JEC-europe-paris-2012 Technological watch report

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EXIBITION WATCH REPORT

JEC Europe 2012 – Paris, Porte de Versailles Research, Testing and Industrial Instrumentation

exhibition

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© VIEDOC – For any further information: [email protected]

TABLE OF CONTENTS ABSTRACT ................................................................................................................................................................ 4 RESUME ................................................................................................................................................................... 4 Part 1. innovations on raw materials for composites ....................................................................................... 5 1.1 Akzo Nobel ............................................................................................................................................. 5 1.1.1 Presentation ...................................................................................................................................... 5 1.1.2 BluCure cobalt‐free curing technology ............................................................................................. 5 1.1.3 New cobalt‐free products ................................................................................................................. 6

1.2 Olnica ..................................................................................................................................................... 7 1.2.1 Presentation ...................................................................................................................................... 7 1.2.2 Anti‐counterfeiting taggants ............................................................................................................. 7

1.3 BYK ......................................................................................................................................................... 8 1.3.1 Presentation ...................................................................................................................................... 8 1.3.2 Innovative coupling agents ............................................................................................................... 8

1.4 3B Fiber glass ......................................................................................................................................... 9 1.4.1 Presentation ...................................................................................................................................... 9 1.4.2 New sizing technology enhances the properties of epoxy composites .......................................... 10

Part 2. innovations in composite manufacturing ............................................................................................ 12 2.1 Axson Technologies ............................................................................................................................. 12 2.1.1 Presentation .................................................................................................................................... 12 2.1.2 Independent heating tool regulated for preg outside the autoclave ............................................. 12

2.2 Chomarat ............................................................................................................................................. 13 2.2.1 Presentation .................................................................................................................................... 13 2.2.2 C‐Ply Bi‐Angle: A new composite reinforcement ............................................................................ 13

2.3 Hexcel .................................................................................................................................................. 14 2.3.1 Presentation .................................................................................................................................... 14 2.3.2 New prepreg curing in under five minutes ..................................................................................... 15

2.4 Gurit ..................................................................................................................................................... 16 2.4.1 Presentation .................................................................................................................................... 16 2.4.2 Velinox: Prepreg compatible with glass, carbon and aramid fibers ................................................ 17 2.4.3 Renuvo Wet Laminate (WL) ............................................................................................................ 18

Part 3. Applications and services for composites............................................................................................ 20 3.1 Munich Composite Gbmh .................................................................................................................... 20 3.1.1 Presentation .................................................................................................................................... 20 3.1.2 BRAID bikes ..................................................................................................................................... 20

3.2 Asterillos Santa Pola ............................................................................................................................ 22 3.2.1 Presentation .................................................................................................................................... 22 3.2.2 Lightweight ceramic with high ballistic properties for ships ........................................................... 22

3.3 Airbone ................................................................................................................................................ 24 3.3.1 Presentation .................................................................................................................................... 24 3.3.2 Thermoplastic spoolable pipe concept for Oil & Gas industry ........................................................ 24

3.4 EADS .................................................................................................................................................... 25 3.4.1 Presentation .................................................................................................................................... 25 3.4.2 LUCIE, the Laser Ultrasonics Composite Inspection Equipment ..................................................... 26

Conclusion ............................................................................................................................................................. 27 About VEILLE SALON ............................................................................................................................................. 28 PRESENTATION of VIEDOC SARL ........................................................................................................................... 29

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DISCLAIMER This report was compiled from interviews conducted by us with the exhibitors present at each event, from gathering and analyzing information in conferences and from the compilation of information on the web afterwards. Thus, the data contained in this report have information value. Although the objective is to disseminate timely and accurate information, VEILLE SALON cannot guarantee the result. Any damage that may result from use of this information can’t be imputed to this site. The use or reproduction of all or part of this document is prohibited without the prior written consent of VEILLE SALON. For full terms and conditions of use of this report, thank you for contacting us.

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ABSTRACT

The JEC Europe 2012 composite show, held in Paris on 27th – 29th March, brought together 1,181 participating companies and occupied an unprecedented surface area of 50,000 m2 (538,195 sq. ft., or 8 times the size of a football pitch!), which is five times bigger than any other composite exhibition in the world. In 2012, attendance increased once again, with a total of 32,256 visitors, as compared to 29,867 in 2011, testifying to the appeal of this platform for the composite market. Environmental concerns and an overwhelming desire to be seen to be first with composite solutions were apparent at the JEC Europe 2012 show. Traditionally, automotive and construction have been the main industries driving innovation in composites in Europe. At this year's JEC Europe show, however, many composites suppliers were pursuing the material's enormous growth in wind turbines and the increasing popularity of biocomposites. But still, there were not much outstanding innovations there and very few can be seen in this report. Although innovations could have been seen in raw materials, composite manufacturing and composite applications, most of the major new development were dedicated to manufacturing. Some companies like Hexcel, Gurit and specially Chomarat really found better ways of using prepregs for better mechanical properties. There is also a push for decreasing manufacturing costs through new fast curing methods or new process flows avoiding the autoclave step. Some big companies like Akzo Nobel and DSM found a way to stay one step ahead of legislators by showing a new eco‐friendly cobalt‐free curing technology, which is already compliant to the new environmental laws. This new innovative manufacturing methods obviously have an impact on applications made of composite applications. Munich Composites displayed a completely new way of making a bike made of carbon composites using much less tubes and more importantly much less man power in the manufacturing process. Airbone found a way to produce kilometer long pipes made of thermoplastics for deep sea applications. Composites are on their way to new field of applications in the future.

