JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - 33

applications. With an increased global awareness of the environmental challenges facing the world, there is a demand to develop bio-based composite solutions. Reinforcing mats have been developed that replace synthetic fibres with natural fibres such as flax, kenaf and hemp. These fibres have a lower density than their glass counterparts. The biomats show promise for replacing fibreglass chopped strand mats in some structural applications, as well as acting as an infusion media. Polyurethane cores are being replaced by cores that are either fully or partially bio-derived from crops such as soy. There is also a variety of resins being introduced to the market that have significant biocontent from soy bean or nut oils. Biocomposite parts, especially those made from thermoplastic resins, are thus trending towards becoming completely biodegradable and/or compostable.

Hybridization
Another trend in the use of composite materials is the hybridization of different material systems. The purpose of hybridization is to use each material in locations where it will offer the most advantage. For example, lightweight, environmentally-friendly biomats can be combined with strong, directional fibreglass mats. The biomats decrease the weight of the part and reduce the amount of synthetic fibres required, while the fibreglass mats provide the required strength. Some mat manufacturers are now supplying reinforcing mats that combine fibreglass and carbon fibres. In this case, the carbon fibres provide extremely high stiffness while the fibreglass is included in order to reduce costs. Hybridization can also take the form of using metals in strategic areas where the composite material may be at a disadvantage. This is leading to the development of improved bonding materials and techniques to join metals to

composites, and composites to composites, which reduces the number of fasteners required in an assembly. In many applications in the past, metallic parts were directly replaced by composite materials with no changes made to the design. Although this process usually worked, it did not provide an opportunity to take full advantage of all the properties offered by composite materials. More emphasis is now being placed on designing parts specifically for the use of composites. One such example is the replacement of an assembly of numerous metallic parts with a single composite component. Complex geometry may require a component to be split into many metal parts, but the same geometry can be built using a single composite mould. This can result in major savings in assembly time and costs, as well as reducing inventory part counts. It also eliminates many fasteners and often results in a lighter part. To support this composite design philosophy, the CIC utilizes finite element analysis software that is specifically tailored for orthotropic and composite materials. Cores are modelled using 3-dimensional elements to accurately calculate the

through-thickness shear stress and identify any potential areas of core crushing. The laminates are modelled using 2-dimensional shell elements that allow for the calculation of stress and strain in each ply and are capable of performing ply-by-ply failure analysis. The analysis is supported by an extensive composite material property database that has been generated to aid the ground transportation industry.

Current applications
Several examples of the current applications of composite materials in ground transportation vehicles are described below. In one instance, the CIC has been performing design and analysis work on the Kestrel automobile that is being developed by Motive Industries of Calgary, Alberta. The Kestrel is an electric vehicle demonstrator that utilizes several new technology platforms including natural materials. The vehicle has front and rear tubs that are a hybrid of bio-based and synthetic composite materials that act as major structural components. The geometry of the tubs is very complex and would be difficult to manufacture using traditional methods. The tubs must be able to withstand bending, torsion and

Fig.1 : Conceptual design of the Kestrel automobile (a), Ply failure analysis of the rear tub (b), Composite front and rear tubs attached to the metallic frame (c), Through thickness shear stress in the soy core of the front tub (d)

No69 November - December 2011 / jec composites magazine

33

Feature land transportation



JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011

Table of Contents for the Digital Edition of JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011

