Innovacion en materiales composites del país vasco edorta larrauri. gaiker-ik4

|1|© 2014 GAIKER Centro Tecnológico

Composite Materials

in Basque Country Science,

Technology & Innovation Network

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Contents

•Introduction to Composite Materials in the Basque Science,

Technology & Innovation Network

•Main Actors & Research Capabilities

•ACTIMAT Strategic Research Project

•Cooperative Applied Research and Contract Research examples

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BASTIN

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RIS3

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Main Actors & ResearchCapabilities

15+ Research Groups225+ Researchers70+ PhD

BASTIN Composite TEAM

http://www.bcmaterials.net/




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MATERIALS•Materials selection•Calculation and design•Development of formulations•Nanomaterials

RECYCLING•Mechanical recycling•Pyrolisys and solvolysis•Life cycle analysis

CHARACTERISATIO

N•Physical and mechanical•Finished surfaces and functionalization•Fire

characterization

PROCESSING•Variables definition•Prototypes and demonstrators•Alternative curing process (UV, MW)

DESIGN & SIMULATION

MATERIALSMANUFACT. PROCESSES

AUTOMATION

PROTOTIPINGV & V

RECYCLING

Inspection & Quality ControlTesting & Characterisation

Lifetime Monitoring

Processing &Manufacturing

Materials

Recycling

2012

RTM

Plasticity and

fracture

CRTM

Damage

(Characterisation,

simulation)

TP-RTM

Forming of

composites

(FML, SRC, TP

composites...)

UV curing applied to

Pultrusion

ATL, FW

Intelligent lightweight

design

Sustainability

Recycling

Ecocomposites

(natural fibres,

renewable resins,

biodegradable…)

http://es.wikipedia.org/wiki/Archivo:Ferrofluid_Magnet_under_glass_edit.jpg


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CHARACTERISATION•Physical and mechanical•Finished surfaces and functionalization•Fire characterization

PROCESSING•Variables definition•Prototypes and demonstrators•Alternative curing process (UV, MW)

Inspection & Quality Control

Testing & Characterisation

Lifetime Monitoring


Materials

Recycling

2012

RTM

Plasticity and fracture

CRTM

Damage (Characterisation, simulation)

TP-RTM

Forming of composites

(FML, SRC, TP composites...)


Pultrusion

ATL, FW

Intelligent lightweight design

Sustainability

Recycling

Ecocomposites

(natural fibres, renewable resins,

biodegradable…)


DESIGN & SIMULATION


AUTOMATION

PROTOTIPINGV & V

RECYCLING




ACTIMAT STRATEGIC

RESEARCH 2002 – 2014

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ACTIMAT EVOLUTION 2002 - 2014

2002 – 2010.- ACTIMAT “Materiales Inteligentes, sensores y actuadores aplicados

a estructuras y procesos inteligentes”.Centrado en smart materials, contempla sus aplicaciones en composites:

Health Monitoring Structures

Amortiguación de vibraciones en estructuras de composite.

Monitorización del curado.

Smart composites.

2010 - 2012.- ACTIMAT “Nuevos Materiales Estratégicos; inteligentes, funcionales

y compounds especiales”. Se eliminan procesos, se abre a todo tipo de materiales estratégicos, Proyecto de Materiales.



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ACTIMAT – Actual – Líneas de actuación

ACTIMAT2013 - 2015

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ACTIMAT – Actual – Resultados

• 2002 - 2010.- ACTIMAT. “Materiales Inteligentes, Sensores y Actuadores aplicados a Estructuras y Procesos Inteligentes”.

2008 - 2010 Participantes: 2002 2004 2005 2007 2008 2010 Total

%

Cumplimi

ento

IND -1 Tesis Publicadas 11 6 20 12 29 22 60 40 66,67

IND-2 Artículos publicados en revistas clasificadas 30 73 66 107 100 130 196 310 158,16

IND-3 Artículos publicados en otras revistas 20 18 34 13 40 22 94 53 56,38

IND-4 Presentaciones en conferencias y Congresos 30 84 66 136 107 126 203 346 170,44

IND-5 Patentes Registradas 12 5 14 11 18,5 13 44,5 29 65,17

IND-6 Acuerdos de colaboración internacionales 19 15 24 30 24 17 67 62 92,54

IND-7 Nº Total esperado de propuestas europeas 32 18 32 18 56,25

IND-8 Investigadores vascos formados (alto nivel) 11 20 11 20 181,82

IND-9 Investigadores vascos formados (tradicional) 40 36 33 21 36 37 109 94 86,24

IND-10 Nº de investigadores internacinales captados 3 2 3 2 66,67

EC-1 Nº esperado de nuevas empresas resultado 3 0 1 0 6 1 10 1 10,00

EC-2 Nº de empresas interesadas 68 51 68 51 75,00

SOC-1 Nº total empleos directos generados en I+D 13 8 11 14 24,5 15 48,5 37 76,29

SOC-2 Nº total otros empleos directos generados 13 0 2 0 11 3,5 26 3,5 13,46

Previsto Realizado

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CONVOCATORIA ETORTEK 2013

2015 2016 2017 2018 2019 20202013 2014

Transporte Energía

Industria de la Ciencia

Salud - Envejecimiento

Construcción

Maquinaria

MetalúrgicoÁrea 1. Desarrollo

de Materiales

Inteligentes

1.1.- Ópticos, electro y magnetoactivos

1.2.- Memoria de Forma

1.3.- Superficies Inteligentes o multifuncionales

Área 2 Desarrollo

de Materiales

Funcionales

2.1.- Composites laminados de altas prestaciones

2.2.- Materiales para condiciones críticas

2.3.- Polímeros renovables

Área 3. Desarrollo

de materiales para

Procesos

Avanzados

3.1.- Materiales con curado y calentamiento alternativo.

3.2.- Materiales electrohilados.

3.3.- Materiales para la industria de la ciencia.

9 líneas y 20 sublíneas


ETORTEK 2013

Sectores ?

? líneas y ? sublíneas

ETORTEK 2015

ETORTEK 2018

SECTORESLIN

EA

S D

E I

NV

ES

TIG

AC

IÓN

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RESEARCH PRIORITIES – ACTIMAT 2013-14

Transporte Energía

Focalización = Hacia sectores donde ACTIMAT tenga mayor valor.

- Mayores capacidades de los socios ACTIMAT- Colaboración

- Impacto industrial


ACTIMAT 201312 líneas y 54 sublíneas

ACTIMAT 2012

1. Las sublíneas para Transporte y Energía• Mayor definición orientada hacia una máxima colaboración.• Definir hasta donde se va a llegar en cada línea.• Tarea horizontal de ensayos singulares. • Mapa de Infraestructuras. Equipamiento especial en común.

2. Nueva gestión para asegurar objetivos 2015• Tarea de Contraste Industrial – Empresas Singulares - GOVA• Poner en valor los resultados de ACTIMAT. Que se aprecie el resultado en el 2015

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Título actual del Proyecto: Desarrollo de Materiales Inteligentes, Materiales Funcionales y Materiales para Procesos Avanzados – ACTIMAT, 2013 – 2014.

Área Línea Sublínea

Área 1

Desarrollo de Materiales

Inteligentes

1.1.- Ópticos, electro y

magnetoactivos

1.1.1.- Materiales con propiedades Quimo y electro-

Ópticas.

