Upload
others
View
5
Download
0
Embed Size (px)
Citation preview
Completely Renewable and Recyclable “Green” Composites
for Automotive Industry
Iryna Gagauz
www.bris.ac.uk/composites
Introduction
Prediction for 2050: 2 billion cars on the road !!!!
Completely Renewable and Recyclable “Green” Composites for Automotive
Industry
Introduction
Source: J. Sutherland, et al, “A global perspective on the environmental challenges facing the automotive industry: state-of-the-art and directions for the future,”
7-8 million tonnes of automotive waste every year in European Union
Completely Renewable and Recyclable “Green” Composites for Automotive
Industry
EU Directive 2000/53/EC on End-Of-Life Vehicles:
Aims:• Reduce the amount of waste produced from vehicles when they are
scrapped.• Limit the use of hazardous substances and increase the quantity of
recycled material used in the manufacture of vehicles.• Encourage producers to design vehicles for easy recycling• Ensure producers pay all or a significant part of the costs of free take-
back of no or negative value vehicles to treatment facilities (since 2007).
• Set recovery and recycling targets for producers to achieve by 1 January 2006 and 1 January 2015
Target (2015):• reuse and recovery: 95 % by an average weight per vehicle and year. • reuse and recycling: 85 % by an average weight per vehicle and year.
Completely Renewable and Recyclable “Green” Composites for Automotive
Industry
Henry Ford’s Model-T
Hemp panels
Hemp ethanol fuel
Hemp plastic panels said to be 30% lighter than a steel
Impact strength was 10 times stronger than steelSource: http://www.corbisimages.com/stock-photo/rights-managed/U1776993/henry-
fords-soybean-car
Completely Renewable and Recyclable “Green” Composites for Automotive
Industry
Green compositesAdvantages:
Environmentally friendly Light Recyclable Good sound insulation Renewable recourses Favourable mechanical properties
Challenges: Hydrophilic Poor fibre/matrix bonding Improvement of strength and toughness Cost-effective processing techniques
Completely Renewable and Recyclable “Green” Composites for Automotive
Industry
Current ApplicationInterior parts: Exterior parts:
the Mercedes-Benz TravegoCoach: flax reinforced engine/transmission cover;
Mercedes-Benz A-Class:the spare wheel compartment cover
various panels shelves trim parts brake shoes
Car’s manufactures:
Source: http://www.globalhemp.com/2011/02/automotive-composites.html
Completely Renewable and Recyclable “Green” Composites for Automotive
Industry
Green Composites
Completely Renewable and Recyclable “Green” Composites for Automotive
Industry
NATURAL FIBRES
BIOPOLYMERS
Natural Fibres (1)VEGETABLE
BAST:flax, kenaf, hemp, jute, ramie, isora
LEAF:sisal, abaca, curaua, palm
SEEDS:coton, coir, kapok, soya
FRUIT:luffa
GRASS:Bamboo, totora
WOOD:hardwood, softwood
ANIMAL
WOOL AND HAIR:sheep, camel, goat, horse, rabbit
SILK:natural, spider silk
MINERAL
ASBESTOS
GLASS
MINERAL WOOL
BASALT
CERAMIC
ALUMINIUM
CARBON
SILICATE
BORATE
Completely Renewable and Recyclable “Green” Composites for Automotive
Industry
Natural Fibres (2)
Completely Renewable and Recyclable “Green” Composites for Automotive
Industry
Advantages (in comparison with glass fibres) The production of natural fibres is less hazardous Possible reduction of polymer base content Fewer emissions in the manufacturing stage of the eco-composite part Production of more fuel efficient cars due to low density of natural
fibres
Excellent choice for specific automotive application:Flax Kenaf Hemp Jute Curaua
Biopolymers
Completely Renewable and Recyclable “Green” Composites for Automotive
Industry
THERMOSETS THERMOPLASTICS
Obtained from natural oils(e.g. soybean, castor, linseed)
Low cost
Availability in large quantity
Renewability
Environmentally friendliness
Good tensile strength and flexural properties
Polylactic acid (PLA)• derived from raw materials (e.g.corn) • good strength properties• but brittle
Polyhydroxyalcanoates (PHA)• produced by bacteria fermentation• high melting point• stiffer but brittle
Thermoplastic starch• produced from corn, potato or
wheat• sensitive to humidity• often used to “extend” other
polymers
Processing of Natural FibresPHYSICAL TREATMENT CHEMICAL TREATMENT
BUT: large quantities of hazardous chemicals are usually involved in the process; high costs of the complicated techniques
Corona or plasma treatment: improvement of mechanical
properties
effect of hydrophobicity
Silane, alkaline, enzyme treatment, acetylation, maleatedcoupling : increasing adhesion of NF with
matrix, improvement thermal stability
Completely Renewable and Recyclable “Green” Composites for Automotive
Industry
Nanoparticles
Source: H. Qian, E. S. Greenhalgh, M. S. P. Shaffer, and A. Bismarck, “Carbon nanotube-based hierarchical composites: a review,”
Adding nanoparticles into matrix:
Possible to use sawdust, wood dust and cellulose nanofibres
Very little material is needed (typically <2vol%)
Improvement of mechanical properties
Nanoparticles non-uniform distribution
Chemical pre-treatment is necessary in case of nanocellulose
Completely Renewable and Recyclable “Green” Composites for Automotive
Industry
Grafting:
Nanocellulose attached onto hemp and sisal surfaces (Hierarchical structures)
Improvement of matrix dominated properties, such as interlaminar shear strength
Improvement of fibre/matrix interface
Improvement of water resistance
Nanoparticles
Source: H. Qian, E. S. Greenhalgh, M. S. P. Shaffer, and A. Bismarck, “Carbon nanotube-based hierarchical composites: a review,”
Conclusions1. Green composites are eco-friendly and economical materials
2. The application of green composites is possible in the automotive industry
3. Action should be undertaken in solving challenges related to green composites (moisture absorption, poor fibre/matrix interaction)
4. Grafting of eco-nanoparticles could be the best solution for material property improvement
5. Traditional manufacturing techniques can be used to produce green composites (e.g. RTM, compression and injection moulding)
Completely Renewable and Recyclable “Green” Composites for Automotive
Industry
Thank you for attention!
Questions?
Completely Renewable and Recyclable “Green” Composites for Automotive
Industry