Click on each speaker below to view the abstract.
Opening address by the Hon. Richard Dalla-Riva
The Hon. Richard Dalla-Riva is the Victorian Minister for Employment and Industrial Relations and Manufacturing, Exports and Trade, and has held various Shadow Ministerial roles including Manufacturing and Export, Community Development, Innovation, Scrutiny of Government, Freedom of Information, Industry & State Development and Major Projects. Minister Dalla-Riva is the State Member for Eastern Metropolitan Region.
Keynote speaker from Japan
Keynote speaker from the U.S.
Following is a list of papers, presentations, workshops and tutorials in alphabetical order by surname.
From oil to soil - Growing tomorrow's fibres (A case for the growing and processing of industrial hemp in Victoria)
The ‘decarbonisation’ of the transport system is also driving the need for lighter and more recyclable vehicles. Because of its technical characteristics of length and strength industrial hemp is a natural solution for the composite industry. Industrial hemp fibre reinforced plastics show considerable energy and greenhouse gas (GHG) savings, in comparison to their fossil based counterparts. Mr Bailey will present the case for developing an industrial hemp processing industry in Victoria.
Manufacturing of bridges using Composites
The different manufacturing processes for composite bridges are largely dictated by client needs, intent on providing simple installation, and the ideal surface finish for final users. Anurag Bansal will present the processes used to create two award-winning Spanish pedestrian bridges: The Almuñecar bridge, which employed resin infusion technology, and the Cuenca bridge, manufactured using carbon fibre pre-stressed cables as the load bearing member. This was a first in composite history for a structure of this type - at 216 metres long with three equal spans of 72 metres - made using CFRP pre-stressed cables.
The future is predatory marketing
We know the applications for fibre composites are limitless, however we’re often in a position of defending FRP technology against traditional materials in the process of pitching for business. Predatory Marketing is a new method of convincing a client. It's about standing out and being chosen above competing products, processes and countries for manufacturing. ‘Step Change’ takes you on a myth-busting ride through 'giant slaying, marketing style’, and will leave you in no doubt that the future is predatory. We'll even give you tangible and practical tools to survive.
Developing manufacturable and merchantable composite products: The Edge Project
Vaughan Bolwell, Director of Design at Bolwell Corporation, will talk about turning a composite design concept into manufacturable reality. He is responsible for the highly successful Bolwell Edge Caravan, marking the company’s 50th year in transport innovation using composites technology. In 2008 Vaughan began a design journey which resulted in production of the most innovative caravan on the market today. The project utilised Bolwell's design and engineering capability as well as their expertise in advanced composites and aerodynamic design styling.
Composites innovation at Airbus
Since the company’s inception, Airbus has established itself as a pioneer in aircraft design and manufacture, resulting in an industry – leading product line of economical and environmentally – friendly large commercial civil aircraft. Since the 1970’s, Airbus has progressively built up experience of composite materials and step-by-step increased the complexity and number of applications of composite structural applications onto jetliners. Today there are major structural composite components in the A380, including the rear unpressurised fuselage section and the centre wing box. Later this year is the first flight of the A350XWB with 53% of structural weight made of composites. The company envisions a future for improved structural efficiency via multi disciplinary and optimised design processes, multi function materials and nanotechnologies for smarter structures which span the life of the aircraft.
Tailoring laminate bend-twist coupling through ply position
The use of unbalanced symmetrical or unsymmetrical laminates is often avoided due to complex and undesirable structural behaviour, such as warping and twisting resulting from material elastic couplings. However, in fields such as aerodynamics, tailored elastic coupling can be exploited to achieve performance gains via ‘aeroelasticity’. This research explores bend-twist coupling and structural response in thin laminated cantilever beams subject to transverse loads (with a focus on ‘through thickness ply position’ effects). Lorin Coutts Smith will present the findings.
Shrinkage and warping – Understand it and avoid it
Shrinkage plagues composite manufacture, whether producing aerospace components, chemical tanks, car parts, or even playground equipment. When shrinkage is excessive parts can warp, crack, print, pre-release, or fail. However, interesting concepts and technologies can be utilised to combat the problem. Dr Chris Cranitch will describe precisely what causes shrinkage and the ways it can be minimised, including low profile polyesters, matrix controlled shrinkage epoxies and by examining thermal expansion rates of parts and moulds.
Why not to buy composites
On some projects engineers and end users have shown resistance to buying composite products in preference for alternative materials such as rubber, concrete and steel. A number of major projects which span infrastructure, chemical and mining applications have been analysed to reveal exactly what these perceived hurdles were. Dr Lucy Cranitch will present her findings and engage composite industry members to discuss solutions for the greater promotion and uptake of composites.