1.1.2.- Magnetoreológicos

1.1.3. - Piezoeléctricos y laminados magnetoeléctricos

1.3.- Superficies Inteligentes o

multifuncionales

1.3.2.- Materiales activos en película delgada.

1.3.3.- Recubrimientos funcionales

Área 2

Desarrollo de Materiales

Funcionales

2.1.- Composites laminados de

altas prestaciones

2.1.1.- Desarrollo de composites termoplásticos (TP)

2.1.2.- Caracterización singular de composites.

2.2.- Materiales para condiciones

críticas

2.2.1 Aleaciones especiales para altas temperaturas

2.2.3.- Materiales para unión

2.3.- Polímeros renovables 2.3.1.- Biocomposites

Área 3

Desarrollo de materiales

para Procesos Avanzados

3.1.- Materiales con curado y

calentamiento alternativo.

3.1.1.- Desarrollo de materiales para el curado y

calentamiento con UV y MW

3.2.- Materiales para

electrohilados.3.2.1.- Filtros funcionales

Los materiales composites se identifican actualmente en ACTIMAT en las siguientes líneas:

RESEARCH PRIORITIES ACTIMAT 2013 - 2014

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COMPOSITE RESEARCH – ACTIMAT 2013-14

Desarrollo de composites termoplásticos (TP).Gaiker-IK4, Tecnalia, Univ. Mondragón

Desarrollo de composite laminado a partir de compactación de fibra y velos.

Composites textiles y tapes TP vía fundido, reactiva (ROP) y autoreforzados.

Desarrollo de composites híbridos: mediante la combinación de laminados

termoplásticos laminados fibra/metal (FML).

Caracterización singular de composites.CTA, IK4 – Ikerlan

Caracterización de las prestaciones mecánicas, impacto, adhesión interlaminar

y fuego.

Materiales con curado y calentamiento alternativo. Univ. Mondragón, Gaiker-IK4, IK4-Tekniker

Materiales para curado ultravioleta (UV).

Materiales poliméricos con curado y calentamiento con microondas (MW)

Estudio comparativo de materiales para curado UV y MW

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Expected Impact 2013-2014

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ACTIMAT BUDGET

ACTIMAT 2002 2003 2004 2005 2006

Presupuesto

anual total 1.087.661 € 2.618.031 € 3.050.546 € 2.890.219 € 3.773.961 €

Subvención

concedida total 390.366 € 699.218 € 862.831 € 886.503 € 1.076.159 €

ACTIMAT 2007 2008 2009 2010 Total

Presupuesto anual

total 3.213.513 € 3.788.769 € 4.222.878 € 4.342.670 € 28.988.248 €

Subvención

concedida total 1.035.746 € 755.215 € 543.237 € 587.824 € 6.837.099 €

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| ERAS BK BT 16 VERSALES MINUSCULAS|

R&D PROJECTS - Cooperative Applied Research and Contract Research examples

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Coordina MGEP-MU/GAIKER- IK4/ INCAR/CONDEPOLS/ UPC-CCP/ REPSOL YPF/ UNIVERSITAT JAUME I/LABPLAST/VFUS ARMONÍA/ FPK, S.A/ETSI-UP/ TEAMS/FIDAMC/EASY INDUSTRIAL SOLUTION, S.A/PSA PEUGEOT CITROËN/CTAG/AICIA/GRUPO UNIOVI /SERNAUTO

Objectives:

Reduction of the environmental impact of cars.

Structural lightening based on low cost carbon composites

Safe and comfort

LIGHTCARBONCAR

R&D

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FASE 1Desarrollo de sistemas

de resinas furánicas

FASE 3Desarrollo, caracterización y análisis

del ciclo de vida de los eco-composites

FASE 2Selección y tratamientode fibras y nanofibras

naturales

Sistemas de

Resinas

Furánicas con

Polimerización a

alta temperatura

Sistemas de Resinas

Furánicas con

Polimerización a

temperatura ambiente

Selección del tipo

y formato de fibra

adecuado para el

proceso

de transformación

y las máximas

prestaciones

Desarrollo de

nanofibras

naturales para el

refuerzo de eco-

compoites

VALIDACIÓN DE ECO-COMPOSITES

COMPOSITES FROM RESINS AND REINFORCEMENTS FROM RENEWABLE SOURCES.

Fibras naturales

Fibras de madera

Fibra

virgenFibras

recicladas

- Maderas

duras y blandas

- Fibras de papel

de periódico

-Fibras de pastas

- ……….

Fibras naturales no procedentes de la madera

Paja/Cereal

Fibras de:

- Arroz

-Trigo

- Maíz

-……

Proc. corteza

de plantas

-Kenaf

-Lino

-Yute

-Cáñamo

- ……..

Proc. hojas

-Sisal

-Henequén

-………..

Proc.

Semillas/fruta

-Algodón

-Coco

-………..

Fibras de

hierba

-Fibras de

bambú

- ……..

Fibras naturales

Fibras de madera

Fibra

virgenFibras

recicladas

- Maderas

duras y blandas

- Fibras de papel

de periódico

-Fibras de pastas

- ……….

Fibras naturales no procedentes de la madera

Paja/Cereal

Fibras de:

- Arroz

-Trigo

- Maíz

-……

Proc. corteza

de plantas

-Kenaf

-Lino

-Yute

-Cáñamo

- ……..

Proc. hojas

-Sisal

-Henequén

-………..

Proc.

Semillas/fruta

-Algodón

-Coco

-………..

Fibras de

hierba

-Fibras de

bambú

- ……..

+

Resina Furánica

Desarrollo de Eco-composites

Caracterización de Eco-composites

R&D

3Rs

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IMPROVED INFUSION TECHNIQUE, USING SILICOM BLANKETS INSTEAD OF VACUUM FILM PRESENT, TO

OBTAIN COMPOSITE PARTS FOR RAILWAY

Objectives:

Improve the infusion technique in order to reduce costs due to the manual process and high rejection.

Use silicon blankets instead of vacuum films, so they act as a countermould and it is possible to reuse.

INFUSION TECHNOLOGY FOR PROCESSING OF A TRAIN HEADWALL

INFUSIL

R&D

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DEVELOPMENT OF PREPREG COMPRESSION MOULDING APPLIED TO AIRCRAFT INSIDE PARTS

Objectives:

Achieving repeatability in geometries: curvatures and radii

Improved surface finishing

Process out of autoclave to reduce cycle time

Applying decorative finishes

R&D

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BASF / DEMCON / CENTRO RISERCHE FIAT / LIGHTMOTIF / GAIKER-IK4 / MAIER, S.COOP. / UNIVERSITY OFTWENTE

DEVELOPMENT AND INDUSTRIALIZATION OF HYDROPHOBIC SURFACES NANOCOMPOSITES AND NANOSTRUCTURED MOULDS COMBINED WITH THERMOPLASTICS.

