (1975 - 2000)

12 Carbon Composites - The Future 29.10.2017

 CFRP Costs Prediction

Cost Prediction [ €/kg]

30

20

10

1 2 3 4 5 6 7 8 9 10 11
Steel Aluminium CFRP
2005 2012 2020
Quelle: Benteler SGL

13 Carbon Composites - The Future 29.10.2017

 Polymer Infiltration
is one of the cost-generating processes

From cost and efficiency aspects the infiltration process of a textile

reinforcing architecture with a polymer or the polymerization of monomers
to macromolecules within this textile structure is the most time-consuming
and cost generating process.

14 Carbon Composites - The Future 29.10.2017

 Cost influencing sub-processes

Key Process
PAN C-Fiber Textile

Textile Polymer CFRP

Polymer

tprocess = t1 + t2 + t3 + t4 + t5 + t6

t1 t2 t3 t4 t5 t6
Textile Polymer / Infiltration / Consolidation / Cooling Finishing
Architecture Monomer Powdering Reaction Period Operations
Preparation Preparation

Heating

15 Carbon Composites - The Future 29.10.2017

 Process Relevant Topics

• Viscosity at impregnation stage [f(temperature)]

• Reaction time for polymerisation [f(temperature)]
• Reaction time for polymerisation [f(h*ⱱ)]
• Degree of curing
• Byproduct handling
• Exothermal behaviour
• Shape / Volume behaviour

16 Carbon Composites - The Future 29.10.2017

 Application Relevant Topics
(key properties)

• Glass transition temperature / max. temperature of usage

• Elongation at break of polymer
• Youngs Modulus
• Tenacity
• Notched impact strength
• Polarity (water uptake)
• Resistance against defined media
• Flame resistance
• Resistance against load cycles
• Price of polymer
• World capacity of polymer

17 Carbon Composites - The Future 29.10.2017

 Target Industries (in general)

 Automotive
 Aircraft / Aerospace
 Wind Energy, Offshore
 Rail / Buses / Mass Transport
 Building / Construction
 Civil Engineering / Infrastructure Focused
 Marine / Shipping market
exploration
 Consumer Products, Leisure
necessary
 Industrial / General Engineering
 Leisure
 Electrical / Electronics
 Medical
 Water Control / Sewerage
 Agriculture
 Corrosion / Chemical Resistant Equipment
18 Carbon Composites - The Future 29.10.2017
 Industrial Innovation Information Days
Brussels 3-4 October 2017

Brockerage Event
Paralel Session: Open Innovation Test Beds
Proposal Number:
Proposal title “Process Adapted Polymers” - the
Luca Polizzi key for a breakthrough of carbon composite
DG Research & Innovation lightweight materials
 „Process Adapted Polymers“
- the key for a breakthrough of carbon composite
lightweight materials
DT-NMBP-01-2018: Open Innovation Test Beds Universitätsstraße 1
86159 Augsburg/Germany
for Lightweight, nano-enabled multifunctional
composite materials and components (IA) P. +49 821 598 3131
P. +49 821 598 3437 (Sekr.)
F. +49 821 598 3411
M. +49 171 47 40710
Prof. Dr. rer. nat. Michael Heine www.mrm.uni-augsburg.de
Universität Augsburg / Lehrstuhl Materials Engineering www.mrm.uni-augsburg.de/gruppen/heine/
Institut für Materials Resource Management (MRM) https://www.researchgate.net/profile/Michael_Heine2

29.10.2017 Carbon Composites - The Future 20

 Innovative Aspects
Nano-Structural Approach
(crystalline / noncristallin)

Nano-Additive Approach
(Matrix & Fibre/Matrix Area)

Structural Networks with reversible bondings

(chemical & physical crosslinking)

29.10.2
Carbon Composites - The Future 21
017
 Expected Impact
• Weight reduction compared to classical materials > 40%;
• Process cost reduction from currently 75% to 25% of the total carbon composite costs
• Cost reduction from 30-50 €/kg to 15 €/kg for the composite material
• Potential for new material design with further cost reduction equivalent of < 15 €/kg by
material property related parameters (strength/stiffness per cost)
• Potential for new polymer systems for additive manufacturing concepts