Cover
Edito
Point of view - Umeco: focused on growth
Contents
Agenda of Events
COMPANY & BUSINESS
- In brief
- Australia - A continuous fibre tissue machine at Regina Glass Fibre
APPLICATIONS
- Marine - Signature marine projects and record-breaking super yacht
- Automotive - World’s first production-ready thermoplastic wheel rim
- Building & construction - A definite and technical success to help the fight against AIDS
MARKET
- China - The Chinese composite market: bright prospects
- CFRP - Wind surpasses aerospace as top user of advanced compositematerials
- Sustainability - Acting on sustainability for business value
FEATURE LAND TRANSPORTATION
- Raw material - Resin and gelcoat compliant with the new railway standard
- Prepreg - Phenolic prepreg is welcome aboard Bombardier’s class 379 Electrostar EMU passenger trains
- Sandwich construction - Rolling stock: weight reduction pays off
- CFRP - New carbon-fibre-reinforced composite for vehicle bodies and electric vehicles
- Design - Next generation composites – driving innovation in the ground transportation sector
- Structures - Hybrid structures for tailored structural automotive components
- Process - Composite reduces vehicle and sunroof weight and enables assembly and process innovations
RESEARCH & DEVELOPMENT
- Joining - Investigating the properties and failure mechanisms of a damage-tolerant 3D-reinforced joint for lightweight structures
- Bonding - 3D sandwich panel manufacturing with great properties as result
TECHNOLOGY & INNOVATIONS
- Corrosion - Glass fibre reinforcement type determines FRP corrosion performance
- Thermoplastics - The promise of fibrereinforced thermoplastics: low weight and recyclability
- Manufacturing - New mould manufacturing process
- Foam - A new product range for marine applications
Index
In the world
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - Cover
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - 2
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - Edito
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - Point of view - Umeco: focused on growth
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - 5
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - Contents
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - 7
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - 8
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - COMPANY & BUSINESS
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - - In brief
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - - Australia - A continuous fibre tissue machine at Regina Glass Fibre
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - - Marine - Signature marine projects and record-breaking super yacht
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - 13
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - - Automotive - World’s first production-ready thermoplastic wheel rim
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - - Building & construction - A definite and technical success to help the fight against AIDS
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - 16
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - 17
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - - China - The Chinese composite market: bright prospects
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - 19
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - - CFRP - Wind surpasses aerospace as top user of advanced compositematerials
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - - Sustainability - Acting on sustainability for business value
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - 22
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - 23
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - - Raw material - Resin and gelcoat compliant with the new railway standard
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - 25
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - 26
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - - Prepreg - Phenolic prepreg is welcome aboard Bombardier’s class 379 Electrostar EMU passenger trains
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - - Sandwich construction - Rolling stock: weight reduction pays off
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - 29
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - - CFRP - New carbon-fibre-reinforced composite for vehicle bodies and electric vehicles
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - 31
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - - Design - Next generation composites – driving innovation in the ground transportation sector
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - 33
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - 34
