Developments

Composites for car part manufacturing

The US Environmental Protection Agency (EPA) mandated in 2012 that the national automobile fleet should average 54.5 miles per gallon by 2025 in order to reduce reliance on fossil fuel and minimize emissions, many other nations have also implemented similar new standards. To meet these new standards the automotive industry has had to find new ways to make lighter cars without sacrificing their strength and structural integrity. Here Jari Sopanen, Regional Manager at leading composites manufacturer Exel composites explains why one of the best replacements for steel is thermoset components. Thermoset composites are formed using glass, carbon, or aramid fibres, which are then combined with resins such as polyesters, vinyl esters, epoxies, or phenolic resins. These composites are used in various industries but are particularly prominent in the manufacturing of aircraft and spacecraft parts. Thanks to research and development in the aerospace sector, composites are also being used across other forms of transportation due to the high demand for lightweight vehicles and components. This trend, called light-weighting, seeks to use innovative materials to reduce the weight of products. As a result, composite materials are being increasingly used in production, especially for automotive parts and components. According to the American Composites Manufacturers Associations, fiberglass is one of the key reinforcing materials used in the US thermoset composites industry. Thanks to its durable properties, it is a good replacement for steel in vehicle structural components, including drive shafts, bumpers and roof beams Reducing component weight is crucial for raising the efficiency of automotive systems. For example, carbon fibre has comparable properties to steel, but is only one-fifth the weight. Regardless of the mode of transport, it is easy to see the benefits that shaving this amount of weight from a vehicle will achieve. Additionally, when directly compared to steel, composite materials can […]

Space experts focus on small sat technology

Australia’s rebooted space industry is positioning itself as a world leader in the development of smart satellites and associated technologies that will streamline communication, drive the Internet of Things, enhance Earth Observation and shape the defence forces of the future. The Australian Government backed SmartSat CRC – or Cooperative Research Centre – is playing a leading role during “Space Week” in the South Australian capital, which includes the 8th Space Forum (formerly South Australia Space Forum) and the 19th Australian Space Research Conference. Supported by the Australian Space Agency and the SmartSat CRC, the 8th Space Forum included a panel session hosted by SmartSat CRC Industry Director Peter Nikoloff about the opportunities and challenges facing Australia’s newest major space organisation. The 19th Australian Space Research Conference followed. The A$245 million SmartSat CRC was awarded in April and has established a headquarters in Adelaide to co-ordinate its 99 industry and research partners. Nikoloff, who is also a co-founder of Adelaide-based defence and space company Nova Systems, said the panel discussion would focus on highlighting the research and application of intelligent technologies to space systems and opportunity for Australia’s growing space industry. He said the panel will seek to identify niche areas of autonomous systems and how the participating universities, industry and defence members could potentially exploit those opportunities. “The intelligent systems from our perspective aren’t just what’s on a spacecraft, we’re looking at the whole chain that goes from the spacecraft down to the ground stations and the applications of how that information is being presented,” Nikoloff said. Nikoloff said developing applications to process data and streamlining data transfer before sending it to Earth is critical as the sensing capabilities aboard satellites became more complex and data intensive. “We need to look at processing data on board the satellite through the […]

