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The off icial magazine of Composites Austral ia Inc. Issue 25 October 2010
Composite engineer's viewpoint 7
Infusing the Buizen 52 Sailing Yacht 9
10
Environmentally friendly gel-coats launched 5
12
New International Focus for Composites Research
Back to Basics
16
Letter from the President 3
ConnectionMagazine
State News
Silver Sponsor
Conference & Trade Show 2011Conference & Trade Show 2011
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In conjunction with Derakane® Vinyl Ester Resin corrosion barrier, which has proven to be the market leader in chemical resistance for over 30 years, Aquaguard® Eco-Plus System is the ideal choice for the next generation of composite swimming pools.
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Connection 3Connection 3
Letter from the President The 2010 Board of Composites Australia are:
GeneLLe CoGhLAn – President Colan Products [email protected]
MArk STerBiC – Vice President DIAB Australia [email protected]
TreVor PAnozzA – Treasurer Ampelite Australia [email protected]
ALexAnder kryGer Aptec Composites [email protected]
MArTin JoneS CRC for Advanced Composite Structures (CRC-ACS) [email protected]
roBerT huTChinSon Composite Solutions [email protected]
PhiL BoViS Cool Composites [email protected]
FLoreAnA CoMAn Engineered Materials Australia [email protected]
MiChAeL di STASi Fiber Glass International Email: [email protected]
ShAron SwAn LSM Advanced Composites [email protected]
MiChAeL LeGGeTT Oceania Composites Engineering [email protected]
dArren BiShoP RPC Technologies [email protected]
SiMon TAyLor The Valspar (Australia) Corporation [email protected]
Thiru ArAVinThAn USQ – CEEFC [email protected]
Composites Australia Level 15, 10 Queens Rd Melbourne 3004 Tel +61 3 9866 5586 Toll Free 1300 654 254 Fax +61 3 9866 6434
www.compositesaustralia.com.au
Winter is over – well, almost, anyway, for those in the southern states! Since the last issue of Connection, Composites Australia has instigated some very exciting developments and programmes.
One highlight is that we are pleased to announce the 2011 Composites Australia & CRC for Advanced Composite Structures (CRC-ACS) Conference & Trade Show. Note the dates in your diaries – Thursday 17th and Friday 18th March, 2011. The venue is once again the very beautiful Hyatt Regency Sanctuary Cove on the Gold Coast. Everything you need to know about the conference – program, location, accommodation, trade displays, demonstrations, the conference dinner and registration information – will be detailed on Composites Australia’s dedicated conference page, www.compositesconference.com
At the 2011 Conference, the popular “Fabricator’s Friday” will be joined by “Engineering Thursday”. While Friday will again feature sessions especially for fabricators and their staff, with manufacturing techniques and special demonstrations, Thursday’s programme will focus on composites for engineers, and engineering concerns and applications. In educating the engineering world, we hope to increase the awareness and general usage of composites.
In addition, by popular demand there will be presentations designed to assist delegates with the operations of their businesses – including targeting for sales & marketing, using the new online media, financial management and more.
Anyone interested in holding a demonstration exhibiting and/or making a presentation should contact Ann at Composties Australia.
For all conference information, go to the easy-to-use link www.compositesconference.com.
There has been considerable activity within our association in the area of education and training. A grant from Enterprise Connect enabled Composites Australia to fund three one-day practical workshops on closed moulding. The one-off grant allowed us to offer this workshop to the industry at a very low registration
fee. EMP Composites developed and is presenting the workshop in three locations. Each workshop “sold out” in a very short time! It is planned to present this workshop again in 2011, although due to the costs involved in running this type of course, without grant funding, the registration fees will of necessity be higher.
A one-day workshop on Non Destructive Examination of composites was also offered to the industry in October 2010. This course serves as the first step for awareness of the techniques involved and how they can be used on composite materials and structures. If there is sufficient interest in this workshop, it too will be offered in additional locations in future.
The Board continues to work on additional practical training and other areas of most interest to members and to the industry.
The Annual General Meeting will be held on 2 December at 5 pm, at Victoria University in Newport (Melbourne). All members are encouraged to attend; an industry briefing and the Christmas party will follow.
With the AGM coming up, this is a great time to remind members of the current Board, listed in the column to the right.
This year, five Board sub-committees were formed to focus on key areas. They are:
•Finance – Genelle Coghlan, Trevor Panozza
•Membership – Robert Hutchinson, Sharon Swan, Floreana Coman
•events – Martin Jones, Floreana Coman, Mike Leggett, Simon Taylor, Robert Hutchinson
• education – Phill Bovis, Floreana Coman Thiru Aravinthan, Darren Bishop
•editorial – Thiru Aravinthan , Michael Di Stasi, Mark Sterbic, Sharon Swan
•Standards – Mike Leggett, Trevor Panozza, Darren Bishop
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In closing, I would like to remind all members that Composites Australia is your association; the Board and the executive can only deliver the tools and information you need if you participate by communicating your thoughts and observations. Contact details for the Board can be found on page 3 and also on the Composites Australia website.
You can also contribute to the functioning of the association by becoming a Board member. If you are interested in possibly joining our board of directors, please contact myself or the association executive.
I hope to meet up with you at the AGM and again at the Conference in March 2011.
Genelle Coghlan
Letter from the President (cont.)
THE FABRIC OF AUSTRALIA WWW.COLAN.COM.AU
RANGE:· CSM / Core / CSM· CSM / Core· CSM / Core / Multiaxial
WHY EZI FLOW?· Australian Made· Custom designs · Multiple layer combinations· Quality input materials· 100 MM - 3300 MM widths
EZI - FLOW MAT
Multiaxial(±45°, 0°, 90°)
T 02 9672 7888 F 02 9672 7666
Flow Layer (180/250 gsm)
Australia’s range of specialty reinforcements for use in closed mould systems
CSM (150 - 900 gsm)
There is more news than fits in this issue!
See more – including RPC Technologies' new facility in Victoria – on the CA webpage at www.compositesaustralia.com.au.
Connection 5
new eco Plus Gelcoats reduce workshop and environmental Styrene emissions during Fabrication, and Provide Antibacterial Protection in ServiceDean Voice BSC, CCT, NaTioNal ProduCT MaNager,PolyeSTer reSiNS, gelCoaTS & iNiTiaTorS, FiBer glaSS iNTerNaTioNal – a diviSioN oF NuPlex iNduSTrieS, auSTralia.
As overseas legislation continues to impose greater volatile organic compounds (VOC) compliance constraints on composites manufacturing sectors, Fiber Glass International leads the way for the Australian industry by launching the next generation range of environmentally friendly gel-coats under the tradename Aquaguard ECO Plus. The company describes the new gel-coats as added value products since they offer more than just low VOC properties.
Unsaturated polyester resins and gelcoats typically contain styrene monomer. Monomers in these resin compounds react with the base polymer to initially form a viscous liquid which subsequently cures to produce a durable, thermoset plastic product. However, many of these monomers are released into the environment during open moulding processes, particularly during spray application, laminate consolidation (rollout) and curing stages. The use of resins and gelcoats with lower styrene contents can significantly reduce these VOC emissions.
A move to low VOC resins and gelcoats in the workshop can significantly reduce annual ventilation costs, while providing a healthier working environment for operators. In the likely event of more stringent regulations being imposed to limit styrene and other workplace VOC emissions in Australia, local open mould composite operations would be well positioned to comply with any future legislation changes, by making the change to low VOC products now.
