Pricing and Turnaround

According to Perry Martin of Martin Testing Laboratories in McClellan, Calif.[MS1] , price is a determining factor. “Anyone can find test labs on the internet or directories. The buyers get a list of labs, send requirements out and price plays heavily in their decision.” Closely related to this is turnaround, or the time in which testing is completed. “We have found that the quality, turnaround time, and customer service that people expect trump most other considerations,” says Mary Ann Acresi of the M&P Lab in Schenectady, N.Y. Jim Carnahan, who independently runs Edison Analytical Laboratories in Schenectady, makes this a focal point of his business. “Something we try to offer, which differentiates us from multi-person lab aggregators, is to turn a job around in quicker time, say in three days instead of ten,” he says.

Qualifications

Take a close look at what a business has to offer. “You can tell a lot by seeing the certifications of the companies a firm is working with,” says Harry Hansen of Hansen Aerospace Laboratory in Danvers, Mass. “Anyone can purchase a piece of equipment and put a promotion on their website that they can run a test,” notes Alan Boerke of Q-Lab Corporation in Cleveland, Ohio. “But if there’s no accreditation, you have to wonder if they will run the test properly, and should you make a business decision based on that?” Some companies, like Intertek Plastics Technology Laboratories in Pittsfield, Mass., stress their accreditations for precisely this purpose. “What that does is provides proficiency-type guidelines regarding your capabilities,” says Jim Galpo of Intertek.

Longevity

Some laboratories point to how long a firm has been in business as another factor often raised by customers. “The experience level of the testing company is important. Not only in terms of depth of experience, but also in terms of the longevity in providing that service. It’s a multi-dimensional, experience-based expectation,” says Paul Braun of Cincinnati Testing.

Equipment

Another important consideration is availability to proper equipment and standards for conducting testing. ‘Not just in terms of conducting test, but also using the materials that might be tested because a metal will test different than a composite,” says Braun. “It could be beneficial for customers to see some actual inspection results on an image,” says Hansen. Boerke notes that industry approvals is important, but doing due diligence in researching materials, looking at science and spectrums is very important. “Don’t base your choice just off who’s been out there a long time,” he says.

Whatever the case may be, the important thing for manufacturers to consider is to be well-informed. With laboratories offering a variety of services and features, it is best to talk to a variety of firms to figure who best suits your needs.

No top hat needed here, as Scott Bader has upgraded its new Crystic Fireguard 75PA intumescent topcoat. The new Excel version of the product offers better fire-retardant properties and significant handling improvements, yet is still cured with a standard MEKP catalyst (2 percent addition by weight). It has been used for interior parts in buildings, rail and other public transport vehicles, as well as in the marine sector where it is used to protect the engine compartments of both pleasure craft and working boats. The company says upgrades in the Excel edition include improved consistency and cure, with much better handle ability. The upgraded product has been implemented by such companies as Wright Composites, which incorporated it into a range of different bus parts which can go up to 10 sq. meters in size.

Plataine is not softening its efforts in composites as it unveils its FabricOptimizer software for composite parts manufacturers. FabricOptimizer is part of Plataine’s Total Production Optimization (TPO) product suite that offers composite parts manufacturers an integrated solution for dynamic nesting, optimized material-selection and cut-planning. Integrated to the manufacturer’s ERP/MRP and CAD systems, TPO creates ready-to-cut production plans by optimally selecting the composite fabric rolls to use, and generating the optimal nests for each roll. TPO achieves this by matching the orders’ due dates and product quantities with actual inventory data (such as material expiration date, width & length). TPO also considers the full order plan for additional optimization opportunities. In addition to optimizing daily operations, the company says TPO now enables manufacturers to use FabricOptimizer as a cost estimation tool for bids and RFQs.

Ritchey keeps on riding along with the launch of new lightweight road materials. The SuperLogic wheels have 46mm deep aero rims with glass-reinforced Scrim sidewalls to cope with the heat of hard and/or prolonged braking and to prevent rim deformation. The hubs are cold forged Ritchey SuperLogics with new SKF bearings, the rear one featuring a forged six-pawl micro-clutch freehub body for fast engagement when you kick the cranks round. The company is also releasing bar designs in carbon fiber and alloy. The WCS Carbon Curve comes in a shallow drop (128mm) and short reach (73mm) that the company says suit riders looking for a slightly more upright than normal, back-friendly ride position.

