JEC Paris 2010 - Conferences and Forums program

PARIS APRIL 13-14-15, 2010 Paris Porte de Versailles

Conferences & Forums

12 forums
© P. Wartenweiler, Mäder Composites
in
2010
End-user Industry forums
Aeronautics • Automotive • Construction & Civil Engineering • Marine • Rail & Road Transportation • Wind Energy

Cross-Industry forums
Automation • Bio-based Materials • Recycling & Life Cycle Management

Technical conferences
Design • Simulation • Process Time to book
your seat!
www.jeccomposites.com in partnership with:

Key Topics
Gain Insight into the JEC 2010 Program ...................................................... p.4

6 Industry end-user forums:
• Aeronautics................................................................................................................ p.14

• Automotive ................................................................................................................ p.8

• Construction/Civil Engineering ................................................................................ p.7

• Marine ........................................................................................................................ p.15

• Rail & Road Transportation ..................................................................................... p.17

• Wind Energy.............................................................................................................. p.16

3 Cross-industry forums:
• Automation................................................................................................................ p.11

• Bio-Based Materials................................................................................................. p.12

• Recycling and Life Cycle Management .................................................................. p.6

3 Technical conferences:
• Composites Design in partnership with Stanford University ............................. p.10

• Composites Simulation in partnership with ESI Group ...................................... p.13

• Composites Development Process in partnership with DLR CFRP Research .. p.9

With the testimony of:
3XN architects • 5D composite A Accudyne Systems • Airbus • Airbus Deutschland GmbH • Airbus Operations Ltd • Ashland Finland Ltd • Audi Lightweight
Center • Automobili Lamborghini S.p.A B BASF SE • Beijing Institute of Aeronautical Materials • Bombardier Aerospace C Carbo-Link • CFK Valley Stade
Recycling • Composites Evolution Ltd • CPIL • CTC GmbH D Daher Socata • Dantec Dynamics GmbH • D’Appolonia S.p.A • Dassault Aviation • Dassault Systèmes
Decathlon / Artengo (Oxylane group) • DLR - The German Aerospace Research Center Dow Deutschland GmbH & Co. OHG • DSM Composite Resins AG • DSM
Composite Resins AG E EADS - Astrium Space Transportation • EADS Deutschland GmbH • Ecole Polytechnique at University of Montreal • EPL Composite
Solutions Ltd. • ESI Group • Eurocopter F Fokker Aerostructures G Gamesa, Gruntech Polymer Consultants • Gurit UK • GWEC H HDS • Huntsman Advanced
Materials I Icolﬁbra • Ifremer • Invent GmbH • ITCA S.p.A. • I-Trans L LCPC (Laboratoire Central des Ponts et Chaussées) • Lineo M MAG Europe • Mainz
University of Applied Sciences • Mikkeli University of Applied Sciences N National Technical University of Athens • NCD • NpSp P Pôle Européen de la Plasturgie
PPE • Premier Composite Technologies • Premium Aerotec GmbH R Ruredil S Stanford University • Swerea Sicomp AB T Technical University of Munich
The Katholieke Universiteit Leuven (Belgium) • The University of Tokyo • The University of Washington • The University Tokyo • Total Petrochemicals • Toyota
Motor Corporation • Trimarine SRL • TTT The Team Technology GmbH U UAM • University of Bristol • University of Nottingham V Vistagy Aerostructures.

2 www.jeccomposites.com

Edito
C
omposite materials have rapidly become a mainstream technology and
material of choice within many industries, from aerospace to wind energy.
And today, environmental regulations act as a new innovative driver for
a paradigm shift in the composite market.
Replacing metals by composites is fundamentally environmentally responsible.
In land transportation lightweight composite structures have a big role to
play in reducing both the use of petrochemicals and CO2 emissions.
Demand for more composite applications keeps on increasing.
Now is the time for Add to this the fact that low-weight carbon fibre structures
Eco composites reach the ends of their service lives, and it then becomes obvious
that Recycling and Life Cycle Management is now a key eco
challenge. This is why JEC launches in 2010 its first observance
forum on this subject.
Bio-based fibres and resins derived from natural, renewable
sources have also increasingly received significant interest in
recent years due to increased environmental awareness, concern
about the depletion of non-renewable resources and the insta-
bility in oil prices. In the 2010 forum, you will discover more
and more significant innovations in particular in transportation,
architecture and sports & leisure.
© P. Wartenweiler, Mäder Composites

Another main topic at the 2010 JEC Conferences and Forums pro-
gram, will be cost control and process automation. The tran-
sition from metal parts to composite is an ongoing process but
often labor intensive and therefore expensive. To exploit the full
potential of composite materials for high performance lightweight
structures, it is necessary to consider the entire process chain. Automation can
bridge that gap for a long-term profitable serial production.
Eco-design, along with cleaner and more eco-efficient processes, highly auto-
mated manufacturing techniques, weight reduction, lower production costs…
The JEC 2010 Conferences and Forums program will help you gain insight on
major market drivers and new energy-saving strategies for composites.
We look forward to meeting you at JEC Composites Show Paris.