Composite repair technician training and certification
Safety is the primary concern in the maintenance of aircraft. There has been a rapid growth of composites used in both commercial and military aircraft. Mark Dimond will break down the regulatory data and reports to date concerning the control and repair of aircraft built with composite components. Mr Dimond will also examine recent aircraft incidents, and those relevant areas of composite repair technician training and certification.
Carbon Nexus: The Australian Carbon Fibre Research Facility
The Australian Carbon Fibre Research Facility (ACFRF), located at the Geelong Technology Precinct, Deakin University Waurn Ponds Campus, is part of the Australian Future Fibres Research and Innovation Centre (AFFRIC). The ACFRF will incorporate a pilot scale research plant capable of producing industry relevant quantities of aerospace grade carbon fibre and facilitate research into the chemical, mechanical and nano-scale characteristics of the carbon fibre product.
Development of a composite system for offshore pipeline repairs
To solve the considerable challenge of corrosion and other damage sustained by piping, pipelines and risers, widely used in the oil and gas industry, a new glass/epoxy prepreg system has been developed. Applicable for dry, wet and fully submerged underwater conditions this is highly effective for both rehabilitation and corrosion protection of steel infrastructure. Paul Falzon will present the mechanical, hydrostatic and corrosion protection testing undertaken to validate the system, and outline a new carbon fibre reinforced version.
A user friendly guide to the R&D Tax Incentive
The Research & Development Tax Incentive is described by the government as a targeted, generous and easy to access entitlement program that helps businesses offset some of the costs of doing R&D. The program is designed to help businesses undertake R&D and to innovate, all of which will assist bringing new products, processes and manufacturing advances into the Australian market place. Alan’s presentation will demystify the complexities of the R&D Tax Incentive program and explain how it applies to firms that make things.
Introduction to FEA and its use in composites design
Nowadays Finite Elements Analysis (FEA) is a more commonly used engineering tool that is critical to the reliable design and engineering of composites structure. This presentation provides a practical introduction to FEA by explaining the general processes and vocabulary used, as well as referring to some specifics of composites design. Pierre Gouhier will also describe how FEA can support the effective engineering of composites structures as they relate to final manufactured goods.
Shaping the future of FRP with additive manufacturing
Additive manufacturing (or 3D printing) is a process of making three dimensional solid objects from a virtual design or digital model using additive processes of successively layering material to form a dimensional shape. This technology is progressively challenging traditional machining techniques that rely on the removal of material by methods such as cutting and drilling. Mr Grey will outline the additive manufacturing technologies that will change the future of product design and development and accelerate the accuracy and process by which moulds are made for fibre-reinforced polymers.
The art and science of bonding composite materials
When joining composite structures there is the general option to ‘bolt’ or ‘bond’. Factors which drive this decision are structural thickness, materials being used (glass, aramid, carbon, etc.), fibre orientation and stiffness, environmental factors, loads and more. Bonding involves the complex science of adhesive joint design. Dr Heslehurst will delve into the detailed and evolving design issues that ultimately determine successful joint design and fabrication. Of central importance, ply layup configuration, peel and taper arrangement.
The effect of resin flow additives on the mechanical properties of vacuum infused composites
For both end-user and fabrication requirements additives are often added to resin systems. In processes such as ‘Vacuum Infusion’ solvent is added to improve resin infusion rates. Also, fire and smoke inhibiting agents may be added to resin to meet specific certification authority regulations. In this investigation both an additive and solvent were separately added to a resin mix for infusion into a glass fibre composite, via vacuum assistance. Rikard Heslehurst will present the findings.
JAXA, CERC, and aviation: Moving beyond metals
Keynote speaker from Japan:
Dr Takashi Ishikawa of the Composite Engineering Research Center (CERC) based in Nagoya University, Japan, directs a team which investigates advanced composites and their capabilities. Recent developments for Boeing have included the application of carbon fibre reinforced plastic (CFRP) in aircraft. Exceptionally strong and lightweight, additional benefits are derived creating a cabin of largely non-corrosive material, where humidity levels may be elevated for passengers. Dr Takashi will present on the outcomes of recent CERC research for Japanese and international aviation, and particular methods used in the development of these breakthrough CFRP’s.
Dr Martin Jones - Intellectual Property and Quality Manager, Advanced Composite Structures Australia Pty LtdUsing incentive schemes to fund your company’s initiatives - A guide for 2013
State government vouchers, enterprise connect incentives and the core federal R&D Tax Credit are among the wide range of incentives that can be leveraged by composites companies to make a significant improvement to their bottom line. Incentives can help a company achieve key objectives, while reducing or even eliminating the investment made. Unfortunately, each incentive has different eligibility and entitlement rules. Mr Jones will suggest ‘adopting’ an incentive to do what the organisation had planned to do anyway - modifying the business plan just enough to meet the criteria.
