Mineral/microfibrillated cellulose composite materials: High performance products, applications, and product forms

TAPPI Journal ◽  
2018 ◽  
Vol 17 (09) ◽  
pp. 507-515 ◽  
Author(s):  
David Skuse ◽  
Mark Windebank ◽  
Tafadzwa Motsi ◽  
Guillaume Tellier
Keyword(s):  
Composite Materials ◽  
High Performance ◽  
Aqueous Suspension ◽  
Production Capacity ◽  
Cost Savings ◽  
Cost Effective ◽  
New Materials ◽  
Wet Strength ◽  
Product Forms ◽  
Cellulose Composite

When pulp and minerals are co-processed in aqueous suspension, the mineral acts as a grinding aid, facilitating the cost-effective production of fibrils. Furthermore, this processing allows the utilization of robust industrial milling equipment. There are 40000 dry metric tons of mineral/microfbrillated (MFC) cellulose composite production capacity in operation across three continents. These mineral/MFC products have been cleared by the FDA for use as a dry and wet strength agent in coated and uncoated food contact paper and paperboard applications. We have previously reported that use of these mineral/MFC composite materials in fiber-based applications allows generally improved wet and dry mechanical properties with concomitant opportunities for cost savings, property improvements, or grade developments and that the materials can be prepared using a range of fibers and minerals. Here, we: (1) report the development of new products that offer improved performance, (2) compare the performance of these new materials with that of a range of other nanocellulosic material types, (3) illustrate the performance of these new materials in reinforcement (paper and board) and viscosification applications, and (4) discuss product form requirements for different applications.

Co-ground mineral/microfibrillated cellulose composite materials: Recycled fibers, engineered minerals, and new product forms

TAPPI Journal ◽  
2021 ◽  
Vol 20 (1) ◽  
pp. 49-58
Author(s):  
DAVID SKUSE ◽  
JONATHAN PHIPPS ◽  
TOM LARSON
Keyword(s):  
Composite Materials ◽  
Cost Savings ◽  
Cost Effective ◽  
Microfibrillated Cellulose ◽  
High Solids ◽  
Recycled Pulp ◽  
Recycled Fibers ◽  
Equivalent Strength ◽  
Product Forms ◽  
Selection Of

When pulp and minerals are co-processed in suspension, the mineral acts as a grinding aid, allowing cost-effective production of mineral/microfibrillated cellulose (MFC) composite materials. This processing uses robust milling equipment and is practiced at industrial scale. The resulting products can be used in many applications, including as wet- and dry-strength aids in paper and board production. Previously, we have reported that use of these MFC composite materials in fiber-based applications allow generally improved wet and dry mechanical properties with concomitant opportunities for cost savings, property improvements, or grade developments. Mineral/MFC composites made with recycled pulp feedstocks were shown to offer at least equivalent strength aid performance to composites made using virgin fibers. Selection of mineral and fiber allows preparation of mineral/MFC composites with a range of properties. For example, the viscosity of such formulations was shown to be controlled by the shape factor of the mineral chosen, effective barrier formulations were prepared, and mineral/MFC composites with graphite as the mineral were prepared. High-solids mineral/MFC composites were prepared at 75% total solids (37% fibril solids). When resuspended and used for papermaking, these high-solids products gave equivalent performance to never-dried controls.

scholarly journals Challenges and Opportunities in Remote Laser Welding of Steel to Aluminium

2019 ◽  
Vol 269 ◽  
pp. 02012 ◽  
Author(s):  
Hiren R. Kotadia ◽  
Pasquale Franciosa ◽  
Dariusz Ceglarek
Keyword(s):  
Laser Welding ◽  
Aluminium Alloys ◽  
High Performance ◽  
Cost Savings ◽  
Critical Factor ◽  
Cost Effective ◽  
Automotive Body ◽  
Design Flexibility ◽  
Challenges And Opportunities ◽  
Remote Laser Welding

In the last two decades, the automotive industry has been facing demands to reduce fuel consumption and to meet CO2 emissions through applications of lightweight materials. Therefore, aluminium alloys have replaced substantial amounts of steel; and they are receiving significant attention to achieve greenhouse emission targets. However, a critical factor in applications of advanced aluminium in automotive Body in White (BIW) designs depends on availability of cost effective and high performance joining processes. Currently, a Self-Pierce Riveting (SPR) process is extensively used for aluminium BIW sheet metal parts joining which is expensive, additionally increase the weight of the vehicle and cause inefficiency in manufacturing operations. As aluminium alloys are difficult to weld by conventional technologies such as electrical resistance spot welding, MIG arc welding etc., various joining technologies had proposed to weld aluminium alloys and dissimilar alloys over the years. Often, these technologies restrict design flexibility and are expensive for mass production. In this context, Remote Laser Welding (RLW) has gained popularity because of its distinct advantages such as design flexibility, production speed, material and cost savings. This paper provides a critical review of challenges and opportunities for application of RLW to dissimilar metal welding of steel to aluminium. Next steps of research and development are also highlighted.