Key words: composite, resin, fiber, prepreg, carbon, glass, aramid, cobalt, pipe, thermoplastic, epoxy, curing

RESUME

Le salon JEC Europe 2012 s’est déroulé du 27 au 29 mars 2012 avec une affluence grandissante par rapport aux éditions précédentes : 1181 sociétés sur plus de 50 000 m2 de stand et 32256 visiteurs. Le contexte économique lié à des contraintes environnementales de plus en plus sévères était visibles sur ce salon. Les bio‐composites étaient présents sans vraiment être innovants. Le secteur des énergies renouvelables avec les éoliennes était surreprésenté, supplantant les traditionnels secteurs de l’automobile et de la construction. Mais peu d’innovation sur ce secteur. Les faits marquants sont à trouver principalement au niveau des procédés de fabrication pour les composites, tant au niveau des résines se cuisant plus vite qu’au niveau d’une nouvelle conception de l’utilisation des pré‐imprégnés pour aller vers de nouvelles propriétés mécaniques. Ces techniques innovantes de fabrication se voient également sur les applications comme le vélo en carbone de Munich Composites ou les tuyaux flexibles de plusieurs kilomètres de long en thermoplastique, réalisés par Airborne. Cela dit, anticipant des législations plus sévères, notamment sur le cobalt, Akzo et DSM ont anticipé en présentant une nouvelle génération d’accélérateur de cuisson de résine entièrement de cobalt, qui fera date dans le secteur des matériaux composites.

Mots clés : composite, plastique, résine, fibre, verre, carbone, pré‐imprégné, cuisson, époxy, thermoplastique

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PART 1. INNOVATIONS ON RAW MATERIALS FOR COMPOSITES

1.1 AKZO NOBEL

1.1.1 Presentation

Address :AkzoNobel Functionnal Chemicals Amersfoort, The Netherlands Website: http://www.akzonobel.com

Contact :Roel Zujiderduin Technical Sales manager Thermoset Tel : Mail:

AkzoNobel is the largest global paints and coatings company and a major producer of specialty chemicals. It supplies industries and consumers worldwide with innovative products. Its portfolio includes well known brands such as Dulux, Sikkens, International and Eka. Headquartered in Amsterdam, the Netherlands, AkzoNobel is a Global Fortune 500 company and are consistently ranked as one of the leaders on the Dow Jones Sustainability Indexes. AkzoNobel operates in more than 80 countries with its 55,000 people around the world.

1.1.2 BluCure cobalt‐free curing technology

At the JEC Europe 2012 show in Paris in March, DSM Composite Resins and AkzoNobel also unveiled the BluCure quality seal, which manufacturers of composite components can use to show that their products are based on 100% cobalt‐free BluCure technology. AkzoNobel and DSM Composite Resins are introducing BluCure™ cobalt‐free curing technology for unsaturated polyester and vinyl ester resins. With the use of cobalt‐based curing agents currently under regulatory review in Europe, the two companies have decided to combine their respective intellectual property and offer the technology for license to manufacturers of resins and composite products. BluCure™ opens up access to 100% Cobalt‐free curing technologies through sub‐licensing, providing genuine alternatives to traditional Cobalt‐based accelerator systems for all composite component and resin manufacturers.

The BluCure technology has been developed for users of organic peroxide curable unsaturated polyester and vinyl ester resins and provides an alternative to widely used cobalt‐based curing systems. BluCure™ Products are either Cobalt‐free pre‐accelerated resins or ready‐to‐use Cobalt‐free accelerators meeting the following strict criteria:

100% Cobalt‐free Easy‐to‐use in composite manufacturing processes Not labelled as mutagen or toxic to human beings Do not contain chemical components listed in the list of Substances of Very High Concern (SVHC List)

The driver behind this technology is the increasing legislative pressure on cobalt. Cobalt salts such as cobalt octoate and cobalt acetate are widely used accelerators (also called promoters) used to control the cure of unsaturated polyester and vinyl ester resins. A very small amount of the accelerator (0.01 phr) is either incorporated in the resin (to produce a pre‐accelerated or pre‐promoted resin) or added separately to a non‐accelerated resin. However, there is currently uncertainty concerning the classification of cobalt under the complex new European REACH (Registration, Evaluation, Authorisation and Restriction of Chemicals) legislation. Cobalt

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chloride and cobalt diacetate are already on the Candidate List of Substances of Very High Concern (SVHC). SVHCs are chemical substances identified as having hazardous properties to humans or the environment eg. they are carcinogenic, mutagenic or bio‐accumulative and toxic. Chemicals on the SVHC list are in line to be strictly regulated within the EU and EEA Member States and their use restricted. The classification of cobalt octoate is currently under review. The Cobalt REACH Consortium has proposed a testing programme for cobalt octoate to the European Chemicals Agency (ECHA) and is awaiting feedback. This is expected by the middle of this year. According to DSM, there is a chance that ECHA will decide to apply the 'read‐across' approach to cobalt octoate ie. cobalt chloride and cobalt diacetate will be used to make predictions concerning the physicochemical, toxicological and ecotoxicological properties of cobalt octoate. This means that cobalt octoate could become category CMR (carcinogenic, mutagenic or toxic for reproduction) 1B classified and in a second step SVHC listed soon after that change in classification. CMR 1B classification means that the exposure of workers, consumers and the environment with the substance involved have to be minimised. Chemicals containing more than 0.1% of a CMR 1B substance have to be classified and labelled accordingly. For cobalt salts this limit may even become a factor lower i.e. 0.01% (calculated for the cobalt metal content). For manufacturers of composite parts, this means that the process for obtaining operational permits is significantly more complicated if they continue to work with these CMR 1B substances.

1.1.3 New cobalt‐free products

At JEC Europe 2012, DSM Composite Resins launched three pre‐accelerated resins under the BluCure brand: Atlac® 580 A 10 vinyl ester resin for use in the hand lay‐up, spray‐up and filament winding processes; Atlac 580 A 20 vinyl ester resin for the vacuum infusion process; and Synolite™ 7877‐P‐1 unsaturated polyester resin for use in hand lay‐up, spray‐up and filament winding.

