Berry presentation - iacmi - sandia blade workshop 2016

1. IACMI / Wind Technology Area
Derek Berry
IACMI Wind TA Director
Sandia Blade Workshop
August 31, 2016

2. 2
Presentation Overview
•NNMI / IACMI
•Wind Technology Area
•Manufacturing facility
•Project topics
•Thermoplastic project
•Engaging with IACMI
•Wrap-up

3. 3
Additive Manufacturing
3D Printing
Youngstown, OH - 2012
National Network for Manufacturing
Innovation(NNMI)
Digital Manufacturing
Chicago, IL - 2014
WBG Semiconductors
NCSU - Raleigh, NC - 2014
Lightweight Metals
Detroit, MI - 2014
Composites
Knoxville, TN - 2015
President Obama’s 2013 and 2014 State of the Union Addresses

4. 4
Existing Institutes in the Network
Department of
Defense (DOD)
National Institute
of Standards and
Technology (NIST)
Department of
Energy (DOE)

5. 5
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

6. 6
January 9, 2015: President Obama Announces
New Composite Institute
“…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.
”

7. 7
Shared RD&D facilities will
support industry

8. 8
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

9. 9
• 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
characterizationand
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

10. 10
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

11. 11
An Integrated Approach to meet our Goals
and Metrics

12. 12

13. 13
IACMI has 140 Members and Growing
National Labs
2%
SMEs
45%
Industry Large
32%
Academic
12%
Industry Assoc.
4%
Economic Development
1%
States
4%

14. 14
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 Partner
Geographic Extensions
Members
Interested Parties

15. 15
Successful integration means IACMI
becomes the Industry’s Institute

16. 16
$70M - DOE
$189M - Other
122 - Member
Consortium
6 States
Strong Leadership
5 FocusAreas
Production
Capacity
Jobs
- 75%
CFRP Embodied
Energy Savings
- 50%CFRP
Production 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

17. 17
IACMI Wind Technology Area (Wind TA)
• NREL leads the Wind TA – building on a 30 year history of
collaboration with every major wind turbine OEM and US blade
manufacturer
• Team of industry and university partners, including: Johns
Manville, TPI Composites, Vestas, Siemens Wind, GE Wind,
Colorado State University, Colorado School of Mines, University of
Colorado Boulder and Iowa State University
• Wind turbine composites manufacturing innovation projects in
such areas as:
• Thermoplastic resin systems
• Pultruded spar caps (FRP / CF)
• Manufacturing automation
• Additive manufacturing – tooling and components
• Segmented blade design and manufacturing
• Recycling of wind turbine blades and components
• In-process non-destructive evaluation (NDE) IACMI Wind Technology Area Objectives:
• Provide comprehensive expertise and
capabilities to enable achievement of DOE
and IACMI goals and metrics
• Drive down COE for wind power
• Coordinate with DOE EERE WWPTO to
leverage investments

18. 18
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

19. 19
• 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

20. 20
FOR 60m BLADES
IACMI Wind TA CoMET Facility

21. 21
IACMI Wind TA CoMET Facility Wind Tooling
In Kind Cost Share Donation of wind turbine component tooling
• DowAksa, GE and others

22. 22
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

23. 23
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 SWiFT
blades)
• Large area rapid NDE
• Modeling and manufacturing Simulation
• Panels, material test coupons and components
• Structural testing: coupons, component, joints
• Workforce development / training

24. 24
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 sizing
Resin process
modeling
TRL 5-6 (BP2)
Panel production
Coupon testing
Techno-economic
modeling
TRL 7 (BP3)
Full-scale blade
root component
Component
testing

25. 25
Thermoplastic Project Team

26. 26
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

27. 27
• 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

28. 28
Work Underway: BP2 Work Completed
ID
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 structuralproperties - 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.

29. 29
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.
Technical
Collaborations
$20K—
$600K
Minimum
1:1 (large
entities:
50% being
cash)
Up to 2
years
• Phase 1 is <6
months 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.

30. 30
Project
Proposal
and Review
Process
§ Evaluation criteria is
in RFPs
§ Responsive to
roadmap needs
§ Evaluators include
Directors, TAB, BOD,
and/or DOE

31. 31
US
Department
of Energy
Partner
States
Core
Partners
Charter,
premium,
and resource
members
Consortium
members
Supporters
Thank
You
Thank You & Questions