Martine Vesco
JEC Forums and Conferences Manager

www.jeccomposites.com 3

Gain Insight into the JEC 2010 program
AERONAUTICS
Aircraft structures: This Aeronautics forum will look at what has to be done to meet current and likely
Cost control - the new battle future requirements for cost reductions. The recently founded UK National Composi-
Next generation composite wings: tes Centre will be briefly described and its mission to tackle the issues around low
Airbus, Bombardier Aerospace, cost composites will be outlined. Finally, next generation wings at Airbus, Bombar-
Daher-Socata dier Aerospace and Daher-Socata, integrating as much composite in the wing as
New thermoplastic and recyclable possible to make aircraft more fuel efficient, will be presented.
solutions

AUTOMOTIVE
Energy saving strategy 2010 will be the Automotive year at JEC. Come and discover how Audi, Lamborghi-
Cost-effective and lightweight ni, Nissan, Toyota Motor Corporation rely on composite to meet the most stringent
materials and processes environmental regulations.
Constructors experiences:
Audi, Lamborghini, Nissan, Toyota
Motor Corporation

CONSTRUCTION AND CIVIL ENGINEERING
Efficient seismic solutions Designers in Construction and Civil Engineering are getting better and better at
Reinforcements for tunnels integrating all the potential of composites. Composites address very utilitarian
and building needs, notably for earthquake risks. They serve just as well in new constructions,
Case studies: spectacular applications in renovation and rehabilitation. In civil engineering, new modular and lightwei-
ght bridges, that can be assembled and disassembled manually on site, will be
presented.

MARINE
New solutions as part of the industry Given the opportunities for further expansion, the marine industry represents
recovery a highly attractive market for OEMs, material suppliers, engine suppliers and part
Comparative studies of materials suppliers. Resin and reinforcement producers constantly improve their products to
Solutions for quality improvement achieve better strength, fatigue properties, surface quality, lighter products as well
Thermoplastic penetration in Marine as cheaper and healthier manufacturing processes.

RAIL AND ROAD TRANSPORTATION
Green and thermoplastic solutions Reducing the environmental footprint of terrestrial vehicles is the roadmap of the
Agro vehicles innovative cluster I-Trans. In Rail and Road Transportation, composites are in-
Low CO² emissions creasingly used since they have the advantages of strength, durability and corro-
sion resistance together with low weight. This increases the potential useful load
and also helps to save on energy. A new urban collective vehicle, a monocoque
trailer made of carbon composite, a modular bus body and composite cylinders for
automobile and gas transportation, all reap the benefit of the high properties of
composites.

WIND ENERGY
The Global World Energy Council Wind energy growth demands more and more blades being manufactured. At the
market vision same time, wind turbines produce more and more power, which means that the
Automation: better quality at lower blades grow larger and larger. Robustness of the design and the manufacturing
costs processes is becoming more and more critical. Increasing competition forces ma-
nufacturers to increase their throughput while reducing their manufacturing costs.
This forum will demonstrate what wind energy companies can learn from aerospace
composites best practices and how to maximize the efficiency and the robustness
of the manufacturing process by introducing automation.


RECYCLING AND LIFE CYCLE MANAGEMENT
Recycling processes and applications JEC launches the first observance forum on Recycling and Life Cycle Management
Life Cycle Management (LCM). Long-fibre, high-grade carbon is a valuable commodity, costing upwards
Economical and Ecological benefits of £10,000 per ton when new. Add to this fact that consumption is increasing,
offering competitively priced material having minimally impaired mechanical pro-
perties and good surface chemistry is key. Do not miss this forum! This is a unique
opportunity to compare European and Japanese LCM-strategies for carbon fibre
composite aircraft and cars. You will network with all actors: universities, industry
and reclaimers.

BIO-BASED MATERIALS
A booming market With the demand for safer and healthier products enabled by strict environmental
Green materials advances regulations, there is a growing need for Bio-based materials. Different aspects give
Innovative case studies: 3XN architect, the grounds for the choice of these materials: from an environmental, technical
Decathon/Artengo, NPSP and economical point of view. The forum will highlight different innovations case
studies and applications in construction, sports and leisure and transportation.

AUTOMATION
Automation through new materials, Automation is key for reducing the cost of manufacturing composites parts. Europe
processes and equipments has the highest rate of automation with 83% of its processes automated. A
Trends for the future market overview of the Automotive, Aerospace and Wind Energy requirements for
automation will be presented. You will also learn about the most promising tech-
nologies and successful examples.

COMPOSITES DESIGN
Opportunities for composites design Stephen W. Tsai, Professor Research Emeritus and its speakers will present the
Micromechanics and design tools best available theory and also design tools that can be used to implement predic-
Analysis for damage tolerance and repair tions of failure, life and damage tolerance of composites.
Standard master curves for rapid life
prediction
Practice session

COMPOSITES SIMULATION
The complete simulation chain: Despite of great advances demonstrated by the academic world, the Manufactu-
new effective processes ring Process Simulation (MPS) is still in its infancy in the industry. In this forum,
Case study: a wing assembly a case study (composite wing assembly) will enable to introduce to the numerous
challenges of MPS. Then, the presentations will demonstrate the benefits of using
the numerical simulation of manufacturing. The forum will cover the underneath
material modeling and how to use it in simulation like for instance fan blades RTM
manufacturing for an aircraft engine.

COMPOSITES DEVELOPMENT PROCESS
New energy-efficient design To exploit the full potential of composite materials for high performance lightwei-
and manufacturing techniques ght structures, it is necessary to consider the entire process chain. No single
Research projects: key aerospace process step can be optimized without taking into account the impact to preceding
players testimonials: Airbus, Eurocopter, and subsequent steps. The integration of additional functions into the load carrying
Premium Aerotec structure offers further advantages of composite technology. Some examples from
actual research shall illustrate the potentials and challenges in the composite
development process.


RECYCLING & LIFE CYCLE MANAGEMENT FORUM
Tuesday, April 13 - 10.30 am / 1.00 pm

Recycling as part of an integrated life cycle management
3. Falcon JET Eco-design: The environmental Japanese new national project, and repair and
MODERATOR footprint recycling of CFRTP for automotive application.

The University of Nottingham Dassault Aviation Life cycle analysis of recycled CFRP.