Low VOC resin-based products can be produced by various methods, including utilization of polymer molecules with shorter chains, or replacement of styrene with alternative monomers which evaporate less when exposed to air. These products typically contain 35% or less styrene on a weight basis. In the past, low VOC polyesters and gelcoats commercially produced via these methods have often shown reduced chemical resistance and mechanical properties, combined with poorer handling properties (high viscosity, slow cure), requiring adjustment of application techniques and equipment settings.
In general terms, good operating practice, use of low VOC resins and gelcoats and non-atomising application equipment can reduce styrene emissions by up to 50% or more.
Styrene suppressants (usually waxes) can also be added to resins to reduce monomer evaporation. These resin systems (typically referred to as ‘Low Styrene Emission’ or ‘LSE’) work by forming a barrier layer on the surface of the resin to reduce emissions by 30% to 50% in the static laminate, following roll out. The use of styrene suppressants however must be supplemented with a suitable adhesion promoter system to enhance secondary bonding performance in the event of delays between lay ups. In any case, sanding or grinding of cured LSE laminate surfaces is required to optimize secondary bonding of subsequent layers applied. Unlike the low VOC content resins and gelcoats mentioned above, these styrene-suppressed LSE products do not provide any significant reductions in emissions during the dynamic spray phase of the process.
Aquaguard ECO Plus is a new generation of premium, high performance gelcoats combining advanced performance and dramatically reduced VOC emissions, as a consequence of extremely low styrene contents of less than 28% by weight. These gelcoats provide up to 50% less VOC emissions than standard gelcoats. This means a better working environment and cost savings in gelcoat consumption. Aquaguard ECO Plus also overcomes previous deficiencies shown by other Low VOC polymer systems, by providing excellent sprayability, flow and handling properties. Handling and application properties similar to standard gelcoat characteristics can be achieved, without any significant adjustment of application techniques or equipment settings.
Aquaguard ECO Plus gelcoat will be available in a range of highly decorative cosmetic effect finishes, with excellent UV, blister and chemical resistance, and will cover a wide range of composite applications including Swimming Pool, Marine, Transport and Sanitaryware.
In addition to low VOC content, the new ECO Plus gelcoats also contain an antimicrobial system which is designed to inhibit the growth of harmful organisms such as bacteria at the gelcoat surface. The particular antimicrobial additives contained in these gelcoats provide long term protection against various microorganisms, without posing hazards to human health – and have also gained EPA, EFSA and FDA approvals. They do not leach out, have no environmental impact and are also listed on the European Biocidal products directive. Antibacterial properties of Aquaguard ECO Plus have been verified via independent testing to the JIS Z 2801:2000 standard.
Contact:
Dean Voice BSc,
National Product Manager,
Polyester Resins, Gelcoats, Initiators,
Fiber Glass International - a division of Nuplex Industries (Aust) Pty Ltd,
Tel: +61 7 3271 7337 Fax: +61 7 3271 3603
THE FABRIC OF AUSTRALIA WWW.COLAN.COM.AU
RANGE:· CSM / Core / CSM· CSM / Core· CSM / Core / Multiaxial
WHY EZI FLOW?· Australian Made· Custom designs · Multiple layer combinations· Quality input materials· 100 MM - 3300 MM widths
EZI - FLOW MAT
Multiaxial(±45°, 0°, 90°)
T 02 9672 7888 F 02 9672 7666
Flow Layer (180/250 gsm)
Australia’s range of specialty reinforcements for use in closed mould systems
CSM (150 - 900 gsm)
EXHIBITS | DEMONSTRATIONS | EDUCATION | NETWORKING | BUSINESS MEETINGS | AWARDS SHOWCASE
COMPOSITES 2011 connects the entire composites industry from over 40 countries to provide you the broadest range of networking, vendors and education — face-to-face and under one roof. Find everything from basic materials to cutting-edge, high-tech products and equipment to help you grow and remain competitive in traditional and emerging markets around the world. Plus, learn with in-depth education and demonstrations focusing on real world applications of materials, processes and innovations.
You’re invited to connect, learn and grow with the composites industry at COMPOSITES 2011. Plan to Attend!
Connect. Learn. Grow.
February 2–4, 2011Ft. LauderdaLe, FLorida, uSa
www.acmashow.org
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Part 2A – Bearing Strength
In the last newsletter I stated that we would be investigating the 10 major issues that composite engineers face when joining composite structures with fasteners. The first of these issues is determining the bearing strength of the composite laminate. The bearing strength of composite structures is notably lower than that in metals. The bearing strength is also a function of the ply orientation and through-the-thickness distribution.
Bearing strength in composite materials is influenced by both the compressive strength and shear strength of the laminate configuration. We must note that there is a conflicting issue with the configuration, since increasing the 0 degree ply orientation will improve compression strength, but decrease shear strength. On the other hand, more angled ply orientations (in particular 45 degree plies) the shear strength improves, but compressive strength reduces. This trend has similar effects with the bearing strength. There is a dominance of the shear strength relationship as shown in early investigations resulting in Figure 1 (early edition of MILHBK 17), and more recently the work of John Hart-Smith, Figure 2.
Figure 1
Figure 2
Thus it seems rather clear that fibre angle has a significant effect on bearing strength. Too many 0 degree fibres will have a negative impact on bearing strength and the 90 degree plies have little impact. The angle plies, particularly the ±45 degree orientation provide the greatest beneficial influence to the bearing strength. The same effects are seen with woven cloth, with the cross-ply cloth giving reasonable bearing strength, but the angled ply cloth being significantly more superior. Further refinement with tow placement will provide the greatest bearing strength, Figure 3.
Figure 3
Cross-Ply Cloth Angle-Ply Cloth
Tow Placement
Mechanically Fastened Joints in Composite StructuresComposite Engineer’s Viewpoint by Rik Heslehurst Phd, MeNg, BeNg(aero) FieauST, FraeS, CPeNg
Connection8
The comparative bearing strength properties of composite materials and conventional metals is shown in Table 1 and supported by the figure to the right (Hart-Smith). The bearing strength of composite materials is significantly less that comparable metals and thus only achieves marginal joint efficiencies. To improve this poorer bearing performance we can vary the local thickness of the composite joint region by adding extra plies (specifically more angled plies). Note well that as you increase the number of 0 degree plies the first three listed properties in Table 1 increase, but at the expense of shear and bearing strength. The reverse is true by increasing the percentage of angled (45) degree plies in the laminate.
In the next article we will discuss bearing strength with a review of plate bending effects and through-the-thickness reinforcement. I also welcome questions, comments and your point of view. Feel free to contact me via [email protected]. I may publish your questions and comments, and my response in future newsletters.
Table 1: Material Property Comparison
MATERIAL PROPERTY
ALUMINIUM 7075-T6
TITANIUM 6Al-4V
GRAPHITE/ EPOXY AS4/3501 (QI)
Elastic Modulus GPa (msi)
71.0 (10.3) 110.3 (16.0) 54.8 (7.95)
Tensile Yield Strength MPa (ksi)
448 (65) 827 (120) First Ply Failure 317 (46)
Tensile Ultimate Strength MPa
517 (75) 896 (130) 710 (103)
Shear Strength MPa (ksi)
324 (47) 524 (76) 331 (48)
Bearing Strength MPa (ksi)
965 (140) 1,680 (244) 415 (60)
Composite Industry Insurance Specialists
Specific Industry Related Policies
David McAllister, Greg McDonald,
Bruce Bailey.
