Advances in Reinforcement Materials

(Glass Fiber Materials)

October 13-16, 2014

Orange County Convention Center

Orlando, FL

Dave Hartman

Owens Corning Composite Solutions

October 15, 2014 Copyright © 2014 Owens Corning. All Rights Reserved.

ADVANCES IN GLASS FIBER REINFORCEMENTS

Sustainability Growth Opportunity

Global Megatrends

Material Drivers

High Performance Fibers

Attributes Form Function

Hybrids

Collaboration

3

Owens 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™ roof

Source: Owens Corning road-show images 9/22/2014

Energy use, availability and efficiency

Climate change

Population / consumption

Personal desire to achieve sustainability

Green construction materials and renewables demand

WHY CHOOSE OWENS CORNING?

Operations sustainability

Product and supply chain sustainability

Innovation and collaboration to deliver energy efficiency and renewable energy solutions at scale

SUSTAINABILITY

4

DRIVING TO BE NET POSITIVE

STRONG GLOBAL MACRO TRENDS – BIG OPPORTUNITIES IN GLASS FIBER MARKETS

A GLOBAL AND GROWING GLASS FIBER MARKET

5

Construction 35%

Transportation 28%

Industrial 14%

Consumer 17%

Wind 6%

Glass reinforcements market defined as glass fiber reinforcements and direct conversion products as consumed, excluding yarns Source: 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 • Recreation

A Key Material Enabling Solutions Essential to Everyday Life

A $7 Billion Global Market

-

1,000

2,000

3,000

4,000

5,000

1981 1989 1997 2005 2013

GLASS FIBER MARKET DEMAND

6

Gla

ss F

ibe

r K

To

ns

Glass fiber market demand excludes E-glass yarns Sources: Fiber Economics Bureau, Glass Fiber Europe, Global Trade Information Services, Inc. and Owens Corning management estimates

Glass Fiber Demand Has Grown at 1.6 Multiple of Industrial Production Growth

Historical Glass Fiber Market Growth Averaging 5%

0.5

1.1

0.9

1.7

0.4

0.5

2005-09 2010-12 2013-16

50%

60%

70%

80%

90%

100% 2004 2006 2008 2010 2012 2014 2016

GLASS FIBER INDUSTRY SUSTAINABLE GROWTH

7

Tighter Capacity Environment with High Facility Utilization Rates Expected in the Near Term

Glass 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 probability additions)

0.1/ yr 0.3/ yr 0.1/ yr 0.1/ yr 0.4/ yr 0.2/ yr

Change in global demand (MM T)

Change in global capacity (MM T)

Supply Tension

90% Threshold

Esti

mat

ed

Cap

acit

y U

tiliz

atio

n

WHY CHOOSE OWENS CORNING? GLASS REINFORCEMENT PRODUCTS AND THEIR APPLICATIONS

CHOPPED STRAND MAT AND CONTINUOUS FILAMENT MAT

Marine, transportation, recreation, corrosion resistance, construction

Construction, industrial, automotive, road paving

NON WOVEN VEIL

Wind, pipe, thermoplastic composites, industrial, recreational

KNITTED OR WOVEN FABRICS

Construction (panels and translucent panels), corrosion resistant pipe and tanks, consumer (sanitary, recreational vehicles), transportation (headliner, body parts, semi-structural parts)

CONTINUOUS FIBER MULTI-END ROVING

Transportation, consumer electrical/ electronics and appliances

CHOPPED STRAND, DRY-USE

Building products (roofing and gypsum), industrial specialties

CHOPPED STRAND, WET-USE

Chemical 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 ROVING

8

Applications

Processes

1932-1946 Start of the Industry

OC introduces FiberglasTM

Commercial Boat Hulls

FRP Car Body (Stout Scarab)

CSM / CFM Process

Resin Systems Developed

Hand Lay-up Process

1947-1960 Niche Applications

Chopped Strands Process

Carbon Fibers Developed

Direct Roving Process

Spray-up Process

Pultrusion Process

Commercial FRP Car Body

Composite Panels (Trucks)

Helicopter Blades (Alouette II)