Stephen Pickering Philippe Vautey 6. Automotive recycling of production scraps
Associate Professor Head of Department for New
and Reader: Division Technologies, Materials and Testing WIPAG Süd GmbH & Co. KG
of Materials, Mechanics Aerostructure Direction Dassault
Ulrike Steigemann
Aviation Airframe R&T Strategy
and Structures Sales Manager
Coordinator
Three main drivers for the operations phase: Demands on recyclates.
Biography: aerodynamism, engine and lightweight.
Dr Steve Pickering has a BSc and PhD in Me- Innovative recycling technologies.
chanical Engineering from the University of Major composite weight saving opportunity:
wing box. Economical and ecological benefits.
Nottingham, where he is currently is an As-
sociate Professor and Reader in the Faculty of Materials and process issues for greener
Engineering. He has broad research interests in manufacturing alternatives.
the general area of thermo fluids engineering For
the past 10 years, he has led research activities Life Cycle Analysis: a global approach.
on the recycling of carbon fibre composites, in
collaboration with the broader activities of the Preliminary comparison between composite
Polymer Composites Research group at Nottin- and aluminum approaches on a wing panel.
gham University.

Automotive
What’s new with Recycling?
4. Life Cycle Analysis of composite cars:
strong, light and green!
1. Recycling processes and applications for
using carbon fibre recyclate Katholieke Universiteit Leuven
The University of Nottingham Ignaas Verpoest
Professor
Stephen Pickering
Associate Professor and Reader.
Division of Materials, Mechanics A brief introduction of the concept of Life
and Structures Cycle Analysis (LCA), and the challenges for
it’s application to products using composite
Recent developments in the recycling of carbon
materials.
fibre reinforced polymer (CFRP) composites.
A critical assessment of data used for
A review of current recycling processes for CFRP.
performing LCA-studies involving composite
Focus upon applications for re-using the materials.
carbon fibre recyclate and two multi-partner
A comparison of European and Japanese LCA-
industry/university projects: HIRECAR and
studies for carbon fibre composite cars (and
AFRECAR.
car components).

An outlook to the future: how can an increased
use of composites further reduce the ecological
Aeronautics impact of cars?
© All rights reserved

2. Recycling carbon fibre as part of an integra- 5. Recycling strategy of CFRP
ted waste management system
The University of Tokyo
CFK Valley Stade Recycling Uzawa Kiyoshi
GmbH & Co. KG Professor
Tim Rademacker
Head of Marketing & Sales, Global prospect of CFRP recycling. Also attend
Business Development
Japanese national project, and the results of The AUTOMOTIVE FORUM (p.8)
Cost savings by sustainable CFRP recycling
the CFRP recycling for automotive application. The AERONAUTICS FORUM (p.14)
solution.

Recycled carbon fibre products.


CONSTRUCTION & CIVIL ENGINEERING FORUM
Tuesday, April 13 - 10.30 am / 1.00 pm
In partnership with

Composites becoming established

MODERATOR Concrete Structures Strengthening Modular and Transportable Bridges
Laboratoire Central
des Ponts et Chaussées 3. Vaccum process for strengthening concrete 6. A modular CFRP bridge for military
structures purposes or civil protection
Monssef Drissi Habti
Director of Research UAM Invent GmbH
Amando Padilla Ramirez Carsten Schöppinger
Professor Dipl.-Ing.
Biography:
Presently head of the Cable Behaviour and Effectiveness of externally bonded GFRP glass Mobile composite bridge, aero-transportable,
Metal Consultancy Unit at the Division for Me- fiber fabric for increasing the flexural strength modular assembly, integral composite design,
tals Reinforcements and Cables in Structures of concrete beams. high loads by low mass.
at LCPC in Nantes. Senior researcher for the
Japanese Ministry of International Trade and A uniform and “high pressure” vacuum process Innovative production processes, light-weight
Industry (MITI, 1995-1998). Visiting professor to assure close contact between concrete surface structure, high quality standards.
at the University of Tokyo (1999-2000) and at and FRP system.
the Brown University of Engineering (2001-
2003). PhD in 1994 and Habilitation to Manage 4. An innovative solution for strengthening of
Research in 1999. timber structures in reconstruction

Mainz University
of Applied Sciences
Composite Seismic Solutions
Kay-Uwe Schober
Professor of Timber Engineering
1. Intelligent seismic composite wallpaper for and Structural Design
the retrofit of masonry structures vulnerable A hybrid timber composite beam for structural
to earthquake rehabilitation and upgrading.

D’Appolonia S.p.A. An increase of the load-carrying capacity up to
Thomas Messervey 200% for short-term loading.
Project Manager A pilot project: Reconstruction of the «Blue
Hall», Mansfeld Castle, Germany.
4-year investigation involving research centres,
testing laboratories, industrial partners,
universities, and specialised high-tech small to The Largest Use of Composite
medium enterprise companies. Cladding in the World
200% increases in structural strength (max
5. The dokkaae tower, Saudi Arabia: compo-
load) and over 200% increases in structural
ductility (max deformation).
site cladding and clock

Embedded sensors to take preventive measu- Premier Composite Technologies
© Mock Up of Quarter Clock for Dokkaae Tower, Mecca, KSA

res during an earthquake and assess structural Sebastian Schmitz
integrity post earthquake. Production Manager

2. Reinforcement systems for buildings and
tunnels Gurit
Mark Hobbs
Ruredil
Senior Engineer
Giovanni Mantegazza
Technical Director
35,000 sqm of composite cladding for the
largest clock in the world: 23m carbon fibre
Efficacy of FRCM in earthquake: proofing of pre-preg clock hands.
the church of Madonna di Centurelle (L’Aquila-
Italy). Presentation of the unique challenges of the
project and the composite materials, testing,
Strenghtening of a reinforced concrete tunnel,
Omikron Consulting Motor Way (Odos-Greece).
processing and fabrication technologies which Also attend
were used to realize this landmark project.
The BIO-BASED MATERIALS FORUM (p.12)