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - - Structures - Hybrid structures for tailored structural automotive components
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - 36
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - 37
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - - Process - Composite reduces vehicle and sunroof weight and enables assembly and process innovations
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - - Joining - Investigating the properties and failure mechanisms of a damage-tolerant 3D-reinforced joint for lightweight structures
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - 40
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - 41
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - 42
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - 43
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - 44
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - - Bonding - 3D sandwich panel manufacturing with great properties as result
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - 46
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - 47
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - 48
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - - Corrosion - Glass fibre reinforcement type determines FRP corrosion performance
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - 50
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - 51
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - - Thermoplastics - The promise of fibrereinforced thermoplastics: low weight and recyclability
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - 53
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - - Manufacturing - New mould manufacturing process
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - 55
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - - Foam - A new product range for marine applications
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - Index
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - In the world
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - 59
JEC COMPOSITES MAGAZINE - Issue #69 - November/December 2011 - 60
https://www.nxtbook.fr/newpress/jeccomposites/jcm2211_148
https://www.nxtbook.fr/newpress/jeccomposites/jcm2209_147
https://www.nxtbook.fr/newpress/jeccomposites/jcm2206_146
https://www.nxtbook.fr/newpress/jeccomposites/jcm2204_145
https://www.nxtbook.fr/newpress/jeccomposites/jcm2201_144
https://www.nxtbook.fr/newpress/jeccomposites/jcm211_143
https://www.nxtbook.fr/newpress/jeccomposites/jcm2109_142
https://www.nxtbook.fr/newpress/jeccomposites/jcm2107_141
https://www.nxtbook.fr/newpress/jeccomposites/jcm2105_140
https://www.nxtbook.fr/newpress/jeccomposites/jcm2103_139
https://www.nxtbook.fr/newpress/jeccomposites/jcm-experts-digest-additive-manufacturing-2020
https://www.nxtbook.fr/newpress/jeccomposites/jcm2101_138
https://www.nxtbook.fr/newpress/jeccomposites/jcm2011_Special_Issue4
https://www.nxtbook.fr/newpress/jeccomposites/jcm2011_137
https://www.nxtbook.fr/newpress/jeccomposites/jcm2009_136
https://www.nxtbook.fr/newpress/jeccomposites/jcm2007_135
https://www.nxtbook.fr/newpress/jeccomposites/jcm_2020_Q1_Innovation_Report
https://www.nxtbook.fr/newpress/jeccomposites/jcm2005_Special_Issue3
https://www.nxtbook.fr/newpress/jeccomposites/jcm2005_134
https://www.nxtbook.fr/newpress/jeccomposites/jcm2003_133
https://www.nxtbook.fr/newpress/jeccomposites/jcm2001_132
https://www.nxtbook.fr/newpress/jeccomposites/jcm1911_Special_Issue2
https://www.nxtbook.fr/newpress/jeccomposites/jcm1911_131
https://www.nxtbook.fr/newpress/jeccomposites/jcm1909_130
https://www.nxtbook.fr/newpress/jeccomposites/jcm1907_129
https://www.nxtbook.fr/newpress/jeccomposites/jcm1905_128
https://www.nxtbook.fr/newpress/jeccomposites/jcm1903_Special_Issue1
https://www.nxtbook.fr/newpress/jeccomposites/jcm1903_127
https://www.nxtbook.fr/newpress/jeccomposites/jcm1901_126
https://www.nxtbook.fr/newpress/jeccomposites/jcm1811_125
https://www.nxtbook.fr/newpress/jeccomposites/jcm1810_124
https://www.nxtbook.fr/newpress/jeccomposites/jcm1808_123
https://www.nxtbook.fr/newpress/jeccomposites/jcm1807_122
https://www.nxtbook.fr/newpress/jeccomposites/jcm1805_121
https://www.nxtbook.fr/newpress/jeccomposites/jcm1804_120
https://www.nxtbook.fr/newpress/jeccomposites/jcm1803_119
https://www.nxtbook.fr/newpress/jeccomposites/jcm1802_119-Supplement_Innovation_Report
https://www.nxtbook.fr/newpress/jeccomposites/jcm1801_118
https://www.nxtbook.fr/newpress/jeccomposites/jcm1711_117
https://www.nxtbook.fr/newpress/jeccomposites/jcm1710_116
https://www.nxtbook.fr/newpress/jeccomposites/jcm1708_115
https://www.nxtbook.fr/newpress/jeccomposites/jcm1707_114