The company says several non‐accelerated DSM resins have also been evaluated with AkzoNobel's Nouryact™ cobalt‐free accelerators, which are now also under the BluCure brand. The Nouryact accelerators are based on copper, manganese and iron and can be used in most ambient cure systems. They allow for low‐cobalt and cobalt‐free curing of unsaturated polyester resins, including orthophthalic, isophthalic, vinyl ester and DCPD resins, while maintaining existing cycle times and mechanical properties. They can be fine‐tuned on geltime, time to peak, peak exotherm. AkzoNobel has already introduced Nouryact copper‐based accelerators and it recently launched Nouryact manganese‐based and iron‐based products. The company is also working on a new generation of iron accelerators, which is close to commercialisation. All of these are now BluCure products as follow:

Nouryact CF12 Nouryact CF13 Nouryact CF20 Nouryact CF30 1. Copper‐based 2. Recommended for ambient temperature curing 3. Used to pre‐accelerate VE resins allowing curing with Butanox M‐50 without gassing

1. Copper‐based2. Recommended for ambient temperature curing 3. To increase pot‐life of pre‐accelerated resins without geltime drift

1. Manganese‐based 2. Recommended for elevated temperature curing 3. Very low discoloration after curing

1. Iron‐based 2. Ability to reduce the activation temperature of peroxyesters 3; Suitable for curing artificial marble slabs (at elevated temperature using tert‐butylperoxylbenzoate)

The development of BluCure technology meets both AkzoNobel and DSM's strategies for sustainable growth.

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1.2 OLNICA

1.2.1 Presentation

Address :20 avenue des buttes de Coësmes Campus INSA de RENNES Batiment 11, CS 70839 35708 RENNES cedex 7 Website : www.olnica.com

Contact :M. Nicolas Kerbellec Tel : +33 (0) 2 23 23 82 24 Mail: [email protected]

OLNICA, a French company that specializes in anti‐counterfeiting solutions for materials protection, has developed a wide range of invisible marking powders to secure materials against counterfeiting in many applications. Thanks to its specialists, OLNICA works with companies to define and to install security systems for their materials and/or products. OLNICA's technology is the result of several years of research within the laboratory SCR/MI of the National Institute of Applied Science of RENNES. Rewarded twice by the French research ministry in 2008 and 2009, this technology can be adapted to a large number of materials.

1.2.2 Anti‐counterfeiting taggants

Thanks to its marking technology, OLNICA can offer invisible markers according to different security levels (Covert ou Forensic). This new technology allows manufacturers to solve their counterfeiting problems with a simple and robust system. Multiple levels of security are possible with the same marker without changing the production process. Due to their high chemical and thermal resistance, these taggants can be integrated into a wide range of host materials (plasters, concretes, textiles, plastics, inks, adhesives, etc.) with no impact on the material's characteristics. This technology provides a covert and forensic security for materials using a unique taggant.

Olnica produces robust powders that can be introduced directly into fabrication process of a lot of materials. Each marker has a unique composition offering to the customer his own signature which it will be able to find by a legal expertise. However, it’s also possible to visualize the powder under UV light and an analysis of the emission signal is realizable thanks to an adapted reader.

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Here all the services and products that Olinca can propose : ‐A single chemical composition and optical signature (for each lot or set of product) of marker (millions of possibilities).

‐A very easy incorporation in your product (into production process) ; because of the high chemical and temperature resistance of our marker (T< 450°C, 3<pH<12 )

‐No coloration of the marked product :marker invisible to eye (micrometer sized) ; and no modification of the marked material properties

‐A very moderate impact in the product final cost (quantity required of marker around 10ppm) ‐The multilevel signature for each marker :

o Identification (under UV lamp). o Authentication on field: the portable reader to analyze spectral emission of marker directly on

the material. o Expertise in Laboratory, to certify the product identity with the chemical analyze of the single

marker composition. With that innovative solution, you will save time in identification of materials, and will also have possibility to authenticate on field and make an expertise of any materials. This is the best legal proof in case of health probe, defect or batch recall. Our product will have a weak impact on your finish product cost, and you can argue about material recycling (differentiation of components – materials with the marker).

1.3 BYK

1.3.1 Presentation

Address :BYK‐Chemie GmbH Abelstraße 45 46483 Wesel Germany Website : www.byk.com

Contact :Tel +49 281 670‐0 Fax +49 281 657‐35 Email: [email protected]

BYK is one of the world's leading suppliers of additives and instruments for the quality control of color, appearance and physical properties. Now, BYK is ALTANA Group’s successful global Additives & Instruments business unit. It encompasses the additives of BYK‐Chemie and the instruments business of BYK‐Gardner. Both companies rank exceptionally high within their respective markets. Additives are chemical substances that – even when added in small quantities – enhance product properties such as scratch‐resistance or surface gloss. Moreover, entire manufacturing processes can also be optimized by means of additives. The main uses for BYK additives include application areas in the coatings, printing ink and plastics industries. But the demand for BYK additives is also growing rapidly in paper coatings, in the production of adhesives and sealants and in construction chemistry – because they are also being used to continuously optimize product properties and manufacturing processes in these sectors as well. In 2009, BYK expanded its product portfolio with the addition of raw materials used in the manufacture of release agents for aluminum die‐casting. For the coatings and plastics markets, BYK offers complete and unique system solutions: additives for the enhancement of coatings and plastics properties, and instruments for the objective assessment of the color, appearance and physical properties of coatings and plastics.

1.3.2 Innovative coupling agents

At a past JEC show, BYK presented its innovative coupling agent BYK®‐C 8000 for filled, radical curing systems such as polymer concrete. BYK®‐C 8000 improves key characteristics such as flexural, compressive, and tensile strength as well as impact resistance by up to 50%. The mechanical strength achieved even allows the thickness of components to be reduced without any loss of quality, thereby saving considerable costs.