AUTOMOTIVE FORUM
Tuesday, April 13 - 2.30 pm / 5.00 pm In partnership with
Exclusive sponsor

Meeting ever more stringent environmental regulations
The use of state-of-the art and new techno- A project in cooperation with Deltatech S.p.A
MODERATOR logies such as compression injection RTM,
carbon-SMC, 3D curved braiding, 3D stitching, An integrated molding system.
The University of Tokyo molded rigid PU foam cores, thermal plastic
A low-cost semi-impregnated micro-sandwich
Jun Takahashi CFRP, etc.
system for part fabrication.
Professor Department As a result, the CFRP body weighs just 131kg
High-performance release agents to reduce the
of Systems Innovation, including the weight of metallic inserts.
number of surface treatments.
School of Engineering
3. Industrializing CFRP - challenges for the
automotive industry 6. RTM vs. autoclave prepreg process for
Biography: monocoque in road cars: specific analysis for
Jun Takahashi is specialized in mechanical en- Audi Lightweight Center a high-performance vehicle only electrically
gineering and graduated from the University Günter H. Deinzer powered
of Tokyo in 1987, and got a doctorate from the Head of Technology Development
same University in 1992 in the field of fracture YCOM
Composites
mechanics. He worked for a national research Mario Saccone
institute (AIST, METI, Japan) from 1992 to 2000 How the Audi experience in aluminum-lei- Composites Materials Specialist
in the field of composite materials. Then, he was ghtweight-design helps to develop CFRP-
promoted Responsible for national programs applications.
concerning composite materials, such as stan- Roberto Catenaro
Chances generated by industrialization.
dardization of testing method, ultra-high tempe- Consultant at Ycom
rature application, structural health monitoring, CFRP in automotive industry - designed by
recycling, and LCA (life cycle assessment). Now Audi. The new vehicle for 2012: the first supercar
he worked for the University of Tokyo and has
with only 4 electrical engines and featuring
been doing research on energy saving strategy
Out-of-the-autoclave 1,000 horse powers and a joint venture among
in the field of transportation and automotive
several companies each one at the excellence
application of CFRP and CFRTP. Molding Processes in its own industrial field.

4. RTM for primary automotive structures An extensive use of composite solutions all
Global Energy-Saving Strategy around the car in particular for the structural
in Transportation Automobili Lamborghini S.p.A components like the tub.
Luciano De Oto
A detailed analysis between RTM and standard
1. Energy-saving strategy in transportation by Head of BIW&Trim and Composite autoclave process.
using CFRP Engineering and Development

The University of Tokyo Huntsman Advanced Materials
Non-Destructive Inspection
Jun Takahashi Stephan Costantino Techniques
Professor Department of Systems Process Application Specialist
Innovation, School of Engineering 7. Building block approach to composite
Global energy saving strategy in trans- High-performance parts for high-end crashworthiness analysis
portation. automotive.
University of Washington
Effect of weight lightening on energy saving of RTM: a process of choice for parts
Paolo Feraboli
gasoline and/or electric vehicles. manufacturers.
Professor and Director of the
Research trend of CFRP and CFRTP for airplane Development of automotive structural parts Automobili Lamborghini, Advanced
and automobile applications. and resin selection criteria. Composite Structure Laboratory
Cost-effective and repeatable production of How the building block approach is being uti-
structural parts with mechanical and thermal lized at Automobili Lamborghini for the design
From Luxury cars to Mass Production performances comparable with autoclaved of new structural concepts that are being
prepregs. evaluated as technology demonstrators.

2. The development of the new Lexus LFA’s 5. Speedy-infusion for the fabrication of a GT
Also attend
CFRP monocoque car composite underfloor
Toyota Motor Corporation ITCA S.p.A The RECYCLING AND LIFE CYCLE
Nobuya Kawamura Massimo Fazzi MANAGEMENT FORUM (p.6)
Project General Manager Composites Technologies Specialist The COMPOSITES SIMULATION
CONFERENCE (p.13)
Is the LFA’s carbon technology conservative? Roberto Catenaro The RAIL AND ROAD TRANSPORTATION
No! FORUM (p.17)
Technical Director


COMPOSITES DEVELOPMENT PROCESS CONFERENCE
CE
Tuesday, April 13 - 2.30 pm / 5.00 pm In partnership with

