rus
In January three years marks the company "Nanotechnology Center of Composites" (the NCC), which is one of the most modern engineering and manufacturing organizations in the Russian composite industry. The NCC develops and manufactures products made of composites, conducts research and prototyping, invests in innovative start-UPS, provides consulting services.
The NCC is equipped with a set of equipment for implementation of the most modern technologies for the production of composites, and many machines have been modified and improved by the Centre’s engineers.
Laboratories
The NCC has laboratories for testing of construction materials and composites that solve a wide range of tasks: serve as a base for R&D, perform incoming inspection of raw materials and quality control of manufactured products, as well as perform tests for third parties.
Composites testing laboratory has the equipment to test tensile strength, compression strength, bending strength, impact strength, dielectric strength, for falling weight test. Stress control system measures the deformation under load and is used for non-destructive testing. 3D scanner allows to create digital models of finished products, and a 3D printer is used to make prototypes of products for verification of their geometry.
The laboratory has a certificate of technical competence in the field of testing of plastics, composites, textiles, binders and building materials issued by the system of voluntary certification of nanotechnology products Nanocertifica.
Machining shop
In machining shop elements for process equipment, embedded fittings, forms, tool sets are manufactured. The shop is equipped with high-precision lathe and mill-turn equipment of Japanese and Russian production.
Also in the shop precision machine of the latest generation for water jet cutting is operated, which allows to work with a variety of materials, including alloy steel and carbon steel, non-ferrous metals and alloys, concrete, stone, plastics, composites, glass, wood. The speed of the water jet with abrasive particles at the outlet of the cutting head is several times the speed of sound. In the cutting process, there is no thermal effect on the material with a minimum of shock load. There are linear and shape cutting possible, the edges receiving the item do not require additional machining. It is possible both linear, and shape cutting, and edges of the finished parts don't require additional machining.
Vacuum infusion
In vacuum infusion system the material and/or a filler on previously prepared mould is laid out and a sealing package is formed. Under the vacuum binder fills voids and impregnate the filler. Vacuum infusion provides high quality composite products, combined with the efficiency of the process and allows to produce parts of large dimensions. A lot of the equipment was designed by engineers of the NCC.
Vacuum infusion is used in the manufacture of products for the aerospace, automotive engineering, shipbuilding, construction, agriculture. In particular, this technology will be used in the production of composite elements of the body for modular buses – an agreement was signed in mid-October at the Open innovations Expo 2014 with the Hungarian engineering company Evopro. The use of lightweight fiberglass reduces the weight of the buses with the possibility of using efficient engines operating on diesel fuel, compressed gas or electricity. The high strength of the composite determines the safety and durability of the body. The modular principle allows to create vehicles of various sizes from standardized parts and components. Final assembly of buses will run in Hungary, but in the framework of the project the Russian side creates a set of design and technological documentation, which will allow to establish licensing production of bodies in other companies. It should be noted, that specialists of the NCC optimized design elements with anisotropic properties of composite materials. The prototype of a bus was shown at the exhibition of public transport ExpoCityTrans 2014, and it was highly appreciated by experts. The first 50 buses will be assembled in 2015.
Pultrusion
Pultrusion is a broaching of a impregnated fiberglass or carbon fiber through a heated die for manufacture of durable parts with a constant cross-section. The area is equipped with Pultrex and MPI lines, which have a high degree of automation and can be operated in continuous mode. Pultrusion allows to produce profiles of unlimited length, different geometry and is characterized by minimal technological waste.
The resulting profile is used in the manufacture of windows, stained glass windows, enclosures and supporting structures. In particular, on the basis of this profile, the NCC has developed a composite railings for bridges. These railings are not subject to corrosion are not covered by the ice and do not require painting, which leads to low cost of operation over the entire lifetime. In case of damage the constructive elements can be easily replaced. Already running a pilot project in framework of which railings will be installed on 14 bridges in Penza, Ulyanovsk, Saratov and Orenburg regions, including in the Federal highway M5 "Ural" (Moscow – Chelyabinsk). The total length of the installed constructions will exceed 1300 meters.
Another interesting development is trash lattice for hydroelectric power plants, which protect the turbine from ingress of large debris. Use of pultruded fiberglass instead of metal profiles provides not only increase of the lifetime of the lattice, but also the reduction of power losses in the winter. Because the composite is exposed to the icing to a much lesser degree than steel, at low temperatures there is no substantial reduction in head, and therefore, does not reduce the amount of generated electricity. Fiberglass trash lattices were successfully tested on small SHPP "Kalliokoski" in Karelia.
The possibility of producing pultruded profiles of unlimited length used to create the core for overhead power lines. The use of lightweight composite core instead of the steel core provides the opportunity to maximize the wire cross-section and, accordingly, to increase transmit power without replacing the transmission towers. In addition, the use of composite helps to reduce thermal deformation of the wire.
