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George Epstein-Composites Aerospace Consultant
George Epstein is known for his pioneering work in a wide variety of composites and structural adhesives materials and applications. He received commendations for his work with the U.S. Navy, NASA and other programs. At the age of 83, he is now retired but continues to consult with the Aerospace Corp., the Air Force Space & Missile Systems Center and serves on the Board of Directors—Los Angeles chapter of SAMPE (Society for the Advancement of Material and Process Engineering).
What growth areas exist for composites besides renewable energy and aerospace?
I think there are several areas where composites could make a difference. For example, here in California we have water pipes made of cast iron, which corrode and eventually explode. It wastes a large amount of water in a state that already has a shortage of drinking water! Pipes made of composites would help immensely. We’ve already been using composites on boats exposed to salt water, so we ought to be able to use it on drinkable water.
I also think a lot more could be done with composites on bridges. Composites are a natural fit; they have a high strength and rigidity. I worked on a few bridge projects in California and we found that we could use composites to repair cement and concrete columns. After earthquakes, we discovered that bridges with composite columns were the most stable.
Another place there is untapped potential for composites is in pressure vessels and scuba tanks. If they were made of composites they would be a lot lighter and therefore easier to handle, making them a lot safer than metal tanks.
What do you view as the biggest accomplishment for composites?
The fact that Boeing embraced composites for its new B787 is a huge accomplishment for the industry. It strongly indicates that composites are on their way up. To me it shows that companies realize they need to utilize advanced composites in our world.
What misconceptions about composites do you encounter?
Using advanced composites is not a simple process of analysis, building and then testing. It requires an understanding of science and how the materials are created and work. To make a quality product, people need to understand how resin interacts with fibers, various molding process and what causes wrinkling. I think if purchasing companies understood those things, they’d have an easier time identifying potential problems.
Why aren’t more manufacturers making their products out of fiberglass?
When there is a failure or anomaly, such as has occurred with the Boeing 787, the mistakes are publicized, whereas successes are not. But it depends on the industry. In the aerospace industry composites are essential. There isn’t a satellite used that doesn’t rely on composites.
What impact has Boeing had on the industry?
The program started several years ago with great promise, with the usage of composites in over 50 percent of the aircraft, when typically it was only for secondary structures. This signifies a remarkable evolution. As people gained more confidence in composites usage for aircrafts, it will be used more and more. But it is a gradual evolution. Boeing took a giant step using advanced composites for its wings, fuselage, tail etc.
How do Boeing’s delays impact the composites industry?
Boeing is having serious problems, such as wrinkles in the fuselage, which could and should have been avoided. These anomalies have impacted the rollout of the 787, putting it two years behind schedule. These problems have made other companies leery of using advanced composites in their systems, mistaking correctable manufacturing problems by suppliers to inherent problems with composites. I know there are some that were planning to use composites but no longer are and others are not sure if they should. The point is, the industry has struggled since the 60s to build confidence in the material and now it’s taken a large blow.
How can the industry counteract this misperception?
The industry as a whole needs to take an example from the Manufacturing Problem Prevention Program by the Air Force Space and Missile Systems Center. It was developed when the Air Force first started testing the use of composites in their equipment to identify anomalies and failures. It permits all involved to learn, so the same mistakes aren’t repeated.
As a past university professor, what are benefits for company/university collaboration?
Universities such as Rice and Michigan State, who are leaders in nanocomposites research, are great sources for research. But like carbon fiber 40 years ago, the industry must develop, establish applications and be able to accept an initial higher cost.
What can the industry do better?
Most meetings we have today stress new developments and new technologies. They don’t emphasize lessons learned or how to avoid problems. I think a lot could be said about a portion of any website, blog, or show that focuses on learning from the past.
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