High-quality film production for next generation devices

ULVAC Inc. has announced the successful launch of PZT piezoelectric thin-film sputtering technology and a high volume manufacturing (HVM) solution to solve technical issues that have hindered the development of MEMS devices, which are crucial in applications from autonomous driving to next generation wearable terminals (such as smart glasses). The company has begun selling production systems incorporating the new technology. Evolutions in technologies such as 5G and AI are expected to accelerate the journey towards smart societies, in which the digitisation of all types of industries will improve industrial performance and enhance convenience for people. With increasing levels of multi-functionality found in autonomous driving, AR/VR, security, and smartphone applications, actuators are needed in order to activate devices based on signals received from various types of sensors. Demand for actuators is projected to explode and key issues in their development have come to the fore, including the need for miniaturization, reduced production costs, lower power consumption, and higher performance. It used to be impossible to fabricate PZT piezoelectric thin films, which constitute the key technology in sensors and actuators, using a low-temperature process with the conventional coating method (Sol-Gel). However, in 2015, ULVAC successfully developed the world’s most advanced technology for forming PZT piezoelectric thin films using a low-temperature sputtering process. ULVAC has continued developing this as next-generation MEMS technology. By further advancing this proprietary technology, ULVAC has reduced running costs by optimizing system operation and has greatly improved the technology’s reliability, which is critical for device commercialization. The result is a groundbreaking mass-production technology that is now incorporated into systems ULVAC has begun to sell. This technology allows MEMS devices to be integrated with semiconductors (CMOS), and enables other positive outcomes such as miniaturisation, reduced production costs, lower power consumption, and higher performance. It is expected to pave the way […]

Collaboration results in interleaving veils for composite toughening

New Zealand company, Revolution Fibres, has collaborated with Mitsubishi Gas Chemical Company, Inc. to develop a next-generation nanofiber interleaving veil for improving the toughness of carbon fibre composites. The new nanofibre veil material, called Xantu.Layr XLB, has particularly strong application possibilities in the aerospace sector. Xantu.Layr XLB is made from Mitsubishi’s recently developed XD10 thermoplastic, bio-based polyamide resin, LEXTER. LEXTER is a xylylenediamine-derived polyamide resin that has been demonstrated successfully as a thermoplastic matrix for composite materials. It is tough, strong, and chemically resistant, and has the added benefits of being hydrophobic and highly compatible with epoxy resin when in the form of a nanofiber veil. These properties enable Xantu.Layr XLB nanofibre interleaving veils to improve the performance of thermoset composite laminates without being compromised by exposure to high humidity, gasoline or a range of other chemicals. Another benefit of this new nanofibre veil is the lower cost of manufacture, resulting in a lower sale price. Dr. Nobuhiko Matsumoto, a Research Manager at Mitsubishi Gas Chemical, said that they “were thrilled to see LEXTER in the form of a nanofiber veil and could see many commercial possibilities for applications.” Xantu.Layr is produced using a proprietary production method (Sonic Electrospinning Technology), and is an ultra-thin non-woven web consisting of kilometre long thermoplastic nanofibres, with each one around 500 times thinner than a human hair. When placed in-between the plies of carbon fibre in a composite laminate, Xantu.Layr significantly improves the fracture toughness (delamination resistance), compression after impact strength (damage tolerance) and fatigue resistance of the composite without adding any significant thickness and weight. Xantu.Layr nanofibre veils can improve composite materials by providing nano-scale reinforcement of the brittle matrix resin, resulting in a tougher resin (even when used with already toughened resin systems) which is less prone to micro-cracking when stressed or […]

Smart technologies can improve safety in the oil and gas industry

By Gaurav Sharma, Head of Industries Business, ANZ, Cognizant Employee safety remains a key concern within the oil and gas sector. The nature of tasks and activities makes it a riskier industry than others. Workers’ fatigue is another factor increasing that risk. However, the oil and gas industry is in a prime position to take advantage of technologies such as robotics, wearables, artificial intelligence (AI) and machine-learning (ML) to minimise some of the risks, as well as drive innovation. The risks of fatigue Fatigue is a major contributor to safety incidents in the oil and gas industry. An oil and gas worker’s job includes inherently risky routine and physically demanding tasks such as positioning heavy equipment, climbing on scaffolds, and physical inspections and maintenance. Characteristics specific to the oil and gas industry are also factors increasing that risk, such as fly-in fly-out and shift work conditions, dealing with time zone changes and 24/7 operations, handling hazardous chemicals or working in extreme weather conditions. Research indicates that the injury rate of Australian shift workers is two times higher than other workers, due to fatigue-related factors such as insufficient sleep, disrupted sleep patterns, and extended working hours. Using digital technologies to predict fatigue risk There is an increasing awareness across risky industries that digital technologies have an important role to play in improving work safety. Leading oil and gas providers are now looking to improve their current standards even further through data collection, monitoring, and automation. However, there is still a long way to go to full adoption, as estimates suggest that just one percent of the data currently captured by operators is being used for improvement purposes. These technologies can provide companies with better control on workplace hazards and better training, while improving onsite communications and overall workforce and business asset […]