Phone: 1300 85 35 88 Fax: 1300 85 39 33
www.verisure.com.au
Connection 9
Mastercraft Marine Pty Ltd of Terrey Hills in Sydney’s north, builds the very well respected Buizen Pilot House yachts. The established 48 model has been joined by a new and exciting 52 – there is also a plan to extend the range to encompass a 60. Peter Lowe Design has come up with a modern but evolutionary design for this new sailboat.
EMP assisted the naval architects to optimize the structural laminates of the hull and deck in response to Buizen’s desire to get into closed moulding for the first time. While meeting the requirements of the European Recreational Craft Directive and its CE mark to Category A under International Standard ISO12215, the composite laminates also needed to be optimized for EMP’s processing specialty, vacuum resin infusion.
EMP undertook flow simulations using its in-house RTM-Worx software from Polyworx, backed up by permeability trials of test panels reproducing the actual production laminates in its Sydney workshop. Concurrently, Lachlan Welch, our Senior Applications Engineer, ran a training program with Buizen’s shipwrights, setting up the hull mould for the first infusion (photo top right) and advising on correct handling of the FGI materials that were used throughout the construction.
The actual infusion of the two hull shell halves was a great success (photo below). The Saertex stitched fabrics consolidated very well with excellent wet-out from less than 300kg of tailored FGI SPV infusion vinylester resin over DIAB end-grain balsa core material in each hull half-shell. Low-shrink SPV tie-coat resin also ensured very good surface cosmetics.
Buizen’s Steve Howe was very pleased with the results, endorsing the systematic approach taken by EMP’s engineers while working alongside the builder’s workforce to clearly define the overall combination of composite design, materials selection and process optimization.
www.buizenyachts.com.au
www.empcomposites.com.
infusing the Buizen 52 Sailing yacht EMP Composites Assists NSW Yacht Builders with New System for Improved Sailboats
Composite Design& Processing
Consultants
Design: Laminate engineering & costing Codes and Standards compliance Finite element analysis, CATIA and resin flow modelling Mechanical investigation and testing On-site process implementation & workshops
We know composites:Lightweight marine structural designClosed moulding – infusion specialists
A division of Nuplex Industries (Aust) Pty Ltd ABN 25 000 045 572
Tel +61 (0)2 9910 7300 | [email protected] 1, 92A Mona Vale Road, Warriewood, NSW, 2102, Australia
www.empcomposites.comThe hull demoulded
Image courtesy of Buizen Yachts.
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On 20 August 2010, the Cooperative Research Centre for Advanced Composite Structures (CRC-ACS) held its inaugural board meeting, signalling the commencement of a five-year international research program based in Australia. CRC-ACS has been one of Australia’s most successful Cooperative Research Centres, and has brought Australian composites expertise and technology to the world stage. Building on this theme, the objectives of the CRC-ACS Extension Program are to:
•Focusoninternationaldevelopmentofcompositesandrelatedtechnology in Australia, using a highly successful collaborative research model.
•FacilitatetheintegrationofAustraliancompositesmanufacturing,materials supply and engineering support enterprises into international value chains.
•Bringarangeofnewtechnologiestomarketincludingbreakthrough aircraft structure assembly technology, low-cost infrastructure repair, and sustainable plant-fibre biocomposites.
By securing a fourth term of CRC Funding, CRC-ACS has again established its position as the longest continually running CRC in the history of the CRC Program. Since its inception in July 1991, CRC-ACS has delivered significant benefit to the Australian economy, including technology underpinning Australia's $4 billion engagement in the Boeing 787 program.
research Program Participants
Australia will have unprecedented opportunities to engage in the European aerospace market. EADS Australia Pacific, part of the world's largest aerospace manufacturer – EADS, will commence its first ever major R&D program in Australia through this Extension. The German Aerospace Center – DLR will also commence its first major composites R&D engagement in Australia, providing access to
unrivalled facilities in the development and implementation of aerospace technologies.
Support of Australia's defence forces will also be enhanced, by maturing research into health monitoring systems and repair technology, and developing life-saving crash systems for helicopters. Australia’s Defence Science & Technology Organisation – DSTO, a long-term participant in CRC-ACS, will play a major role in the development of these technologies in support of Australia’s defence forces.
The benefits of using composites, including light weight, durability and high strength, will be developed in a program focused on oil, gas and petrochemical infrastructure expansion and repair. Businesses in the oil & gas industry will benefit directly from the new technology, while additional businesses will have new capabilities that can also be applied to infrastructure in the civil and mining sectors.
PETRONAS is sponsoring the development of sustainable composite materials solutions. The use of plant fibres in composite materials will be developed, to allow replacement of some composite materials with more sustainable solutions. Using plant fibres in this way provides a tangible means of carbon capture and storage, with outputs directed to the replacement of wood and fibreglass products. Additional benefits are the lowering of energy use in the field and improved recyclability.
Twenty-eight organisations have joined CRC-ACS, including nine organisations from outside Australia. The organisations represent an impressive array of research institutions, materials suppliers, engineering service organisations and end-users. Australian Small to Medium Enterprises (SMEs) include Regina Glass Fibre, Structural Monitoring Systems, Specialty Coatings (Aust), Brenco and Piber Plastics, plus Australian software providers MSC Software and Pacific ESI.
new international Focus for Composites research in Australia CrC-ACS begins $65 million research Program
The new Board of Directors for the Cooperative Research Centre for Advanced Composite Structures (CRC-ACS) left to right: Dr Colin Wong Hee Huing, Prof. Murray Scott, Mr Paul Barratt, Dr Bill Schofield, Mr Fabrice Rochereau, and Prof. Grant Steven.
Connection 11
overview of the new CrC-ACS programmes and projects
There are three programs running within the new CRC-ACS including Materials and Manufacturing, Simulation and Systems Development, and Operations and Sustainment.
Since 1 July, CRC-ACS has held establishment meetings to commence the eight projects within these programs and all projects are now building steadily.
In addition there is an Education, Program and Utilisation & Intellectual Property Program which is embedded in each of the projects.
Composites Australia collaboration
How will Composites Australia (CA) members benefit from this research program? Apart from the continued support to the annual Composites Conference, CRC-ACS is working with participant industry support organisations to help industry in Australia to take a leading role in composites development, positioning Australian SMEs prominently amongst international industry. Engagement will allow the Australian Composites Industry to take-up new opportunities in the Aerospace, Defence and Oil & Gas sectors, with a focus on utilising specialised skills and technologies already developed within the industry. In collaboration with Composites Australia, CRC-ACS has developed a stream within the overall program above that includes the following:
• Developmentofaminimumofthreeeducationmodulesforindustry training, for delivery by CA. The subject of the first module to be delivered is design and analysis. The subject of the second education modules is manufacturing.
• Developmentofatleastonedraftstandard,relatedtotheapplication of composites in civil engineering.
• Thedevelopmentofdesignguidelinesfortheuseofbiocomposites by the composites Industry.
• Provisionofreportsonresearchinbiocomposites,witha specific focus on implementation by the composites industry.
This continuation of CRC-ACS will allow Australia to take a prominent role in composites development, leading the Australian composites iIndustry into a strong and competitive future. It is a source of great satisfaction to Centre staff that they have built strong relations with members of CA over the years. They intend to continue to add value to those relations – and build new relationships with CA members – for many years to come.