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Now, three years later, BYK has extended its portfolio of innovative coupling agents with BYK®‐C 8002, which is especially designed for ATH‐filled acrylic resins. Like BYK®‐C 8000, BYK®‐C 8002 also increases the mechanical properties of the finished product. Its active groups connect with the surface of the ATH and build a bridge to the resin using a double bond. Its multifunctional structure also prevents fillers from settling or separating in the liquid mixture. BYK®‐C 8002 strengthens the interface between filler and resin by forming strong chemical bonds, resulting in a remarkable improvement of the mechanical properties. It has no negative impact on hot water and weather resistance and, depending on the system and usage, BYK®‐C 8002 also improves the anti‐settling properties of the ATH (aluminum trihydroxide) in the acrylic resin (PMMA in MMA). Although it has strong polar groups, it does not have a negative impact on other important properties such as the yellowing of pigmented parts or water absorption.

1.4 3B FIBER GLASS

1.4.1 Presentation

Address :Route de Maestricht 57 B‐4651 Battice, Belgium Phone +32 87 69 24 11 VAT BE0467608690 Belgium Website:www.3b‐fiberglass.com

Contact : M. Eric Debondue Phone +32 499 55 54 65 Mail: eric.debondue@3b‐fibreglass.com

3B‐the fibreglass company is a leading European developer and supplier of fibreglass products and technologies for the reinforcement of thermoplastic and thermoset polymers. 3B is an innovative and entrepreneurial company with two state‐of‐the‐art fibreglass manufacturing facilities in Battice (Belgium) and Birkeland (Norway) as well as a dedicated R&D Centre located in the very heart of Europe.

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With a fully dedicated Customer Service Centre near Brussels, 3B is a dynamic company with a rich heritage in fibreglass development and production as well as a special commitment to supporting its customers. The company operates two unique eco‐responsible and high performance glass technologies, Advantex® and HiPer‐tex™. These two well established brands combine durability with eco‐responsibility and versatility, making them the materials of choice for a wide range of applications.

1.4.2 New sizing technology enhances the properties of epoxy composites

3B was one of many companies showing new solutions for the wind market. In Paris it launched HiPer‐tex W3030 high performance roving, a product specifically developed and engineered for polyester and vinylester resin systems and for resin infusion processes. 3B claims that HiPer‐tex W3030 allows OEMs to manufacture longer and lighter blades for the larger multi‐megawatt wind turbines located both onshore and offshore.

* Value with original glass content of 62‐65% by volume According to 3B, the new HiPer‐tex W3030 roving offers up to 10% weight saving for the same design and length when compared to rotor blades manufactured with traditional E‐glass. In addition, the turbine blade span can be lengthened by up to 6% while still maintaining the same weight, increasing energy output by up to 12%, says 3B. In a typical unidirectional polyester or vinylester laminate with an average glass volume fraction of 60%, the new HiPer‐tex™ W3030 roving offers:

54‐56 GPa E‐modulus 1400‐1500 MPa tensile strength Up to 50% improvement in transverse strength Up to 10 times longer lifetime in fatigue resistance versus traditional E‐glass

To meet wind turbines manufacturers' needs for the production of longer and lighter blades, 3B has been collaborating with the whole value chain in the wind industry to bring to market two cost‐competitive, high‐performance reinforcements with an optimized sizing technology. Advantex® SE2020 and HiPer‐tex™ W2020 have been specifically engineered for epoxy polymer systems and push further the limits of glass fiber blade designs to address new challenges facing the wind industry and to support the growth of multi‐mega‐watt turbines.

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Compared with conventional materials, 3B’s new sizing offers better wet‐out, therefore providing a more consistent laminate quality, a significantly improved resin matrix adhesion which delivers higher shear strength (up to 15% in‐plane shear strength), and substantially greater interfiber strength (up to 50%).

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PART 2. INNOVATIONS IN COMPOSITE MANUFACTURING

2.1 AXSON TECHNOLOGIES

2.1.1 Presentation

Address :ZA Biliais Denaiaud, 5 rue Albert de Dion, 44360 Vigneux de Bretagne, France Website: http://www.axson.fr

Contact : M. Patrick Noirclerc Tel :+33 (0) 6 15 88 38 15 Mail: [email protected]

Leader in the field of elastomers and resins applied to design, tooling and prototyping, Axson Technologies offers a comprehensive product range for the creation of models and moulds used for style trials, product testing and pre‐production studies. Axson Technologies polymer expertise also extends to advanced technologies for composites, structural adhesives and dielectrics. Leading industries around the world chose Axson Technologies solutions in markets such as aerospace, automotive, construction, renewable energies, transportation, foundry, machine tools and the electronic industry among others. In addition to the industrial sector, Axson Technologies provides solutions for other markets such as model making, art, interior decoration, furniture design, household appliances, ceramics, filtration, medical, sports and leisure among others.

2.1.2 Independent heating tool regulated for preg outside the autoclave

The only independent heating tool regulated for preg outside the autoclave This tooling, created in co‐operation with ENSAM from Lille, produces a vacuum and creates parts as prepregs to be heated outside the autoclave. The heating tool consists of a rigid moulded part in 2092 Axson Technologies epoxy infused carbon or in metal, which provides the part with its geometry, and a flexible heating counter‐mould projected in the exact shape of the part in Axson Technologies SVB20 Silicone.

According to Patrick Blosse (vice‐president of Axson Technologies), Axson is the only company to propose a system which provides integration of the heating and of the vacuum and sealing system. Indeed, the principle of heating the two parts of the mould enables sandwich parts to be created (thermal insulation). The fact that this tooling can operate independently encourages the creation of large moulds, while economizing on large dimension autoclaves.