Sealing skills focussed on medical problem solving

A company dedicated to solving complex challenges involving seals and interfacing components involved in health care, hospital, scientific and laboratory technology is expanding its services in response to growing demand. CSGtech has expanded into larger national headquarters in Rydalmere, Sydney, sharing more extensive research, engineering and distribution facilities with its parent company Air Springs Supply, which is a long-established Australian leader in actuation and isolation technologies, including Airmount® isolators used beneath operating tables and sensitive computerised equipment. CSGtech (new website: www.csgtech.com.au) partners with clients in diverse areas of the medical and scientific community to customise high performance solutions for complex problems where seals and interfacing components must achieve durability, reliability and precision in analytical, therapeutic, surgical and research equipment, says CSGtech Manager, Mr Vinh Lam. “Sometimes the issues we address involve correct sealing of technology from ambient conditions, while in other cases they are directed at ensuring reliability and durability of wear components in service. In both cases, small but vital seals and interfacing components must be correctly specified to cope with chemicals, gases, liquids and harsh operating environments.” Mr Lam heads an expanded Sales and Technology team which brings together under one roof decades of experience in process engineering, problem solving, product development, proving and production. The team also provides expertise to CSGtech sister company Thomson Rubber Products. “Our expanded network of internationally accredited manufacturers enables us to supply an exceptionally high level of product, extending from specialist O-rings to moulded rubber fittings, fasteners and castings.” he says. “Correct seals and interfacing components are integral to a huge range of medical, healthcare and scientific technology, where they must be absolutely correct for purpose, traceable and achieve compliance with local and global standards for manufacturing, clinical, therapeutic and laboratory applications. Often the application involved may be non-standard standard technologies, where […]

HandySCAN 3D scanner meets Boeing’s requirements

Creaform, the worldwide leader in portable 3D measurement solutions and non-destructive testing (NDT) solutions, has announced that its HandySCAN 3D metrology-grade 3D laser scanner can now be used for recording physical attributes of aircraft dents and blends on all models of Boeing commercial airplanes. Boeing has released a service letter with guidance on the use of 3D scanners for measuring dents and blends on airplanes. The SmartDENT 3D solution and the flagship HandySCAN 3D scanner were used in the process of guiding Boeing’s quality requirements for the service letter. “Creaform is proud to see leaders such as Boeing, turn to 3D scanning solutions for surface defect inspection. With SmartDENT 3D, our goal is to provide the most accurate damage assessment to our customers, so they can make informed and safe decisions, while getting their aircraft back flying with minimal down time,” said Jérôme Beaumont, Global NDT Business Manager at Creaform. Overview of SmartDENT 3D benefits: Speed: 80 times faster than the pit gauge technique. It is the fastest and most reliable aircraft surface damage inspection tool available on the market. Metrology-grade measurements for aircraft maintenance: The scanner is accurate to 0.025 mm (0.0009 in.) and has a resolution of up to 0.100 mm (0.0039 in.) with high repeatability and traceable certificate. Intuitive pass/fail assessments: With its intuitive design and real-time software visualization, Creaform’s NDT solutions ensure short learning curves and minimal operator experience influence on the accuracy of results. Live visualisation and portability: Weighting less than a kilo, the handheld scanner is the perfect tool for work in hangars or directly outdoors. Users can easily perform 3D surface inspection of any part of an aircraft on which they would use manual techniques—including on and under wings. In addition to complying with Boeing’s service letter, Creaform HandySCAN 3D scanners are listed […]

