SAE 2014 Design, Manufacturing and Economics of Composites

Technical Session Schedule

Wednesday, June 11

Day Two: Automotive, Wind Energy and Other Composites
(Session Code: DTMC2)

Room Habana  ALL DAY

Time Paper No. Title
9:00 a.m. ORAL ONLY
The Future of Thermoplastic Composites
Composite materials show a very high lightweight potential due to the low density of the single components, especially in comparison to materials like steel. In addition to weight reduction there are some other aspects, such as surface quality, paint ability, function integration, and sustainability in terms of recyclability, which determine significantly the use of composites.
Luisa Medina, Institut für Verbundwerkstoffe GmbH
9:30 a.m. ORAL ONLY
Automation in Composites - Are We There Yet?
Automation in composite production has seen a huge increase over the last years, e.g. with ATL, AFP, and automated RTM lines. Management of part production companies expect this equipment to be “single push button” solutions. This presentation is about the actual current status of equipment, and whether it can actually fulfill this demand.
Michael Muser, Ingersoll Machine Tools Inc.
10:30 a.m. ORAL ONLY
Structural Health Monitoring Technologies Applicable to Composite Wind Turbine Blades
SHM is defined as “the process of acquiring and analyzing data from on-board sensors to evaluate the health of a structure.” (SAE-ARP6461). It is clear that large wind turbine blades, and particularly offshore systems, may benefit from a fully automated surveillance procedure for continuous monitoring of peak structural loads, and early damage detection, with considerable savings in maintenance. This presentation reviews the basic concepts to implement a SHM system on a large composite structure (sensor selection and embedability issues, algorithms for data processing, system considerations). Examples of current usage are given.
Alfredo Guemes, Universidad Politécnica de Madrid
11:00 a.m. ORAL ONLY
The Increasing Migration of High Strength Composite Materials And Processes Into The Manufacture of High Strength Advanced Wind Turbine Blades and Towers.
As wind turbine blades and towers have grown in size, original materials and manufacturing processes have failed to translate to a robust design for use in harsh environments. This presentation will describe the current move towards high strength carbon fiber blades using aerospace manufacturing methods for the production of very large blades and towers. Examples and new blade designs using foam core GFE skinned blades will be provided.
George Nicholas Bullen, Smart Blades Inc.
11:30 a.m. ORAL ONLY
AMTL - Automated Multi-Tape Layer, a step forward on the ATL technology
Most aircraft part manufacturers using Automated Tape Layer machines have faced the dilemma of whether using wider tape material in order to maximize the productivity or narrower material in order to minimize the amount of scrap material or to meet the steering needs in certain areas of the part.
Manu Motilva, Mtorres Group
1:00 p.m. ORAL ONLY
Reclaiming and Repurposing Carbon Fiber
James Stike, Materials Innovation Technologies LLC
1:30 p.m. ORAL ONLY
Five Design Issues that Drive Cost and Producibility
When engineers transition from designing for metals to composites, it is common for them to make a variety of poor design decisions that can have a significant negative impact on the cost and producibility of a design. These mistakes are generally related to common misunderstandings about how composites are produced and how composite material properties differ from those found in metals. This presentation will discuss some of the average design mistakes that are made, how they can be avoided, and how composite designs can be substantially improved by utilizing the inherent benefits of composites through conscientious, informed design.
John Wanberg, Metropolitan State University
2:00 p.m. ORAL ONLY
Engineering Software for Designing Cost Effective Composite Lightweight Automotive Structures
Discussion on Industry trends for the use of composite materials in light weight structures. This talk will describe use of engineering software tools for engineering with composite materials. Final discussion on factors to consider when making tradeoffs of performance, cost and weight when designing lightweight composite automotive structures .
David Watson, Siemens PLM Software
2:30 p.m. ORAL ONLY
High Volume Composites
Gary R. Lownsdale, Plasan Carbon Composites
3:30 p.m. ORAL ONLY
Reclaiming and Repurposing Carbon Fiber
James Stike, Materials Innovation Technologies LLC
4:00 p.m. Panel
Expert Panel Discussion: The Economics and Value Proposition of Composites
Moderators - Carroll G. Grant, Aerospace Composites Consulting
Panelists -
George Nicholas Bullen, Smart Blades Inc.
David M. Champa, M Torres Group
Dan Day, Boeing
Gary R. Lownsdale, Plasan Carbon Composites