Further information on the new CRC-ACS Program, including the Associates program and opportunities for engagement, can be obtained from Andrew Beehag by email ([email protected]) or telephone (02 9772 8486).
www.crc-acs.com.au
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Back to Basics
Closed Moulding – Process Selection Considerations for Closed Cavity Bag Moulding (CCBM®)
Often fabricators who are considering looking into closed moulding as an alternative to traditional open moulding processes ask, “Where should I start?” My answer is always the same. “You need to answer one very important question first: How many?” How many parts you want to produce is the starting point when considering any manufacturing process for a specific application.
Frequently many overlook Closed Cavity Bag Moulding (CCBM) or variations of it as a process option and initially focus on Light RTM instead. But if we answer the question of how many parts are to be produced and then other important considerations that are “need to know”, you will then be well informed to choose the right process for your application.
Guidelines
The following guidelines will help you to meet your expectations on what you can expect to achieve. They are not strict rules that must be adhered to, as there are always exceptions to every rule and some may not be valid for all part types, sizes, complexities and specific combinations of labour, materials and capital costs. The more informed your decision is regarding process selection, the greater the chances are of meeting all of your expectations. Wrong choices can lead to additional costs which were not originally taken into consideration when jobs are quoted - and therefore the economics will not be realised.
Important considerations in the process selection include the life expectancy of the mould and countermoulds, complexity of the shapes and “how many”. The expected volume requirements for production, usually narrows down the number of choices for consideration.
By Larry Nunes, Business Development Manager – Valspar (Australia) Corporation Pty Ltd
“The key benefit in any closed moulding system is that you consistently have process control in your manufacturing environment.”
Connection 13
Closed Cavity Bag Moulding is a patented infusion system. Many years ago licensing agreements for patented closed moulding systems were quite expensive for smaller fabricators to absorb, but today many are very low cost or free. CCBM borrows desirable features from both the LRTM and VIP processes. It is simple to adopt with existing rigid open contact moulds with a fabricated reusable, flexible silicone rubber countermould, providing you have a wide enough flange. If you are a traditional contact moulder, the best investment in building any new tooling is to incorporate a large 200mm wide flange, as extending flanges on existing moulds is costly and usually causes issues with vacuum integrity.
The CCBM process utilizes vacuum to clamp the mould halves together and pull the resin through the reinforcements. In true CCBM, the resin is injected rather than infused as in the VIP process. The use of injection pressure and vacuum is commonly referred to as a “push / pull” system. Lower pumping pressures and vacuum levels are used versus LRTM & VIP. The most common mistake made in most any of the closed moulding systems is for the pumping and vacuum levels to be set at maximum levels. Relatively low pressure and lower vacuum levels will provide much better cosmetics and the fill times on most intermediate size parts will not be extended greatly. High vacuum levels should be considered when you are looking to optimize high glass to resin ratios.
Pumping equipment to inject moulds is not mandatory. Parts can be readily infused and the same holds true for LRTM moulds. It is a great way to initially enter into closed moulding before expending capital equipment dollars. Let your first few closed moulding jobs pay for your injection equipment. Without injection equipment, you will be sacrificing the labour savings aspect, especially in larger volume production requirements.
CCBM has one of the lowest costs for tooling of all of the closed moulding options and works well in many applications. Parts with very complex geometries, high glass to resin ratios, high strength, light weight and part to part consistency are easily achievable. Labour savings can be realized versus open moulded parts in general, and they can become significant savings since the CCBM process readily allows threaded inserts, bosses and core structures to be moulded in a single infusion, eliminating secondary bonding applications.
The downside of CCBM is that you cannot have a gelcoat finish on both sides as is possible in LRTM. I always recommend fabricators show their end-user customers two versions of the CCBM finished parts and quote for both. Produce one part with a 2-3% by weight pigment addition to the resin that matches the gelcoat colour and one without. A pigmented resin system makes any part look much more professionally manufactured and only costs a few cents per part. Most people will choose the pigmented resin part.
The key benefit in any closed moulding system is that you consistently have “process control” in your manufacturing environment. This will relate into less defective rework parts to
repair, producing better quality parts consistently, while reducing labor costs. Reduced styrene emissions and a cleaner, better working environment are other benefits of closed moulding processes versus open moulding.
Material Choices for Producing a Reusable Vacuum Bag
One of the cost savings achieved using a reusable silicone rubber vacuum bag countermould is the elimination of costly consumable/disposable vacuum bagging materials that are used once and disposed of, as well as the high labour costs to set up a bag manually.
Cured Silicone Sheet Stock
Cured silicone sheet stock is available to produce bags but it has the highest labour costs compared to other systems. Skilled employees are required for pattern cutting, seaming and sealing bags and bags may leak at the seams if not fabricated correctly. Cured sheet stock has difficulties fitting tightly over mould contours and can be prone to bridging in radii. There are some companies that currently sell reusable vacuum bags mounted in frames that have ports already installed which exhibit excellent elongation and conform well in radii but they can limit part size capabilities.
Spreadable Liquid Silicones
Many of these products today are one part, no mixing required (cures via exposure to atmospheric moisture) and allow you to build a countermould bag quickly to be in production within a day or two. Most feature low odour and no solvents, VOC’s or HAP’s. These systems are the most widely used today. They are ideal for making durable bags for molding complex geometries, conforming and fitting tightly, even in radiused areas and over complex contours. Construction of these reusable bags allows for the construction of vacuum ports, resin ports and flow media channels directly into the finished bag.
Sprayable Liquid Silicones
All the advantages of the spreadable liquid silicones, but will also save you time in producing a bag and will cut labour and material costs. The down side is the capital equipment expenditure required. So if you do not have large volume tooling requirements this may not be a consideration. These systems are generally designed for producing large bags/large parts.
Life Expectancy of Countermoulds
What is the life expectancy of a reusable silicone rubber bag countermould? That is a very good question. It is not an easy question to answer, as there are many issues such as part geometry, size, cross sectional thickness, peak exotherm temperature development of the moulded part etc. that can directly affect the life of your countermould.
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For quite a few years when reusable silicone rubber bags became popular, fabricators were told to expect a life cycle of 1,000 parts was achievable. I’m still waiting to meet the company that has been able to achieve that…
Most material suppliers are much more realistic today as to what life expectancy you can really expect. Some of the spreadable liquid silicone material suppliers talk in generalities of 100+ parts because of all of the variables involved. Others are so confident that they cite a maximum of 500 to 1000 parts.
Conservatively a range from 300 to 500 parts can be achieved with many projects but when costing a project is involved and you need to produce close to or more than that number, a safety cushion should be built into your costs for producing a second bag. I have met many companies moulding complex, thick cross sectioned parts such as large truck bodies that are easily getting 400+ parts per countermould. So what’s their secret? Several key issues are always mentioned in their practical experience over years of utilizing this production method.
The surface that the bag is made from is very important. Often if the cross sectional thickness is less than 3mm thick, the bag can be made from the actual mould surface which will produce a flawless surface. For thicker cross sectioned parts, it is usually recommended that an actual part be left in the mould and the back surface be sanded smooth (320 grit or higher), buffed and polished. The surface on the backside of the part will be replicated by the bag and every part moulded from it. The smoother the surface created when producing the reusable bag will help to maximize its life expectancy. Large labour savings and reduced costs for reusable silicone rubber countermoulds are realized versus LRTM countermould fabrication due to the higher costs of labour and sheet waxing materials required to develop the precise mould cavities for LRTM.