Your next press release will not be written by a robot

Fears that automation will take our jobs are rife but press officers need not feel threatened by new tools that translate technical research into lay summaries. By Ruth Francis I recently attended a seminar that looked at tools we can use to help promote research. One of the panelists, Sabine Louët of Science Pod, sparked a discussion I had afterwards with two other press officers about the value we bring compared to what can be automated. Louët showed examples of news content that was written by Natural Language Processing, a sub-discipline of artificial intelligence. For example, in 2014, the first news article reporting a small earthquake in Los Angeles, California was generated in this way, and others were created from crawling data on street crime or climatic events. For those of us who struggle with headline writing, A*STAR and Singapore Press Holdings in Singapore may be able to help: they are using AI to make headlines more engaging without resorting to pure clickbait. At Science Pod, they have software that can augment the work of a press officer by automatically creating a lay summary of a research article. In this way, it demystifies the original research much like a press release. Although next-generation summaries should be good enough to publish with little human intervention, press officers need not worry. These summaries are simply straight translations, not in-depth analyses or stories that we and journalists write. A good press release should do much more than simply translate a research article. We can and should engage the reader and persuade them to find out more. We do this by adding detail gleaned by talking to the researchers, finding out why they did the work and what it adds to the field and beyond. Our ability to improve prose to clarify research, to […]

200 kilometres in eight minutes: powering the e-mobility revolution

What started as a small start-up in one of ABB’s business units almost a decade ago is now an integral part of the company’s innovative push for sustainable mobility. One innovation after another is coming from ABB developments in electric-vehicle (EV) chargers. The Terra HP is the world’s fastest EV-charger, adding up to 200 kilometres of range to an electric vehicle in just eight minutes. With the number of electric vehicles on the road rising, the global demand for powerful and energy efficient vehicle charging stations is ever increasing. ABB EV-chargers, like the Terra High Power charger, are the driving force behind the efforts of nations to reach sustainability targets and charges have become a critical part of sustainability policies. With more than 7,000 DC fast charging stations installed in 60 countries, ABB is a global leader in that segment. The technology behind e-mobility is truly coming of age, which is also shown in ABB’s partnership with the ABB FIA Formula E Championship. ABB is bringing its name, innovation and technology leadership to the first fully electric motor sport series. The ABB FIA Formula E Championship perfectly supports ABB’s belief that we can run the world without consuming the earth. The series’ next race will be in Zurich on June 10. The ascendance of sustainable mobility and the charging infrastructure required to keep electric vehicles moving is evident by the increasing number of ABB EV charging projects around the world. German energy supplier EnBW alone has 185 EV fast chargers on German motorways and in April, ABB was selected to supply its Terra HP charging stations as part of the biggest electric vehicle infrastructure project to date in the United States. The chargers were selected for deployment by Electrify America, which plans to place hundreds of charging stations within and around 17 […]

3D printing of human heart

Scientists in Israel have unveiled a 3D print of a heart with human tissue and vessels, a first and a “major medical breakthrough” that advances possibilities for transplants. Scientists hope one day to be able to produce hearts suitable for transplant into humans as well as patches to regenerate defective hearts. The heart produced by researchers at Tel Aviv University is about the size of a rabbit’s. It marked “the first time anyone anywhere has successfully engineered and printed an entire heart replete with cells, blood vessels, ventricles and chambers. People have managed to 3D-print the structure of a heart in the past, but not with cells or with blood vessels. But the scientists said many challenges remain before fully working 3D printed hearts would be available for transplant into patients. Journalists were shown a 3D print of a heart about the size of a cherry, immersed in liquid, at Tel Aviv University as the researchers announced their findings, published in the peer-reviewed journal Advanced Science. Researchers must now teach the printed hearts “to behave” like real ones. The cells are currently able to contract, but do not yet have the ability to pump. Then they plan to transplant them into animal models, hopefully in about a year. Maybe, in 10 years, there will be organ printers in the finest hospitals around the world, and these procedures will be conducted routinely. However, hospitals would likely start with simpler organs than hearts.

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