Top 10 CompositesWorld articles of 2023

Photo Credit: CW

CW delved into an array of editorial content, encompassing burgeoning trends pivotal to shaping the future of the composites industry, spanning hydrogen, advanced air mobility (AAM) and more. Explore the top 10 CW articles of 2023 to catch up on what might have slipped under your radar!

10. Jeep all-composite roof receivers achieve steel performance at low mass

Photo Credit: Stellantis

Traditionally, the belief has been that longer fiber reinforcement leads to stronger composites. However, the introduction of nanocomposite additives has somewhat challenged this idea. Now, a new type of ultrashort carbon fiber-reinforced thermoplastics (CFRTP) designed for injection molding is proving to outperform both short and long fiber thermoplastics, whether glass or carbon. These materials, known as KyronMax and produced by Mitsubishi Chemical Advanced Materials Inc.(MCAM, Mesa, Ariz., U.S.), excel especially in complex shapes where achieving good fiber penetration is challenging. They not only surpass conventional thermoplastic composites but also outperform metals. A prime example is their use in the roof receivers of 2021 Jeep Wrangler SUVs and Gladiator pickups by Stellantis. This is the story behind how this application came to fruition. Read the full article.

9. Infinite Composites: Type V tanks for space, hydrogen, automotive and more

Photo Credit: Infinite Composites

Infinite Composites (Tulsa, Okla, U.S.), established in 2010, specializes in Type V composite pressure vessels, which are the lightest among various tank types due to their all-composite construction — primarily reinforced with carbon fiber and lacking a liner. However, crafting linerless tanks that maintain reliability during high-pressure conditions has been a significant challenge, as the liner usually acts as a barrier to prevent gas or cryogenic liquid permeation. Despite this hurdle, Infinite Composites has succeeded in creating these linerless tanks, ranging from 5 to 325 liters, used across industries like aerospace, aviation, transportation and gas applications. The company has obtained certifications for space systems and is actively collaborating on developing Type V tanks for hydrogen storage, including cryogenic liquid hydrogen. Through extensive testing, including pressure cycles and safety assessments, the company has proven the effectiveness of its technology across diverse applications and are now focused on scaling production for wider use. Read the full article.

8. A new era for ceramic matrix composites

Photo Credit: (top left, clockwise): GE Aerospace, MATECH, Hypersonix and ©DLR-WF via the Ceramic Network

Ceramic matrix composites (CMC) use ceramic fibers in a ceramic matrix to create strong structures that perform exceptionally well at high temperatures. GE Aerospace (previously GE Aviation, Evendale, Ohio, U.S.) produces a CMC for LEAP engines that withstands extreme heat, enabling higher efficiency and reduced fuel consumption compared to metal alloys. CMC are becoming essential in aerospace for supersonic and hypersonic vehicles due to their ability to handle these extreme temperatures. Research is underway to develop ultra-high temperature CMC for even hotter environments. Beyond aerospace, CMC are gaining traction in power generation. Limited supply of certain fibers has been a challenge, but companies are ramping up production to meet the demand. Despite challenges in production time, ongoing research aims to improve manufacturing methods and sustainability in CMC development. This article will further explore these advancements and the expanding applications of this material. Read the full article.

7. TU Munich develops cuboidal conformable tanks using carbon fiber composites for increased hydrogen storage

Photo Credit: TU Munich LCC

Fuel cell electric vehicles (FCEVs) running on hydrogen offer a zero-emission solution for climate goals, boasting quick refueling and a 500-kilometer range. Yet, their higher cost is tied to low production volumes. To cut expenses, a proposed solution involves using a single platform for both battery electric vehicles (BEVs) and FCEVs. Current cylindrical tanks for storing hydrogen don’t fit well into BEV battery enclosures, hindering this idea. However, research projects led by the Technical University of Munich (TUM, Munich, Germany) aim to develop pillow-shaped, cuboidal pressure vessels that could fit into the flat space intended for batteries. These projects, Polymers4Hydrogen (P4H) and Hydrogen Demonstrator and Development Environment (HyDDen), are creating prototypes for conformable hydrogen tanks using carbon fiber composites, with the aim to streamline production and lower costs for FCEVs. Read the full article.

6. Manufacturing the MFFD thermoplastic composite fuselage

Photo Credit: STUNNING project, GKN Fokker

The Multifunctional Fuselage Demonstrator (MFFD) program, initiated in 2014 under the Clean Sky 2 (now Clean Aviation) initiative, aims to innovate aircraft technologies and sustainability in Europe. One of its goals was to construct an 8-meter-long, 4-meter-diameter fuselage section entirely from carbon fiber-reinforced thermoplastic polymer composites, reducing fuselage weight by 10% and recurring costs by 20%, potentially enabling faster aircraft production. Airbus Research & Technology (Bremen, Germany) led the project, issuing multiple calls for proposals and engaging more than 40 companies to work on various aspects, from automated assembly to testing methods. The completed lower shell has been sent for final assembly, with plans to use laser and ultrasonic welding techniques. This article summarizes completed manufacturing steps and highlights the laser-based co-consolidation process for fuselage joints. Read the full article.