https://www.nxtbook.fr/newpress/jeccomposites/jcm1706_113
https://www.nxtbook.fr/newpress/jeccomposites/jcm1704_112
https://www.nxtbook.fr/newpress/jeccomposites/jcm1703_111
https://www.nxtbook.fr/newpress/jeccomposites/jcm1701_110
https://www.nxtbook.fr/newpress/jeccomposites/jcm1611_109
https://www.nxtbook.fr/newpress/jeccomposites/jcm1610_108
https://www.nxtbook.fr/newpress/jeccomposites/jcm1608_107
https://www.nxtbook.fr/newpress/jeccomposites/jcm1607_106
https://www.nxtbook.fr/newpress/jeccomposites/jcm1605_105
https://www.nxtbook.fr/newpress/jeccomposites/jcm1604_104
https://www.nxtbook.fr/newpress/jeccomposites/jcm1603_103
https://www.nxtbook.fr/newpress/jeccomposites/jcm1601_102
https://www.nxtbook.fr/newpress/jeccomposites/jcm1511_101
https://www.nxtbook.fr/newpress/jeccomposites/jcm1510_100
https://www.nxtbook.fr/newpress/jeccomposites/jcm1509_99
https://www.nxtbook.fr/newpress/jeccomposites/jcm1507_98
https://www.nxtbook.fr/newpress/jeccomposites/jcm1505_97
https://www.nxtbook.fr/newpress/jeccomposites/jcm1504_96
https://www.nxtbook.com/newpress/jeccomposites/jcm1503_95
https://www.nxtbook.com/newpress/jeccomposites/jcm1501_94
https://www.nxtbook.com/newpress/jeccomposites/jcm1412_93
https://www.nxtbook.com/newpress/jeccomposites/jcm1410_92
https://www.nxtbook.com/newpress/jeccomposites/jcm1409_91
https://www.nxtbook.com/newpress/jeccomposites/jcm1406_90
https://www.nxtbook.com/newpress/jeccomposites/jcm1405_89
https://www.nxtbook.com/newpress/jeccomposites/jcm1404_88
https://www.nxtbook.com/newpress/jeccomposites/jcm1403_87
https://www.nxtbook.com/newpress/jeccomposites/jcm1401_86
https://www.nxtbook.com/newpress/jeccomposites/jcm1311_85
https://www.nxtbook.com/newpress/jeccomposites/jcm1310_84
https://www.nxtbook.com/newpress/jeccomposites/jcm1308_83
https://www.nxtbook.com/newpress/jeccomposites/jcm1307_82
https://www.nxtbook.com/newpress/jeccomposites/jcm1305_81
https://www.nxtbook.com/newpress/jeccomposites/jcm1304_80
https://www.nxtbook.com/newpress/jeccomposites/jcm1303_79
https://www.nxtbook.com/newpress/jeccomposites/jcm1301_78
https://www.nxtbook.com/newpress/jeccomposites/jcm1212_77
https://www.nxtbook.com/newpress/jeccomposites/jcm1210_76
https://www.nxtbook.com/newpress/jeccomposites/jcm1208_75
https://www.nxtbook.com/newpress/jeccomposites/jcm1207_74
https://www.nxtbook.com/newpress/jeccomposites/jcm1206_73
https://www.nxtbook.com/newpress/jeccomposites/jcm1204_72
https://www.nxtbook.com/newpress/jeccomposites/jcm1203_71
https://www.nxtbook.com/newpress/jeccomposites/jcm1201_70
https://www.nxtbook.com/newpress/jeccomposites/jcm1111_69
https://www.nxtbook.com/newpress/jeccomposites/jcm1110_68
https://www.nxtbook.com/newpress/jeccomposites/jcm1108_67
https://www.nxtbook.com/newpress/jeccomposites/jcm1107_66
https://www.nxtbook.com/newpress/jeccomposites/jcm1105_65
https://www.nxtbook.com/newpress/jeccomposites/jcm1104_64
https://www.nxtbook.com/newpress/jeccomposites/jcm1103_63
https://www.nxtbook.com/newpress/jeccomposites/jcm1101_62
https://www.nxtbook.com/newpress/jeccomposites/jcm1011_61
https://www.nxtbook.com/newpress/jeccomposites/jcm1010_60
https://www.nxtbook.com/newpress/jeccomposites/jcm1009_59
https://www.nxtbook.com/newpress/jeccomposites/jcm1006_58
https://www.nxtbook.com/newpress/jeccomposites/jcm1005_57
https://www.nxtbook.com/newpress/jeccomposites/jcm1004_56
https://www.nxtbook.com/newpress/jeccomposites/jcm1003_55
https://www.nxtbook.com/newpress/jeccomposites/jcm1001_54
https://www.nxtbook.com/newpress/jeccomposites/jcm0911_53
https://www.nxtbook.com/newpress/jeccomposites/jcm0910_52
https://www.nxtbook.com/newpress/jeccomposites/jcm0909_51
https://www.nxtbook.com/newpress/jeccomposites/jcm0907-08_50
https://www.nxtbook.com/newpress/jeccomposites/jcm0906_49
https://www.nxtbook.com/newpress/jeccomposites/jcm0904_48
https://www.nxtbook.com/newpress/jeccomposites/jcm0903_47
https://www.nxtbook.com/newpress/jeccomposites/jcm0901_46
https://www.nxtbook.com/newpress/jeccomposites/jcm0811_45
https://www.nxtbook.com/newpress/jeccomposites/jcm0810_44
https://www.nxtbook.com/newpress/jeccomposites/jcm0809_43
https://www.nxtbook.com/newpress/jeccomposites/jcm0807_42
https://www.nxtbook.com/newpress/jeccomposites/jcm0806_41
https://www.nxtbook.com/newpress/jeccomposites/jcm0805_40
https://www.nxtbook.com/newpress/jeccomposites/jcm0803_39
https://www.nxtbook.com/newpress/jeccomposites/jcm0801_38
https://www.nxtbook.com/newpress/jeccomposites/jcm0712_37
https://www.nxtbook.com/newpress/jeccomposites/jcm0710_36
https://www.nxtbook.com/newpress/jeccomposites/jcm0709_35
https://www.nxtbook.com/newpress/jeccomposites/jcm0707_34
https://www.nxtbook.com/newpress/jeccomposites/jcm0706_33
https://www.nxtbookmedia.com