Sometimes, it takes more than one set of minds to make the best product. With that in mind, Goodrich Corporation and Lockheed Martin Aeronautics are teaming to design and develop polymer matrix composite (PMC) landing gear drag braces for the F-35 Lightning II. In addition, Goodrich signed an agreement with Netherlands-based Fokker Landing Gear for the supply of PMC drag braces for the F-35’s main landing gear. Goodrich is the exclusive landing gear system supplier and integrator for the F-35. Under the three-year agreement, Goodrich and Fokker will work together to design, qualify and produce prototype PMC drag braces to be incorporated into the main landing gear for F-35 conventional take-off/landing (CTOL) and short take-off/vertical landing (STOVL) variants. The companies say that compared to the metallic drag brace equivalent, using PMC materials will result in reduced weight and lower maintenance costs over the life of the F-35.

the new Vector Series Model VB10C by Liquid Process Systems

Liquid Process Systems hopes to have the whole package with its Vector Series Model VB10C Thermal Fluid Filtration System, a heat transfer fluid filtration system specifically developed for the polyethylene terephthalate (PET) plastic packaging industry This is designed to keep thermal fluids or hot oil clean for higher heat transfer and plant efficiency, longer fluid life and minimum maintenance downtime. System flow and pressure available from the plant process is used to re-circulate fluid or hot from the pump discharge through the filter. Clean fluid is then returned to the suction side of the pump.

MAG is going retro…sort of. A new CNC retrofit program from the company is designed to get machines upgraded and back into production quickly, with pre-engineered application software and mechanicals that reduce installation and run-off time. MAG has pre-engineered retrofit kits available for G&L vertical turning lathes and horizontal boring mills, Cincinnati Cinturn lathes and Arrow, Sabre and Lancer vertical mills. A retrofit kit is also available for MAG aerospace profilers. The retrofit program is designed to be modular, offering control-only, control and servos, or control, servo and spindle options.

VAST Enterprises realesed the Pro Pavers for contractors

VAST Enterprises, LLC is further paving the road of green masonry by releasing the newest product in its line of VAST Pro Pavers for professional contractors: VAST Composite Permeable Pavers. VAST Composite Permeable Pavers reduce rain runoff into storm drains and decrease storm water pollutants by infiltrating rainwater on building sites. The pavers have a tested infiltration rate of more than 450 inches per hour (4.9 gallons per square foot per minute) when installed with aggregate conforming to ASTM D448 No. 8. The pavers weigh 8.2 pounds per square foot, versus 30 or more pounds per square foot for concrete permeable pavers.

Heads are spinning at Quantum as they unveil a new Accurist PT spinning fishing reel. The product features a graphite-composite-aluminum frame, which the company implemented to provide a tough exterior and keep drive and pinion gears stayed amply aligned, while 10 total stainless bearings provide long-term smooth internal operations. The reel weighs 9.2-ounces, which the company says is one of the lightest in its class. The reel also features performance-tuned components like a bend resistant, nickel titanium bail wire that has a lifetime warranty.

If job creation is the next phase of economic recovery, the renewable energy industry is doing its part. Vestas announced it will hire more than 1,000 people at three Colorado-based turbine manufacturing plants after receiving a surge of orders. Daewoo finalized an agreement with the government of Nova Scotia, Canada to build a wind turbine plant, creating 120 jobs within the first year and up to 500 in the next three. Meanwhile, support for ‘green’ initiatives from governments and industry continues to grow. State lawmakers in Massachusetts moved ahead with a bill that would make it easier for wind projects to receive permits and overcome opposition, while GE issued a call for entries in a 10-week contest to speed global power-grid upgrades, promising investment and marketing help for the best submissions, to the tune of $200 million. Also, the Sierra Nevada Corporation provided $1 million to the University of Nevada, Reno for research into a transportable, renewable energy generating system. The project will bring together the mechanical, thermal, electrical, chemical and advanced composites departments within the university. However, reaching renewable energy goals is still a distant future for some: With six months left to hit their target, California utilities struggle to meet mandated renewable-power requirements.

Boeing grabbed most headlines in this week’s aerospace news. The new 787 aircraft made its European debut on Monday at the UK-based Farnborough International Airshow, and the F-15 Silent Eagle demonstrator made its first flight, used to validate the initial engineering design approach. The company forecasts a $3.6 trillion market for new commercial airplanes over the next 20 years.

In marine news, U.S. Navy vessel manufacturer Northrop Grumman is considering a sale or spinoff of its shipbuilding unit; but will take several quarters to make a decision. UK-based Composite Mouldings is now manufacturing pram dinghies made entirely of surplus materials, thus preventing large amounts of waste within the yard.