Bag handling is very important. Large bags are heavy and can be difficult to handle. The larger the bag, the easier it is to tear and damage. Incorporating recommended reinforcement fabrics that stretch into the bag construction will also provide greater strength and tear resistance. Special framing and lifting points are incorporated to help eliminate the potential for tearing a bag. Remember, if a bag is damaged, it can be readily repaired, but you may lose one production day while the repair is completed. Care in demoulding the bag when breaking parts out of the mould is critical. Typical on many production floors is to grab at one point and pull it off. Rough handling can and will reduce bag life dramatically.
Many people believe silicone is impervious to chemical attack and that there is no need to use mould release because it has self-releasing properties. On the contrary, styrene monomer will permeate a silicone bag or mould given enough part moulding cycles. After a time period, there will be enough unreacted monomer permeated in the walls of the bag such that eventually you will have a cross linking reaction as you
mould a part and no matter how delicately you try to remove a bag, you will tear and damage it. Many bag users will put their seasoned bags into low temperature ovens or out in the sun to drive off any unreacted styrene monomer to prevent this from happening. It will also help the bags to maintain their elasticity and not become brittle due to the monomer crystallizing. Mould releases will also extend the life expectancy of your reusable bags.
Reinforcements for Production Parts
CCBM offers the greatest flexibility with respect to changes in the reinforcement material choices. The flexible countermould easily accommodates design changes to increase or decrease part thickness. Material choices can be very important as the ply schedule of reinforcements can become very compressed and reduce the permeability of the resin flow.
There are more reinforcement choices today than ever before that will allow you to achieve any properties your finished part may require. Besides choosing a material(s) that will meet your requirements, also focus on those that will allow you simpler loading, conformability as required and that minimize the number of plies to be loaded. This will greatly reduce the possibilities of a poorly loaded mould, resulting in a potentially bad fill and rejected part as well as minimizing your labour intensity.
Many fabricators want to use low cost standard open moulding chopped strand mats, especially when they have large flat panels, etc.. You can break rules, but you must know what you are giving up. Traditional chopped strand mats with emulsion binders will have very poor permeability and the binder takes a long while for it to break down after the resin wets through the mat. Injection port locations would be critical as once wet out and the binder dissolves, the mat can wash away from the injection port location. These mats are not very conformable and would infuse very slowly. Powder bound mats will infuse slightly faster but all of the same issues apply.
Stitched Chopped Strand Mats are very cost-effective, will help to build bulk and have much greater conformability due to poly fiber cross stitching and binder free glass. Costs are very competitive versus chopped strand mats and would be the preferred choice for bulking up laminate thicknesses.
More structural stitched materials, commonly referred to as Knit Fabrics are ideal for most all closed moulding processes and are now designed for infusion, maximizing permeability and flow rates. Most suppliers can provide you with the infusion speed of the material, resin consumption in known laminate thicknesses, etc. These products are ideal for reducing the number of plies required for higher structural property parts and even the heavyweight fabrics are very conformable. They are readily available in E-Glass, Aramid and Carbon fibres. Many options can be attained, such as stitched mats in combination with multiaxials or surface veils already attached.
Back to Basics (continued)
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Special nonwovens developed for closed moulding systems consist of three layers stitched together. Two layers of chopped strand glass and or a multiaxial on the outside surfaces with a porous thermoplastic infusion aid in the middle that provides excellent resin flow properties. Well known brand names of Rovicore®, Combiflo® and Flowmat® are but a few. When considering these for use in a CCBM moulding process, the part thickness should be used when fabricating the bag so it will not over compact these materials and use only -0,4 / -0,6 vacuum (bar) to avoid crushing the infusion aid media. These products can help to reduce the number of plies in your laminate construction. They also have many different construction options available. Products moulded with these types of reinforcements will have lower inter-laminar shear strength due to the low strength of the polyethylene or polypropylene infusion media.
Mould Considerations
There is not enough space to address all types of moulds for the different closed moulding applications in this article and it will have to be addressed in another article dedicated to just that. For most all of the process applications, a rigid structure needs to be achieved. I am a big proponent of fully cored structures for tooling applications. If you currently build contact moulds that are experiencing long life expectancies, they can be the foundation for your conversion to closed moulding. More premium resin and tooling gelcoats re: vinyl ester based products should become more of a consideration when planning to produce large volumes, cycling multiple parts daily.
An often overlooked consideration when fabricating LRTM or CCBM tooling is to incorporate some kind of locating and indexing of the two mould halves to ensure the placement of the countermould is exact and will ensure that all of the vertical wall structures are the same thickness.
Conclusion
The CCBM process is highly versatile because it works so well in so many applications. It is the simplest and is the lowest cost of all of the closed moulding processes. This could be why it continues to gain in popularity and use by composites fabricators around the world. Gather more information to be able to make an informed decision by attending some of the low cost trade association and supplier workshops on closed moulding processes. See it work live and get answers to your specific questions and concerns as it can be a viable alternative to open moulding.
Understanding some of these basic concepts in the process selection for entering into closed moulding from an open moulding process will help to ensure you are successful in producing better quality parts, reducing costs and emissions, while improving your workplace environment.
Isn’t it time for you to consider taking another look into closed moulding processes?
You are welcomed to contact me with any questions and comments,
at [email protected] I may address your questions and comments
in a future article.
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Queensland
A Day of Visiting Composites Facilities in Toowoomba
In June, Composites Australia, in conjunction with the University of Southern Queensland’s CEEFC (Centre of Excellence in Engineered Fibre Composites), organised a full-day program of visits to composites facilities in Toowoomba, QLD, a regional hub of the industry. This rare and fascinating opportunity to have an inside look at
some of the top composites companies in the country attracted industry members from every state in Australia.
Some 75 participants took part, including fibreglass companies, those in the aviation and marine industries, local government, universities, PARTEC, and composite suppliers .
Two bus-loads of delegates alternated visits – the first stops were a tour of the CEEFC at USQ and a visit to nearby LOC Composites. Next on the agenda were trips to LSM Advanced Composites, Wagners Composite Fibre Technologies (CFT), and Felco Manufacturing.
Delegates stopped at each facility and had the opportunity in most cases to walk through the factories, view operations in
progress and talk to representatives about the technology and systems they use. For example, at LSM Advanced Composites, attendees could observe the 6-axis kuka robot for plug and mould machining in action, as well as watch staff work on projects with laminating & pre-pregs, and view the autoclaves.
If delegates could not be allowed in to the working area of the factory, representatives met them in other parts of the premises and provided samples and a presentation on their products and methods. One originally-scheduled stop had been forced to cancel due to a last-minute project; this allowed time for the delegates to tour Wagner’s near-by working composites bridges.
There was also a very enjoyable and convivial lunch stop at Angelo’s House restaurant, as well as morning & afternoon tea and plenty of opportunities for meeting and talking to industry colleagues!
Delegates’ comments included much praise for the opportunity and the organisation of the tours. The only criticism received was however mentioned by many: disappointment in not being able to see the production processes at the site where this was not allowed.
A report from a participating factory:
As a member of the Composites Australia industry association, Felco Manufacturing recently opened its doors to other members and associated visitors.
People from across Australia were invited to inspect both finished products as well as tankers on the production line. Comments and feedback following the event revealed that people had previously seen Felco Tankers on the highways, but had not realised where they originated from.
