advances in reinforcement materials (glass fiber materials)

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Presentation by David Hartman, Senior Technical Staff, Owens Corning at CAMX on October 15, 2014. Advances in reinforcement materials, specifically glass fiber materials, should not go unnoticed. In this presentation discover new advances in glass fiber technology areas, applications to various markets and the needs of those markets, as well as current advances in fiber reinforcement materials and forms.

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  • 1. Advances in Reinforcement Materials (Glass Fiber Materials)October 13-16, 2014Orange County Convention CenterOrlando, FLDave HartmanOwens Corning Composite SolutionsOctober 15, 2014Copyright 2014 Owens Corning. All Rights Reserved.

2. ADVANCES IN GLASS FIBER REINFORCEMENTSSustainabilityGrowth OpportunityGlobal MegatrendsMaterial DriversHigh Performance FibersAttributesFormFunctionHybridsCollaboration3Owens Corning and General Motors announced the first production automobile to be made entirely of Fiberglas -reinforced plastic, the Chevrolet Corvette, in 1953.In the post-war years, Owens Corning expanded its product range to support the first Fiberglas-reinforced plastic fishing rods, serving trays and pleasure boats.The Hajj airport terminal in Saudi Arabia is constructed with a 105-acre Fiberglas roofSource: Owens Corning road-show images 9/22/2014 3. Energy use, availability and efficiencyClimate changePopulation / consumptionPersonal desire to achieve sustainabilityGreen construction materials and renewables demandWHY CHOOSE OWENS CORNING?Operations sustainabilityProduct and supply chain sustainabilityInnovation and collaboration to deliver energy efficiency and renewable energy solutions at scaleSUSTAINABILITY4DRIVING TO BE NET POSITIVESTRONG GLOBAL MACRO TRENDS BIG OPPORTUNITIES IN GLASS FIBER MARKETS 4. A GLOBAL AND GROWING GLASS FIBER MARKET5Construction 35%Transportation 28%Industrial 14%Consumer 17%Wind 6%Glass reinforcements market defined as glass fiber reinforcements and direct conversion products as consumed, excluding yarnsSource: Owens Corning management estimates as of Feb 2014 Residential Commercial Water transportation and storage Cars Trucks, buses, trains Marine Factories Mining Offshore platforms Appliances Electronics RecreationA Key Material Enabling Solutions Essential to Everyday LifeA $7 Billion Global Market 5. -1,0002,0003,0004,0005,00019811989199720052013GLASS FIBER MARKET DEMAND6Glass Fiber K TonsGlass fiber market demand excludes E-glass yarns Sources: Fiber Economics Bureau, Glass Fiber Europe, Global Trade Information Services, Inc. and Owens Corning management estimatesGlass Fiber Demand Has Grown at 1.6 Multipleof Industrial Production GrowthHistorical Glass Fiber Market Growth Averaging 5% 6. 0.51.10.91.70.40.52005-092010-122013-1650%60%70%80%90%100%2004200620082010201220142016GLASS FIBER INDUSTRY SUSTAINABLE GROWTH7Tighter Capacity Environment with High Facility Utilization RatesExpected in the Near TermGlass fiber market demand excludes E-glass yarns Sources: Fiber Economics Bureau, Glass Fiber Europe, Global Trade Information Services, Inc. and Owens Corning management estimates as of September 2014(high probabilityadditions)0.1/ yr0.3/ yr0.1/ yr0.1/ yr0.4/ yr0.2/ yrChange in global demand (MM T) Change in global capacity (MM T)Supply Tension90% ThresholdEstimated Capacity Utilization 7. WHY CHOOSE OWENS CORNING?GLASS REINFORCEMENT PRODUCTS AND