Composites: Materialising a better future Composites: Materialising a better future. Obstacles and opportunities & How African companies can tap into the global composites supply chain Prof. K. Kanny Composites Research Group Department of Mechanical Engineering Durban University of Technology Email: kannyk@dut.ac.za Tel: 031373 2230; Fax: 0313732139

Composite: Structural Particle-reinforced Fiber-reinforced Structural • Stacked and bonded fiber-reinforced sheets -- stacking sequence: e.g., 0º/90º or 0/45/90º -- benefit: balanced, in-plane stiffness • Sandwich panels -- low density, honeycomb core -- benefit: light weight, large bending stiffness honeycomb adhesive layer face sheet Adapted from Fig. 16.18, Callister 7e. (Fig. 16.18 is from Engineered Materials Handbook, Vol. 1, Composites, ASM International, Materials Park, OH, 1987.) Adapted from Fig. 16.16, Callister 7e.

OBSTACLES Production capabilities-There are no automated processors available to manufacture small and complex components to high quality standards and volumes. The majority of composites manufacturing is dependant on manual labour and craftsmanship skills High material costs- Constituent materials can be costly for the process. fibre production- inhibits high volume deployment The process of fiber preparation like embedding fibres in matrix, cutting, drying and synthesizing for processors like layup, fiber winding and pultrusion is hugely expensive

OPPORTUNITIES Light weight high strength and corrosion resistant products Less fuel consumption & road damages Less CO2 emission Greater use of automation to improve cycle times out-of-autoclave tooling New and novel processing techniques – integration of natural fibers, bio-resins, and other “green” materials development of other high performance exotic material systems

Synthesis of a Natural Resin System Cavendish Biocomposite V.Paul, K.Kanny, GG Redhi “Formulation of a novel bio-resin from banana sap” Industrial Crops and Products

Wheat Protein Isolate for Packaging Application GREEN POLYMERS Wheat Protein Isolate for Packaging Application WPI Glutaraldehyde Glycerol NaOH Nano GREEN POLYMERS Dani. Jagadeesh, B. Prem Kumar,, Jong IL Song Preparation and Properties of Propylene Glycol Plasticized Wheat Protein Isolate Green Films, Journal of Polymers and Environment (2013) 21(4):930–936.

Processing Thermoset processing SMC Fiber spraying Resin Transfer Molding Thermoplastic processing putrusion Extrusion compression Injection molding Compression molding thermoforming Resin transfer molding

Fiber treatment Clay infusion+ alkali, silane, acetylation, grafting and maleated coupling

BIOCOMPOSITES Natural Fibers Natural Resins systems SKATEBD DIVING BD TROLLEY

Natural fiber products prepared at our CRG centre, DUT Banana fiber extraction and knitting Threading and strand making Vacuum infusion of fiber mat Fiber mat epoxy composites

How Africa can be part of the global composites supply chain continuous development of new product & processes Africa benefits from export of large natural resources require innovation in processes and product beneficiation of natural resources access to unlimited markets- globalisation specialisation and the reaping of scale economies enhance production capabilities (exploiting the benefits of cluster dynamics and supply chain linkages the development of local supply chains the development of industrial clusters and supply chain upgrading beneficial insertion into global value chains Co-location - generates external economies enhances the competitiveness of firms in the cluster. build on these external economies cooperate to meet common challenges benefit from collective efficiency  

STRUCTURE & ANALYSIS IN-HOUSE BUILD MOULD DESIGN AND MANUFACTURING FOR HIGH IMPACT RESISTANCE Manufacturing of a Train nosecone demonstrator Work on the adaptation of a sisal plain weave (furnishing fabrics) for composite application

Air box as installed on the aircraft engine COMPOSITE AIR BOX FOR AIRCRAFT ENGINE: TECHNOLOGY DEMONSTRATOR – RESIN VACUUM INFUSION FOR COMPLEX SHAPED COMPOSITE PARTS USING ADDITIVE MANUFACTURED TOOLING Tooling – inner and outer tools for the bottom section of the airbox Dry- fibre preforms loaded into the bottom section outer tool Air box as installed on the aircraft engine

Composite Pedestrian Bridge

Composite Housing Slide by A. Madiba

CONCLUSION Composites based product manufacturing possess many challenges in production capabilities, production cost and high raw material cost. Equally there are many opportunities and scope for a variety of new fit for purpose applications includingthe use of biopolymers and natural fibers for biocomposites With the advent of nanofillers as a reinforcement the scope has widen The high cost may be mitigated by greater market penetration and economies of scale