1961-1978 Industrial Applications

Filament Winding Process

SMC Process

High-Strength Glass Process (S)

Kevlar® Fibers Developed

Glass Reinforced Thermoplastics

SMC Air Deflector

Glass Mat Reinforced Shingles

Commercial Wind Turbine Blades

1979-1996 Corrosion Resistance

Continuous Fiber Thermoplastic Laminates

Long-fiber Thermoplastics

Resin Infusion Process

Composite Storage Tanks

Fiberglass Windows

Hybrid Front-End Modules

1997-Present Hybrid Technology Integration

Hybrid Molding Technologies

Commercial Wind Turbine

Commercial Aircraft

Structural Automotive Parts

Consumer Electronics

COMPOSITE APPLICATIONS AND PROCESSES

9

0

1MM

2MM

3MM

4MM

5MM

Graph depicts glass fiber market demand, in kilotons Kevlar is a registered trademark of E. I. du Pont de Nemours and Company

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 people

Providing housing and infrastructure to a growing population in developing and third-world countries

Reducing the weight of modes of transportation to responding to increasing cost of energy

CLEAN ENERGY

WATER INFRASTRUCTURE

URBAN INFRASTRUCTURE

INDUSTRIAL LIGHT WEIGHTING

COMPOSITES OPPORTUNITY - GLOBAL MEGATRENDS

10 © iStock pictures

DRIVERS FOR COMPOSITES IN THE WIND MARKET

Long and light blades

Increased blade performance

Development of low-wind and off-shore sites

Cost-of-energy reduction

11

MATERIALS TO ENABLE LONGER BLADES

6,05,55,04,54,0

700

650

600

550

500

450

400

350

LOG (N)

Pe

ak S

tre

ss [

MP

a]

ADV

H

Fiber

Source: Risoe / DTU tests 2013 on UD laminates, Momentive Epoxy resin L135/H137

800750700650600

1200

1100

1000

900

800

700

Compression Strength, MPa, 95/5% CI

Te

nsile

Str

en

gth

, M

Pa

, 9

5/

5%

CI

Advantex® E

Windstrand® H

Fiberglass type

Higher Composite Stiffness and Fatigue Performance

Fatigue Performance at R=0.1, E-glass vs H-glass UD Fabric/epoxy

12

13

Acoustic and fracture surface analysis of 45o tension in Advantex®glass/epoxy lamina The improved fiber-matrix adhesion leads to a higher transverse strength

Source: Owens Corning WindStrand® fibers and data. Panels dry-wound roving and infused using Momentive epoxy RIMR 135/H137

E-glass UD/epoxy WindStrand® UD/epoxy

Higher Composite fiber-matrix adhesion for Durability

MATERIALS TO IMPROVE BLADE DURABILITY

DRIVERS FOR COMPOSITES IN AUTOMOTIVE

© iStock picture

Fuel Consumption Reduction

CO2 Emission Reduction

Vehicle Light Weighting

Enhanced parts performance and durability

Efficiency gains

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BODY PANEL LIGHT-WEIGHTING MATERIAL ANALYSIS

MS Cost Availability

Manufacturing compatibility

Weight Welding Corrosion 0 0

AHSS Cost Availability Manufacturing compatibility

Welding Ductility Providing Class A finish

13-15 (2.3 kg)

2.08

Al Cost Availability Light weight Forming Corrosion Low melting temperature

high CTE

35-40 (6.5 kg)

2.76 – 3.27

Mg Light weight Damping High temperature performance

Availability Ductility Corrosion, welding, fire

safety

40-45 (7.5 kg)

4.45 – 4.52

LFTP Functional integration

Part consolidation

Cost, corrosion resistance

Semi structural

Low melt temp, High

CTE

Crash worthiness

20-35 ~2 – 7

SMC Class A finish Cost, corrosion resistance

Part consolidation

Inner to outer

adhesion

High CTE Crash worthiness

15-20 (2.7 kg)