THEIR APPLICATIONSCHOPPED STRAND MAT AND CONTINUOUS FILAMENT MATMarine, transportation,recreation, corrosion resistance, constructionConstruction, industrial, automotive, road pavingNON WOVEN VEILWind, pipe, thermoplastic composites, industrial, recreationalKNITTED OR WOVEN FABRICSConstruction (panels and translucent panels), corrosion resistant pipe and tanks, consumer (sanitary, recreational vehicles), transportation (headliner, body parts, semi-structural parts)CONTINUOUS FIBER MULTI-END ROVINGTransportation, consumer electrical/ electronics and appliancesCHOPPED STRAND, DRY-USEBuilding products (roofing and gypsum), industrial specialtiesCHOPPED STRAND, WET-USEChemical and sewage, oil, water processing (pipe and tanks), industrial (high-pressure vessels, pultruded items), wind energy, aerospace, ballistics, transportation (muffler filling), electrical (optical cable)CONTINUOUS FIBER TYPE 30 SINGLE END ROVING8 8. ApplicationsProcesses1932-1946Start of the IndustryOC introduces FiberglasTMCommercial Boat HullsFRP Car Body (Stout Scarab)CSM / CFM ProcessResin Systems DevelopedHand Lay-up Process1947-1960Niche ApplicationsChopped Strands ProcessCarbon Fibers DevelopedDirect Roving ProcessSpray-up ProcessPultrusion ProcessCommercial FRP Car BodyComposite Panels (Trucks)Helicopter Blades (Alouette II)1961-1978Industrial ApplicationsFilament Winding ProcessSMC ProcessHigh-Strength Glass Process (S)Kevlar Fibers DevelopedGlass Reinforced ThermoplasticsSMC Air DeflectorGlass Mat Reinforced ShinglesCommercial Wind Turbine Blades1979-1996Corrosion ResistanceContinuous Fiber Thermoplastic LaminatesLong-fiber ThermoplasticsResin Infusion ProcessComposite Storage TanksFiberglass WindowsHybrid Front-End Modules1997-Present Hybrid Technology IntegrationHybrid MoldingTechnologiesCommercial Wind TurbineCommercial AircraftStructural Automotive PartsConsumer ElectronicsCOMPOSITE APPLICATIONS AND PROCESSES901MM2MM3MM4MM5MMGraph depicts glass fiber market demand, in kilotonsKevlar is a registered trademark of E. I. du Pont de Nemours and Company 9. Production of energy with no emission of CO2 (wind, tidal, solar, geothermal)Providing the basic infrastructure to deliver clean water to excess of 5-billion peopleProviding housing and infrastructure to a growing population in developing and third-world countriesReducing the weight of modes of transportation to responding to increasing cost of energyCLEAN ENERGYWATER INFRASTRUCTUREURBAN INFRASTRUCTUREINDUSTRIALLIGHT WEIGHTINGCOMPOSITES OPPORTUNITY - GLOBAL MEGATRENDS10 iStock pictures 10. DRIVERS FOR COMPOSITES IN THE WIND MARKETLong and light bladesIncreased blade performanceDevelopment of low-wind and off-shore sitesCost-of-energy reduction11 11. MATERIALS TO ENABLE LONGER BLADES4,0 4,5 5,0 5,5 6,0700650600550500450400350LOG (N)Peak Stress [MPa]ADVHFiberSource: Risoe / DTU tests 2013 on UD laminates, Momentive Epoxy resin L135/H137600 650 700 750 800120011001000900800700Advantex EWindstrand HFiberglass typeHigher Composite Stiffness and Fatigue PerformanceFatigue Performance at R=0.1, E-glass vs H-glass UD Fabric/epoxy12 12. 