amif2014 – [plenaria] luigi barone, innovazione ecosostenibile nel settore dei trasporti - il...
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Advanced Materials International Forum, Bari 18-19 settembre, conferenza internazionale dedicata ai materiali avanzati e alle loro possibili applicazioni nei settori industriali, con un focus particolare sui trasporti (aerospazio, automotive, navale e cantieristico).TRANSCRIPT
Sustainable innovation for transportation: new frontiers per materials and processes.
CETMA contribution
Advanced Materials International Forum
Bari 2014 september 18
Luigi Barone – CETMA General Manager
CETMA is a RTO, Research an Technology Organization. It is a non-profit organization and all its profits are reinvested in R&D.
CETMA was founded in 1994 by ENEA with the aim of developing the Innovation System of Southern Italy
85 employees:Researcher, engineers, designers & innovation managers
SKILLS•Materials and Structures engineering•Computer science and engineering•Industrial design
One of 50 (out 5100) research organizations with more than 50 employees in Italy
One of the biggest research center not linked to a Great Enterprise
One of 50 (out 5100) research organizations with more than 50 employees in Italy
One of the biggest research center not linked to a Great Enterprise
CETMA is located in the area of “Cittadella della Ricerca” close to Brindisi.
Laboratories and offices take up about 5.000 sq.mt
A well equipped laboratory of advanced materials tecnologies
One of the biggest Virtual Reality Center in Europe
A prototyping laboratory
Knowledge and skills acquiredfrom our independent research projects are transferred to our customers by means high qualification services
Profits coming from services are totally re-invested to co-fund research projects
University & Academy
Equipments Supplier
Industrial user
MaterialSupplier
CETMA Research activities are compliant with main trends of new productions
Reducing ecological impact
Reduction of energy consumption
More and more «smart» products
Products increasingly interconnected
The role of materials
Reducing ecological impact•Recycling•Recycled materials utilizing•Bio-based materials
Reduction of energy consumption•Materials for more efficient power generation•Materials for lighter transportations
More and more «smart» products•Multifunctional materials•Processes to integrate electronic component and materials
Products increasingly interconnected•Processes to integrate tag and trasponder
CETMA IS VERY INVOLVED IN ALL THESE ACTIVITIES
Materials for Lighter Transportation
10% weight reduction → 7% fuel consumption
Target for passenger car weight reduction
Materials for weight reduction
CETMA is working since 15 years about Composites in order to exploit their potential
CETMA is working since 15 years about Composites in order to exploit their potential
Gaps to overcome for a fully exploitation of composites
1. Raw materials cost
2. Lack of knowledge about materials behavior and predictive methods
3. Cost-effective Manufacturing processes
4. Joining techniques
5. Lack of knowledge about defect detection
6. Recycling
Raw materials cost
All over the world there are initiatives in order to improve production processes of carbon fiber and there are setting up joint ventures to increase the production.
Fibre recuperate con processo batch Fibre recuperate con processo continuo
Fig. 4: Materiale recuperato
Fibre recuperate con il processo ENEA Materiale vergine
Fig. 5: Micrografia SEM del materiale recuperato in confronto al materiale vergine
Another way: recovered fibers
ENEA, Karborek and CETMA are setting-up a partnership to exploit recovered carbon fiber
Knowledge about composite behavior and predictive methods
• Composite materials are a product of human ingenuity and not a natural product.
• Their behavior can not be represented with few parameters. In addition, the behavior is strongly influenced by the processes of production
• A correct approach of design and engineering of composite parts is multidisciplinary
Typical design approach for composite materials
The integration of experimental characterization and numerical tools is essential to fully exploit the potential of composites
Cost-effective Manufacturing processes
Out of autoclave technologies
Advanced liquid moulding technologies
Induction welding
Compression moulding of thermoplastic composites
Vacuum bag of out of autoclave prepregs
Sheet moulding compound
Bladder Moulding
Other processes
Investigated Processes-1
Investigated Processes-2
Investigated Processes-3
Sheet and Bulk Molding
Bladder Molding
Joining techniques
One of the limitations of thermoplastic composites is impossible to obtain complex shapes as for the autoclave. For these reasons it is of fundamental importance the definition of new systems of junction with high performance. CETMA has developed along with Sinergo a new machine for induction welding of thermoplastics. In this technique an electromagnetic field at high frequency is used to weld the thermoplastic component by the Joule effect.
Nuova saldatrice ad induzione realizzata al CETMA
Principio fisico dell’induction welding
CETMA is one of the few research centers in the world capable of performing continuous induction welding of thermoplastic composites, even on complex geometries
Outstanding values of single lap shear strength were found for carbon-PEEK, carbon PEI and carbon PPS joinings
Composite Defect detectionInfraRed Thermography is a non - contact and non - destructive method, which provides rapid visual information about the structural integrity of a component
Impact Fault
Honeycomb
CFRP
Delamination
Hybrid GFRP sample with SMA
Void/detachment
CFRP
RecyclingA gap to overcome for an enhanced utilization of composites concerning recycling issue.
A present trend aims to use more and more thermoplastics composites
However some other solutions concerning utilization of composite waste for other sector (i.e. building)
CETMA carries out activities on recycling processes, technologies and new applications of recycled materials
Bio-based Composites
Development of new bio-based composites is a response to the growing demand for so-called environmentally friendly materials.
Bio-based composites can have matrix and/or fiber coming from renewable resources.
There is an increasing use of bio-based composites in non-structural part in the automotive
However, recent developments have shown that some physical-mechanical properties of biocomposites are comparable with lower performance composites properties (Glass FRP).
Typical Natural fiber•Flax •Cellulose•Jute•Hemp•Coconut •Bamboo
Example of Natural Resin•Pine oil•Castor oil•Soybean oil
Some applications in Mercedes
Biobased composites: some CETMA case studies
Smart materials
Cetma is working on processes to integrate Bragg fiber into composite materials in order to detect continously structural health
Conclusions• Composite materials can contribute to make transportation more
sustainable
• Fully exploitation of potential and advantages of composites
• The full exploitation of the potential benefits of composite materials requires an approach consisting of multidisciplinary and integrated competencies
• In Apulia, Cetma has created a center of expertise capable of addressing all the issues of product development in composite materials. These skills are further enhanced by the network in which this center operates as a connection link.
University & Academy
Equipments Supplier
Industrial user
MaterialSupplier