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The clever aspect of the tool is that the flexible part of the tool is also heated. This can replace the autoclave and therefore saves a considerable amount of time and energy, especially for large parts. This innovation has several applications, in particular in the wind turbine field. Studies for the manufacture of tooling for wind turbine blades are taking place at present.

2.2 CHOMARAT

2.2.1 Presentation

Address :39 avenue de Chabannes, 07160 Le Cheylard France Website: www.chomarat.com

Contact :M. Philippe Sagnial Tel :+33 (0) 4 75 29 81 00 Mail: [email protected]

The Chomarat Group is an international textile group with a staff of 1,700 (including 700 in France) and a presence on 4 continents. It is a private company, owned by the Chomarat family. It has been run for over a century by 4 succeeding generations, each rising to the challenge of continual development in a ever changing world. The group now has an extensive range of technologies and know‐how. A wide variety of activities, which is rare for textile companies, enables it to be present in many markets and to offer greater added value to its customers. Chomarat has a global market presence and has set up an organization based on Strategic Business Units, which are:

The Textiles Strategic Business Unit The Composites Strategic Business Unit The Fashion Strategic Business Unit

The Group has been active on the composites market for over 50 years and is one of the pioneers in this sector. It designs and manufactures a wide range of reinforcement materials: fabrics, multiaxials, complex combinations, sandwich structures, thermoplastic reinforcement materials, nonwoven, woven, grids, etc. It serves many markets such as construction, transport, marine, ballistics, recreation and wind energy. Chomarat is well known on the market through flagship brands such as ROVICORE™ , ROVIFLOW™ , ROVIMAT™ , ARAMAT™, C‐GRID™, MeC‐GRID™, etc. Chomarat is an innovative company and is now improving the spectrum of products it offers in the carbon field by developing ranges specifically adapted to direct technologies (RTM, Infusion).

2.2.2 C‐Ply Bi‐Angle: A new composite reinforcement

C‐PLY™ Bi‐Angle is a non‐woven carbon reinforcement (non crimp fabric, or NCF) that was launched in 2011 by Chomarat in partnership with a research group of manufacturers and academics working under Professor Tsai from Stanford University. Chomarat gave the 2012 JEC Europe a preview of the latest technical advances and the first parts obtained with C‐PLY™ Bi‐Angle, which makes use of innovative fiber orientations within the composite. By eliminating the fibers placed perpendicular to the main loading axis and/or using extremely thin plies (75G/M2), it is possible to develop completely new multiaxial materials. C‐PLY™ Bi‐Angle is a carbon reinforcement that makes it possible to manufacture even lighter and stronger composites more rapidly and cost effectively. The range is expanding and developing, since it is now possible to produce C‐PLY™ Bi‐Angle from glass or glass/carbon hybrid, and to alternate thin and thick plies at angles as low as 20°. According to Philippe Sanial, R&D Manager at Chomarat, the 20° angles give laminates optimum performance: producing them is simpler, up to three times faster, and there are fewer ply placement errors.

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To meet demand from aerospace builders and equipment manufacturers, the C‐PLY™ Bi‐Angle range is expanding to include constructions that will allow optimizing all composite aerospace parts. The thin plies (50‐75 g/m²) in C‐PLY™ Bi‐Angle are a key element in the performance of the composite used for the fuselage. Other parts, like the beams, can also benefit from this multiaxial assembly at shallow 20° or 30° angles, which allows exceptional weight savings – up to 30% compared to a standard carbon construction. The final use of this development concerns composite parts that require greater strength in certain directions (anisotropy). A two‐layer multiaxial with one layer at 0° and the other at +20°, like C‐PLY™ Bi‐Angle, establishes a bend twist coupling that makes the material work in a revolutionary manner: the interaction of the bending and torsional stresses actually works to keep the part from bending or twisting. In the aviation sector, this material is being tested in parts like wings, wing components and engine blades. The research team is currently working on a project to make a demonstrator for a lightweight sports aircraft incorporating all these innovations. The material is also being tested to open up possibilities for a new wind turbine blade design, in the expectation of significant weight reductions. Hybrid shapes are used to increase the material’s bend twist coupling effect. The team is working on the weights of material used for individual directions, and on the use of different types of fibre, e.g. carbon or glass. The weight‐reduction prospects offered by these materials in wind turbine blades would have been unimaginable before the development of C‐PLY™ Bi‐Angle. These research projects in high‐technology sectors will also be applicable in the automotive industry, where performance and weight‐reduction issues are a challenge.

2.3 HEXCEL

2.3.1 Presentation

Address :281 Tresser Boulevard, 16th Floor Stamford, CT 06901‐3261, USA Website: http://www.hexcel.com

Contact :M. Sylvain Delande Mail: [email protected]

Hexcel today offers a breadth and depth of products and services that is unmatched in the industry. From their worldwide manufacturing facilities they manufacture the full spectrum of advanced material solutions ‐ this includes everything from carbon fiber and reinforcement fabrics to pre‐impregnated materials (or "prepregs") and honeycomb core, tooling materials and finished aircraft structures. With 4,000 employees worldwide and 18 production sites (including JV in Malaysia), the primary markets of Hexcel are commercial aerospace, space & defense, wind energy and industrial. Hexcel’s net sales were $1,174 million in 2010.

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2.3.2 New prepreg curing in under five minutes

To assist manufacturers of sports equipment and other industries in their search for more efficient composite solutions that permit production rates to increase ‐ without affecting investment and labor costs ‐ Hexcel has developed a new epoxy resin system able to break the psychological barrier of the 5 minute cure cycle.

Curing in only 2 minutes at 300°F/150°C, HexPly® M77 brings significant advantages to the market especially as this reactive system also has a long shelf life of 6 weeks at 23°C.

It is highly suitable for large‐volume production, such as the manufacture of skis as shown below.