Carbon fiber applications continue to find acceptance in the automotive and motor sports market. Lamborghini opened an Advanced Composites Research Center (ACRC) in the brand’s hometown of Sant’Agata Bolognese. The facility will research cutting-edge carbon fiber production and design processes. The Indy Racing League announced it will stick with current chassis-builder Dallara for the next generation of lighter-weight, all-carbon fiber chassis. Tesla Motors announced it will soon tour its pure-electric, hand-build carbon fiber Roadster. And after a fatal accident in Seattle last week, the NHRA announced that carbon fiber brake rotors and pads will be a mandatory part on Top Fuel dragsters and cars by August 11, 2010.

In other news, West Virginia University Professor Barbero, of mechanical and aerospace engineering, recently completed a second edition of “Introduction to Composite Materials Design”, aimed at undergraduate students and practicing engineers. Core-composites supplier Tricel Honeycomb announced Sue Mesmer as its new customer service manager.

Buehler reveals its new ReVel diamond abrasive discs

Buehler has some revealing news: the company says its ReVēl (pronounced “reveal”) diamond abrasive grinding/polishing discs feature technology that prepares specimens from planar grind to final polish in four to seven minutes, reducing total polishing time by 63 to 78 percent, on respective materials. The discs are also designed to reduce cleaning/changeover time by 25 percent, reduce the number of steps by 25 percent and reduce the number of consumables to order by 33 percent. ReVēl’s diamond abrasive nanotechnology features diamond particles (coarse for high removal rates) coated with smaller colloidal silica particles (fine for polishing) to create a simultaneous material removal/polishing action. The company also claims two minutes of use with a disc that replaces all intermediate polishing steps between grinding and final polish.

LumenGel Ltd. is reaching the finish line with its new in-line gel coat finishing system for pultrusion products. This patent pending technology allows pultruded parts to be gel-coated in-line with a durable, near zero VOC gel coat developed by Red Spot Paint & Varnish Co., Inc. The in-line coating system allows users to finish parts with a durable gel coat that provides significant advantages over post painting at competitive prices. The system is designed to provide cost savings through lower energy cure requirements, rapid production of finished parts, low scrap rates, modular production/fabrication ability, low labor costs, and less manufacturing space required. This advanced coating system is easily retrofitted to existing pultrusion lines and is now available for world wide applications.

Wheeling onto the page is Kistler Group’s new RoaDyn S615: a wheel force transducer tailored to address issues such as weight and rolling resistance. Reduced vehicle masses and narrower tires allow further reduction of the weight of the carbon fiber reinforced plastic (CFRP) components of the transducer. It consists of an aluminum rim ring and matching wheel disk manufactured from carbon fiber reinforced plastic. The positive and frictional connection of these components ensures great strength. The inner part represents the connection with the hub and is also made of CFRP. It is optimized for recording load spectra for durability, vehicle dynamics and power train investigations.

The Hirxch Group launched a new generation of composite transport pallets

The Hirsch Group is launching a new generation of composite transport pallets designed to be a lightweight alternative to traditional wood pallets. Engineers at Hirsch used BASF styrene butadiene copolymer Styroflex 2G66 as a toughness modifier for the HIPS (High-impact polystyrene) film that protects the lightweight core of the new pallets against damage. In order to minimize the weight of their new plastic pallet, Hirsch developed a rigid and strong core made of expanded polystyrene for this standard transport structure. The one to two-millimeter 2G66 skin is designed to wrap the pallet tightly and withstand damage daily routine of logistical operations. The company says the product that weighs up to 75 percent less than wooden pallets or solid plastic pallets.

Coats aren’t too common in the summer – unless you’re referring to material surfaces. Mikron Industries launched its new SuperCoat window coating for composite window and door manufacturers, especially those competing in the replacement market. The new coating technology features a patented durable color coating system, which is vacuum-applied and cured by ultraviolet light. The company says its system offers a color surface that is eight times harder than paint, and is also a much more environmentally sensitive system than paint since it is a zero volatile organic compound (VOC) technology. The technology is only available to Mikron’s partners producing PVC, composite or fiberglass window and door profiles.

The next time you’re cruising on your motorcycle, you may want to ride composites style with a helmet from Davida. Its new Ninety Two model is a lightweight helmet weighing just over 2.43 pounds. The small-profile helmet has been manufactured to the highest quality control required by British Safety Standard certification BS 6658: 1985 Type B. made with a fiberglass composite shell reinforced with Kevlar, a polystyrene shock absorption liner with additional protection around the ears and a detachable washable fabric interior lining, the Davida Ninety Two is designed to combine safety with style. The Ninety Two comes in one shell size and two helmet sizes: Small (54-56) and Medium (56-58).