One interstate visitor commented “Felco’s production methods are simple, plus tried and proven, and obviously have stood the test of time - given the amount of tankers seen on the road!”
The management of Felco are dedicated to promoting the fibre-composite industry and educating people about the infinite benefits of fibreglass composite products. Felco believe that transparency between Industries will help to promote and assist the story of fibreglass composites to the benefit of all people involved, both manufacturers and end-users.
Managing Director of Felco Manufacturing Tim Wheeler was quoted as saying “We welcome any opportunity to network with other companies within our Industry, and the Tour Day has been an excellent way to achieve that. In the same way we also welcome our clients to visit the factory so they have the opportunity to see the benefits first hand”.
Contact: Ph (07) 4630 2213 Email: [email protected]
State news
Factory Tour day hosted by Composites Australia in Toowoomba
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Queensland
PArTeC Trains in the Torres Strait
Shown at right are photos of some of the first 16 students who learned basic laminating on Badu Island in the Torres Strait recently with a PARTEC Trainer.
By the time you are reading this, PARTEC will have also started training on Yorke Island for a period of three weeks, with students from Yorke and Mabuiag Island. Yorke is also known as Masig, and is where the television series “Remote Area Nurse” was filmed a few years ago.
State news
new South wales
Pacific resins welcomes Chris Bourke In July, Pacific Resins Pty. Ltd. welcomed Chris Bourke as Business Manager – Composites. This is a national role. Amongst his duties, Chris is managing the Swancor range of epoxy vinyl esters and epoxy laminating resins as well as other products for the composite industry.
Chris has over a decade of industrial experience in technical sales and has a Masters of Technology. Chris’s experience includes hands-on manufacturing support, technical support, business development, product management and sales management in raw materials, water treatment, pulp & paper manufacturing, surface coatings, plastics and composites.
In addition to continually learning about applied chemistry, manufacturing processes, business and customer service, Chris also enjoys being involved in family and sport interests.
Please feel free to contact Chris anytime on 0418 720 586 or [email protected].
Keith Stanistreet, PACIFIC RESINS PTY LTD, Tel: 02 4272 3005
new South wales
Plant Fibres, Profiling and rockets, oh my!
In July, DIAB Australia hosted a Trade Night & Industry Briefing at its premises in Seven Hills, NSW. The presentations included “a taste from Conference 2010”, with two talks from the April Conference being given, along with a third presentation on smart marketing for our industry.
Tim Banicevich (left), a Laboratory Supervisor at
Fiber Glass international, brought along a number of his model rockets. Model rockets are fabricated with composites because they are lighter, stronger and more versatile than conventional materials and are non-metallic (for increased safety). He spoke about the implications for airframe tubes, and fins, and showed a number of videos of his rocket-building and launching projects undertaken by himself with different methods and results.
Although it was not possible to stage a live launch at this event, we heard from Tim that he launched the Saturn 1B model for the first time a week or so later. As he wrote, “It was awesome! The launch and recovery went almost perfectly, with only a superficial dent on one of the fins and propellant soot as evidence of the flight.”
In another “taste of Conference 2010”, Andrew Beehag, Advanced Composite Structures Australia Pty Ltd, spoke on “Emerging Applications and Opportunities for Biocomposites in Australia”.
Considerable research has been taking place into plant fibre biocomposites as potential replacements for glass fibre composite materials, with more environmental sustainability. The CRC for Advanced Composite Structures and CSIRO have been assessing the performance of plant fibre biocomposites for a range of industry applications, and assessing market demand
amongst composites manufacturers. Andrew’s presentation discussed the practicality of plant fibre biocomposite applications, the market sectors interested in using them, and progress made in improving biocomposite performance.
In the third presentation, host Mark Sterbic, Managing Director of DIAB Australia, spoke about how companies can use customer profiling to get better results, by approaching as few potential customers as possible. Why approach fewer, rather than more, customers? It’s marketing with smart focus to get better results. Based upon the “technology adoption curve”, you can profile your customers so that you will know who will be best to approach when introducing new technology, and who to target when trying to market your products and services to companies not familiar with composites.
(Note: Missed this presentation? It will be given again at Conference 2011 – be there!)
The PARTEC teacher was a long term resident of Yorke Island, until he moved to Cairns a few years ago. The students all aim to get jobs on the "mainland" in Cairns or Townsville, and to become apprentice Composites Technicians.
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Perth's biggest sculpture, with its conceptually “different” and innovative design, is now the prominent feature in the forecourt of St George's Cathedral on St Georges Terrace in Perth. A very abstract representation of the story of St George slaying the dragon, the sculpture is named “Ascalon” after St George's lance.
Its construction, an innovative engineering achievement, cost over $500,000 and involved many industrial & fabricating processes.
The artists, Marcus Canning and Christian
de Vietri, have noted that their concept relied on top-end technology and fabrication. It features a billowing white cloak and an 18m lance (a chrome tube emitting a beam of light into the sky at night), together representing the hero, and black plate-steel mounds in the ground representing the dragon.
Composites was chosen for the sculpture for many reasons, including its light weight, corrosion resistance, low fatigue issues, freedom of shape, continuity of strength through the complex curves and changes of direction, and long life of the product.
The billow form cloak was built at Composites Australia member Glenn Swarbrick’s Henderson boatyard (Swarbrick & Swarbrick Yachts) in West Australia. It is made from the same hybrid composite technology used to make aircraft, and was sculpted by CNC router robots at Glenn’s factory. It was so big (18-metres) it had to be created in four sections using robot-cut polystyrene moulds.
The billow was initially provided to Swarbrick as a 3D surface model. This was then broken up into segments that could be easily machined. Polystyrene was used for the mould because of the many areas that lock to the mould which would need to be broken out in demoulding.
The bottom parts were laminated first, and then the next piece of mould was added and laminating continued. A few smaller mould pieces were joined together and laminated before being joined on to the main structure. The main structure usually had to be lifted and turned to suit the laminating of the next section. Laminate consisted of 30mm pvc foam core with vinylester resin and chop-strand matt skins, all hand consolidated.
The bottom mounting point has a large buildup of unidirectional glass. The upper mounts are 40mm thick solid laminate, tapering to over 1 metre in diameter. The billow is finished in epoxy hibuild primer and gloss top-coated with two-pack polyurethane.
Much modelling and testing was needed to ensure the final work could withstand strong winds on the terrace where it would be installed. A small model was created to assist with calculating the mounting point loads for the pole. The attachment of the billow to the pole needed to appear minimal yet be structurally very sound. The billow is attached by a bolt at the base and two groups of four bolts where the billow passes near the pole.
See more on this story at www.compositesaustralia.com.au
On 23 September, a Trade Night was held at Challenger Institute of Technology in Henderson, WA, attended by some 70 industry members. The presentations and demonstrations made the event very worthy for the attendees.
•helping Advance the Composites industry – Speakers from Challenger Institute of Technology, ApprentiCentre, MEGT and CIAB can provide apprenticeships, certify Recognition of Prior Learning for your staff, and practical training services for industry. Challenger now has the capacity to deliver training in Pre Pregs (Frisbee project - photos left).
• NewOpportunitiesfortheCompositesIndustrywithCRC-ACS – Andrew Beehag, Cooperative Research Centre for Advanced Composite Structures (CRC - ACS). Andrew told the attendees about the CRC - ACS's new research program, which aims to engage Australian SMEs into international supply chains.