On pultrusion lines in NCC also composite reinforcement and other high-tech products are produced.
winding
At the Moscow plant of NCC is installed the equipment for the discrete winding of pre-impregnated roving or tape on the form (mandrel), which allows to produce pipes, structural shapes, cylinders and tanks. After winding of the required number of layers of glass-, carbon - or combined fiber product on the mandrel is placed in the oven for polymerization of the binder. The maximum diameter of the parts is 1600 mm.
Filament wound pipes can be used in housing and communal services and in oil and gas industry. Compared to steel counterparts with equal diameter, they have 3-4 times less weight, which provides a significant reduction of costs of transportation and installation works. Composite pipes are characterized by high chemical resistance and low heat conductivity. To increase the strength they are reinforced and can withstand high pressure. Depending on operating conditions, the service life of the products ranges from 50 to 100 years.
Also by winding are made transmission towers, poles for lighting systems, advertising and information boards. These poles are lighter than steel and concrete constructions and do not require maintenance during operation.
Areas of spray lay-up,
thermal forming
and injection molding
In the spray lay-up system chopped fibers, dispersed in a binder stream, sprayed from a special gun onto a reusable mould, followed by compaction of the resulting layer by roller. The technology allows to produce large-size parts, not subject to high loads, and is suitable for small and medium production volumes.
Using thermal forming method in the NCC are made the trim panels, parts of ventilation equipment, covers for lights and lamps.
Another technology, which is common in the polymer production, is injection molding. This method is characterized by high performance and is easily automated, and the products do not require further processing. Injection molding allows to add in the composition of the thermoplastic glass- and carbon fibers, and other additives. Using this technology, the NCC produces accessories for various products, and heads for fire hoses, that are not subject to corrosion and can withstand two times more pressure than the metal counterparts, and other products.
The introduction of nanotechnology
and other trends
In the manufacture of certain products in the binder are injected nano-additives that modify the properties of composite materials – increases strength and durability, increases the fire resistance as well as resistance to ultraviolet radiation. In addition, the company uses nanostructured carbon fiber.
In addition to the introduction of nanotechnology, improvement of composites production determine a number of trends. About them told Alexey Rannev, Director of Product Department of NCC: "It can be noted the decline in the share of manual work and increasing of automation of technological processes. For example, in large-scale production the automated solutions for laying out and cutting of fabrics, impregnation and perform other operations are implemented. That can improve performance, reduce costs and reduce impact on the quality of the "human factor". Another trend is the improvement of the properties of materials, such as fibers and polymers. We closely monitor trends in the development of composite industry and strive to implement in NCC the leading edge solutions". ■
The editors thank Alexey Rannev for a excursion to the production. In the next issue of the journal: an interview with General Director of NCC Mikhail Stolyarov.
Laboratories
The NCC has laboratories for testing of construction materials and composites that solve a wide range of tasks: serve as a base for R&D, perform incoming inspection of raw materials and quality control of manufactured products, as well as perform tests for third parties.
Composites testing laboratory has the equipment to test tensile strength, compression strength, bending strength, impact strength, dielectric strength, for falling weight test. Stress control system measures the deformation under load and is used for non-destructive testing. 3D scanner allows to create digital models of finished products, and a 3D printer is used to make prototypes of products for verification of their geometry.
The laboratory has a certificate of technical competence in the field of testing of plastics, composites, textiles, binders and building materials issued by the system of voluntary certification of nanotechnology products Nanocertifica.
Machining shop
In machining shop elements for process equipment, embedded fittings, forms, tool sets are manufactured. The shop is equipped with high-precision lathe and mill-turn equipment of Japanese and Russian production.
Also in the shop precision machine of the latest generation for water jet cutting is operated, which allows to work with a variety of materials, including alloy steel and carbon steel, non-ferrous metals and alloys, concrete, stone, plastics, composites, glass, wood. The speed of the water jet with abrasive particles at the outlet of the cutting head is several times the speed of sound. In the cutting process, there is no thermal effect on the material with a minimum of shock load. There are linear and shape cutting possible, the edges receiving the item do not require additional machining. It is possible both linear, and shape cutting, and edges of the finished parts don't require additional machining.
Vacuum infusion
In vacuum infusion system the material and/or a filler on previously prepared mould is laid out and a sealing package is formed. Under the vacuum binder fills voids and impregnate the filler. Vacuum infusion provides high quality composite products, combined with the efficiency of the process and allows to produce parts of large dimensions. A lot of the equipment was designed by engineers of the NCC.
Vacuum infusion is used in the manufacture of products for the aerospace, automotive engineering, shipbuilding, construction, agriculture. In particular, this technology will be used in the production of composite elements of the body for modular buses – an agreement was signed in mid-October at the Open innovations Expo 2014 with the Hungarian engineering company Evopro. The use of lightweight fiberglass reduces the weight of the buses with the possibility of using efficient engines operating on diesel fuel, compressed gas or electricity. The high strength of the composite determines the safety and durability of the body. The modular principle allows to create vehicles of various sizes from standardized parts and components. Final assembly of buses will run in Hungary, but in the framework of the project the Russian side creates a set of design and technological documentation, which will allow to establish licensing production of bodies in other companies. It should be noted, that specialists of the NCC optimized design elements with anisotropic properties of composite materials. The prototype of a bus was shown at the exhibition of public transport ExpoCityTrans 2014, and it was highly appreciated by experts. The first 50 buses will be assembled in 2015.