Exploring challenges of process chain for CFRP structures
Energy absorption concept validated by
MODERATOR experiments testing triggered sandwich panels Adaptronics
under mixed compression – bending loads.
DLR - The German Aerospace
Research Center Case study: Airbus Deutschland GmbH.
5. Droop nose morphing structure
Martin Wiedemann DLR CFRP Research
Head of Research Composite Design Olaf Heintze
Institute Research Field Leader High Lift
3. Advanced concepts for composite airframe
Biography: door and door surround structures A gapless and flexible wing leading edge
Martin Wiedemann has held the different po- structure strongly supporting airframe reduc-
sitions: Head of DLR Institute for Composite Eurocopter tion and allowing for a wing design with a
Structures and Adaptive Systems (2007), Full Christian Seyffert fully natural laminar flow. Serious reduction of
professor Adaptronics, Technical University flow resistance and, thus, emissions.
Senior Manager Engineering
Braunschweig (2007), Chief-Engineer, A400M Airplane Door Systems A composite design allowing for the union of
Fuselage and Empennage, Airbus, Site Germany
contradicting requirements such as flexibility
(2005-2007), Head of Development Processes DLR CFRP Research
for nose droop and stiffness along the wing
and Payload Accomodation, Airbus, Site France Tobias Stroehlein span for shape conformity.
(2004-2005) and Head of Specific Design Work
Project Coordinator Carbon Fuselage
Structure, Airbus, Site Germany (2001-2004). Full-scale testing in cooperation with Airbus
Major challenges of door and door surround and EADS. A successful application of the hi-
structures in CFRP fuselage, current and future ghly efficient process chain in the Institute of
technical solutions to fulfill the requirements. Composite Structures and Adaptive Systems.
Functional Materials
Interfaces and interactions with the focus on
CFRP concepts highlighted.
1. Fast processing of polymer composites for Production Technologies
New design techniques with state-of-the art
high volume production
software to achieve maximum accuracy of flat
pattern simulation and furthermore reduce 6. Advanced automated fibre placement (AFP)
Dow Deutschland GmbH
the weight and manufacturing costs of the
& Co. OHG technology
highly integral complex door and door surround
Damian Feord structures.
MAG Europe
Epoxy R&D Leader
Christian Boge
Executive Vice President Industry
DLR CFRP Research Composite Manufacturing Team Aerospace
Peter Wierach
Head of Department DLR CFRP Research
4. Sustainable production of high perfor-
Methods to optimize process parameters using Dirk Röstermundt
mance CFRP components
already established resin systems. Research Engineer
Premium AEROTEC GmbH Requirements for improved efficiency of AFP
Overview about possibilities and limits to
Christian Kulik up to the level for future large parts.
realize fast process cycles and meet the
requirements for a high volume production of A large mobile robot based-platform under pre-
polymer composites. paration in cooperation with the company MAG.
DLR CFRP Research
2. Crashworthiness aspects of CFRP airframe Characteristic features.
Markus Kleineberg
panels in fold core design
Head of Department
Foldcore GmbH Energy-efficient manufacturing strategies.
Rainer Kehrle Adaptable mould concepts for flexible compo-
CEO site component manufacturing.

Online monitoring of essential production
Also attend
DLR CFRP Research
parameters.
Ralf Sturm
Research Engineer Custom-tailored automation concepts for effi- The AUTOMOTIVE FORUM (p.8)
cient composite component manufacturing.
Development of a trigger concept for CFRP The AERONAUTICS FORUM (p.14)
composite sandwich structures based on local Challenges for future composite component The COMPOSITES DESIGN
modifications in the fold pattern of the core to manufacturing concepts. CONFERENCE (p.10)
control the failure mode of the sandwich panel.
The AUTOMATION FORUM (p.11)


COMPOSITES DESIGN CONFERENCE
Wednesday, April 14 - 10.30 am / 1.00 pm
In partnership with

Acquiring proficiency in composites design
Stephen W. Tsai Sung K. Ha Daniel Melo

Department of Aeronautics Professor, Dept. of Mechanical Engineering Department of Materials Engineering,
& Astronautics, Stanford University Hanyang University, Korea Federal University of Rio Grande do Norte;
Visiting Professor, Department of Aeronautics Visting Professor, Department of Aeronautics
& Astronautics. Stanford University & Astronautics, Stanford University

Composites Design and Tools Lekhnitskii’s Exact Solutions Test Methods and Error Estimation

This forum provides not only an authoritative Analytical solutions in Lekhnitskii’s Aniso- Widespread use of quasi-isotropic symmetric
book: Strength & Life of Composites, but also tropic Plates cover various applications of laminates known as “black aluminum” makes
a set of software tools with instructions of anisotropic beams and plates. The Stanford composite materials uncompetitive. Additio-
the underlying theory and sample problems. Composite Design Team started a project to nally, many design recommendations have
Materials and process engineers must reach program solutions of nearly all cases pre- been established without scientific basis,
this minimum proficiency level. The tools are sented in this classic book. The first version which further penalize composites. Using
devised for practical design. They can also is now released covering sections on stress uniaxial tests data to generate knock-down
challenges archaic rules that often add mass distribution in a plate with elliptic or circular factors and design allowable cost millions
and cost without rational bases. We believe openings. Arbitrary normal and shear in-plane of dollars and are limited to the specific
in closed-formation and numerical simulation loads can be applied to the orthotropic plate loading conditions. They are often not directly
tools to guide design and testing. In parti- with elastic inclusion. The inclusion in the applicable to structural design. Biaxial test
cular, we recommend 3 ply angles instead of openings can be either open or filled with data using open-hole and smooth specimens
4. We also believe in homogenized laminate elastic or rigid materials. Inner pressure and will be presented. These data indicate
and use ply angles as continuous variables. shear loads and rigid interferences can be that even for simple QI laminates failure
These designs will increase toughness and applied to the holes. Once laminate stresses envelopes are not boxy shaped and cannot
lower cost. They will reduce empiricism and are analytically obtained, each ply stress is be generated by few anchor points. The use
increase confidence in design. This forum is calculated by stress transformation. Finally, of numerical simulations to produce notched
an abbreviated presentation of our biannual strength ratios after failure analyses are strength data for structural design allowable
Stanford-certificated online Composites Design calculated and plotted in Excel worksheets. is encouraged, in combination with biaxial
Workshop that offers 44 hours of intensive These solutions are effective, preliminary test data to verify the predictions. Using few
training delivered live over 11 days. design tool for many problems for bolted ply angles and as continuous variables will
joints, hole repair and others. make laminates competitive. The importance
of using statistical tools for error estimation
3D Beam in test data will be presented.
Modeling of composite structure prior to