• The Making of “Ascalon”: Composites Slaying the Steel dragon – Glenn Swarbrick, Swarbrick & Swarbrick Yachts (See article above - also see story and presentation on Composites Australia website).
• nutech rapid Tooling System – Owen Hall, Nupol Composites. Nupol displayed the Nutech rapid tooling system for building high quality dimensionally stable production moulds.
• Tutorial: how to do Basic infusion, from Set up – Owen Hall & Duane Davison. This step by step demonstration of vacuum infusion took place in minutes as attendees watched, showing how easy infusion can be with relevant training and the right products.
Composites Australia Trade night held at Challenger institute of Technology
State news
CA Member Swarbrick & Swarbrick yachts help Create Perth’s Colossal new Modern Sculpture
western Australia
western Australia
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State news
“Tendering for Government Business” workshops are being delivered by the Queensland Government for existing and potential suppliers to government departments and agencies.
Participants will:
• learntheprinciplesofQueenslandGovernmentprocurementpolicies and processes, including sustainable procurement.
• learnhowtocompletecomplexoffer/tenderdocumentsusedby departments and agencies for high value, difficult-to-secure goods and services.
• learnhowtointerpretandrespondtothestandardtermsandconditions contained in complex Government offer and tender documents
• understandhowtosearchGovernment purchasers requirements for:
- value and range of products and services they source locally
- notification procedures used
- prerequisites in being an eligible supplier.
Cost: $44.00 (including GST). Duration: 5 Hours.
Since 1 July, more than 200 people have participated in tendering for government business workshops state-wide.
To register your attendance or find information on the variety of workshops offered by the Department, please contact the Business Hotline on 1300 363 711 or visit www.deedi.qld.gov.au.
Tendering for Government Business workshops offered by QLd GovernmentQueensland
Dates Time(s) Locations Contact
21 October 2010 8am/1pm Brisbane Northside [email protected]
09 November 2010 8am Brisbane Southside [email protected]
11 November 2010 8am/1pm Sunshine Coast [email protected]
18 November 2010 8am/1pm Brisbane Northside [email protected]
25 November 2010 8am/1pm Gold Coast [email protected]
02 December 2010 8am/1pm Brisbane Northside [email protected]
03 March 2011 8am Brisbane Southside [email protected]
10 March 2011 8am/1pm Brisbane Northside [email protected]
07 April 2011 8am/1pm Brisbane Northside [email protected]
05 May 2011 8am Brisbane Southside [email protected]
02 June 2011 8am/1pm Brisbane Northside [email protected]
Press releases
Composites Australia welcomes new Members:
n Fibreglass and Resin Sales (WA) - Charles Urwin, MD n Applied Research of Australia (AROA) (SA) – Matthew Boot, MD
welcome new Members
Fibreglass and Resin Sales Pty Ltd commenced business in 1986 and grew out of its parent company Universal Plastics.
Universal Plastics started out in 1975 and specialized in aviation composites. It was one of the first to gain Department of Civil Aviation (now called CASA - Civil Aviation Safety Authority) approval for manufacture and repair of composite components. It also held major repair approvals for composite, metal and wooden sail planes under the auspices of the Gliding Federation of Australia.
Because of the company’s familiarity with aviation type composite materials, Universal Plastics was often asked to supply materials, in particular epoxy resins and woven fabrics; hence for the commencement of Fibreglass and Resin Sales.
The aviation business also lead into the manufacture, repair and modification of all manner of things including race cars, race bikes and subsea markets to name a few.
What this meant was that when Fiberglass and Resin Sales came into existence we already had a lot of practical knowledge on
the use of composite products and the various ways to use them.Some 5 years ago Universal Plastics was sold and Fibreglass and Resin Sales became a stand-alone entity.
Fibreglass and Resin Sales can still make the claim that “we have used all the products we sell” and albeit we are epoxy specialists we keep a range of polyester, vinylester polyurethane and silicone systems. Also stocked are a range fibre glass, carbon and aramid fabrics, vac pumps and consumables.
The FRS team is all girls – plus Charlie Urwin, who does the trouble shooting and consultancy. The girls are often called Charlie’s Angels … [not!] and are well known for their friendly, helpful and confident manner.
Our shop front caters for both industry and public sales and is open 8 am to 5 pm weekdays and 9 am until noon on Saturdays.
Fibreglass and Resin Sales Pty Ltd 111 Kew St, Welshpool WA. Telephone 08 9740 2571
new Member Profile: Fibreglass and resin Sales Pty Ltd
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This is a first-rate opportunity for everyone in the composites and fibreglass business, as well as all those who may use these processes and end-products, to keep up with what is taking place and to learn more about the industry.
The conference and its concurrent trade show will focus on the latest state of the art technology, manufacturing, processes and products. We expect over 400 participants from Australia and New Zealand, and from around the world.
The Conference & Trade Show will take place over two days, Thursday and Friday 17-18 March, 8:30 am to 5:00 pm each day.
Information will be available soon online: www.compositesconference.com
This year, the Thursday programme will focus especially on composites in engineering, and will feature presentations imparting information to engineers on the specifications, standards, and advantages of composites.
Friday will once again feature “Fabricators Friday” presentations and demonstrations aimed especially at composites fabricators.
In addition, on both days there will be sessions aimed at managing and improving your business and business practices.
The popular networking events will of course be part of it! The Conference Dinner takes place on the Thursday evening; Welcome Drinks will be held on Wednesday evening, 16 March; and there will be closing refreshments in the Trade Show area on Friday, 18 March. We encourage everyone to stay for the weekend and take advantage of the many tours and activities available in this beautiful area of Queensland.
If you would like more information about:
• Exhibiting at the Trade Show
• Staging a Practical Demonstration
• Giving a presentation, tutorial or workshop
• Attending
or have any questions, please do not hesitate to contact
Ann Byrne by e-mail ([email protected])
or telephone (+61 3 9866 5586)
Register online www.compositesconference.com
Trade Show 2011Trade Show 2011Conference &
17-18 March
Gold Coast
Hyatt Regency Sanctuary Cove, Gold Coast, Queensland, Australia
The Conference will feature two days of presentations, a trade show and live practical demonstrations.
The Conference Dinner is a must!
Give a Presentation, workshop or tutorial
Exhibit your products & services at the trade show
Stage a practical demonstration
Attend the conference & trade show Sponsorship options also available
Speakers Exhibitors Sponsors Delegates
Invitation to Participate
The Composites Australia & CrC-ACS will hold their eighth annual Conference & Trade Show on 17 & 18 March 2011, at the hyatt regency Sanctuary Cove on the Gold Coast in Queensland.
Connection 21
radical new Bolwell Moulded Composite VanAn Australian manufacturer of sports cars and industrial composites launched a radical new moulded composite caravan at this year’s Melbourne Leisurefest in September.
Bolwell RV launched its Edge five metre luxury soft-roader van, featuring fully moulded aerodynamic construction with independent off-road suspension and space-age composite reinforcement.
The van draws on Bolwell’s experience in designing and building sports cars, truck bodies and advanced composites. Famous for its Nagari sports car, Bolwell has also built more than 30,000 truck bodies for Kenworth.
Designer Vaughan Bolwell has drawn on his engineering and aerodynamics experience with sports cars, trucks and racing bicycles to create a robust luxury soft-roader van with low weight, low drag and exceptional aerodynamic stability.