R&D

NANOCLEAN

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Objectives:

Long fiber reinforce polypropylene composite, study of properties

Study of polypropylene core properties

Design and development of structural parts

Validation and test of final parts

R&D

DEVELOPMENT OF PANELS AND PARTS IN COMPOSITE

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MANUFACTURING TECHNOLOGY OF MOLDS FOR RTM AND INFUSION

Objectives:

Analyse the manufacturing process of the molds for RTM and Infusion process, looking for the best finished surfaces, surface tolerance…

Obtain lower quality parts, reduce manufaturing costs, reduce cycle time.

Polymeric matrix mold, moldable high performance

Molds obtained byaluminium casting

Thermoplastic mould,s machinable Molds obtained by electroposition or projection on model

Metal mold, of low meltingpoint for machining

R&D

MOLRTM

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OPTIMIZATION OF THE FORMULATION AND MANUFACTURING PROCESSFOR CLASS A COMPOSITE PARTS, TRANSPORT SECTOR

Objectives:

Improved surface quality of parts manufactured by Compression processes.

Decrease of the rejection

Composite parts manufactured

MATERIALS

R&D

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DEVELOPMENT OF PREPREGS ADAPTED TO THE CONDITIONS OF LOW TEMPERATURE AND PRESSURE MOLDING

Ignifugated prepeg ( M1/F2) Composite moulds

Final part (hide and not hiden face)

Polikea.S.A.

PREPREG

R&D

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NEWCASTLE UNIVERSITY / EADS DEUTSCHLAND GMBH / BOMBARDIER TRANSPORTATION / FLENSBURGER SCHIFFBAU-GESELLSCHAFT MBH & CO. KG /GERMANISCHER LLOYD / ADVANCED COMPOSITES GROUP / AMORIM CORK COMPOSITES / TRANSFURANS CHEMICAL / ANTHONY, PATRICK ANDMURTA EXPORTACAO LDA / APC COMPOSITE / BALANCE TECHNOLOGY CONSULTING / PROPLAST / GAIKER / INSTITUT NATIONAL DES CIENCESAPPLIQUEES DE LYON / SP SVERIGES TEKNISA FORSKNINGSINSTITUT AB / SWEREA SICOMP / VTT TECHNICAL RESERACH CENTRE OF FINLAND

Proyecto FIRE-RESISTVII FP / Large-scale integrating Collaborative Project

PARTNERS

Proyectos Europeos

Desarrollo de novedosos materiales composites

de matriz polimérica de alta tecnología que

establezcan mejoras en el comportamiento al

fuego. El proyecto consta de 5 paquetes de trabajo

relacionados con materiales en el que Gaiker lidera

la temática composites de matriz furánica altamente

carbonizables, amigables con el medioambiente al

ser obtenidos de fuentes naturales.

|PROYECTOS I+D+I|

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NETCOMPOSITES LTD / LAVIOSA CHIMICA MANERARIA SPA / GAIKER / YTRON PROCESS TECHNOLOGY GMBH & CO. KG / SCOTT BADER LTD / IRISVERNICI S.R.L. / APC COMPOSIT AB / DR. TRITZSCH FIRE AND ENVIRONMENT PROTECTION SERVICE / SHEFFIELD HALLAM UNIVERSITY / LEIA / PROCOAT

Proyecto POLYFIREVII FP / Small or medium-scale focused Collaborative Project

PARTNERS

Proyectos Europeos

Desarrollo de técnicas para procesado

de materiales con nanocomposites

retardantes y coatings libres de

halógenos, basado en poliéster insaturado

y nanoarcillas para los sectores de la

construcción, ferroviario y marítimo, donde

el peso y el comportamiento ante el fuego

son factores clave.

|PROYECTOS I+D+I|

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Coordina: ULMA C Y E, S.COOPParticipan: ANGEL RUIZ IBAÑEZ S.A. / ILARDUYA PRODUCTOS DE FUNDICIÓN S.U.L /INSTITUTO DE CIENCIA Y TECNOLOGÍA DE LOS POLÍMEROS

(CSIC)/ GAIKER-IK4 / FIBER PROFIL S.L./LABORATORIO DE QUÍMICA MACROMOLECULAR UPV/EHU

Proyecto ECOPULPROYECTO TRACTOR, Ministerio de Industria , Turismo y Comercio, 2007 - 2008

“Desarrollo de la tecnología de pultrusión de ecoperfiles para construcción basados en materias primas provenientes de fuentes renovables “

SOCIOS

|PROYECTOS I+D+I|

Diseño de formulaciones novedosas en base resinas furánicas, mejoradas con refuerzos naturales con el fin de cumplir con las especificaciones técnicas de los componentes a fabricar mediante el proceso de pultrusión,

para el sector de la construcción.

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Proyecto EURECOMPPROYECTO EUROPEO

Desarrollo de un proceso de solvólisis como solución viable para el reciclado

y la reutilización de materiales compuestos en aplicaciones de sistemas de transporte

de superficie.

BPF (BRITISH PLASTIC FEDERATION) / ECRC / GAIKER-IK4 / ICAM NANTES / MIXT / COMPOSITES RECYCLABLES / OMNIUM AUTO EXTERIOR / SACMO / UNIVERSITÉ D’EXETER / UNIVERSITÉ DE BRISTOL / UNIVERSITÉ DE LIMERICK / URIARTE SAFYBOXVOLVO TECHNOLOGY CORPORATION / XIETONG AUTOMOBILE ACCESSORY

SOCIOS

|PROYECTOS I+D+I|

RTM

32

Compression RTM

Thermoplastic RTM

High temperature RTM

Fibre Metal Laminates (FML)

33

34

Staübli TX60

Pultrusion + UV curing + Robot

Crash_Can_Simu.avi

Crash_Can_Simu.avi

Carsh_Can_Experim.MPG


Pultruv.mp4-.mp4

Pultruv.mp4-.mp4

617.avi

617.avi

Improvement of large structural parts manufacturing, by operations automation:

Manufacturing automation

AUTOMATED IMPREGNATION

In-situ impregnation before lay-up

UV CURING

From hours to seconds


DRY GLASS FIBER IMPREGNATED AND CURED COMPOSITE

IMPREGNATING DEVICE CURING ANDCOMPACTION DEVICE

Traditional approach:External chip/dust extraction

systems

ASPIRATE approach:Internal chip/dust extraction

systems

Chip – dust extraction machining


“'High productivity manufacturing process of compositeparts based on zero emissions fast curing coatings andheated moulds”

(Contract : FOF-NMP-2013-10-609203)

The Ecogel Cronos project will look to develop an innovative ecologicalcoating for composites parts in order to help eliminate styrene emissions fromthe workplace. The concept is to establish a powder gel coat suitable for usein the Resin-Transfer Moulding (RTM) process. The project will develop:

• Fast curing “zero Volatile Organic Compounds (VOCs) emissions” via thedevelopment of new powder gel coats.• Electrically conductive hot-skin-mould technologies based on laminates ofcarbon fibre suitable for powder coating process.

Two automotive case studies will be used to demonstrate the advantages ofthe new technologies developed in the project. In addition, a fully automatedprocess will be proposed to drastically improve the current production speed.

Thermoplastic Nanocomposites: Nanoparticles functionalization allows to create tailoredproperties to be applied in polymer nanocomposites with added value technical futures.

Fire retardant nanocomposites

Graphene based nanocomposites: mechanical and gas barrier

properties.