Pultrusion
Pultrusion is a broaching of a impregnated fiberglass or carbon fiber through a heated die for manufacture of durable parts with a constant cross-section. The area is equipped with Pultrex and MPI lines, which have a high degree of automation and can be operated in continuous mode. Pultrusion allows to produce profiles of unlimited length, different geometry and is characterized by minimal technological waste.
The resulting profile is used in the manufacture of windows, stained glass windows, enclosures and supporting structures. In particular, on the basis of this profile, the NCC has developed a composite railings for bridges. These railings are not subject to corrosion are not covered by the ice and do not require painting, which leads to low cost of operation over the entire lifetime. In case of damage the constructive elements can be easily replaced. Already running a pilot project in framework of which railings will be installed on 14 bridges in Penza, Ulyanovsk, Saratov and Orenburg regions, including in the Federal highway M5 "Ural" (Moscow – Chelyabinsk). The total length of the installed constructions will exceed 1300 meters.
Another interesting development is trash lattice for hydroelectric power plants, which protect the turbine from ingress of large debris. Use of pultruded fiberglass instead of metal profiles provides not only increase of the lifetime of the lattice, but also the reduction of power losses in the winter. Because the composite is exposed to the icing to a much lesser degree than steel, at low temperatures there is no substantial reduction in head, and therefore, does not reduce the amount of generated electricity. Fiberglass trash lattices were successfully tested on small SHPP "Kalliokoski" in Karelia.
The possibility of producing pultruded profiles of unlimited length used to create the core for overhead power lines. The use of lightweight composite core instead of the steel core provides the opportunity to maximize the wire cross-section and, accordingly, to increase transmit power without replacing the transmission towers. In addition, the use of composite helps to reduce thermal deformation of the wire.
On pultrusion lines in NCC also composite reinforcement and other high-tech products are produced.
winding
At the Moscow plant of NCC is installed the equipment for the discrete winding of pre-impregnated roving or tape on the form (mandrel), which allows to produce pipes, structural shapes, cylinders and tanks. After winding of the required number of layers of glass-, carbon - or combined fiber product on the mandrel is placed in the oven for polymerization of the binder. The maximum diameter of the parts is 1600 mm.
Filament wound pipes can be used in housing and communal services and in oil and gas industry. Compared to steel counterparts with equal diameter, they have 3-4 times less weight, which provides a significant reduction of costs of transportation and installation works. Composite pipes are characterized by high chemical resistance and low heat conductivity. To increase the strength they are reinforced and can withstand high pressure. Depending on operating conditions, the service life of the products ranges from 50 to 100 years.
Also by winding are made transmission towers, poles for lighting systems, advertising and information boards. These poles are lighter than steel and concrete constructions and do not require maintenance during operation.
Areas of spray lay-up,
thermal forming
and injection molding
In the spray lay-up system chopped fibers, dispersed in a binder stream, sprayed from a special gun onto a reusable mould, followed by compaction of the resulting layer by roller. The technology allows to produce large-size parts, not subject to high loads, and is suitable for small and medium production volumes.
Using thermal forming method in the NCC are made the trim panels, parts of ventilation equipment, covers for lights and lamps.
Another technology, which is common in the polymer production, is injection molding. This method is characterized by high performance and is easily automated, and the products do not require further processing. Injection molding allows to add in the composition of the thermoplastic glass- and carbon fibers, and other additives. Using this technology, the NCC produces accessories for various products, and heads for fire hoses, that are not subject to corrosion and can withstand two times more pressure than the metal counterparts, and other products.
The introduction of nanotechnology
and other trends
In the manufacture of certain products in the binder are injected nano-additives that modify the properties of composite materials – increases strength and durability, increases the fire resistance as well as resistance to ultraviolet radiation. In addition, the company uses nanostructured carbon fiber.
In addition to the introduction of nanotechnology, improvement of composites production determine a number of trends. About them told Alexey Rannev, Director of Product Department of NCC: "It can be noted the decline in the share of manual work and increasing of automation of technological processes. For example, in large-scale production the automated solutions for laying out and cutting of fabrics, impregnation and perform other operations are implemented. That can improve performance, reduce costs and reduce impact on the quality of the "human factor". Another trend is the improvement of the properties of materials, such as fibers and polymers. We closely monitor trends in the development of composite industry and strive to implement in NCC the leading edge solutions". ■
The editors thank Alexey Rannev for a excursion to the production. In the next issue of the journal: an interview with General Director of NCC Mikhail Stolyarov.
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