end
structural analysis first requires specification

Also attTICS
of geometry, laminations and loads. Such
modeling process can be very tedious and
NAU often requires high-end modeling and analysis
The AERO .14) tools. Now a new 3D Beam, based on FEM,
FORUM (p
15 2010 is developed as an easy-to-use yet power
day, April
Thurs
/ 1:00 pm
tool for analysis and design of composite
10:30 am structures. Modeling time is now reduced by
one or two orders of magnitude compared What you get
to conventional modeling and analysis FEM during the
tools. Successful applications of the 3D Beam conference?
covers various types of structures ranging
from very complicated wind turbine blades Each participant will receive:
and airplane fuselages to simple beams
such as golf shaft and box beam. Vertical 1 disk that will contain all
and in-plane loads and bending and twisting
viewgraphs, and design tools
moments can be applied to any location of
the structure. Once the global deformations
of MicMac-Inplane, MicMac-Hole
are calculated, ply stresses and the failure and 3D Beam.
indices are calculated and plotted. The natural
frequencies and vibration shapes of up to 10
modes can be additionally computed. The 3D
Beam can be also effectively used for error
estimation with selected design experimental
parameters.


AUTOMATION FORUM
Wednesday, April 14 - 10.30 am / 1.00 pm

Reducing the cost of manufacturing composite parts
6. Process monitoring and control applied in
MODERATOR New Processes for Automation FRP parts production: present and future
University of Stuttgart National Technical University
Institute of Aircraft Design 3. Highly automated sequential processes for of Athens
already qualified prepreg
Klaus Drechsler Nikos Pantelelis
S.A.B.C.A Research Engineer
Professor
Bertrand Vaneghem
Project Manager R&T Process monitoring and control applied in FRP
parts production.
Biography:
Klaus Drechsler studied Aerospace Engineering Production flow based on the use of efficient Automation of the curing process.
and has a Phd at University of Stuttgart. He and highly-automated sequential processes
has held different positions: Head «composite» including automatic tape laying processes, hot
at DaimlerChrylser /EADS research department forming and SQRTM (adaptation of the RTM
Ottobrunn, Professor at University of Stuttgart, process for prepreg technology) for the rapid
Head of Institute of Aircraft Design, Professor manufacturing of integrated structures in one
at University of Munich, Head of Chair for Carbon shot.
Composites, Head of Fraunhofer Project Group
Example of a single aisle aircraft pressure floor
«Functional Lightweigth Design», Augsburg and
demonstrator.
SAMPE Fellow.

4. Automated preform production line for
CFRP aircraft frames
What’s new with Automation?
EADS Deutschland GmbH
Matthew Beaumont
1. Overview needs, markets and technologies
Manager Structure Programme
Technical University of Munich Management
Klaus Drechsler Highly automated method of producing carbon
Professor fiber aircraft frames.

Very efficient use of materials.
Market overview of the Automotive, Aerospace
Enabler for high-volume production.
and Wind Energy requirements for automation.

Most promising technologies like advanced

© EADS Innovation Works/SGL Kümpers
material systems, textile preforming, tow-pla-
New Equipments for Automation
cement technologies and process simulation.

Successful examples.
5. Applying automation to the fabrication
of composite-based aerospace parts and
developing a machine specification
New Materials for Automation
Accudyne Systems, Inc.
John Melilli
2. In-line complete system to produce
Vice President of Sales & Marketing
thermoplastic foam core panels

5D composite Developing machine specifications based
Andrew Rekret on part requirements.
President Using tow path optimization software
to predict material behavior.
Flexibility of construction using standard basic
shapes of thermoplastic foam core.

In-line production with CNC fiber placement
reducing cost, increasing ease and speed of

Also attend
production, improving quality and eliminating
potential delamination.
The AERONAUTICS FORUM (p.14)


BIO-BASED MATERIALS FORUM
Wednesday, April 14 - 2.30pm / 5.00pm
In partnership with

Going green!
Case studies: interior and exterior automotive
MODERATOR Green Sport and Transportation parts, marine headliner panel.
Applications
Pôle Européen de Plasturgie
6. Composite resins’ vision on sustainability
3. Flax yarn-based prepreg for vibration
Charlyse Pouteau damping in sport applications DSM Composite Resins AG
Project Manager
Saris Floor
Lineo
Key Account Manager
François Vanfleteren
Biography: CEO
Marian Szkudlarek
Charlyse Pouteau has been PhD, Project Manager R&D DSM Composite Resins
at « Pôle Européen de Plasturgie » since 2003.
Decathlon / Artengo (oxylane groupe)
With a master in “Chemistry and physico-che-
mistry of polymer“ at the University Pierre and Vincent Duminil A 55% bio-content resin for SMC and BMC
Marie Curie, she worked at the Institut National Innovation Manager applications.
de Recherche Agronomique in Reims. She studied
there the anti-oxidant activity of lignin in polyo- The first commercial application: the cradle-to-
Lineo: Advantages of flax fibres. How to inte- cradle (C2C) street bench developed by VelopA.
lefin polymer matrix. She gets her PhD degree in
grate flax fibres into composite parts. Past and
Chemistry in 2002. Her current research interests
future developments and solutions for direct
are covering recycling, biodegradable polymers,
processing. Round Table: Learning from Today
and natural fiber-plastic composites.
Decathlon: Process innovation, Flax Fiber (Why and Planning for Tomorrow
and How?). Next flax developments at Artengo.
What’s new with Bio-Based Katholieke Universiteit Leuven
Materials? 4. Monocoque structure of electrical scooter Ignaas Verpoest
out of flax fibre-reinforced composite Professor
1. Bio-based materials: new developments and
recent advances NPSP Composieten BV
A brief introduction on the European Flax
Willem Böttger and Hemp Federation (CELC) and its Scientific
Pole Européen de Plasturgie General Manager Committee.
Charlyse Pouteau
Project Manager The research agenda for flax- and hemp-based
A structural part made of natural fibre reinfor-
composites: in which R&D-programs companies
ced composites.
and governments should invest to increase the
Overview of the different works in the domain Lighter than the glass fibre with a factor 10%, use of natural fibres in composites.
of natural fiber composites. recyclable and with an environment impact
A synthesis and analysis of the natural fibre
Different innovations case studies and 60% lower than glass fibre reinforced hand
composite applications: what do they tell us
applications. laminated body parts as calculated with the
for future developments?
Life Cycle Assessment method.
R&D projects.
Natural fibres: from fillers towards a high
performance material.