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Other features such as a Tg of 120°C/250°F and good adhesive properties (eg. when bonding to aluminum) make HexPly® M77 highly suitable for large volume production as experienced in the ski industry and automotive components manufacture. Being aware that we need to deliver performance without expense to the environment, HexPly® M77 is fully compliant with REACH regulations. Based on HexPly® M77 resin system, Hexcel has launched a range of prepregs with glass or carbon reinforcements in multiaxial form ‐ as well as woven fabrics and UD tapes.

2.4 GURIT

2.4.1 Presentation

Address :Gurit Services AG Schaffhauserstrasse 339 CH‐8050, Zürich, SWITZERLAND Website: http://www.gurit.com

Contact : Telephone: +41 44 316 1550 Fax: +41 44 316 1569 Email: [email protected]

Gurit is a global leader in the development and manufacture of advanced composite materials as well as composite process equipment and tools for the global wind energy, tooling, transportation, marine and engineered structures markets.

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The companies of Gurit Holding AG, Wattwil/Switzerland, (SIX Swiss Exchange: GUR) are specialised on the development and manufacture of advanced composite materials and related technologies featuring bespoke physical and chemical characteristics. The comprehensive product range comprises fibre reinforced prepregs, structural core materials, gelcoats, adhesives, resins and consumables as well as certain finished parts. Gurit supplies growth markets in wind energy, tooling, transportation, marine and engineered structures. The international Group has production sites and offices in Switzerland, Germany, United Kingdom, Canada, Spain, Australia, New Zealand, USA, India, and China.

2.4.2 Velinox: Prepreg compatible with glass, carbon and aramid fibers

Gurit is keenly interested in the wind sector. In Paris it introduced Velinox, a resin system developed as a next‐generation resin platform to enhance Gurit's current wind energy prepreg and SparPreg products. The company claims that Velinox is ideal for thick laminate sections, such as wind turbine blade spars and roots. The resin system does not react exothermically in the same ways as a standard epoxy, enabling the cure profile to be modified to eliminate dwell periods, for controlled exotherm. Indeed, despite curing Velinox™ at 125°C, only a 15°C exotherm above the air temperature (dashed lines on the plot below) is observed compared to 105°C using a standard resin.

Velinox is a revolutionary prepreg compatible with glass, carbon and aramid fibers that provides less than half the curing time of current prepregs, extremely low exotherm in any section thickness, no cold storage with a 4‐month shelf‐life at 35°C, 1 month at 50°C, and over 18 months at 20°C, improved mechanical performance. Velinox further reduces the barriers for using high‐performance prepreg as an alternative component manufacturing technology. For existing prepreg processes, it doubles the throughput with existing tooling or potentially halves the number of tools required. Velinox has been successfully tested for wind turbine blade sparcap applications and is currently undergoing production scale‐up with beta test planned at major wind turbine OEM. Velinox enables the market to have access to prepreg by removing key barriers to prepreg adoption:

Lower tooling costs (minimal exotherm) No need for cold storage Significantly lower energy costs for curing

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Velinox resins can be combined with existing Gurit technologies such as SPRINT and Sparpreg for out‐of‐autoclave manufacture of high‐quality composite components.

2.4.3 Renuvo Wet Laminate (WL)

Gurit also launched Renuvo Wet Laminating (WL), a product specifically developed for wind turbine blade manufacturers' in‐factory applications. RENUVO™ Wet Laminating System (WL), is a breakthrough UV curing resin system, developed by Gurit as a repair system for straight from the mould turbine blades. RENUVO™ WL offers a step change in materials for the repair market. RENUVO™ WL has demonstrated a practical solution to an engineering problem, how to perform out of the mould repairs efficiently. The company says Renuvo will improve the maintenance and repair of today's wind turbine blades, as well as the blade manufacturing process.

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The single‐component RENUVO™ WL resin eliminates the human error of mixing, dispensing and working associated with traditional 2‐component repair systems. Additionally the material offers the operator the security that wherever the material has been sourced it is the same product manufactured to the same high exacting process. Renuvo uses UV light from specially designed lamp equipment to achieve full cure in a few minutes. Renuvo WL has been formulated to behave like a traditional wet laminating system, and is suitable for infusion repairs and leading and trailing edge finishing processes.

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PART 3. APPLICATIONS AND SERVICES FOR COMPOSITES

3.1 MUNICH COMPOSITE GBMH

3.1.1 Presentation

Address : Boltzmannstr. 15 D‐85748 Garching bei München Germany Website:http://www.munich‐composites.de

Contact : M Boris Mittermaier Tel: +49‐89‐289‐15798 Email: info@munich‐composites.de

Munich Composites was founded in July 2011 as a spin‐off company at the Institute for Carbon Composites at the Technical University of Munich. The company focuses on the braiding technology, resin transfer molding and core technologies: BRAID mandrel.

BRAID is a brand of a company spun off the Technical University of Munich. The concept of Braid (www.braid‐bikes.de) is based on years of experience of the engineers from Munich composites. In collaboration with an industrial designer, was created by a combination of production‐ready design and appealing design of this unique design.

3.1.2 BRAID bikes

Most carbon fibre bicycles are currently manufactured out of prepreg. This involves a huge amount of manual labour. The shapes are cut out of fabrics and cured in an autoclave to form parts that are then bonded, filled up, smoothed and finally coated. As a result, all carbon fibrebicycles, apart from small series, are currently produced in China.

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The bicycle frame was re‐engineered using the braiding technique ‐ a preform technique with a very high productivity and potential for automation. The number of tubes was cut in half, limiting the number of parts and joints in the frame. One of the main advantages of the braiding technology is the ability to fully automate the placement of carbon fibres. This minimizes manual work and hence optimizes quality by eliminating potential sources of errors. The frame manufacturing process can be fully automated, which means that manufacturing in high wage countries is profitable.