13Acoustic and fracture surface analysis of 45o tension in Advantexglass/epoxy lamina The improved fiber-matrix adhesion leads to a higher transverse strengthSource: Owens Corning WindStrand fibers and data. Panels dry-wound roving and infused using Momentive epoxy RIMR 135/H137E-glass UD/epoxyWindStrand UD/epoxyHigher Composite fiber-matrix adhesion for DurabilityMATERIALS TO IMPROVE BLADE DURABILITY 13. DRIVERS FOR COMPOSITES IN AUTOMOTIVE iStock pictureFuel Consumption ReductionCO2 Emission ReductionVehicle Light WeightingEnhanced parts performance and durabilityEfficiency gains14 14. BODY PANEL LIGHT-WEIGHTING MATERIAL ANALYSISMSCostAvailabilityManufacturing compatibilityWeightWeldingCorrosion00AHSSCostAvailabilityManufacturing compatibilityWeldingDuctilityProviding Class A finish13-15 (2.3 kg)2.08AlCostAvailabilityLight weightFormingCorrosionLow melting temperature high CTE35-40 (6.5 kg)2.76 3.27MgLight weightDampingHigh temperature performanceAvailabilityDuctilityCorrosion, welding, fire safety40-45 (7.5 kg)4.45 4.52LFTPFunctional integrationPart consolidationCost, corrosion resistanceSemi structuralLow melt temp, High CTECrash worthiness20-35~2 7SMCClass A finishCost, corrosion resistancePart consolidationInner to outer adhesionHigh CTECrash worthiness15-20 (2.7 kg)~2 4GFRP prepregLight weightPart consolidationCorrosion resistanceCostThroughputCrash worthiness35-45~4 8CFRP prepregLight weightPart consolidationCorrosion resistanceCostThroughputCrash worthiness50-70 (12 kg)~10 30Material Largest Benefits Largest DrawbacksSource: US DOT NHTSA- August 2012 Mass Reduction for Light-Duty Vehicles for Model Years 2017-2025% WeightSavings*$/kg CostPremium* Example calculation: baseline mild steel design mid-size hood is 17.9 kg -15.6= 2.3kg AHSS weight saved at $4.80 cost increase or $4.80/2.3kg= 2.08 $/kg cost increase premium15Baseline of % weight savings and cost premium to mild steel design for mid-size hood 15. DurabilityPollution ControlRising costs for traditional materialsCorrosion resistanceDRIVERS FOR COMPOSITES IN INDUSTRIAL APPLICATIONS Paulo Manuel Furtado Pires / shutterstock.comCourtsery Plasticos Industriales de Tampico (PITSA), of Tampico, Mexico Courtersy of Potok-M LLC, RU16 16. ~40 hrsSS-304*STRESS CORROSION CRACKINGOF STAINLESS STEEL VS. COMPOSITE Boron-Free-E-CR-Glass-FRP composite provides superior corrosion performance Stress rupture of composite rods in 1 Normal acids (HCl - H2SO4) Superior corrosion resistant resin used in both samples Based on analytical calculations considering iso-corrosion charts without corrosion resistant coatings for SS-304*17 17. LOWERING COST OF CORROSIONWITH BORON-FREE-E-CR-FRP Scrubber system built with SS-2205 Inspected after 12 months Severe corrosion inspected resulted in $5 million losses within a short period of time E-CR-FRP material offered exceptional corrosion resistance for such units. FRP units are in operation with minimal maintenance Lowering cost of corrosionChemical and power plant stack liners Coal power plant scrubber units Each scrubber unit holds ~ 1 million gallons of lime slurry highly corrosive environment Each unit costs ~ $200- $500 Million Huge investmentSource: Lieser, M., How to Use FRP Material to Lower Corrosion Costs, Polymer Society vol. 5, No.5, (2013): p.22-27 shutterstock.com18 18. shutterstock.comDRIVERS FOR COMPOSITES IN THE CONSTRUCTION MARKETDurabilityPerformance & Design FlexibilityMaterials Conservation & Energy efficiencyProduct Availability in All Business CyclesProductivity Improvement19 19. OPPORTUNITY FOR COMPOSITES GROWTHGlobal Structural Materials Market 800MM tons, $xxxB IndustryGlobal Composites Materials Market 9.2MM tons, $21B IndustryGlassReinforcement4.5MM tons (94%)$7B (58%)AdvancedReinforcement0.3MM tons (6%)$5B (42%)E-glassECR-glassR-glassCostPerformanceH-glassAramidCarbonUHMWPEGlobal Reinforc

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