SYNTHESIS AND FUNCTIONALIZATION OF

NANOMATERIALS

400nm

Functionalized NpHO-Np:

TiO2, SiO2, ZrO2,CeO2, Diamond, Graphene

R-Si-X3R-Si-O-

•COMPOUNDING

•INJECTION

MOULDING

APPLICATIONS

Low friction and wearnanocomposites

AUTOMOTIVE INDUSTRY

Anti-scratch propertiesPrivate projects:•NANO4CAR-Basque Government funding.•AUTONANO- National Government

funding.

TECNALIA- Composites- Representative projects

Basque Country

• INDUSTRIAL programmes:

• AEROSPACE: ATEA-AERO- New generation of landing gear doors for future single aisleaircrafts. Industrial Leader: Fibertecnic (Aernnova Group)

• RAILWAY: ESTAVRIL- New Generation of Lightweight Composite Coaches for High SpeedTrains. Industrial Leader: Talgo

• AUTOMOTIVE: Superlightweight components with hybrid structures for zero emmisionsfuture cars.

• ETORTEK programme- ACTIMAT. Enabling technologies development

European FP7 Programme - Spanish leader for Participation as partner in Clean Sky and other FundingProgrammes.Extensive list of representative projects for composite development in Transport, NMP, FoF, Space and Clean Sky programmes, in collaboration with OEMs, Tier 1, Tier 2, raw material providers, etc…

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gracias

thank youmerci

eskerrik asko

gracias

thank you

eskerrik askoeskerrik asko

gracias

grazie

danke

evgaristó

spaisívaarigatoShokrán

cám òn qúi vi rhât

Xié Xie

bedankt

moltes gràcies

khrap

go raibh maith agaibh

matu suksama

ありがとうございます

谢谢 شكرا

Parque Tecnológico de Bizkaia, Edificio 20248170 Zamudio | Bizkaia | Spain

T. 0034 94 [email protected] | www.gaiker.es

Edorta LarrauriDirector Adjunto

e-mail : [email protected]

mailto:[email protected]


Annex: Individual Contributions

• GAIKER-ik4• TECNALIA Research & Innovation• IK4 Research Alliance• MU – MGEP• POLYMAT


GAIKER TECHNOLOGICAL COMPETENCES

PLASTICS AND COMPOSITE MATERIALS13|05|2014,

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Composite technology



CHARACTERISATION•Physical and mechanical•Finished surfaces and functionalization•Fire characterization

PROCESSING

•Variables definition•Prototypes and demonstrators•Alternative curing process (UV, MW)



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MATERIALS : HALOGEN FREE MATERIALS IGNIFUGATION

EXPERTISE

Development of formulations: thermoplastics and thermoset resins systems

Development of new lightweight polymers from natural sources, to achieve astep beyond the start of the art in fire behavior for transport industry

processing development (at industrial scale) of fire retardant composites andhalogen free coats, based on polyester and nanoparticles.

Fire characterization, according to construction, rail and maritime sectorsregulations

POLYFIRE (EU): PROCESSING AND UPSCALING OF FIRE-RESISTANT NANO-FILLED THERMOSETTING POLYESTER RESINS.FIRE RESIST (EU). DEVELOPING NOVEL FIRE-RESISTANT HIGH PERFORMANCE COMPOSITES

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STRUCTURAL AND LIGHTWEIGHT MATERIALS DEVELOPMENT.

EXPERTISE:

•Lightweight: •Thermoset Prepreg formulation and transformation. •Thermoplastic composite•Prototypes fabrication with vacuum and infusion•Sandwich thermoset and thermoplastic structures development•Physical and mechanical characterization

LIGHTCARBONCARS (AGE): REDUCCIÓN DEL IMPACTO AMBIENTAL DE AUTOMOVILES MEDIANTE EL ALIGERAMIENTO

ESTRUCTURAL BASADO EN COMPOSITES DE CARBONO DE BAJO COSTE, SIN COMPROMETER LA SEGURIDAD Y ELCONFORT

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PROJECTS

POLYFIRE (EU): PROCESSING AND UPSCALING OF FIRE-RESISTANT NANO-FILLED THERMOSETTING POLYESTER RESINS.FIRE RESIST (EU). DEVELOPING NOVEL FIRE-RESISTANT HIGH PERFORMANCE COMPOSITES

COMPOSITE PROCESSING

•Hand lay up

•Projection

•RTM

•Vacuum molding/Infusion

•Filament winding

•Pultrussion

•SMC/BMC

•Compression

•Resin Transfer Molding

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INFUSION AND RTM

Mould filling simulationDevelopments of formulations with polyester resins, phenolics, furane, vinylester and epoxy.Processing variables optimizationPrototypes and demonstrators fabrication

Expertise



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MANUFACTURING: SMC AND PREPREG

•SMC: A class polyester, good fire behavior, Phenolics,Furane, Vinylester, carbon fiber…•Prepregging : Vacuum and/or compression

Expertise



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FILAMENT WINDING AND PULTRUSSION

EXPERTISE:•Numeric control program definition•Formulations: polyester resins, phenolics,furane, epoxy, vinylester. Glass and carbonreinforcements•Prototypes fabrication•Hydrostatic tests

•Fire retardant formulations•Thermoplastic profiles•Ecoprofiles



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THERMOPLASTIC COMPOSITES COMPRESSION

Expertise:

•Moulding consitions definiton•PP and glass fiber compression•Themoplastic tapes moulding•Vaccum moulding

ADAPTA (CENIT): TECNOLOGIAS DE FUNCIONES DE SISTEMAS DE PROTECCION INTEGRALES, INTELIGENTES YADAPTATIVOS

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ALTERNATIVE CURING EQUIPMENT.

•Promotes composites curing process with microwaves, with higher mechanical properties due to the homogenous heating

Energetic costs reduction against current technologies (autoclave) and processing costs

HORNO MICROONDAS HEPHAISTOS VHM100/100 (VOTSCH)

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TESTING: ANALYSIS OF PROPERTIES

PROPERTIES TECHNIQUES

Physical and mechanicaltests

Universal tool. Traction, compression (10 T), flexion (14 T)Universal tests tool 5 KN, 500N y 50 NServo hydraulic equipment for dynamic tests (10 T)FatigueTraction impact: Charpy. IzodBarcol durometer - Shore A , D durometer.ColorimeterBrightmeterAcoustic emission equipmentKarl – Fischer automatic valuatorErischen testerPendulum Persoz y KöningCoat characterization: Impact, dry time, flexibility.

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Fire equipment Automotive material combustibility chamber Flammability tests (Inflamabilidad (horizontal and vertical)Oxigen indexEpiradiatorElectric burnerRadiant panelDrippingFlame propagation velocityCalibratorsNBS chamberSmoke combustion analisysTubular owenM0 equipmentLittle burnerSBIPump calorimeterFloor radiant panelCalorimetric cone

|55|


High speed ageing Xenotest 150 SATLAS Ci 3000Intemperimeter: Panel QUVConditioning chamberTABER abrasion

Espectroscopyanalysis

Fourier transform Infrared spectroscopy (FTIR)Near Infrared spectroscopy (NIR)UV-VIS spectroscopy

Microscopictechniques

Optical microscopy and microphotographyPicture analizerAFMSEMTEM

Electrical testing Lowe and high resitances, Transversal resistivity and surfacesresistivity, conductivity.


|56|

COMPONENT DESIGN

• Computer assist design (CAD

2D/3D). NX Program

Statical Structural calculation of

pieces by finite elements (FEM).