A comparative study of mechanical and machining performance of polymer hybrid and carbon fiber epoxy composite materials

2021 ◽  
pp. 096739112110206
Author(s):  
A Tamer Erturk ◽  
Eser Yarar ◽  
Fahri Vatansever ◽  
Alp Eren Sahin ◽  
Mert Kilinçel ◽  
...  
Keyword(s):  
Composite Materials ◽  
Carbon Fiber ◽  
Glass Fiber ◽  
High Performance ◽  
Cost Effective ◽  
Fiber Reinforced Polymers ◽  
Fiber Reinforced ◽  
Machining Performance ◽  
Polymer Hybrid ◽  
Carbon Fiber Epoxy

Fiber-reinforced plastics are known as advanced composite materials thanks to their high strength and lightweight features. Carbon fiber reinforced polymers (CFRPs) are one of the high-performance and high-cost fiber-reinforced polymer (FRPs) materials. They are used in several high-performance engineering applications such as motorsports, marine, aviation, energy and defense industry. The cost of carbon fiber is higher compared to many other materials, more competitive and cost-effective productions will spur the demand for composite parts exponentially. Thus, hybrid laminate composite containing carbon and glass fiber materials were manufactured as an alternative for CFRP materials. Because using glass fiber prepreg instead of carbon fiber prepreg will lead the material to become cheaper. However, machining of the FRP materials is still an important issue. For this reason, the present study is focused on the mechanical and machining performance of the polymer hybrid and carbon fiber epoxy composites.

Development of New Materials for Construction Sector Obtained from Renewable Resources

2013 ◽  
Vol 649 ◽  
pp. 231-235
Author(s):  
Sebastian Teodor Aradoaei ◽  
Mihaela Mosneagu ◽  
Raluca Darie ◽  
Gabriela Constantinescu
Keyword(s):  
Composite Materials ◽  
Renewable Resources ◽  
High Performance ◽  
Mechanical Characteristics ◽  
Wood Dust ◽  
Residential Construction ◽  
Construction Sector ◽  
New Materials ◽  
Composites Materials ◽  
Recycled Polyethylene

Article tries to highlight the advantages of using in construction area of composites materials obtained from recycled polyethylene and wood dust in the presence of compatibilizing agents. The composite materials have been evaluated in terms of dielectric properties and mechanical characteristics to take into account for the optimum materials structure. The advantage of composite materials made of plastic is that those can be designed in accordance with the formulas of composite plastic and technology to achieve high performance properties in a wide variety of commercial and residential construction applications.

Preconstruction Priming: A Cost-Effective Solution to Painting Ship Ballast Tanks

2004 ◽  
Vol 20 (02) ◽  
pp. 122-129
Author(s):  
Benjamin S. Fultz
Keyword(s):  
High Performance ◽  
Protective Coatings ◽  
Cost Savings ◽  
Surface Preparation ◽  
Cost Effective ◽  
Labor Cost ◽  
New Construction ◽  
Ballast Tanks ◽  
High Performance Coating ◽  
The Cost

In both Asia and Europe, preconstruction primers (PCP) are routinely used and retained as an integral part of the coating system. The retention of PCPs can significantly reduce the painting cost of new ship builds. The cost of protective coatings (paint) application in new construction can be upwards of 10% of the total ship cost. The process is labor intensive; therefore, it is logical that most savings are derived from reducing labor steps. Retaining PCP eliminates the necessity of a second blast operation, thus reducing labor cost and hazardous waste disposal cost. This paper addresses the feasibility of retaining PCP as the permanent primer for protective coatings systems applied in such high-performance areas as exterior hull, underwater bottom, and most importantly ballast tanks. Should the retention of PCP be proven as a viable option, the process of coatings application can be improved resulting in significant cost savings. Spending of new construction dollars will not be necessary to remove the PCP prior to the application of high-performance coating and lining systems. The test program discussed in this paper was based on work sponsored by the National Shipbuilding Research Program Advanced Shipbuilding Enterprise (NSRPAES) and the US Navy. The Surface Preparation and Coatings Panel, SP3, of the Ship Production Committee formulated the program and provided direction during the course of the work. The Ship Production Committee is one of SNAME's nine technical and research committees, and consists of the chairman supported by the ship production major initiative panel chairs and selected others.