Demo-Building of a Process Chain for

Manufacturing of Adapted Polymers followed by
the Composite Formation Process

with New Polymers suitable for

• Thermoplastic processing before final curing step
• Reversible network formation
• Mouldability and complete dissolution possibility Activities will start at TRL 4 and
• Stimuli-responsive composite behaviour achieve TRL 7 at the end of the
• Shape memory behavior of pure and reinforced polymers project
29.10.2017 Carbon Composites - The Future 22
 5th SPIRE
Brokerage
event
03 October 2017

MICRO FLOW REACTOR APPROACH

FOR NEW POLYMERS

Prof. Dr. Michael Heine

michael.heine@mrm.uni-augsburg.de
 PROJECT IDEA
Micro flow reactor approach for new polymers suitable
for light-weight carbon fiber constructions

CE-SPIRE-03-2018: Energy
and resource flexibility in PAN C-Fiber Textile
highly energy intensive Textile Polymer CFRP
industries Reactant 1

Reactant 2
Infiltration
Polymer
Pre-Polymer Polymerization
Solidification
Reactant 3

Reactant 4 Source: Macromolecules 2010, 43, 8424– Additive Processing

8429
DOI: 10.1021/ma101663x

WWW.SPIRE2030.EU 24 29.10.2017
 Leading Edge Cluster MAI Carbon
In the Augsburg Area we are fostering the development of process optimized
polymer systems to increase the chance for a breakthrough of this material
group.

25 Carbon Composites - The Future 29.10.2017

 Innovation Park Augsburg
Basic Research
University Research Prozess Technology

MRM Institute

Physik
Institute Interdisciplinary Institute DLR ZLP und Fraunhofer FIL
Interdisziplinäres
Institut
Materials
Materials
ResourceResource
Management
Management Applied Research
Enduser

Technology Center
Innovation Park Augsburg
26 Carbon Composites - The Future 29.10.2017
 Campus Carbon 4.0
at University of Augsburg / Innovation Park

• The new Research Campus

is starting in 2017 to realize
technology under the Polymer Engineering
concept of Industry 4.0 Center Center
• Carbon 4.0 generates
knowledge along the
process chain Carbon Fiber
Reinforced Polymers Industrie
• The structures of the 4.0
Leading Edge Cluster MAI
Carbon and the Bavarian
Cluster Mechatronic &
Automation are used Industrie
Production Recycling
4.0
Center Center

27 Carbon Composites - The Future 29.10.2017

Strategic Concept for Future CFRPs Applications
based on a integrated approach

Process & Life Cycle

Raw Materials Residues

PAN C-Fiber Textile

Process Chain
Textile Polymer CFRP CFRC CSiC

Polymer

28 Carbon Composites - The Future 29.10.2017

 New Processing Options
Additive Manufacturing without Mold

Fabrication ICD/ITKE
Forschungspavillon
2013-14
© ICD/TKE
Universität Stuttgart

29 Carbon Composites - The Future 29.10.2017

 Additive Processing without Mold
Examples xFK in 3D by AMC

http://www.automotive-management-consulting.com/xfk-3d
30 Carbon Composites - The Future 29.10.2017
 Any Questions ?
Prof. Dr. Michael Heine
michael.heine@mrm.uni-augsburg.de michael.heine@carbon-composites.eu

Universität Augsburg Innovation Mentor

Institut für Materials Resource Management (MRM) Carbon Composites e.V. (CCeV)
Lehrstuhl Materials Engineering
Universitätsstraße 1
86159 Augsburg/Germany Am Technologiezentrum 5
P +49 821 598 3131 86159 Augsburg
P +49 821 598 3437 (Sekr.) P +49 821 2684 11-02 (Sekr.)
F +49 821 598 3411 M +49 171 47 40710
M +49 171 47 40 710

www.mrm.uni-augsburg.de/gruppen/heine/ http://www.carbon-composites.eu/
http://www.carbon-
composites.eu/de/projekte/innovationsmentor/
https://www.researchgate.net/profile/Michael_Heine2

31 Carbon Composites - The Future 29.10.2017

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