DuPont's new thermoplastic vehicle armor solution, Kevlar ACV

DuPont is driving up military protection by launching a new thermoplastic vehicle armor solution, Kevlar ACV (Advanced Composites for Vehicles). The new material is an extension to DuPont’s Kevlar product range and has been designed for the protective vehicle market. The development of this new product has primarily focused on incorporating optimum ballistic properties to ensure maximum protection as well as durability. The ACV has been developed to be fully compliant with material standards for use in vehicles requiring thermal stability up to 120 C while not compromising the ballistic efficiency for use by the private sector as well as the military.

This next update has two – two – two products in one! Reynolds Polymer Technology added R-Cast Mirage and R-Cast Textures into its architectural portfolio of products. R-Cast Mirage uses proprietary resin-based materials to reproduce colors, images, or graphics. With this product, the company says there are infinite design possibilities utilizing custom colors, graphics, or images. R-Cast Textures is meant to extend design options by sculpting customized patterns into the resin panel. Architects and designers can select from a range of standard patterns or choose to create a customized texture in both opaque and translucent colors.

BASF launches its new Ultramid Endure product

BASF is heating up with a new polyamide (PA) specialty grade Ultramid Endure, a glass-fiber-reinforced polyamide that combines resistance to heat aging with the processability of PA 66. The company says that compared to the standard PA 66 grade Ultramid A3WG7, the processability has improved. The product is designed to produce under-the-hood automotive components that are exposed to very hot air, which could contribute to a significant weight reduction. It easily withstands continuous use at temperatures up to 240 C, which BASF says extends the field of application of polyamides into the high-temperature realm. Possible applications include all components of the charge-air duct such as intercooler end caps, resonators, charge-air lines and throttle valves as well as components on the somewhat cooler side of the turbocharger.

Sense anything new from KaZaK Composites, Inc.? You’d be right, as the company created an acoustic vector sensor (AVS) mount that combines the essential benefits of existing mounts without compromising the performance of the AVS. The design consists of a sensor mounting plate which is connected to a vehicle mounting plate via three orthogonal planes. The choice and layout of this material is tuned to absorb and attenuate the frequencies of interest. The three orthogonal plane design ensures that any vibration noise traveling through the mount to the sensor must pass through at least two shear planes. The company adds that the materials used to construct the mount are buoyancy neutral, lightweight and corrosion resistant.

DSM Engineering Plastics has the environment on the brain with Arnitel Eco, a high performance thermoplastic copolyester (TPC) with 20-50 percent content derived from renewable resources, depending on the hardness of the grade. The product has been designed to show a reduction in greenhouse gas emissions of up to 50 percent versus oil based thermoplastic copolyesters. Being a first generation product, it is not currently suitable for high temperatures, although the company plans to address this issue in future generations of the product. The new material, which is already being sampled to selected customers, is specifically suited for applications in consumer electronics, sports & leisure and automotive interiors.

NatureWorks LLC is hoping a new online implementation will work for them. The company is making details for Ingeo 3801X, its new, high-heat, high-impact bio-resin, available by providing open source access to both formulation and compounding procedure. The aim of the measure is to spur innovation and drive biopolymers more widely into injection molding applications. The full details of the proprietary Ingeo 3801X recipe including impact modifier, crystallization accelerant, and agents for reinforcement and nucleation are openly available to Ingeo customers. The company hopes the details of the formulation can serve as a basis for research and development in further tailoring bio-based solutions.

Dow Formulated Systems’ answers, my friend, are blowin’ in the wind. The company introduced two products with characteristics and performance designed for use in fabrication of wind blades. COMPAXX Foams is a core material in the composite construction of wind blades that is designed to replace PVC foams when design conditions allow. The second product is AIRSTONE Latent Mold Building Systems: a new series of advanced solution that comprises the new AIRSTONE 715H Hardener and AIRSTONE 329E & 710E Epoxy Resins. It is meant to provide long pot-life and low exotherm characteristics that allow for a more streamlined mold production process for both infusion and prepreg molding processes.

The new AP-PLY fiber architecture has improved damage tolerance for use with a fiber placement machine

The National Aerospace Laboratory NLR and Delft University of Technology are incorporating more fiber in their diet by jointly developing the new AP-PLY fiber architecture with improved damage tolerance for use with a fiber placement machine. AP-PLY combines the mechanical properties of unidirectional laminates with the higher resistance to impact damage of woven fabrics in an automated composites manufacturing process. Instead of fiber placing parallel fiber bands next to each other, room is left between bands. A second series of interspaced fiber bands is placed at an angle with respect to the first series, and the remaining gaps are subsequently filled up. Adjacent plies are thus more interconnected and delamination damage is contained in a smaller area. According to the groups, preliminary test results show significant improvement in compression after impact strength and smaller delaminations. The consortium also says this process could lead to 10 percent weight reduction in composite structures in aircraft and other transport applications.

