Bristol Composites Institute Launch and ACCIS 10 th Anniversary Conference

Transcription

1 Bristol Composites Institute Launch and ACCIS 10 th Anniversary Conference The Composites Age is Arriving Prof Mike Hinton HVMC Core Team R&T Partnerships 15 th November 2017

2 UK Composites Manufacturing - Some History (1971)

3 UK Composites Manufacturing - Some History (1971)

4 UK Manufacturing of Composites Political & Market View - UK Strategy Strategy published Nov 2009 To develop an integrated and crosssector composites industry In a global market forecast to grow to 75bn by 2015 Driving composites growth using advanced manufacturing Achieved by delivering improved Strengthening capability Increasing sustainability Building capacity With industry and stakeholder leadership Composites Leadership Forum 4

5 Set Up & Funded by The National Composites Centre: Initiated by UK Composites Strategy (Nov 2009) Delivered on time and on budget Has more members and engagement than forecast Working on projects of utmost importance to UK Initiated the Composites Leadership Forum advising BEIS etc. on needs of the sector Capability enhancements supported by HVM Catapult Major capex expansion underway to support ATI funded programs

6 Composites Leadership Forum Established as a result the 2009 UK Composites Strategy to strengthen leadership in the sector. The CLF is working to influence the Government and other bodies to bring together support for composites and ensure growth and industrial success for the UK. Stakeholders: BEIS, Innovate UK, EPSRC, KTN Ltd, DIT (formerly UKTI). Delivery Partners: National Composites Centre, Composites UK, CIMComp. Industry Groups: Strategy refresh delivered Aerospace Growth Partnership, Automotive Council, Motorsport Industries Association, Construction, Defence, Renewables UK, Marine Industries Alliance, Railway Industry Association, Materials Suppliers Composites Leadership Forum 6

7 UK Trade Body for Composites :-

8 UK Manufacturing of Composites Political & Market View - Significant global growth prospects for composite products Global Composite Products 2017:$79.6 Bn 2020: $97 Bn CAGR 7% Polymer Matrix Composites Ceramic Matrix Composites Metal Matrix Composites Carbon Fibre Reinforced Products 2017: $22.6 Bn 2020: $30 Bn CAGR 10.5% Glass Fibre Reinforced Products 2017: $47.0 Bn 2020: $57 Bn CAGR 6.6% Natural Fibre Reinforced Products 2017: $4.2 Bn 2020: $5.8 Bn CAGR 11.68% 2017: $3.3 Bn 2020: $4.3 Bn CAGR 9.7% 2017: $518 M 2020: $619 M CAGR 6.1% Carbon Fibre Aramid Fibre Glass Fibre Composite Resins (TS) 2017: $3.2 Bn 2020: $4.3Bn CAGR 10.8% 2017: $3.5 Bn 2020: $4.6Bn CAGR 6.4% 2017: $11.8 Bn 2020: $14.23Bn CAGR 6.4% 2017: $1.1 Bn 2020: $1.3Bn CAGR 6.4% Source: Markets & Markets data compiled by NCC

9 The UK Market Opportunity Potential growth from composite part production from 2.3bn in 2015 to 12.5bn in Focus on High Growth Markets: Aerospace, Automotive and Defence Composites Leadership Forum : Source 9

10 The UK Market Opportunity Potential growth from composite part production from 2.3bn in 2015 to 12.5bn in Focus on High Growth Markets: Aerospace, Automotive and Defence Composites Leadership Forum : Source 10

11 UK Manufacturing of Composites Political & Market View - Aerospace

12 UK Manufacturing of Composites Political & Market View - Aerospace

13 UK Manufacturing of Composites Political & Market View - Aerospace Sector Body :- AGP Planning Body :- ATI

14 UK Manufacturing of Composites Political & Market View - Aerospace A350 and A400 in production (composite wings) Bombardier C-series EIS in service 2016 (composite wing) Increasing use of composites in engines (blades, cases, nacelles) (Production rates of A320 increasing) Next generation of single-aisle could use composite wing and engines with high composite content Challenges: Production rates Globally mobile/ high value manufacturing

15 UK Manufacturing of Composites Political & Market View - Automotive Government commitment to UK Automotive Sector Advanced Propulsion Centre: 1bn over 10 years Automotive Inward investment organisation Investment in Skills

16 UK Manufacturing of Composites Political & Market View - Automotive High composites growth forecast: due to 2020 and 2025 emission targets Applications include: Structures (body in white) Wheels and brakes Suspension and clutches Interiors (seat frames, consoles) Challenges: Cost, rate and quality (surface finish, painting, joining) Capital cost of new production facilities UK supply chain?

17 McLaren Composites Technology Centre 1 st UK McLaren facility outside campus In-sourcing the development and manufacture of carbon fibre chassis Using advanced know-how and technology developed with HVM Catapult (AMRC) 50m combined investment 200 high level jobs Projected cost saving of 10m 100m GVA to UK economy by 2028 Value of UK sourcing of a McLaren car to grow by 8% (from current average of 50%)

18 UK Manufacturing of Composites Political & Market View - Oil & Gas UK s largest sector by capital investment ( 14b/pa) UK world leader in sub-sea technologies Major opportunities in deep water in Gulf of Mexico, West Africa (up to 30x deeper than North Sea) Challenges: Well depths up to 3000m Well pressures increasing to >20k psi Regulation/assurance (hence IUK mjumper project)