~2 – 4

GFRP prepreg

Light weight Part consolidation

Corrosion resistance

Cost Throughput Crash worthiness

35-45 ~4 – 8

CFRP prepreg

Light weight Part consolidation

Corrosion resistance

Cost Throughput Crash worthiness

50-70 (12 kg)

~10 – 30

Material Largest Benefits Largest Drawbacks

Source: US DOT NHTSA- August 2012 “Mass Reduction for Light-Duty Vehicles for Model Years 2017-2025”

% Weight Savings*

$/kg Cost Premium

* 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 premium

15

Baseline of % weight savings and cost premium to mild steel design for mid-size hood

Durability

Pollution Control

Rising costs for traditional materials

Corrosion resistance

DRIVERS FOR COMPOSITES IN INDUSTRIAL APPLICATIONS

© Paulo Manuel Furtado Pires / shutterstock.com Courtsery Plasticos Industriales de Tampico (PITSA), of Tampico, Mexico Courtersy of Potok-M LLC, RU

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~40 hrs

SS-304*

STRESS CORROSION CRACKING OF 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

LOWERING COST OF CORROSION WITH 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 corrosion

Chemical 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 investment

Source: Lieser, M., “How to Use FRP Material to Lower Corrosion Costs”, Polymer Society vol. 5, No.5, (2013): p.22-27 © shutterstock.com

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© shutterstock.com

DRIVERS FOR COMPOSITES IN THE CONSTRUCTION MARKET

Durability

Performance & Design Flexibility

Materials Conservation & Energy efficiency

Product Availability in All Business Cycles

Productivity Improvement

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OPPORTUNITY FOR COMPOSITES GROWTH

Global Structural Materials Market 800MM tons, $xxxB Industry

Global Composites Materials Market 9.2MM tons, $21B Industry

Glass

Reinforcement

4.5MM tons (94%) $7B (58%)

Advanced

Reinforcement

0.3MM tons (6%) $5B (42%)

E-glass

ECR-glass

R-glass

Cost

Pe

rfo

rma

nc

e

H-glass

Aramid

Carbon

UHMWPE

Global Reinforcement Fibers 4.8MM tons, $12B Industry

S-glass

Glass reinforcements market defined as glass fiber reinforcements and direct conversion products as consumed, excluding E-glass yarns Source: JEC, Lucintel and Owens Corning management estimates as of September 2014

Global megatrends, continued growth in industrial production, and traditional material substitution support market growth at 5-7% CAGR

20

Aluminum

Composites 1-2%

Plastics

Wood Steel

COMPARISON OF HIGH PERFORMANCE FIBER AND UNI-DIRECTIONAL COMPOSITE PROPERTIES

Property Test

Method Unit E-Glass

ECR-Glass

Boron free H-Glass R-Glass S-Glass Carbon

Fiber and Bulk Glass Properties

Density ASTM C693 g/cm3 2.55-2.58 2,62 2,61 2.55 2,45 1.79

Refractive Index (bulk annealed) ASTM C1648 - 1.547-1.562 1.56-1.57 1,566 1.54 1,522

Conductivity ASTM C177 watts/m•K 1.0-1.3 1,22 1,34 6.83

Pristine Fiber Tensile Strength ASTM D2101 MPa 3450-3790 3750 4130 4450-4580 4830-5080 4400

Specific Pristine Strength Calculation × 105 m 1.36-1.50 1,43 1.58 1.74 2.01-2.12 2.46

Young's Modulus GPa 69-72 81 87,5 87 88 230

Specific Modulus Calculation × 106 m 2.73-2.85 3,15 3,33 3.48 3,67 12.8

Elongation at Break % 4,8 4,9 4.9 5.35 5,5 1.8

Thermal Properties

Coefficient of Thermal Expansion, 23-300 °C ASTM D696 × 10-6 cm/cm•°C 5,4 6 5,3 4.1 3,4 - 0.6

Specific Heat @ 23 °C ASTM C832 kJ/kg•K 0,807 0,79 0.75 0,810 1.130

Fiber Tensile Strength v. Temperature

Pristine Fiber Tensile Strength, -196 °C ASTM D2101 MPa 5310 5935 7220 7826

Pristine Fiber Tensile Strength, 22 °C ASTM D2101 MPa 3450-3790 3587 4130 4450 5047 4400