Munich Composite was the winner of a JEC innovation awards in the sports and leisure category thanks to these BRAID bikes.

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3.2 ASTERILLOS SANTA POLA

3.2.1 Presentation

Address :Muelle de Poniente s/n. 03001 Alicante Spain Website: http://www.cnblasco.com

Contact : M Tel: +41 96 644 7730 Email: [email protected]

Astilleros Santa Pola is a shipyard from Alicante in Spain, that constructs ships of professional fishing, sports fishing and professional fishing, constructs on order(request) in P.R.F.V.'s materials not discarding constructions of any nature. Astilleros Santa Pola is also well known for its effort on R&D, especially for finding better materials for boats. Astilleros Santa Pola, founded in 1996, represents the legacy of five generations dating back to 1885. The company built the first fiberglass compound ship in Spain and the largest in Europe. This small firm’s main business is the manufacture and repair of fishing vessels.

3.2.2 Lightweight ceramic with high ballistic properties for ships

Astilleros Santa Pola, together with the AIMPLAS Plastics Technology Institute (Instituto Tecnológico del Plástico), have developed a compound material made of ceramic fiber, fiberglass and aramid that can withstand a shot from a distance of only ten meters, even with 7.62mm caliber bullets. This is the type of bullet generally used by pirates possessing assault rifles and machine guns, shot at speeds of 850 meters per second. Accordingly, this material has the potential to ensure the safety of maritime traffic.

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This new composite laminate with high anti‐ballistic properties is made of a phenolic resin with layers of S‐glass fibres and aramid fibres. It is produced using vacuum bag technology. The main innovation lies in the combination of a ceramic material with the composite laminate. Key benefits include the reduction of the overall weight of the armoured structure , the avoidance of metals in the armoured structure, easy repair after an attack. The laminate has excellent properties, such as corrosion, water and UV resistance. The major advantages associated to its lightweight design are reduced fuel consumption and carbon dioxide emissions, versatility and ease of manufacturing and transport. The main market is the navy industry, especially boats for which protection and safety are essential such as patrol craft and fishing boats in piracy areas. Another important market will be the military sector, for the armour plating of submarines, tanks, special vehicles etc. The material can be configured in order to adapt to any size caliber—even larger sizes—therefore allowing its composition to be modified according to the risk levels of the client. Its strength is owed to its two layers of armoring, whose exterior changes the morphology of the bullet in order to reduce its penetration, while the interior layer absorbs the energy of the impact. The material is also more resistant to sea water corrosion and is lighter than steel, thus reducing CO2 emissions into the atmosphere given that the ship’s engines use less energy to move the vessel about.

Astilleros Santa Pola asserts that it is the only company in Spain building ships with this new armor. This has led the firm to sign various contracts, yet to be fulfilled, with countries from the Meghreb and both western and eastern Africa. The development of this armor has led this company to be the first shipyard in Spain, and only the second in Europe and third in the world, to win the most prestigious European award in the field of composites—at JEC 2012 held in Paris—for marine innovation.

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3.3 AIRBONE

3.3.1 Presentation

Address :P.O.box 24031, 2490 AA The Hague Laan van Ypenburg 70‐78, 2497 GB The Hague, The Netherlands Website: http://www.airborne.nl

Contact : M Marcus Kremers Tel. +31(0)70 3017400 Fax. +31(0)70 3017401Spain Email: [email protected]

Airborne is a design and build company that creates advanced composite products. They work for a variety of markets, as diverse as aerospace, oil & gas, high‐end machines, marine and science. These are high‐end industrial markets where maximum performance and critical applications go hand‐in‐hand, and where failure is not an option. They use their differentiating technologies to produce innovative composite products on an industrial scale, and are constantly pushing the envelope in product performance and production efficiency.

3.3.2 Thermoplastic spoolable pipe concept for Oil & Gas industry

Airborne has won the prestigious JEC Europe 2012 Innovation Award, for its revolutionary technology for thermoplastic composite pipes for the Oil & Gas industry. The pipe is produced in lengths of several kilometers as one piece and spooled on a drum for transport. It uses a fully consolidated, one‐material pipe concept: the inner liner, structural composite layers and outer coating are all of the same thermoplastic polymer material, and all layers are melt‐fused together to form a consolidated pipe wall. This creates a very lightweight, robust, strong and stiff pipe that is still easily spoolable due to the use of ductile, tough thermoplastic materials.

This pipe concept is radically new in an Oil & Gas industry that currently uses non‐bonded flexible pipes, where all the steel reinforcing layers are separate to each other. The market for this new composite pipe concept is estimated at several hundred million Euros a year, to be built up in the coming years. The pipe can withstand high pressures (up to 2,000 bar), high tension, high external pressures if used in deep‐

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sea applications (300 bar at a depth of 3,000 m) and high bending strains due to spooling. The thermoplastic material gives the pipe high chemical resistance and excellent impact resistance properties. Because of the pipe’s solid walls, robust and simple metal end fittings can be used to connect it to the rest of the system. The pipe can be repaired in the field.

The pipe combines the ability to handle high loads (pressure, tension, external pressure) with good spoolability. This pipe concept is inherently more robust and safer than current solutions. The pipe has just one solid wall instead of many separate layers, which eliminates a lot of potential failure modes. It can withstand higher pressure ratings, leading to higher safety factors than are currently possible. Risk reduction is a major concern in the highly critical and conservative oil & gas industry. The pipe is very light weight, has high fatigue and chemical resistance (no corrosion) and has excellent impact resistance. Besides saving cost in operation, this pipe concept also gives new opportunities for enhanced oil recovery (retrieving more oil or gas from the same well).