19 UK Manufacturing of Composites Political & Market View - Oil & Gas

20 UK Manufacturing of Composites Political & Market View - Renewables Siemens Manufacturing Facility Hull, UK

21 UK Manufacturing of Composites Political & Market View - Renewables

22 Current UK Gov t Initiative :- Industrial Strategy Challenge Fund - Faraday (Auto Batteries) - (Digital Manufacturing) - (Materials) Sector Deals - Construction - (Chemical Industry) - (Composites Manufacturing)

23 Composites Sector Deal - Initial Thought Process Technology Sustainability Skills/Workforce Industry Specific Work Delivering: Aerospace and Automotive Composites Roadmapping. XX APC, XX IUK, XX ATI composite innovation projects. Ask: Composite bridge demonstrator. Link to Construction Sector Deal? Delivering: Composites Resource and Efficiency Action Plan. Climate Change Levy Scheme. Ask: Support for icomposites-style collaborative research programme to address market failure. Delivering: Composite Trailblazer Apprenticeship. Composite Accredited Practitioner Scheme. Ask: HEFCE Catalyst fund proposal for curriculum development. Allow Apprenticeship levy to be used on other forms of skills. Cross Sector Work Delivering: HVM Catapult preforming Large Scale Project Scottish Lightweighting Centre. Ask: National Composite Materials Innovation Hub. Materials extension to CIMComp. Composite related extension to HVM Catapult Infrastructure. Supply Chain Delivering: Industry database. Ask: Support for market & industry data refresh, cross sector & supply chain analysis. Funding to support engagement and communication with industry. Regulations & Standards Delivering: Modernising Composite Materials Regulations Paper. Ongoing work challenging materials based standards. Ask: TBC Composites Leadership Forum 23

24 Value / bn Part and Materials Value For UK Automation and process optimisation will lead to material cost dominating composite product cost. Need to capture the material supply chain in the UK, increasing UK GVA and reducing imported goods. (example: without action, up to 3.4bn of carbon fibre may need to be imported by 2030) UK Composite Products Material Value NCMC work increases UK produced materials, increasing UK GVA and Material Value from UK with NCMC Material Value from UK without NCMC

25 NCMC - Indicative Academic Projects M1 M2 M3 M4 M5 M6 M7 M8 M9 M10 Matrix Reinforcement Intermediates Sustainability Large scale production of monomers from biomass High performance discontinuous High-speed weaving of broadcloth More sustainable matrices and sizes (as drop in replacements for selected R1 composites I1 through machine development and S1 (thermosets and thermoplastics) polymers) tow sizing Application of multi-scale modelling techniques to optimise performance through rational design and formulation Development of lower temperature cure processing for thermoset composites Developing new reactors to enable the rapid scale up of new monomers Tailoring existing matrix/reinforcement interface regions to improve mechanical performance Development of reliable self healing polymer R6 matrices Developing tough, high operating temperature ( C) matrices R7 Developing the next generation of multifunctional composites using new nanomaterials Developing standards for routine use of nanocomposites across supply chain Reducing reliance on VOCs by developing waterborne technologies and moving towards circular processing R2 R3 R4 R5 R8 R9 R10 Structured size Next generation carbon fibres Higher performance low-cost (glass) fibres High performance polymer tape composites Next generation fibres to displace conventional carbon In situ formation of reinforcing structures New design tools Fibres as delivery routes for addition components (LINK TO MATRICES) Hierarchical structured fibre tows I2 I3 I4 I5 I6 I7 I8 I9 I10 Variable width broadcloth weaving Nearnet 2D preforming Direct preforming with long discontinuous tows into formable preforms 3D weaving of broadcloth (2.5D weaving) 3D weaving of thick and complex near-net preforms Novel cutting technologies, for example laser based (with AMRC/MTC) Yarns or tows from discontinuous (recycled) fibres and hybrid fibres Novel cylindrical 3D preforms Just-in time prepregging of 3D preforms S2 S3 S4 S5 S6 S7 S8 S9 S10 S11 More sustainable reinforcements (fibres, films, precursers) New solvolysis processes for improved fibre recovery - Current thermoset matrices and carbon & glass fibre Improved pyrolysis processes for carbon fibre recovery from legacy matrices Improved sizes for fibres Composites with variable discontinuous fibre properties QC methods and standards for recovered fibres (NPL-led?) Development of short fibre alignment processes LCA methodologies Processing mixtures of recovered glass and carbon fibre Composites Leadership Forum 25

26 UK Manufacturing of Composites Political & Market View - Big Challenges Increasing demand for large components (aerospace, wind, construction ) Processes and costs that suit increased manufacturing rates (10 5 /y not 10 2 /y) Automated manufacture Reducing cost and time to market (design >certification>in-service) Growing the UK skills/expertise to compete with the world (supply chains)

27 UK Manufacturing of Composites Political & Market View - Big Challenges Increasing demand for large components (aerospace, wind, construction ) Processes and costs that suit increased manufacturing rates (10 5 /y not 10 2 /y) Automated manufacture Reducing cost and time to market (design >certification>in-service) Growing the UK skills/expertise to compete with the world (supply chains)

28 UK Manufacturing of Composites Political & Market View - Big Challenges Increasing demand for large components (aerospace, wind, construction ) Processes and costs that suit increased manufacturing rates (10 5 /y not 10 2 /y) Automated manufacture Reducing cost and time to market (design >certification>in-service) Growing the UK skills/expertise to compete with the world (supply chains) There has never been a better time for Composites

29 Discussion and questions