ANSYS® Program

• Infusion processing simulation.

Polyworx Program

|57|

JOINING TECHNOLOGIES

Expertise:

•Adhesivated union with epoxi,polyurethane resins, etc.•Pulyurethane and polyolefine hot-melt•Thermoplastic films and hot-melt films•Test and characterization

|58|

MECHANICAL RECYCLING OF COMPOSITES

Expertise

Conditioning and characterisation of waste composites

Separation and sorting of fibres and other valuable fractions

from waste composites by means of physical separation

operations

Development of innovative applications for including material

fractions derived from waste composites treatment

Projects

COMPOECO (BFA/DFB): Desarrollo de tecnología para el

reciclado de residuos de composites y concentrados de fibras

en elementos constructivos reforzados

Contracted Project: De-pollution, dismantling and recycling of

boats

Contracted Project: Turbine blade recycling and LCA

Contracted Project: Automotive roof trim panels scrap recycling

Contracted Project: Recycling of printed circuit boards

|59|

CHEMICAL RECYCLING OF COMPOSITES

Expertise

Chemical treatment of waste composites: novel solvolysis

approaches for composite recycling and fibre liberation

Thermal treatment of composites: pyrolysis of waste

composites and selective recovery of fibres

Projects

EURECOMP (EU): Recycling Thermoset Composites of the

Sustainable Surface Transport

COMPOECO (BFA/DFB): Desarrollo de tecnología para el

reciclado de residuos de composites y concentrados de

fibras en elementos constructivos reforzados

PROQUIPOL (AGE): Development of sustainable chemical

processes for the conversion in resources of waste

polymeric streams

|60|

ENVIRONMENTAL ASSESSMENT OF COMPOSITES

Expertise

Life Cycle Assessment (LCA) of composites and composite

containing parts, assemblies and products

Discrimination of waste management alternatives and

recyclability potential for composites and composite

containing products at their end of life phase

Simulation for modelling environmental aspects of

conventional waste treatment alternatives (landfill,

incineration, energy recovery...) to enable easy comparison

towards arising end of life technologies

Projects

EURECOMP (EU): Recycling Thermoset Composites of the

Sustainable Surface Transport

Contracted Project: Comparative LCA of the substitution of

mineral fiber reinforcement in composites by natural fibers

Contracted Project: Turbine blade recycling and LCA

|61|

DEVELOPMENT OF MATERIALS

Thermoset resins systems: reformulation and aditivation, of epoxy, phenolics, vinilester, …

Nano-structued composites: Addition, dispersion and functionalization of nanoparticles, nanofibres….

EcoComposites. Natural resins and fibers Prepregs Alternative curing systems: Microwaves Adhesives: Aditivation of nanofibers, nanoparticles, microfibers, microparticles … Conductive polymers: tiophene, polypirol… Sandwich panels Fiber metal laminates (FML)

THERMOSET MATERIALS

|62|

INFUSION

RTM

PREPREG

THERMOSET MATERIALS PROCESSES

|63|

MOLDING PREPREG

PULTRUSION

THERMOSET PROCESSES

|64|

FILAMENT

WINDING

MICROWAVE

CURING

THERMOSET PROCESSES

|65|

SANDWICH STRUCTURES

THERMOSET PROCESSES

|66|

THERMOPLASTICS

COMPOUNDING

Commodities (Poliolefines, PVC, styrenic,…) Engineering plastics (PC, PA, POM, PBT, …) Biopolymers and biodegradables (PLA, PHb,…)

Properties: Mechanical Thermal properties Antibacterial Anti scratch Self cleaning Conductivity Antimicrobial Antioxidant Fire Proofing …

|67|

PROCESSES

THERMOPLASTIC MATERIALS PROCESSES

Injection (conventional y bi–injection) Mini/Micro-injection Thermoforming/IMD Extrusion Compression Vacuum molding Multilayer Laminates

Wood plastics

|68|

COATINGS

COATINGS Formulation

Anti scratching Self healing Hydrophobic Antimicrobial Antifouling Self cleaning

Finishes Textures Decorative Characterization

|69|

PROCESSES FOR COATINGS

Manual

Application

Automated

Application

Rotary

koater

|70|

COMPONENTS DESIGN

CAD 2D – 3D NX, Ideas… Design and development Thermal simulation analysis

CALCULATION & DESIGN

Calculation

3D Prototype

Functionalprototype

|71|

IDENTIFICATION AND CHARACTERIZATION OF MATERIALS

Identification (Spectroscopy IR, UV, chromatography…)

Mechanical properties

Rheological properties

Thermal properties (DSC, TGA, …)

Physical properties (density, hardness, color,.. )

Barrier properties

Fire retardancy

Electrical conductivity

Contact angle

Thermography

BPL

CHARACTERIZATION AND TESTTING

|72|

MICROSCOPY LABORATORY

Optical x10 – x400 from 1 micron

SEM, EDX, 800 nm

TEM, EDAX, tomography 0.24 nm

Confocal

AFM

Ultracryomicrotome

CHARACTERIZATION AND TEST

|73|

| BIOTECNOLOGIA|MATERIALS RECYCLING

|74|

MECANICAL RECYCLING

Waste characterization

Separation and classification

Development of products with recycled materials

CHEMICAL RECYCLING

Chemical treatment. Solvolisis

Thermal treatment. Pyrolisis

EVALUATION IOF ENVIROMENTAL IMPACTS

Life cycle analysis(LCA)

Alternatives selection and simulation

COMPOSITES RECYCLING

TECNALIA

Composites

Technologies

Industry &

Transport Division

Content

• Our offer

• Capabilities & Equipment

• R&D lines

• Representative projects

TECNALIA- INSPIRING BUSINESS

• R&D Projects

• Technological Services (Tests, Failure Analysis,

Quality Audits, etc.)

• Engineering and Re-Engineering of Products

and Processes

• Technology & Innovation Strategy

(Benchmarking, Technology and Market Trends,

Road mapping, etc.)

• Commercial exploitation of technology

developed by Tecnalia and its partners in the form

of IP, know-how or generation of new technology

based companies

Services and Business Models for Composites

TECNALIA AIMS AT IDENTIFYING AND DEVELOPING BUSINESS OPPORTUNITIES

TECNALIA- Composites- Our offer

DESIGN & SIMULATION


AUTOMATION

PROTOTIPINGV & V

RECYCLING

Competences throughout the whole value-chain

• For Manufacturing: Plastics and Organic Composites Pilot Plant &

Composites/ Adhesives Labs. Main processes:

• For Design/analysis/simulation: Generic and Specific Software for

composites structural analysis and process simulations. Commercial &

Propietary code.

• For Materials characterization: Extensive equipment for mechanical, thermal,

physical, electrical, morphological, etc. characterization.

TECNALIA- Composites- Capabilities & Equipment

• Clean Room• Autoclave & ovens• Various preforming• RTM/infusion• Short fibre: extrusion, injection• Hot forming

• Presses• Hot bonding• Thermoforming• Nanocomposites (Calender, Dispermat, US,

etc)• …….