scholarly journals Recent History, Types, and Future of Modern Caisson Technology: The Way to More Sustainable Practices

2018 ◽  
Vol 10 (11) ◽  
pp. 3839 ◽  
Author(s):  
Eduardo Cejuela ◽  
Vicente Negro ◽  
Jose María del Campo ◽  
Mario Martín-Antón ◽  
M. Dolores Esteban ◽  
...  
Keyword(s):  
Roman Empire ◽  
Composite Materials ◽  
Cost Effective ◽  
New Materials ◽  
Environmental Product Declaration ◽  
Ancient Times ◽  
Recycled Composites ◽  
The Moment ◽  
The Cost ◽  
Water Depths

The construction of caisson breakwaters dates from ancient times (Brindisi battle and Caesarea Maritima, Roman Empire) of yore but has evolved with regards to technology and the materials available at all times (wood, gravel, and rubble mound). The growth in draught in vessels searching for deep water depths for berthing plus environmental problems have led to the 20th century facilitating the boom in vertical types and concrete caissons built in different ways (dry and floating techniques). Furthermore, structural criteria gave way to functional, environmental, and aesthetic criteria. The search for new, more efficient forms led to the construction of increasingly more complex elements including many that still require an economically viable construction system. To where will this search for new materials and forms take us? The use of composite materials could be considered, at the moment, as too expensive, but analyzing the cost with a wider approach, as Life Cycle Assessment, shows us that caissons in composite materials are cost effective and could be a solution. Furthermore, the possibility of using recyclable composites opens up big opportunities of using these materials at affordable costs. Caissons in composites or recycled composites are then a real alternative to concrete caissons. In Spain, two examples can be observed: a berthing area in Canary Island (Puerto del Rosario, South Atlantic Ocean) and a crown wall in Cartagena using polyester fiber bars (Mediterranean Sea). European policy in matters of sustainability promotes the circular economy, which means not only consider construction of caissons in recycled composites should be considered but also the comparison of all materials and construction procedures. Lastly, the calculation of the Environmental Product Declaration (EPD) should be promoted.

Niobium-Bearing Offshore Plate Steel Process Metallurgy, Design and Quality

2016 ◽  
Author(s):  
Steven G. Jansto
Keyword(s):  
Corrosion Resistance ◽  
High Performance ◽  
Cost Savings ◽  
Value Added ◽  
Cost Effective ◽  
Offshore Structures ◽  
Offshore Platforms ◽  
Low Carbon ◽  
Steel Mill ◽  
Excellent Corrosion Resistance

Offshore structural steel design and material requirements continue to present increasing challenges for the steelmaker and fabricators. Niobium-bearing steels currently play a key role in meeting these objectives through the Nb-grain refinement mechanism of the microstructure and cost effective steelmaking. These steels possess a combination of exceptional properties with high strength, excellent weldability, high toughness at low temperature, good ductility, excellent corrosion resistance, and high formability. Reduced variation of Charpy toughness through the thickness of heavy plates is imperative in these offshore platforms to enhance reliability and performance. Toughness variation can be reduced through the proper continuous casting and hot rolling mechanical metallurgy process. These high-performance steels (HPS) possess an optimized balance of these properties to provide maximum cost effective performance in offshore structures at strength levels from 355 to 700MPa with excellent corrosion resistance. This combination of good strength-toughness balance, excellent weathering properties and reduced preheat temperatures for welding in these low carbon Nb-structural steels result in significant cost savings. These enhancements provide structural engineers the opportunity to further improve the structural design and offshore platform performance. Lower carbon Nb-alloy designs have exhibited reduced operational production cost at the steel mill as well, thereby embracing the value-added attribute Nb provides to benefit both the producer and the end user throughout the supply chain.

scholarly journals Factors determining the relevance of creation research infrastructure for the synthesis of new materials in the framework of the implementation of the priorities of scientific and technological development of Russia

2020 ◽  
Vol 22 (4) ◽  
pp. 298-301
Author(s):  
A. A. Zatsarinny ◽  
K. K. Abgaryan
Keyword(s):  
Composite Materials ◽  
Computer Modeling ◽  
High Performance ◽  
Defect Formation ◽  
Technological Development ◽  
Physical Structure ◽  
Research Infrastructure ◽  
Modern World ◽  
World Knowledge ◽  
New Materials