Damage detection techniques for geometrically complex composite structures
Traditional non-destructive evaluation (NDE) methods used to characterise materials and inspect products are visual, operator-dependent, and subjective - often slow and imprecise. New methods use automated, digital techniques such as digital radiography and computed tomography, which can be manipulated for computational analysis. Dr Khatibi presents an experimental study on NDE methods for complex shaped composite structures - such as vehicle composite wheels - using a novel Laser Scanning Vibrometery (LSV) technique, for high-speed identification of manufacturing defects and service damage. This paper investigates the capability and sensitivity of LSV.
Use of CNC in the manufacture of composite parts and tooling
Core Builders Composites have been highly successful in their approach to integrated Computer Numerically Controlled (CNC) technology, used to manufacture tooling for composite parts used in boatbuilding. In 2012 Core successfully built 10 identical 45’ wing-sailed catamarans in a single year and is currently building the AC72 catamarans that will defend the America’s Cup in 2013. Susan Lake will present the integrated use of CNC technology. Also, the key features of tooling used for ambient out-of-autoclave and autoclave composite curing. The primary goal has been to maximise the efficiencies possible for the manufacture of composite parts.
Numerical modelling of glass fibre metal laminates subjected to high velocity impact
As a type of fibre metal laminate, ‘glass fibre metal’ laminates (GLAREs) exhibit superior properties to conventional lamina, and to monolithic aluminium alloys. - GLARE is extensively used in the aviation industry due to its light-weight and impact resistant qualities. Chengjun Liu presents the finite element model (FEM), or numerical model, developed to predict dynamic behaviour of a GLARE beam under high velocity impact (HVI). (Validated against a FEM created for basic ‘glass fibre composite’ lamina only). The FEM for GLARE can computationally predict HVI results well, and may be suitable for investigating impact on different composite laminates, as well as different GLAREs.
Composites in the solar industry
The explosion of alternative energy generation in Australian homes has been satisfied by fixed photovoltaic and heat absorbing panels. CME has been working with an Australian company to develop an electricity / hot water cogeneration system that combines these functions in one package. The core of this technology is solar cells bonded to a heat exchanger that generates electricity, while the waste heat is used to produce hot water. Phil Maxwell will outline this system, also able to track the sun, and the potential for successful manufacture in Australia.
Improving carbon nanotube alignment in nanocomposites
There are significant challenges in scaling up carbon nanotubes (CNTs) into larger structures (macroscopic structures) that express the same, or similar, qualities of bonding strength suitable for fibres/textiles. Proven techniques are by twisting or using solvent to give ‘aligned’ CNTs density and strength. The first step, traditionally, has been to mobilise or break apart the tiny CNTs so they can then be appropriately aligned. Dr Menghe will present a different method, which uses a lubricant to more gently loosen the CNTs, followed by a drawing out operation which slides them into superior longitudinal alignment, to enhance strength.
Use of fibre reinforced polymer linings for controlling corrosion in mineral and chemical processing industries
Fibre reinforced (FRP) epoxy vinyl ester resin demonstrates excellent chemical resistance. When applied as a protective lining for highly corrosive materials of construction, such as steel and concrete (commonly found in tanks, process vessels and piping) this material requires minimal maintenance over the life of the equipment. As an alternative to rubber lining fibre reinforced epoxy vinyl ester resin is also simple to apply. Frank Mizzi will explain how selecting the appropriate resin is fundamental to liner performance, and how outstanding abrasion resistance can be achieved through various additives during the formulation stage.
Advanced Manufacturing CRC
Innovativity Workshop - Pre empting the market
INNOVATIVITY® is a real-world innovation management training program developed by the Advanced Manufacturing Cooperative Research Centre (AMCRC) to provide Australian organisations with the skills and tools to grow profit and reach global markets through innovation.
AMCRC has extensive experience in backing high tech, IP based projects providing you with real insight into what Australian companies really need to commercialise technology. AMCRC doesn't just teach innovation, it backs its own projects. Funding and commercialising Australian IP is their core business - real Innovators telling real stories about real experiences around products and services in the real world. This two hour workshop will give you insight into one of the learning areas of the 3 day program – “Pre-empting the Market” which provides your business the tools to develop and apply a formal process to planning the next generation of novel products and processes.