Fiber Weight Loss @ 96 °C, 24 hours, 17µm

10% HCl % 31,68 7,88 7,59 1,53 0.05

10% H2SO4 % 32,00 6,91 6,48 1,17

1 N Nitric % 23,47 7,21 6,67 1,42

NaOH pH=12.88 % 5,40 3,24 12,65 19,34 1.10

Impregnated Strand Properties

Tensile Strength ASTM D2343 MPa 2000-2500 2200-2600 2400 -2800 3050-3400 3410-3830 4000

Tensile Modulus ASTM D2343 GPa 78-80 81-83 90 - 91 89-91 86.9-95.8 230

Toughness ASTM D2343 MPa 37 56 69 82-90

Unidirectional Composite Properties1

Tensile Strength ISO 527-5 MPa 1120 1200 1260 1560 1550 1780

Tensile Modulus ISO 527-5 GPa 46 48 52,5 51.6 53 153

Poisson's Ratio ASTM D638 - 0,29 0,33 0,33 0.32 0,27 0.28

Fiber Volume Fraction ASTM D2734 % 60 60 60 60 60 57 2

1 MGS RIM 135 epoxy + RIMH 137 hardener 2 EPON 826 DM HS-Carbon Fiber OC data pub..2011

Glass and Carbon Fiber linear-elastic behavior enables structural composites

21

COMPARISON OF GLASS AND CARBON FIBER ATTRIBUTES

Carbon Fiber

High elastic modulus

Low shear modulus

Low strain to failure

Catastrophic failure

Prone to damage

Light-weight

Alkaline resistance

Electrical conductor

Thermal conductor

Shrinks with heat

Glass Fiber

Linear-elastic

High shear modulus

High strain to failure

Ductile failure mode

Impact toughness

Denser fiber

Acid resistance

Electrical insulator

Thermal insulator

Expands with heat

Glass and Carbon Fiber attributes compliment each other for selective placement of hybrid forms and multifunctional integration

Source: Owens Corning Type30® fiber and data © shutterstock.com 22

Steel

Aluminum SMC 50 GF-chop

SMC 55 CF-chop

SMC 55 CF-uni

CM EP 55 CF-uni

CM PA6 55 CF-uni

CM PA6 55 CF-quasi

IM PA6 50 CF-chop

IM PA6 60 GF-chop

0.0

0.2

0.4

0.6

0.8

1.0

1.2

1.4

1.6

1.8

0.00 1.00 2.00 3.00 4.00 5.00 6.00 7.00 8.00 9.00

Spe

cifi

c St

ren

gth

[m

x10

^5]

Specific Modulus [mx10^6]

Composite Specific Strength vs Specific Modulus

COMPOSITE DESIGN AND MATERIAL PROCESS INTERACTIONS INFLUENCE HYBRID FORM AND FUNCTION

Hybrid attributes for composite design:

Selective placement of CF where needed for

design function in a GF composite is efficient

where it compliments the load environment

GF/CF mixed in the process by hybrid form

depends on the material flow, alignment and

orientation for the design load environment

GF enables CF dispersion, flow, wetting and

consolidation to improve IM, LFT, EC, RTM…

productivity and consistency

GF can help reduce materials and process

cost of CF lighter weight structures

GF increases strain to failure for impact and

flexural fatigue resistance in CF structures

GF enables isolation of CF galvanic corrosion

GF improves shear-compression failure of CF

GF improves bearing strength of mechanical

fasteners and adhesive joints

Source: Owens Corning and “Mass Reduction for Light-Duty Vehicles for Model Years 2017-2025” US DOT NHTSA- August 2012 23

Compounding

Polymer Tool in Press

Glass Roving

Compounding

Polymer Polymer Tool in Press

Injection Molding

COLLABORATION IN KEY MARKET SEGMENTS

© shutterstock.com; © iStock picture

INDUSTRIAL

TRANSPORTATION

WIND ENERGY

BUILDING AND CONSTRUCTION

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THANK YOU