Composite materials are important to advancements in these industries because they combine the strength of fibres with the resilience of plastics. Commonly used in the aerospace sector, composites are now becoming more widely used in areas like construction (to make whole bridges, for example) and for lighter, larger and stronger wind turbines. The projects are in collaboration with the Institute for Advanced Composites Manufacturing Innovation (IACMI) and their partner companies and universities in the US.

The projects being funded are led by innovative UK composites producers, working in partnership with universities and leading research and technology organisations such as TWI and HVM Catapult Centres such as the National Composites Centre and the Advanced Manufacturing Research Centre

Simon Edmonds, Innovate UK’s, Deputy Executive Chair and Chief Business Officer

The projects are funded in the UK by the Fund for International Collaboration (FIC), which is designed to support the UK to form new and strengthen existing, bilateral partnerships for research and innovation with leading nations with a reputation for excellence. US funding has been provided by the US Department of Energy, State governments and private industry.

The seven projects, including their respective UK and USA partners, are in brief:

• CADFEC: Fibre Engineered Composites, for car components: Aston Martin and Expert Tooling and Automation, based in Coventry. U.S. partners include DowAksa, Dow Chemical, and Purdue University
• TACOMA: X-ray scanning for high-speed inspection of Automotive composite parts: TWI, Cambridge. U.S. partners include American Chemistry Council and Michigan State University
• HIPPAC: Advanced composites for stronger, lighter wind-turbine blades: Fibreforce Composites, Runcorn; Brunel University. U.S. partners include National Renewable Energy Laboratory, Oak Ridge National Laboratory, GE Energy, and Montefibre
• FibreSteer: Fibre shaping for stronger aerospace components: iComat (a University of Bristol spin-out company), National Composites Centre (part of HVM Catapult) and Airbus. U.S. partners include Airbus Americas and University of Dayton Research Institute
• FibreLoop: Re-cycling carbon fibre production waste into new high-value components: NetComposites, Chesterfield; Far-UK, Nottingham and the Advanced Materials Research Centre (part of HVM Catapult). U.S. partners include Vartega, BASF, Michelman, and Michigan State University
• ENACT: Polymer layering for ‘overmoulding’, allowing more sophisticated design for complex parts: Surface Generation, Rutland, and Nottingham University. U.S. partner is Michigan State University
• TexTape: Trying to substantially reduce the costs of carbon fibre thermoplastics: Composites Evolution, Chesterfield, and National Composites. US partner is Oak Ridge National Laboratory.

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Under terms of the agreement, Dow and Aksa will each hold a 50 percent stake in the joint venture. Following initial equity investments from the two companies, the joint venture will finance its growth through cash flow from operations and financial institutions. Total investment in the project, including third party investments, is expected to reach $1 billion U.S. dollars in five years and create up to 1,000 employment opportunities.

The joint venture will expand on Aksa’s existing carbon fibre production assets in Yalova, Turkey, and will capture growth by creating a large-scale production capability for the manufacture and supply of advanced carbon fibre technologies.

The venture will have a particular focus on bringing solutions to market that reduce overall costs, thereby enhancing economics and driving adoption in a broader array of markets. Dow Chairman and CEO Andrew Liveris said;

This partnership with Aksa is another strong example of how Dow is advancing its innovation and growth strategy, and demonstrates our unwavering commitment to invest in high-value, innovation-rich sectors through strategic partnerships. Together our companies will apply science, world-class manufacturing capabilities and technical expertise to deliver innovative solutions that address some of the world’s most pressing challenges, such as increasing the energy capture of wind turbines, improving the fuel economy of automobiles, and extending the life of roads and buildings.

Akkök Group of Companies Chief Executive Officer and Aksa Board Chairman Mehmet Ali Berkman said:

Making Turkey the second biggest acrylic fibre market in the world with its
leading position in technical fibre and production capacity in acrylic fiber, AKSA has achieved an important position in the international market with the carbon fibre. Carbon fiber composites, which will replace metal as the material of the future, have significant importance for fundamental industries in Turkey such as transportation (automobile, high speed train, vessels, heavy vehicles, etc.), wind energy technologies and construction, particularly for earthquake-resistant buildings. The recognition of carbon fibre and carbon finer composites within the scope of strategically important industries will enable Aksa and Dow to expand their joint investment targets and create significant economic value and employment for Yalova. In addition, this cooperation will contribute to 2023 targets of the Government of Republic of Turkey by creating significant added value and employment in energy efficiency, renewable energy, infrastructure investments and increasing exports.

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The group will work to accelerate the development, demonstration and commercial application of new low-cost carbon fibre and composites materials in many different industry sectors.

Charter members of the consortium include;

• Dow Chemical Company
• 3M Company
• Faurecia
• Toho Tenax America
• Plasan Carbon Composites
• Composite Applications Group
• Umeco Composites Structural Materials
• Graftech International
• United Technologies Research Center
• Harper International
• Hills Material and Chemistry Laboratory
• SSOE Group
• Innovation Valley
• UT-Battelle

For the past 10 years ORNL has led the Department of Energy’s low-cost carbon fiber initiative. ORNL is designing and constructing the Carbon Fiber Technology Facility, a $35 million pilot plant capable of producing up to 25 tons of new low-cost carbon fibers from several different precursors.

Consortium members will convene twice annually for briefings on ORNL’s research, development and demonstration efforts in carbon fibre composites, and to also provide critical insights into market trends and opportunities.

The market for carbon fiber composites is expected to grow significantly over the next several years, especially in key markets such as automotive, wind energy, oil and gas, infrastructure and various industrial applications.

Engaging industrial partners all along the value chain is a critically important aspect of ORNL’s carbon fiber composites program, our ultimate goal is to help businesses develop new commercial applications of low-cost carbon fibers and composites that will help our country address our goal of energy independence.

said ORNL Director Thom Mason.

If you would like to become a member of the consortium, membership costs are $10,000 annually or $5,000 annually for small business and universities, for more information you can download a copy of the brochure here or you can fill out the online application form here

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