In the modern world, knowledge and high technologies determine the effectiveness of the economy, can radically improve the quality of life of people, modernize infrastructure and public administration, and ensure law and order and security. The creation of a research infrastructure based on a high-performance hybrid cluster enabled detailed calculations of complex phenomena and processes without full-scale experiments. It has become possible to most efficiently apply modern methods of multiscale computer modeling when developing prototypes of new materials with desired properties for their further synthesis. Such approaches can significantly reduce the cost and speed up the development of modern technologies for producing new semiconductor materials for nanoelectronics, composite materials for the aerospace industry and others. Thus, the use of multiscale modeling methods in combination with the use of high-performance software tools made it possible to create a computer model of a nanoscale heterostructure, develop tools for predictive computer modeling of the physical structure of nanoelectronic devices, the neuromorphic architecture of multilevel memory devices, defect formation in composite materials, and others.

Regulatory and sustainability initiatives lead to improved polyaminopolyamide epichlorohydrin (PAE) wet-strength resins and paper products

TAPPI Journal ◽  
2018 ◽  
Vol 17 (09) ◽  
pp. 519-532 ◽  
Author(s):  
Mark Crisp ◽  
Richard Riehle
Keyword(s):  
Health And Safety ◽  
Cost Effective ◽  
Worker Safety ◽  
Regulatory Requirements ◽  
Wet Strength ◽  
The Past ◽  
Consumer Safety ◽  
Federal Institute ◽  
Sustainability Initiatives ◽  
The Impact

Polyaminopolyamide-epichlorohydrin (PAE) resins are the predominant commercial products used to manufacture wet-strengthened paper products for grades requiring wet-strength permanence. Since their development in the late 1950s, the first generation (G1) resins have proven to be one of the most cost-effective technologies available to provide wet strength to paper. Throughout the past three decades, regulatory directives and sustainability initiatives from various organizations have driven the development of cleaner and safer PAE resins and paper products. Early efforts in this area focused on improving worker safety and reducing the impact of PAE resins on the environment. These efforts led to the development of resins containing significantly reduced levels of 1,3-dichloro-2-propanol (1,3-DCP) and 3-monochloropropane-1,2-diol (3-MCPD), potentially carcinogenic byproducts formed during the manufacturing process of PAE resins. As the levels of these byproducts decreased, the environmental, health, and safety (EH&S) profile of PAE resins and paper products improved. Recent initiatives from major retailers are focusing on product ingredient transparency and quality, thus encouraging the development of safer product formulations while maintaining performance. PAE resin research over the past 20 years has been directed toward regulatory requirements to improve consumer safety and minimize exposure to potentially carcinogenic materials found in various paper products. One of the best known regulatory requirements is the recommendations of the German Federal Institute for Risk Assessment (BfR), which defines the levels of 1,3-DCP and 3-MCPD that can be extracted by water from various food contact grades of paper. These criteria led to the development of third generation (G3) products that contain very low levels of 1,3-DCP (typically <10 parts per million in the as-received/delivered resin). This paper outlines the PAE resin chemical contributors to adsorbable organic halogens and 3-MCPD in paper and provides recommendations for the use of each PAE resin product generation (G1, G1.5, G2, G2.5, and G3).

Parallel Computing for Tire Simulations

2011 ◽  
Vol 39 (3) ◽  
pp. 193-209 ◽  
Author(s):  
H. Surendranath ◽  
M. Dunbar
Keyword(s):  
High Performance ◽  
Effective Means ◽  
Cost Effective ◽  
Turnaround Time ◽  
Careful Consideration ◽  
Rolling Contact ◽  
Element Analysis ◽  
Parallel Solvers ◽  
Design Changes ◽  
Highly Nonlinear

Abstract Over the last few decades, finite element analysis has become an integral part of the overall tire design process. Engineers need to perform a number of different simulations to evaluate new designs and study the effect of proposed design changes. However, tires pose formidable simulation challenges due to the presence of highly nonlinear rubber compounds, embedded reinforcements, complex tread geometries, rolling contact, and large deformations. Accurate simulation requires careful consideration of these factors, resulting in the extensive turnaround time, often times prolonging the design cycle. Therefore, it is extremely critical to explore means to reduce the turnaround time while producing reliable results. Compute clusters have recently become a cost effective means to perform high performance computing (HPC). Distributed memory parallel solvers designed to take advantage of compute clusters have become increasingly popular. In this paper, we examine the use of HPC for various tire simulations and demonstrate how it can significantly reduce simulation turnaround time. Abaqus/Standard is used for routine tire simulations like footprint and steady state rolling. Abaqus/Explicit is used for transient rolling and hydroplaning simulations. The run times and scaling data corresponding to models of various sizes and complexity are presented.

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