It combines Bolwell’s independent suspension with moulded fibreglass reinforced with carbon fibre and high-tech synthetic fibre for rigidity, impact protection and light weight.
The Edge is designed to tow easily and economically behind medium-sized tow vehicles such as a Subaru Outback.
More information: Owen Bolwell, telephone (03) 8586 5500 or 0417 397 959
Press releases
BEIJING, Sept. 15, 2010 – Owens Corning has announced the semi-finalists for the company’s Composite App Challenge.
The Composite App Challenge invited individuals and teams to submit applications and ideas in four categories intended to help
resolve some of society’s pressing issues – infrastructure durability, fuel efficiency, renewable energy and protection from harm.
The competition offers a $200,000 commercial development award for a composite application that can be introduced by the end of 2012, and a total of $50,000 for four composite application ideas for that effectively address marketplace needs, appear to be technically feasible and have a perceived market opportunity.
Steve Brennan, Sales & Marketing Leader (OCV™ Reinforcements) for Owens Corning Australia Pty Ltd commented, “This world wide contest attracted entrants from 30 countries. I am pleased to advise that 2 Australian companies, including Composites Australia member AC Whalan, have been announced as semi finalists:
•PhilipThicthener,ACWhalan,CarbonandGlassinFilamentWinding (Fuel efficiency – Ideas)
•MichaelGriffiths,AccountableSafeInnovationsP/L,Australia, Safe Systems Poles - (Protection from harm – Ideas)
Semi-finalists have been invited to provide additional information for a second round of review at the end of November. Finalists will be selected and invited to present their concepts to a panel of judges. Winners will be announced in February 2011.
Composites Australia congratulates both Australian winners!
For more about The Composite App Challenge, visit the competition Web site at: www.occompositeappchallenge.com
Composite App Challenge Semi-Finalists includes CA Member AC whalan
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events Schedule 2010-11
The following Composites Australia (CA) events are scheduled for 2010. Please contact Ann Byrne at the CA Secretariat for further details and registration. Don’t forget to check the website for regular updates: www.compositesaustralia.com.au/briefings.htm
This schedule is subject to availability of venues, speakers, resources and equipment and may change from time to time. Composites Australia is not liable for any loss or expenses incurred due to changes in the programme.
Thursday28th october8.30am – 5.00pm
NDE Workshop As a first step in developing awareness of NDE techniques, this one day course will cover methods including applications from glass fibre hand-lay laminates to advanced carbon fibre pre-preg components. It will be delivered by Advanced Technology Testing and Research (ATTAR), an Authorised Qualifying Body and an industry leader in Non-Destructive Testing Limited to 12 participants
MeLBourne ViC ATTAR 134 Springvale Rd, Springvale
wednesday 10th november 9.00am – 5.00pm
Practical WorkshopClosed Moulding Workshop – a guide to lean clean & green moulding. Hands-on practical workshops. Special one-off low price!. Limited to 20 participants.
GoLd CoAST QLdService Rd Stapylton
Thursday 2nd december 9.00am – 5.00pm
Practical WorkshopClosed Moulding Workshop – a guide to lean clean & green moulding. Hands-on practical workshops. Special one-off low price!. Limited to 20 participants.
MeLBourne ViC Victoria University, Newport
Thursday 2nd december 5.00pm – 7.30pm
Composites Australia AGM / Trade Night / Christmas PartyAnnual General Meeting, followed by Trade Night presentation and Christmas party (drinks and BBQ).
MeLBourne ViC Victoria University, Newport
Thursday10th February 2011 5.00pm – 7.30pm
Industry Briefing / Trade NightEngineering with Composites
Sydney nSw SP-High Modulus (Gurit) Mona Vale
Thurs & Fri17 & 18 March 2011
Composites Australia & CRC for Advanced Composite Structures Conference & Trade ShowSee the Conference website at www.compositesconference.com
GoLd CoAST QLd Hyatt Regency Sanctuary Cove
Airtech introduces Beta Prepreg toolingAirtech is proud to introduce its latest development in composite tooling: Beta Prepreg, based on Henkel’s Benzoxazine Resin technology is a unique room temperature storage tooling prepreg, which delivers superior laminate properties to conventional epoxy systems. Beta Prepreg tooling is based on Benzoxazineresin chemistry.
Beta Prepreg systems take advantage of the latest resin and latest toughening technology to provide outstanding ease of use and performance.
Beta Prepreg tooling is stable for a minimum of six months at room temperature. Beta Prepreg has an exceptional low resin shrinkage during cure and develops a very high glass transition temperature, benefiting users with reduced logistical costs, more flexible workshop scheduling and extended tool life.
Features and Benefits:•Exceptionallylongout-lifeallowsvirtuallylimitfreetoolfabrication
time. Customers benefit from increased work crew flexibility and can work around scheduling conflicts. Larger structures are possible with smaller work crews.
•ExcellentpostmachiningqualityofBetaPrepreglaminatesallowsmachining of complex geometry details and maintenance of tight dimensional tolerances. Modifying tool surfaces following engineering change reduces cost of new tool manufacture.
• Theoutstandingtoughness,highglasstransitiontemperatureandstability at high temperature ensure long tool life, reducing the cost of remanufacture and rework through product life.
Contact: [email protected]
Press releases
Connection 23
fgi - the smart choice for compositesWith distribution outlets throughout Australia, New Zealand and Asia fgi offers a complete range of locally stocked composite materials, as well as design and technical solutions.
fgi supplies a huge range of products to the marine industry which includes:
Aquaguard® Gelcoats
Vinyl Ester Resins
Polyester Resins
Epoxy Resins & Adhesives
Carbon, Kevlar® and S-Glass
Stitched E-Glass, Multiaxial
Divinycell® PVC Cores
Vacuum Infusion Materials
Lantor Products
www.fgi.com.au
Bangkok: 66-06-351 6888 Indonesia 62-318-420 391 Vietnam 84-61-383 6503
Cairns 61-7-4035 2126 Townsville 61-7-4728 3085 Brisbane 61-7-3271 3944 Gold Coast 61-7-5563 7771 Sydney 61-2-9938 7222Melbourne 61-3-9550 5650 Adelaide 61-8-8182 0400 Perth 61-8-9256 8400 Auckland 64-9-820 1250 Christchurch 64-3-366 0409
fgi draws upon vast industry experience, in addition to strategic partnerships with our key suppliers.
In partnership with EMP Composites(www.empcomposites.com) we can offer a complete service from PRODUCT DESIGN TO MATERIAL SUPPLY.
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People at Owens Corning have continually used their knowledge of materials to develop new applications and markets for composites. Today, our industry-leading portfolio of specialty reinforcements includes Advantex® boron-free E-CR glass fi bers, Cem-FIL® alkali-resistant glass fi bers, Twintex® co-mingled glass and thermoplastic reinforcements, High-Performance Reinforcements for aerospace and ballistics, TruPave® engineered paving mat and Silentex® material for effective exhaust noise control. These products and others are unlocking new application possibilities for extremely corrosive environments, lighter and stronger solutions, and products that save energy, reduce cost and improve productivity. They are key to expanding the use of composites for years to come.
ocvreinforcements.com
The Intelligence of Specialties
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Accelerating Market Transformation & Growth
Meet us at China Composites, Beiijng, Sept. 15-17, Booth #A502-601China Composites, Beiijng, Sept. 15-17, Booth #A502-601China Composites, Beiijng, Sept. 15-17
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