3.4 EADS

3.4.1 Presentation

Address :37, Boulevard de Montmorency 75 781 Paris cedex 16 – FRANCE‐ Tel: +33 1 42 24 24 24 Website: www.eads.com

Contact : M. Jean Botti Tel :+33 (0) 4 75 29 81 00 Mail: [email protected]

EADS is a global leader in aerospace, defence and related services. In 2011, the Group – comprising Airbus, Astrium, Cassidian and Eurocopter – generated revenues of € 49.1 billion and employed a workforce of over 133,000. Research & Technology (R&T) plays a central role in EADS remaining competitive by being more innovative, better, cheaper and faster in delivering products than its competitors, in view of the fact that European companies suffer from a largely fragmented and generally lower customer funding than their US peers, for

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example. In addition, EADS and its Divisions promote cutting‐edge technologies and scientific excellence to contribute to global progress and to deliver solutions for the challenges posed by such societal issues as environmental protection, mobility, defence and security, and safety.

3.4.2 LUCIE, the Laser Ultrasonics Composite Inspection Equipment

EADS won the JEC Innovation Award in the aeronautic category, a prize granted by the JEC group for achievements in the area of composite materials, for its Laser Ultrasonics Composite Inspection Equipment, LUCIE. JEC is the largest composite industry organization in the world. EADS Innovation Works, the R&T teams from Airbus Nantes, and Ecole des Mines, as well as iPhoton, which offers industrial laser‐ultrasonic systems for the aeronautic industry, and Tecnatom, a Spanish engineering company, all worked on the LUCIE project that won the JEC Europe 2012 Innovation Awards. LUCIE, the Laser Ultrasonics Composite Inspection Equipment, enables non‐contact and non‐destructive inspections and will be used to detect sub‐surface defects in composite structures. The machine offers a completely new inspection means, replacing current ultrasound techniques that require direct contact or the use of a coupling agent, a fluid such as water or gel which acts as an interface. Such currentday processes typically require the inspected element to be sprayed with water jets or immersed in a water tank.

The new laser‐based inspection technology is used with an articulated arm equipped with a device emitting laser beams to generate ultrasonic waves without being in contact with the composites. This articulated arm gives flexibility in movements and a control of the technology which is especially adapted to the inspection of composite parts of large dimensions and with complex geometries that could be applied tomorrow to future programs. The fraction of composites and their complexity have massively increased in the aircraft of the most recent major programs such as the Lockheed Martin F‐35, the Boeing 787, and the Airbus A400M and A350 XWB. As these programs ramp up production, the need for additional non‐destructive testing machines will surge. LUCIE has been installed at the Nantes site of Technocampus, a facility that brings EADS Innovation Works, Airbus and other companies together with academic institutions and additional partners to develop technologies for complex structures.

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CONCLUSION

Environmental concerns and an overwhelming desire to be seen to be first with composite solutions were apparent at the JEC Europe 2012 show in March. European Plastics News visited the Paris exhibition and reports on emerging trends in the European composites industry. Traditionally, automotive and construction have been the main industries driving innovation in composites in Europe. At this year's JEC Europe show, however, many composites suppliers were pursuing the material's enormous growth in wind turbines and the increasing popularity of biocomposites. But still, there were not much outstanding innovations there and very few can be seen in this report. Previously, environmental pressures generated extra work and costs for users of composites by forcing them to remove substances which harm the environment but make production or application harder. But some suppliers have now launched products and developed processes which help the environment but can also solve technical problems. AkzoNobel and DSM have also realized that the curing of composites offers enormous opportunities, in order to stay one step ahead of the legislators. In March 2012, they launched BluCure cobalt‐free curing. The two companies claim that their new eco‐friendly curing solutions offer the market more sustainable alternatives to conventional, cobalt‐based systems. BluCure products are either cobalt‐free accelerators or cobalt‐free pre‐accelerated resins and meet strict criteria. Cobalt octoate is the main component used in accelerators for curing UP/VE resin, either incorporated in the resin (pre‐accelerated resin) or added separately to a non accelerated resin. According to AkzoNobel and DSM the Cobalt REACH Consortium has proposed a testing programme for cobalt octoate to ECHA and is awaiting feedback (expected by mid 2012). AkzoNobel and DSM have said that it is likely that cobalt octoate will become CMR 1B classified. This means that the exposure of workers, consumers and the environment to this substance has to be minimized. Although the benefits of natural materials were heavily promoted at JEC Europe 2012, established materials for use in composites, particularly carbon, were also on show. Some like BYK displayed innovative coupling agents, whereas others like 3B Fiber glass show new sizing technology for epoxy composites. New ideas in raw materials like anti‐counterfeiting taggants within parts were rare. Most of the major innovations were in the field of composite manufacturing. New ways of using prepregs for composite reinforcement are really interesting and could have some impact on the business in the future. Chomarat, Hexcel, Gurit displayed amazing results in their R&D projects. As pressure increases on the world's natural resources such efforts could result in more effective composite solutions. Carbon fibre may be the future material but process issues such as environmentally friendly curing will, as JEC Europe 2012 demonstrated, continue to be important. The BRAID bikes made by Munich Composites Gbmh really show how it is possible to find new way of manufacturing applications made of carbon composites to save money. This again may have an impact in the future.

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ABOUT VEILLE SALON

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PRESENTATION OF VIEDOC SARL

VIEDOC CONSULTING’s core business is information. VIEDOC is your company’s partner from strategy to operation. VIEDOC aims to assist its customers in the first stages of their activities (Business intelligence, knowledge management, competitive analysis, technological watch, market research, patent monitoring, benchmarking, technology transfers, state of the art ...) through information collect and analysis relevant to your business. Business Intelligence does not require mandatory life‐long skills within the company but impose to get the right information at the right time. VIEDOC has worked for customers both on extended and short periods of time to assist companies in decision making. VIEDOC advises companies from all industries (automotive, aerospace and defense, food, cosmetics, health, materials, optics, packaging, telecommunications ...). VIEDOC can assist companies that are ambitious and aware of the importance of investing at this level:

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