5. Plant tour: Spirit AeroSystems, Belfast, Northern Ireland, U.K.

Photo Credit: Spirit AeroSystems

The Airbus A220, previously the Bombardier CS100/CS300, has evolved into a family of single-aisle aircraft produced under Airbus Canada Limited Partnership. Initially launched in 2008, these planes entered commercial service in 2016. Airbus acquired a majority stake in the series in 2018, rebranding it as the A220 family.

Airbus aims to significantly increase production, moving from six to 14 aircraft per month by the decade’s end. It has hinted at an A220-500 variant in the works. More than 40% of the A220’s key structure is comprised of composites, providing corrosion resistance and weight advantages, resulting in enhanced fuel efficiency and reduced emissions. The wings, produced by Spirit AeroSystems (Belfast, U.K.), play a crucial role in this composite-focused construction, with Spirit gearing up for increased production and future developments in this area. CW recently visited Spirit’s facility to explore its manufacturing process and readiness for upcoming endeavors. Read the full article.

4. Plant tour: Albany Engineered Composites, Rochester, N.H., U.S.

Photo Credit: Albany Engineered Composites

Albany Engineered Composites (AEC) (Rochester, U.S.), has been at the forefront of high-quality, automated composite manufacturing since 2013, producing carbon fiber composite components like fan cases, blades and spacers for CFM International’s (Cincinnati, Ohio, U.S.) LEAP aircraft engine. These parts play a crucial role in Airbus, Boeing and Comac aircraft, making the LEAP engine a standard choice for narrow-body aircraft. Safran, the engine’s developer, revealed at an event that LEAP engines hold a significant share in the global market, with a substantial backlog of orders indicating its prominence as the largest consumer of composite fan blades worldwide. AEC’s journey from startup to an industrialized, high-volume production facility showcases the aerospace industry’s future, emphasizing the critical link between manufacturing scale and top-notch quality. The company’s success story holds valuable insights for the entire aerocomposites supply chain. Read the full article.

3. The lessons behind OceanGate

Photo Credit: OceanGate

After the loss of OceanGate’s Titan submersible earlier this year, previous CW publisher, Jeff Sloan, took time to reflect on his 2017 interview with OceanGate CEO Stockton Rush. In the interview, they discussed the innovative use of carbon fiber composites in Cyclops 2, Titan’s predecessor. Rush emphasized the challenges of the deepsea environment, weight reduction, design specifics and safety in crafting a durable submersible. Despite Rush’s passion for exploration, there seemed to be gaps in his technical expertise, relying on expert suppliers for the complex hull development. The U.S. Navy report indicating an implosion near Titan’s contact loss site confirmed the tragic loss of Rush and his team. Speculation regarding the cause flooded various media platforms, intensifying with discussions on potential blame. Read the full article.

2. Cryo-compressed hydrogen, the best solution for storage and refueling stations?

Photo Credit: Cryomotive

Hydrogen stands pivotal in the shift toward cleaner energy, vital for curbing CO₂ emissions amid the escalating climate crisis. The Hydrogen Council’s “Hydrogen Insights 2022” report underscores this, spotlighting 680 global large-scale projects funneling $240 billion into hydrogen by 2030, marking a 50% surge from 2021. Cummins’ (Columbus, Ind., U.S.) executive chairman Tom Linebarger emphasized the necessity for diverse solutions to achieve a zero-emission future, citing hydrogen’s pivotal role. Adaptable solutions within the hydrogen sector are imperative, catering to varied needs like storing and fueling different vehicles and aircraft. Recent articles have explored diverse storage options such as Type IV compressed hydrogen gas (CGH₂) tanks, liquid hydrogen (LH₂) tanks for heavy transportation and the emergence of cryo-compressed hydrogen (CcH₂) for mobility applications. Read the full article.

1. Plant tour: Joby Aviation, Marina, Calif., U.S.

Photo Credit: Joby Aviation

In the future, when historians chronicle the commercial aerospace industry of the 2020s and 2030s, advanced air mobility (AAM) will likely be featured prominently. The narrative remains uncertain — whether it will depict the rapid rise of a new global mobility paradigm or a slow adoption by the public. In its nascent stage in 2023, AAM holds immense promise, with Joby Aviation (Santa Cruz, Calif., U.S.) positioned as a frontrunner in the race to lead this revolution. Joby’s substantial funding, manufacturing prowess, flight testing and impending market entry in 2025 mark it as a primary contender in the AAM sector. A pivotal element in AAM’s development is the use of composite materials and manufacturing techniques at an unprecedented scale, a trail that companies like Joby are blazing as they innovate in both transportation and aerospace-qualified composite structures. Joby’s invitation for CW to explore its composites manufacturing facility in Marina, California, underscores its commitment to pioneering these advancements. Read the full article.