TECNALIA- Composites- R&D lines

Industrial Sectors Covered

• Main focus: Transport- Aerospace, Automotive, Railway

• Others: Eolic, Building, Sports, Industrial…

Our Main drivers

• Costs reduction across the whole product life-cycle, and specially manufacturing costs reduction. Automation

• Eco-efficiency: Lightweight Structures, Energy Efficiency, Reciclability…

• Improved performance & multifunctionality

• Productivity & quality

• …

1. Advanced materials & structures:

• New Out-of-Autoclave materials & fast curing systems

• Advanced integrated structures

• Multifunctional materials/structures:

Polymer matrix modifications (nanotechnologies & active agents

encapsulation)- Thermoplastics & Thermosets.

Development of nano-enabled products: buckypapers, veils, etc.

Surface treatments, functionalizations & coatings


(a) CNT buckypaper, (b) prototype of structure with

integrated buckypaper for aircraft anti-ice solutions

(d) ice tunnel testing

Lightweight high thermal

dissipation composite electronic

box for onboard high power

density electronics

Dry carbon fibre preform - T-

shape stringers stiffened skin

for aircraft fuselage

Clean Sky Project

(a) (b)

(c)

2. Manufacturing Technologies. Main focus: Out-of-Autoclave

• Industrialization and optimization of thermoset moulding processes Preforming & moulding automation Alternative fast & efficient heating, curing and compaction Modelling, monitoring & control of mould filling and curing

• Thermoplastic RTM: In-situ polimerization of PA

• Process automation


Automated preforming cell-

Tecnalia´s propietary technologyThermosplastic RTM-Tecnalia´spropietary technology

Instrumented Liquid Composite Moulding set-up

3. Other Manufacturing Processes

• Machining, drilling, trimming : Tool optimization, adaptive control, new coolingsystems, AWJ, process monitoring

• NDT: Ultrasonics (guided lamb waves, new transducers, modelling, new methodsdevelopment), fiber optics

• Repair technologies


Technological competences

Plastic & composites materials


Testing & Characterisation

Lifetime Monitoring


Materials

Recycling

Design

Composite Technologies

Materials expertise

• FORMULATION

• SMART MATERIALS

• NANOMATERIALS

• FIBER/MATRIX INTERPHASE

• BIOMATERIALS

• PLASTIC ELECTRONICS

TECHNIQUES

APPLICATIONS

FORMULATION

FIBER-MATRIX INTERPHASE

SMART MATERIALS

NANOMATERIALS

BIOMATERIALS

PLASTIC ELECTRONICS

Materials expertise

►FORMULATION

DEVELOPMENT OF FORMULATIONSThermoplastics and thermoset resins systems, lightweight and with high properties

• Halogen free materials ignifugation

• Development of high mechanical properties composites

• Development of new lightweight polymers from natural sources, to achieve a step beyondthe start of the art in fire behavior for transport industry

• Development of SMC and BMC, “A” class surface.

• Tailored synthesis and modification of thermoset resins

• Tailored synthesis and modification of elastomers and rubbers to develop self-healingsealants and adhesives

Materials expertise

► SMART MATERIALS

DEVELOPMENT OF MATERIALS FOR COMFORT AND PASSIVE AND ACTIVE SECURITYIMPROVEMENT

• High impact absorption materials• Shape memory polymers and smart materials• Thermal and acoustical insulation materials development. Noise and vibrations absorption:

magnetoreologic materials• Piezoelectric materials• Chrome active material• Conductive materials• Thermochromic filaments development, phosphorescents, conductives, antifouling

MAGNETOREOLOGIC MATERIALS• Magnetoreologic (MRF) and ferrofluids formulations development• Micro and nanopartIcles• Reological characterization• Stability and Fatigue

Materials expertise

► NANOMATERIALS

SYNTHESIS OF NANOADDITIVESSynthesis and characterization of nanoparticles (metallic, ceramic and carbonaceous) obtained byseveral techniques (pyrolysis, sol-gel,...)

ADDITION, DISPERSION AND FUNCTIONALIZATION OF NANO-ADDITIVESBy means of different techniques: surface activation using acids and sonication, surfactants,generating free radicals on the CNT surface for improving composite properties, moisture uptake,mechanical properties, fire resistant properties, scratch resistance, low friction coefficient, …

POLYMER MATRIX COMPOSITESNanocomposites via incorporation of inorganic and organic nanoparticles as well as bio-derived fibrereinforcements to various thermoplastic and thermosetting systems.

POLYMERIC IONIC LIQUIDS (PILs)PILs retain the intrinsic properties of ionic liquids such as ionic conductivity, thermal and chemical stability while offering very good solubility and processing properties. These characteristics make PILs interesting materials for applications such as solar cells, lithium batteries, supercapacitors, nanocomposites and lubricants.

Materials expertise

► FIBER/MATRIX INTERPHASE

SURFACE TREATMENTSOf natural or synthetic fibers by chemical methods (esterification, alkylation, delignification,…) or sol-

gel technologies in order to enhance matrix/fiber interaction and achieve homogeneousdispersions in polymers. Characterization of fiber morphology and behavior after the treatment byseveral techniques (TGA, SEM, AFM, MO, contact angle, surface analysis (BET),…)

CONDITIONS OPTIMIZATIONFor applying in surface treatment of fibers and in sol-gel technologies (time, concentration,

temperature, reactives and precursors, pH)

Materials expertise

► BIOMATERIALS (I)

BIOCOMPOSITESDevelopment of new resins by changing reactives ratio, replacing reactives by bio resins. Total orpartial replacement of conventional epoxy resins by epoxidized vegetal oils o ester derivates.Optimization of the resin component ratio as a function of final properties (mechanical, thermal…).Characterization of final composites.

SURFACE TREATMENT OF BIOCOMPOSITESModification of the surface of composites by sol-gel technology to obtain surfaces with newfunctionalities: high environmental protection (UV, humidity,…), self-cleaning surfaces, combinationlow surface energy coating with nanoppaterning techniques to enhance the superhidrophobicity ofsurfaces, self-healing coatings…

IMPROVEMENT OF SOL-GEL COATINGBy the use of organic additives obtained from renewable raw or reaction by products

MODIFICATION, INCLUSION & DISPERSION OF NANOADDITIVESNanoclay, nanotube, nanofibers, etc. For the enhancement of final properties (mechanical, thermal, humidity and environmental resistance, gas permeability….)

Materials expertise

► BIOMATERIALS (II)

BIOPOLYMERSSynthesis of a wide variety of tailor made biocompatible polymers, as well as strong experience in the modification and functionalization of readily available biopolymers for biomedical applications. Biopolymer processing and characterization

SYNTHESIS & BIOFUNCTIONALISATION OF POLYMER NANOPARTICLES (NPS)Synthesis of well defined polymer NPs with sizes in the range of 2-15 nm. These polymer NPs can be further functionalized by very simple chemical methods to achieve the desired functionality.

SUPRAMOLECULAR HYDROGELSSupramolecular (or low-molecular weight, LMW) metallophilic hydrogels designed to mimic naturally occurring soft materials, allowing the fabrication of new tailored made hydrogels with potential application as drug delivery vehicles, tissue engineering scaffolds or biolubricants.