Creating new opportunities through composites engineering
Many new markets are opening up to the use of composites. However, it can be daunting to approach an opportunity when composites are unfamiliar to stakeholders. Different terminology, unknown Standards, cost structures and networks create unfamiliar territory for the composites fabricator. Tanya Redfern will describe the active role DIAB has played in approaching new potential market segments. The DIAB vision is to provide increased opportunities for composite fabricators by actively familiarising potential new end-users with the versatility and durability of composite materials. This presentation provides an overview of avenues to entry, feedback and learnings, gleaned from DIAB’s global experience.
GFRP, composite action, sandwich structure
Fibre Reinforced Polymer (FRP) composites are increasingly being used in structural engineering due to their high strength, low weight and resistance to corrosion. This paper describes an innovative modular assembly system of FRP sandwich structures used for beams and slabs in building construction. Sindu Satasivam presents the findings, and explains the potential prefabrication and rapid onsite installation, now possible.
Project managing structural beam innovation and development for Deepsea Challenger
This paper reports on the project scheduling, methodology and innovative approach to developing and constructing the main-structural beam for the Deep Challenger submersible. The Submersible, a single piloted deep sea exploration vehicle, was conceptually discussed eight years ago. Work-breakdown structure approaches and parallel processing allowed significant development work and construction to coincide during 2011 and 2012. The buoyancy material, ISOFLOAT®, developed and patented by Ron Allum & James Cameron was utilised to construct the main structural beam for the submersible. The main structural beam sub-project ran for 12 months and enabled the pilot sphere and all the equipment to return to the surface as designed. The size of the main structural beam meant it received full-ocean depth pressure (1,000 MPa) on the record-breaking dive. This presentation will highlight some of the risks tackled, time constrained project development and final delivery of this composite beam to the assembly team, on the date scheduled.
The use of composites in fire resistant-critical applications
With fire safety requirements in architecture, infrastructure and public transport the composites industry is tasked with finding solutions to meet the required standards, while maximising the benefit of advanced composite construction. Gurit has been involved in many projects where fire resistance has been a key objective, and has carried out a number of in-house and project-specific research initiatives to examine optimal approaches for tackling these challenges. Mr Stanton will provide an overview of the issues, plus a number of case studies from different market sectors which highlight particular areas to be addressed for fire safety and compliance.
The mechanical properties of epoxy based hybrid biocomposites reinforced with harakeke and hemp fibres
Harakeke is the Maori name for the New Zealand native plant commonly known as New Zealand flax. Long fibre extracted from harakeke leaves has an extensive history, used in the production of clothes, sacking and rope. Now harakeke is being investigated for use in composites. For this research Tan Minh Le explains how the harakeke fibre was hybridised with hemp fibre in epoxy resin. Hybrid composites with different layering patterns were prepared using hand lay-up, followed by compression moulding, to evaluate the full range of strength and flexibility.
The global carbon fibre market
Coating, composite, and metal technologies enhance the performance of today’s products, while emerging platform technologies like graphene and 3D printing advance the frontier of tomorrow’s material capabilities. However, even the most remarkable materials won’t generate profits without properly crafted and informed strategies (Lux Research). Mr Vicari will present on the global carbon fibre market.
Keynote speaker from the U.S:
Insights into Composite Manufacturing
Cutting-edge ‘óut-of-autoclave’ technology, developed for composite curing during manufacture, has been utilised by NASA as they seek new methods to reduce the weight and cost of launch vehicles used in space exploration. Through the ‘Composite Cryotank’ project John Vickers engineered a cryotank spanning almost 10 metres in diameter for storing super-cold fuels. Mr Vickers will explain parallel developments in both cryotank and out-of-autoclave technologies, further opening up the US aerospace industry, along with new areas of renewable energy manufacture, to small business.
Performance of multi-step bonded repairs of composites under compression loading
With the increased use of fibre-reinforced composites for aircraft, cost effective repairs that comply with safety standards become a major factor in the overall life-cycle costing. Multi-step bonded repair is a major technique used to restore the structural integrity of composite structures that have suffered damage during service. Prof Chun Wang, Director of Sir Lawrence Wackett Aerospace Research Centre (RMIT University), will present an experimental investigation of the fracture behaviour of multi-step bonded joints under compressive loading - particularly after sustaining impact damage.
3D weaving for large scale composite production on conventional narrow looms
3D woven fabrics are about to shift from niche markets to large scale applications. For example, Airbus will be using 3D woven carbon turbine blades in new LEAP engines for the A320neo. Due to the complex ‘weave architecture’ these fabrics require careful testing. Benedikt Wendland will present the dependencies evident between weaving parameters and impact properties, along with a cost calculation tool which is programmed to compare conventional prepreg to 3D woven and RTM-impregnated parts.
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