Green Architecture for the Future Bio-composites from R&D towards commercial
products.
© 3XN A/S • Decathlon (Oxylane group) • Artengo

2. A sustainable pavilion in bio-composites
and intelligent materials
New Bio-Based Materials
3XN architects
Kasper Guldager Jørgensen 5. Aligned natural fibre-reinforced bio-
Architect, Head of R&D composite materials for high-performance
applications
Learning from nature.
Composites Evolution Ltd
A sustainable pavilion in bio-composites Brendon Weager Also attend
and intelligent materials. Technical Manager
The CONSTRUCTION & CIVIL
Architectural use of bio-composites. ENGINEERING FORUM (p.7)
Biotex: High-performance reinforcements based
How to design our built environment on flax and hemp combined with polypropy- The RAIL AND ROAD TRANSPORTATION
intelligently. lene (PP) and polylactic acid (PLA) biopolymer FORUM (p.17)
using a range of novel comingling techniques.


COMPOSITES SIMULATION CONFERENCE
Wednesday, April 14 - 2.30pm / 5.00pm
In partnership with

Optimizing the design and manufacturing simulation processes
Flow characteristics: permeability study on
MODERATOR A Material Properties Provider ES-Fabrics and simulation of flow and mold
filling process.
ESI Group
2. Enabling use of simulation in composite Success story: path from basic research to
Patrick De Luca
parts development engineered materials and application of inte-
Composites Solution grated structural composites.
Manager
ESI Group
David Prono An Optimized Approach
Biography: Composites Domain Expert
for RTM Simulation
Patrick De Luca has a PhD Applied Mathema-
tics at Bordeaux University and Post-Doc at Composite materials testing through 5. A key parameter for injection simulation:
Stanford University in Mechanical Engineering. simulation. permeability
He has been at ESI Group since 1991 occupying
several positions: Development, Project mana- Enabling use of simulation in composite parts
PPE
ger, Product manager of ESI Composites Suite. development.
His domains of works cover composite forming Jérôme Raynal
Decrease time and cost of material Project Manager, Technical
simulation and the link between mechanical
characterisation. Marketing
performance and the manufacturing of compo-
site parts. His current objective is to deliver to Investigate new material applications. RTM simulation: technical parameters to consi-
industry an end-to-end simulation solution for
der for an optimized approach.
composite products.
Controlling Process Induced Permeability.
Distortion Selection of the strategy.
Case Study:
A Composite Wing Assembly 3. Cure induced shape distortions in a How the simulation is used to secure the
composite c-spar: 2 FE-analysis methods process: «the injection road-map».
1. Managing the complexity of composite
aircraft assemblies and their huge volumes of Swerea SICOMP AB 6. Advanced process simulation of RTM and
highly interdependent design data Magnus Svanberg application to fan blades for an aircraft engine
Senior Researcher
Vistagy Aerostructures Ecole Poytechnique
Steve Peck de Montréal
A very fast and accurate method based on
Director, Product & Market Strategy Edu Ruiz
standard FE-functionality.
Professor, Mechanical Engineering
A state-of-the-art process-beginning with the Another method implying modeling and simula-
pre-production activities involved in creating a tion of the cure processes where material proper-
Fiber volume content and fiber orientations
demonstrator part to full-scale production. ties and residual stresses evolve during cure.
description.
Specific challenges associated with designing Full thermal characterization.
a resin transfer infused wing skin using NCF
materials and an automated material deposi- Defining Manufacturing Processes Optimization of the fabrication process.
tion process.

Design of substructure components, such 4. Advancement in RTM technology
as t-stringers, and managing the assembly
interfaces to support an automated fastening
Beijing Institute
process. of Aeronautical Materials
Yi Xiaosu
Professor

Introduction: state-of-the art of composite
technology and development and the technolo-
gical challenge.
© Courtesy of Azimut Yachts

How to toughen the structural composite ma-

Also attend
terials: reaction-induced phase separation me-
chanism and structure-properties relationship.

EX-situ technology to toughen the RTMABLE The AERONAUTICS FORUM (p.14)
Composites: establishment of inter laminar
tailored structure and ES-Fabrics: an innovative The AUTOMOTIVE FORUM (p.8)
product.


AERONAUTICS FORUM
Thursday, April 15 - 10.30 am / 1.00 pm
In partnership with

Controlling cost of aircraft structures
Dominique Bailly
MODERATOR Next Generation Composite Wings R&T Engineer
University of Bristol
Composites applications and advantages
Kevin Potter 2. Airbus A350XWB: Composite wing spar for general aviation, regional aviation and
Reader in Composites development helicopters.
Manufacturing, Department
of Aerospace Engineering Airbus Specific design constraints of composites
Paulo Lage structures for each of these segments.