KaZaK Composites, Inc. hopes to give steel the shaft by designing a composite power transmission shaft to reduce the overall weight of a shaft without compromising the performance of the component. With existing shafts constructed of steel and weighing between 90 and 290 pounds depending on the configuration, the company says the Navy is looking for a solution that will allow for increased payload on its existing armored combat vehicles (ACVs), the LCAC landing craft and future ACVs such as the SSC. KaZaK says the composite design will not corrode like steel, reducing maintenance costs by removing the need to repaint and replace the shafting. Additionally, the shaft reinforcement and matrix materials are designed to attenuate vibration loads, reducing vibrational stress on the power train which is meant to increase the operational life of some power train equipment, further reducing maintenance costs.

Battenfeld-Cincinnati introduced its fiberexK7 extruder for wood plastic composites.

Battenfeld-Cincinnati might be knocking on wood as they introduce their fiberexK7 extruder for wood plastic composites (WPC). The company said the conical counter-rotating machine is suitable for newcomers to WPC extrusion and offers outputs from 90 to 275 kg/h, making it possible to extrude a wide variety of profiles. The compact machine is suitable for processing pre-blended compounds as well as agglomerates based on PVC, PE or PP and has closed-loop screw core tempering, a fully insulated processing unit, AC drive and an easy-to-operate vacuum unit with a twin filter as standard.

Serious Materials has launched a new line of extreme-energy-saving window products for the commercial building market…no, seriously! Its Heavy Commercial SeriousWindows Series are the first heavy commercial rated windows to deliver thermal performance of up to R-value 7.0 (U-value 0.14), over two times the thermal insulation of commonly specified aluminum thermally broken commercial windows (U-value 0.35). Incorporating SeriousGlass super-insulating glass units with fiberglass frames, the company says the windows are meant to offer architects, builders, and building owners more energy efficient commercial window systems for substantial energy cost savings. The company believes fiberglass-framed commercial windows offer super-insulating and structural performance, lower embodied energy, and new design choices compared to traditional aluminum, vinyl, or wood framing materials.

Ensigner's adds a glass fiber reinforced PEEK

Ensinger’s Penn Fiber Division is kicking some glass with the addition of glass fiber reinforced PEEK that meets ASTM D6262 to its line of high performance thin gauge TECAPEEK GF30 sheet materials. At 250°C, the modulus maintains 30 percent of its ambient stiffness as well as about half its room temperature flexural strength. The HDT is 315 C. This addition allows designers to take full advantage of heat aging properties in structural applications, as it may now be possible to manufacture truly structural thermoformed parts that can operate at 260 C continuous for 100,000 hours. The sheets may fit in a variety of components such as fuel cells, ducting, manifolds, and canisters used in heavy trucks, aircraft, trains, and marine applications.

Janicki Industries wants its new 1600 F annealing furnace to be appealing for large-scale, high-precision metal, composite, ceramic and thermoplastic projects. The furnace measures 72 feet long, 24 feet wide and 11 feet high, and the design enables a loaded semi-truck to drive into the furnace with the part. Annealing is used on parts that have been welded or cast, also called heat-treating or stress relief, to enable molecules to loosen and realign relieving any built up stresses and providing dimensional stability during subsequent processing. The furnace can be adjusted in temperature to cure composites, ceramics and thermoplastics.

Airtech Industreis released the new Toolfusion3

Airtech Industries has released Toolfusion3, which despite its name is a two-part low-viscosity epoxy-infusion resin formulated to produce pre-preg composite molds. Toolfusion3 has a low initial cure temperature of 120 F and can be post cured to achieve a high glass transition temperature of 425 F. The company says that void contents of less than 1 percent are achievable, and that the resin will work in various RTM and VARTM processes including single and double bag arrangements to produce autoclave quality laminates. The tooling laminates also have vacuum integrity for vacuum bag processing of parts in oven and autoclave.

Rhodia is taking the road to expand its existing Technyl line of injection, extrusion and blow molding products by developing a new polyamide high-performance composite material. The material is specifically designed for structural applications using thermoplastic composites in the transportation, construction and industrial markets. The company has developed a unique patented polyamide-based matrix, perfectly suited to continuous glass or carbon fiber composite materials. The high fluidity and specifications of this new resin are meant to fully penetrate and impregnate the reinforcing fibers to provide the interface required to meet the performance standards required by the semi-finished products.