Materials expertise

► PLASTIC ELECTRONICS

ELECTROCHEMICAL SENSORSTaylor-made design of polymers to be applied in the manufacturing of biosensors. Low-cost and disposable biosensor technology for pesticides , heavy metals, and poliphenols detection.

PRESSURE SENSORSConducting polymers based pressure sensor technology by printing conductive polymers on flexible plastic films.

ELECTROCHROMIC DEVICESNew conducting polymers in order to get devices with outstanding electrochromic properties such as switching time, stability, coloration efficiency or wide range of colors.

THERMOCHROMIC DEVICESDevelopment of thermochromic films based on cholesteric liquid crystals mixtures with a high-precision color change within a broad range of temperatures.

Materials expertise

Manufacturing techniques

Long fiber:•RTM•VMI•Prepregging•Pultrussion•Compression•Thermoconforming

•FW

Chopper fiber:•Projection•Hand Lay up•SMC/BMC•Thermoplastic injection•Extrusion

Customized processes:•Processes automation •New processes for singular requirements•Structural and light weight materials development

Finishing

•Machining•Aesthetical and functional finished surfaces

Curing

•Microwave•UV•US aided

Mounting and assembling

•Mechanical joints•Bonded joints•Welding

Processing & Manufacturing expertise

INFUSION & RTM

• Mould filling simulation

• Developments of formulations with polyester resins, phenolics, furane,

vinylester and epoxy .

• Processing variables optimization

• Prototypes and demonstrators fabrication

► MANUFACTURING: LONG FIBER (I)

SMC & PREPREGGING

• SMC: A class polyester, good fire behavior, Phenolics, Furane, Vinylester,

carbon fiber…

• Prepregging : Vacuum and/or compression


FILAMENT WINDING & PULTRUSSION• Numeric control program definition• Formulations: polyester resins, phenolics, furane, epoxy, vinylester. Glass and carbon

reinforcements• Prototypes fabrication• Hydrostatic tests • Fire retardant formulations• Thermoplastic profiles• Ecoprofiles

THERMOPLASTIC COMPOSITES COMPRESSION• Moulding consitions definiton• PP and glass fiber compression• Themoplastic tapes moulding• Vaccum moulding

► MANUFACTURING: LONG FIBER (II)


► MANUFACTURING: CHOPPED FIBER

PROJECTION

•…….

THERMOPLASTIC INJECTION

•…….

EXTRUSION

•…….


► MANUFACTURING: CUSTOMIZED PROCESSES

AUTOMATED MANUFACTURING

• New tools and machines to improve the composites manufacturing processes

NEW PROCESSES FOR SINGULAR REQUIREMENTS

• Combining/Varying processes in order to generate:

Desired fiber orientation

Desired fiber volume

• Process development to achieve design requirements

STRUCTURAL AND LIGHTWEIGHT MATERIALS DEVELOPMENT

• Skins and cores development : natural cores, polyurethane, PVC.

• Join techniques: adhesives, thermal join.

• Sandwiches structures: different combinations of skins and cores (metal, wood,

thermopplastic, thermoset)


MACHINING

• Conventional machining processes: drilling, turning, milling, grinding, punching and

trimming.

• New technologies such as laser , US and chemical processes.

• Internal chip extraction technology. This technology allows the complete extraction of

the dust generated during composites machining, providing significant benefits for the

machine elements, machine operator and part quality.

► FINISHING (I)


AESTHETICAL AND FUNCTIONAL FINISHED SURFACES

• Electrodeposition of metals on insulating substrates, (polymers, ceramics, etc.) avoiding

the use of chromium salts

• Electophoretic deposition of polymer coatings, depositing polymers and hybrid

compounds (organic-inorganic compounds) for improving protection characteristics.

• Metal matrix composite coatings, codeposition of polymers (e.g. Teflon) on a metallic

matrix generated by electroless or electrolytic deposition, in order to improve

tribological properties

• Nanoparticles modified coats (Titanium oxide), coat and processing developments to

achieve self cleaning surfaces, self repairing and antiscratching (plastics and coatings)

► FINISHING (II)


CURE KINETIC ANALYSIS

On-line monitoring during the process

CURING PROCESS BY MICROWAVES

With higher mechanical properties due to homogenous heating and energetic costs reduction

UV CURING PROCESS

US AIDED CURING

CURE MONITORING

• Cure kinetic analysis on line monitoring

• Sensor development for industrial applications, mainly machinery Health Monitoring.

Expertise in optical and magnetic sensor systems

• Proper Sensing system to different materials and processes :

− Pultrussion: Ultrasounds− Moulding: Fibre based NIR sensing in a riser or sprue− Spray: Magnetoelastic materials & pzt-s (ultrasound)

► CURING


MECHANICAL JOINTS− Mechanical joints design based on bolted joints with inserts, linkages, …

BONDING− Adhesive joint with epoxi, polyurethane resins, etc.− Hybrid epoxy/polyurethane adhesives with combined properties− Pulyurethane and polyolefine hot-melt− Thermoplastic films and hot-melt films− Development of new formulations for polymeric adhesives or improvement of commercial

adhesives by the inclusion of nanoadditives− Self-healing PU and silicone sealants and adhesives− Analysis of the cure kinetic of the adhesive, dynamic-mechanical properties− Laser surface texturing for improve adhesive bounding of plastic components− Self-developed FEM tool for adhesive joints simulation embeebed in MSC/Patran-Nastran− Development of bonded structures (machine tools made of bonded joints)

WELDING− Development of a laser system for plastic welding (Polycarbonate, Polysulfone,

Polyethersulfone)− Optic design, beam shaping and fiber coupling for several applications, including laser micro

and macro welding of thermoplastics− Design and manufacturing of laser workstations for plastic laser welding and thermal

treatments− Laser Plastic Welding process. Effect of laser beam energy on surface integrity

► MOUNTING AND ASSEMBLING


MATERIALS DESIGNSelection of materials depending on required properties for final composite application.

COMPONENT DESIGN• CAD 2D – 3D NX Program, Ideas, SolidWorks, ProEngineer.• Design and development taking into account:

− Design based on simulation of the component (FEA: MSC/Patran, MSC/Nastran, Ls-Dyna,Ansys, Ideas)+ Laminate materials+ Orthotropic and anisotropic materials+ Joint simulation: bolted, bonded, …

− Manufacturing processes simulation with Polyworx Program, PAM-RTM,+ infusion,+ resin injection

− Correlating model with test− Validating models with test− Ecodesign (LCA)

• Development ability based on: geometrical design & requirements (mechanical, thermal,tribologycal, …) & process -> component-material-process definition as a whole

Design expertise


Physical and mechanicaltests

Universal tool. Traction, compression (10 T), flexion (14 T)Universal tests tool 150 KN, 5 KN, 500N y 50 NServo hydraulic equipment for dynamic tests (10 T)FatigueTraction impact: Charpy. IzodBarcol durometer - Shore A , D durometer.ColorimeterBrightmeterAcoustic emission equipmentKarl – Fischer automatic valuatorErischen testerPendulum Persoz y KöningCoat characterization: Impact, dry time, flexibility.