Biography: Engineering Design Capability Ecowingbox: composites wing demonstrator
Since graduating from Imperial College in 1974 and derivatives aerostructure applications for
Kevin Potter has worked almost exclusively in the Concurrent processes and toolsets. each of these segments.
field of composite materials, with an emphasis
Logic behind the development of an improved
on manufacturing methods and product design.
composite process, the engineering tools, First Welded Thermoplastic Composite
He worked for the UK MoD for almost 10 years
involved logistics, and tooling complexity. Primary Structures in Series Production
on materials and product development, with
major interests in reinforcement deformation
and Resin Transfer Moulding. The work on RTM 3. A full composite lateral and centre wing box 6. Induction welded thermoplastic control
expanded on joining BP Advanced Materials surfaces
to support the development and introduction Airbus Operations Ltd
into series production of complex products. He Simon Topping Fokker Aerostructures
joined the Aerospace Engineering Department Structures Engineer Arnt Offringa
of Bristol University in 1995 and has been able
Director R&D
to continue and extend his research interests
in collaboration with the leaders in the UK Overview of European Commission (FP6) fun-
composites industry. ded project ALCAS (Advanced Low Cost Aircraft
A low cost and lightweight aircraft control
Structures).
surface.
A 20% weight reduction with no increase in
The composite solution: a carbon/PPS thermo-
recurring costs targeted against the state-of-
Cost Control the art metallic aircraft.
plastic composite multirib design.

The induction welding technology and its
Enabling technologies for the ALCAS airliner
1. Controlling cost in aeronautics composites advantages.
wing/rear spar development.
manufacturing Current first applications: rudder and elevators
Structural testing scheduled for 2010 to
of the new G650 business jet.
University of Bristol validate the airliner wing components and all
Kevin Potter tools used during the design phase.
Reader in Composites
Manufacturing 4. Bombardier CSeries: developing a game-
changing aircraft
Automating the production of the far larger
number of secondary and tertiary structures Bombardier Aerospace
such as sandwich panels.
Gavin Campbell
© Bombardier Aerospace

Meeting current and likely future requirements Director, Design Engineering
for cost reductions. & Technology Development, Belfast
Mission of the recently founded UK National Meeting the needs of the 100- to 149-seat
Composites Centre. commercial aircraft market category.

Why the CSeries will be the greenest single-
aisle aircraft in its class. Also attend
Progress of CSeries programme. The RECYCLING AND LIFE CYCLE
MANAGEMENT FORUM (p.6)
Developing and manufacturing the advanced
composite wings using Resin Transfer Infusion The COMPOSITES DEVELOPMENT
technology developed in Belfast. PROCESS CONFERENCE (p.9)
© Bombardier Aerospace / Gulfstream aircraft

The COMPOSITES DESIGN
5. Composites solutions survey for small and CONFERENCE (p.10)
medium-sized aircrafts
The AUTOMATION FORUM (p.11)
Daher-Socata The COMPOSITES SIMULATION
Philippe Villard CONFERENCE (p.13)
Vice President Marketing


MARINE FORUM
Thursday, April 15 - 10.30 am / 1.00 pm

Improving quality and producing at low costs
3. Durable resin and reinforcement solutions 5. Strip plank foam sandwich: an effective
MODERATOR for better boats solution for one-off or small custom series
production
Giovanni Manni Mikkeli University
Marine Consulting of Applied Sciences, Research Trimarine srl
and Business Services Sebastiano Rech Morassutti
Martti Kemppinen CEO
Biography: Research Director,
From 2005 to 2009, Giovanni Manni has been Materials Technology
Fernando Borges De Sena
Ferretti‘s Group Quality Director and from 1997 to Founder Partner of Trimarine
2005, he was Wally Yachts Quality Manager.
Ashland Finland Ltd
Advanced Marine Projects, Ltd
Olli Piiroinen
European Industry Manager, Marine An adaptation inspired by wood strip planking
and other techniques applied to the construc-
tion of composite yachts.
NCD
Signiﬁcant calendar time saved, less yard ﬂoor
Yves Perrot space needed, less initial mould investment
Composite Engineer and only a small work force required.

Ideal for one-off projects or when testing the
Damage resistance and surface quality com- market with a new design as it requires.
parison of feasible resin and reinforcement
Surface Quality and High Damage combinations in modern marine industry. A revisited techniques economically interesting
Resistance at Reasonable Cost at a time when small yards are being pressu-
16 different injected laminates featuring tradi- red by the economic downturn.
1. The required expected quality of the market tional and novel resins and two reinforcement
as compared to actual production types compared with each other and hand-
laminated counterparts.
Giovanni Manni High-Tech Riggings
Marine Consulting Several facts measured by manufacturer-neu-
tral parties.
6. High-tech composite yacht rigging
Research into the maximum surface quality
during principal production phases of compo- Carbo-Link
site technology. New Low Cost Boat Concepts
Andreas Winistörfer
Degradation of surface quality during the life CEO
cycle of composite boats. 4. The use of TP SEAL technology in the
development of large multi-layer marine Stringent material and process requirements
Optimizing research costs into composite applications
surface quality. An innovative process for rigging
Total Petrochemicals manufacturing.
2. Slamming impact behavior of composite Research
sandwich for racing yachts Application: Alinghi.
Eric Mazier
Technical Service & Development
IFREMER
(TS&D) Rotomoulding Technical
Peter Davies Manager
Research Engineer, Materials Boat production by rotomoulding process.
and Structures
TP-SEAL®technology.
© Alinghi • Dreamstime • Mikkeli University of Applied Sciences • Targa

HDS
Structural properties of TP-SEAL® parts com-
Hervé Devaux pared to composite parts.
Director

Recent studies on foam and honeycomb sand-
wich materials.

Development of both test and numerical analy-
sis to simulate a damage.

Correlation between test and simulation
results to validate the model.

Strategies for improving impact response.


JEC Paris 2010 - Conferences and Forums program

JEC Paris 2010 - Conferences and Forums program

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JEC Paris 2010 - Conferences and Forums program