The document discusses trends and challenges in composite materials. It outlines 6 major trends: 1) Proliferation of carbon fibers for high-volume applications. 2) Intelligent fiber architectures like 3D weaves. 3) Development of sustainable composites using natural fibers and biopolymers. 4) Automation driven by demand for high-volume production. 5) Recycling of glass and carbon fiber composites. 6) Use of nano-scale materials and structures to improve properties. The trends are driving wider composite usage but new recycling and sustainable approaches are needed to meet challenges of high-volume applications.

1. Composite Materials:
trends and challenges
Ignaas Verpoest
Composite Materials Group,
Department Metallurgy and Materials Engineering, K.U.Leuven
and
Sirris-Leuven Composites Application Lab
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2. Composites: what?
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3. Composites: why?
• Ashby’s diagrams: Plate bending
Modulus - Density Ceramics
1000
Composites
100 Natural
Young’s modulus E (GPa)
materials Metals
10
Polymers
1
10-1
10-2
foams
10-3
Elastomers
10-4 Tension
0.01 0.1 1 10
Density, ρ (Mg/m3)
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4. Composites: why?
Conclusion:
High specific strength and
stiffness
lighter structures
Less energy consumption
during manufacturing
ànd use
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5. Composites: how important?
• Annual production of fibres for composites (estimations):
– Glass fibres: 250.000 ton
– Carbon fibres: 30.000 ton
– Natural fibres: 40.000 ton
– …compared to
• Steel: 800.000.000 ton
• Polymers: 120.000.000 ton
• Annual growth rates of (some) composite applications
– thermoplastic matrix composites : 8 % (now 37% market share)
– closed moulding (RTM, RTM-light, infusion): 13 % yearly (now 10 % market
share in EU)
– Aerospace structures: +11% p.a.
– Wind energy composites: +16 % p.a.
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6. Composites: how important?
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7. Trends and challenges
TRENDS CHALLENGES
1. Proliferation of carbon fibres
2. Intelligent fibre architectures
3. Sustainable composites
4. Automated manufacturing
5. Recycling
6. …and nano?
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8. Trend 1: the proliferation of carbon fibres
• Carbon fibres:
– started in aerospace in ’80s
– Developed into sports and industrial applications in ’90’s
– Are now penetrating into ‘high volume applications’ because of
• Long term perspective for stable costs (possibly decreasing)
• Strong emphasis on sustainable, hence low energy consumption
products
• Example: BMW decided
– Their “city car” (electrical or
hybrid) will be a carbon fibre
composite car
– They will build their own
carbon fibre manufacturing
plant (together with SGL)
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9. Trend 2: intelligent fibre architectures
• From individual textile layers… to structurally stitched components!
3D Weaves Knitted
fabrics
2D Weaves Braids
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10. Trend 3: Sustainable composites
• Natural fibres: strong
increase in
• Developments for
composites
• Industrial interest
• Biopolymers polymer Bio-based
Resin processing Polymer or Composite
– Preferred route should Material recycling
• No compete with chemical or
(bio)catalytic composting
food modification Controlled-
release
• Add little Gluten Compost
Nitrogen
Fertilizer
‘chemistry’
industrial
agriculture
processing
Wheat
Starch
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11. Trend 4: automated manufacturing
• Driven by trend to ‘high volume applications’
– Already happening in
• Sports equipment
• Aerospace:
– at hundreds of composite aeroplanes/year
– Thousands for similar components have to be produced
– Hence automation is needed!
– Soon expected in automotive!
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12. Trend 5: recycling
• Necessity for ‘high volume applications’
• Two developments:
– Glass fibre composites:
• Trend towards thermoplastic composites
• Potential for alternative fibres which improve recyclability:
– Basalt fibres
– Natural fibres
– Steel fibres
– Carbon fibre composites:
• Processes for recovery of carbon fibres are ready to operate!
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13. Trend 6: and nano?
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14. Trend 6: … and nano?
Meso
Fabric
architecture
stiffness
Micro
Fibers inside
yarns
Cracks in transverse ply Debonding at matrix/fiber interface failure
resistance
Nano
Structure of
matrix
Multiphase epoxy Carbon nanotubes
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14

15. Trends and challenges
TRENDS CHALLENGES
1. Proliferation of carbon fibres
2. Intelligent fibre architectures
3. Sustainable composites
4. Automated manufacturing
5. Recycling
6. …and nano?
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