Testing & Characterisation expertise


Packing and packaging tests

MicrometerEclatometerRigidimeterSKYE Thermoseller

Thermal and reologictests

DSCDMAHumidity tester Karl – FisherBrooffield ViscosimeterCANON-FENSKE ViscosimeterMelt - Flow. Vicat point/ HDTReometer with melt chamber and extruderSoxhlet extractionGel timerMinilab microcompounderTGAThermal diffusivity analysis



Fire equipment Automotive material combustibility chamber Flammability tests (horizontal and vertical)Oxigen indexEpiradiatorElectric burnerRadiant panelDrippingFlame propagation velocityCalibratorsNBS chamberSmoke combustion analisysTubular owenM0 equipmentLittle burnerSBIPump calorimeterFloor radiant panelCalorimetric cone



High speed ageing Xenotest 150 SATLAS Ci 3000Intemperimeter: Panel QUVConditioning chamberTABER abrasion

Espectroscopyanalysis

Fourier transform Infrared spectroscopy (FTIR)Near Infrared spectroscopy (NIR)UV-VIS spectroscopy

Microscopictechniques

Optical microscopy and microphotographyPicture analizerAFMSEMTEM

Electrical testing Lowe and high resitances, Transversal resistivity and surfacesresistivity, conductivity.


INSPECTION

• Finished parts inspection to detect internal defects in composite materials (delamination,irregularities, holes or lacking of resin) by means of non destructive testing: acoustic emission,ultrasonics and active thermography.


WIRELESS SENSOR NETWORKS• Unattended networks: design, development, deployment of proppietary protocols including

smart tools for monitoring and configuring networks.

ENHANCED CAPABILITIES ON TOP OF WSN• Improving robustness, latency, reconfiguration, self-healing, life-time, location, agents.

POWER EFFICIENCY• Power harvesting, power generators, power aware design, dynamic power scaling, ultra low

power design (perpetual units)

SENSORS• Signal conditioning and processing. Connectivity

STRUCTURAL MONITORING BY OPTIC FIBER• Fiber Bragg grating

Lifetime monitoring expertise

MECHANICAL

• Conditioning and characterisation of waste composites

• Separation and sorting of fibres and other valuable fractions from waste composites by means ofphysical separation operations

• Development of innovative applications for including material fractions derived from wastecomposites treatment

CHEMICAL

• Chemical treatment of waste composites: novel solvolysis approaches for composite recycling andfibre liberation

• Thermal treatment of composites: pyrolysis of waste composites and selective recovery of fibres

Recycling expertise

ENVIRONMENTAL ASSESSMENT OF COMPOSITES

• Life Cycle Assessment (LCA) of composites and composite containing parts, assemblies andproducts

• Discrimination of waste management alternatives and recyclability potential for composites andcomposite containing products at their end of life phase

• Simulation for modeling environmental aspects of conventional waste treatment alternatives(landfill, incineration, energy recovery...) to enable easy comparison towards arising end of lifetechnologies

Recycling expertise

EXPERTISEProcess set-up (experimental and simulation) and prototypes

manufactured by RTM, Forming, Pultrusion

Lightweight (stiffness and strength) and safe (impact and

fatigue) design based on FEM and materials characterisation

Multidisciplinary group 3 Dr (2 engineers + 1 chemist)

2 Engineers

8 PhD students

~ 5/7 Undergraduate students

Jon Aurrekoetxea [email protected]

Grupo de Investigación acreditado por

la Viceconsejería de Universidades e

Investigación del G.V.

http://www.mondragon.edu/es/eps/actualidad/noticias/presentacion-del-vehiculo-electrico-de-mondragon/image/image_view_fullscreen

http://www.mondragon.edu/es/eps/actualidad/noticias/presentacion-del-vehiculo-electrico-de-mondragon/image/image_view_fullscreen

RESEARCH PRIORITIES

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2012

RTM

Plasticity and

fracture

CRTM

Damage

(Characterisation,

simulation)

TP-RTM

Forming of

composites

(FML, SRC, TP

composites...)


Pultrusion

ATL, FW

Intelligent lightweight

design

Sustainability

Recycling

Ecocomposites

(natural fibres,

renewable resins,

biodegradable…)

115

RTMCompression RTM

Thermoplastic RTM

High temperature RTM

Fibre Metal Laminates (FML)

116

117

Staübli TX60

Pultrusion + UV curing + Robot

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Crash_Can_Simu.avi



Pultruv.mp4-.mp4

Pultruv.mp4-.mp4

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LIQUID COMPOSITE MOULDING

119

COMPOSITE CHARACTERIZATION

Physic (density, fibre %)

Defectology (porosity, delamination, dry zones): SEM, C-Scan

Mechanical: Tensile, Fracture mechanics, ILSS, Impact, Fatigue

Research Institute devoted to University-industry

relationships in the field of polymers

Main activities

Fundamental investigation of industrially relevant

problems

Characterization and testing

Courses and training

Consulting

Interdisciplinary research covering polymer synthesis and polymer

reaction engineering, rheology, polymer processing, analysis and

material testing and product development.

Polymer reaction engineeringPolymerization in dispersed media

Mathematical modeling

Process intensification

Waterborne hybrid dispersions

RheologyPolymers melts

Blends and multiphase systems

Solutions and gels

ProcessingReactive processing

Micro and nanocomposites.

Polymer blends.

Compounding.

Analysis and material testingOrganic analysis

Morphology

Mechanical and thermal properties

Transport properties of gas and vapors in

polymers

Colloidal characterization

Product developmentMicrogels for drug delivery

Carriers for immunoassays

Injectable acrylic bone cements for

vertebroplasty and kyphoplasty

Carbohydrate based acrylic matrices for

peptides and proteins sustained release

Nanocomposites.

Polymer blends.

This research is further supported by basic research in polymers carried

out in the departments of the School of Chemistry

Polymerization in Dispersed Media

1. Polymer-polymer hybrid systems

1. Alkyd-acrylics (coatings)

2. Silicone-acrylics (coatings)

3. PU-acrylics (adhesives)

4. Semicrystalline acrylics (adhesives, coatings)

2. Polymer-inorganic hybrid systems

1. Clays (coating and adhesives)

2. Silica (Pickering)

3. CeO2/ZnO/TiO2 (coating)

4. Graphene (coating)

5. Quantum dots (multiplexing)

Synthesis of Waterborne Hybrid Nanocomposite dispersions:

Polymer Science

Polyurethane nanocomposites

Polymer solution electrospinning

Transport of gases and vapours in polymers andnanocomposites

•Biodegradable polymers.

•Nanocomposites as barrier materials.

•Polymers and nanocomposites in separationprocesses.

Rheology

Synthesis andPolymerization

MicrostructureChain architecture

End-use properties

RHEOLOGY Processing

Research lines:

*Soft matter and complex fluids: bitumens, gels, liquid-crystals, LCB polymers*SEBS, PVC-PBA and PUR copolymers*Nanocomposites: Polymer matrix/CNT or graphene nanoparticles

Polymer Processing

Main Research Interest:

Processing-Structure-Properties relationships in polymeric

materials

Final propertiesSolid StateStructure

Polymer ChemicalStructure

Processing

Main research lines:

*Polymer blends: Blends of engineering thermoplastics,

compatibilization

*Supertough thermoplastic-elastomer blends

*Polymer/organoclay nanocomposites

Date post:	13-May-2015
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