NEW POLYMER COMPOSITE MATERIALS AND TECHNOLOGIES

20. NEW POLYMER COMPOSITE MATERIALS AND TECHNOLOGIES

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  The complex production technology of carbon fibrous materials (from initial chemical components and the Pan- precursor to a carbon fiber and textile forms of the wide nomenclature and assortment on their basis);
  
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  Technologies of reception of monomers, oligomers, elastomers and new generation of highly nonrigid binding materials with high physic-mechanical characteristics;
  
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  New production technologies precision calibrated prepregs, preforms, etc. half-finished products of polymeric composite materials;
  
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  Technologies non-autoclave formations, including large-sized designs from polymeric composite materials with application modern highly automated processes (RTM, RFI, VaRTM, RIM, Quick Step, ATL, AFP, etc.);
  
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  Technologies of reception of polymeric composite materials of intellectual type II and III generations;
  
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  Economic and power effective technologies of mass production of products from composite materials constructional and a functional purpose on the basis of polymeric (thermoplastic, thermo-jet) and elastomeric multipurpose matrixes, including for application in the building industry and other sectors of national economy;
  
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  Technologies of forecasting of properties, modeling of structures, including at molecular level, and realization of modern processes of designing and manufacture of products from polymeric composite materials with use digital (IT) the methods compatible with CAD/CAM/CAE and PLM by systems;
  

The short description of prospective problems of creation of a technological platform

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  Formation of a uniform industrially-technological platform on working out, manufacture and use of polymeric composite materials and designing of products from them for various industries;
  
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  Wide attraction of results of the fundamental and is fundamental-focused researches of institutes of the Russian Academy of Sciences, the state centers of science and establishments of the higher school for achievement of strategic scientific, technological and industrial problems;
  
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  Working out and realization of curricula and educational programs for preparation and retraining of profile experts of engineering, scientific structure, professional working and administrative shots, attraction and fastening at the enterprises and the organizations of branch of perspective young experts and scientists;
  
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  Essential decrease in expenses for materials, technological processes and consumption of power resources, increase of labor productivity at the expense of realization of new technological approaches, depreciation of products from polymeric composite materials and essential expansion of their functionality;
  
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  Conformity maintenance to the international requirements shown to products from polymeric composite materials, including in civil sectors of economy;
  
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  Creation in Russia hi-tech, universal, with a stock of future development resource, innovative-active manufacture of a full cycle (from initial components to concrete products) and the organization of new workplaces at modernization existing or creation in territory of the Russian Federation of new manufacturing enterprises;
  
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  Strengthening of influence of strategic requirements of a society and business on realization of the major directions of scientifically-technological development in the field of polymeric composite materials;
  
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  Association of efforts of representatives of a science, the state, civil society and the business, interested in the organization of joint activity on strengthening of efforts on creation of the perspective commercial technologies, new products and services;
  
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  Stimulation of innovations, expansions of research-and-production cooperation and formation of new partnership, supports of scientific and technical activity and processes of modernization of the enterprises applying new generation of polymeric composite materials;
  
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  Working out of strategic plans of carrying out of researches and workings out in the field of polymeric composite materials, technologies of their processing and their introduction by means of all interested parties;
  
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  Attraction of additional public, corporate and private financial and other material resources for carrying out of necessary researches and workings out;
  
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  Perfection of is standard-legal regulation in a scope of polymeric composite materials;
  
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  Consolidation of the Russian and foreign community of developers, manufacturers and users of the technologies connected with polymeric composite materials;
  
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  Upholding of interests of community of developers, manufacturers and users of the specified technologies at all levels and creation of mechanisms of influence on acceptance of political-economical decisions by public authorities.
  

Problems on which decision joint activity of participants of a technological platform will be directed

Polymeric composite materials are difficult heterogeneous (non-uniform) systems in which reinforcing filler is responsible for level is stress-strain properties characteristics, and a polymeric matrix, providing their teamwork, defines working temperature of a composite, its ability to resist to deformations, firmness to influence of a moisture and other external factors. Advantage of a composite material is that a material, the technology and a design are created simultaneously – it defines high degree of innovations at all stages of life cycle of a material from reception of initial raw materials before modeling, creation and operation of products.

As the basis for formation of a national technological platform serious backlog of the Russian Federation in the field of research, developmental works and the industry of constructional polymeric composite materials (PCM) serves. Besides, researches and workings out in this area in interests of various customers and for various sectors of economy are conducted is not co-ordinate.

Now attracts attention accent displacement in the world market in application of constructional materials from metal to the nonmetallic. The analysis of foreign sources, and also the general tendencies of development of materials technology show that workings out and researches in the field of the composite materials, the reinforcing components binding for them and technologies of their processing in hi-tech high technology production with the big share of an innovative component now are intensively conducted. Such workings out in the field of PCM spend firms of the USA, Japan, EU, China, India, ЮВА, the South America, guided by transition from research works to their commercial use.

In Russia segments of the market of constructional composite materials and products from them except for aircraft, astronautics and the nuclear industry (application of composites in which, for today it is essentially limited) practically are not mastered, in spite of the fact that there are favorable technological and scientific preconditions for this purpose.

Within last two decades development of direction of PCM has been abroad focused on transition from research works on their commercial manufacture. In Russia as certain backlog already was marked, outlined in this area. Until recently financing of these works practically is not carried out, and for export to Russia as foreign fibers (high-strength and high-modulus) and binding (especially high-temperature), and prepregs of PCM on their basis, essential restrictions as on strategic raw materials operate.

The comparative estimation of technological development has revealed that foreign workings out in the field of PCM considerably surpass domestic level. The alternative of import production – proceeding from reasons of national, economic and technological safety at the same time should be created; for the purpose of elimination of dictate of monopoly of the prices by foreign suppliers; preservations of domestic design, technological collectives, unique industrial-experimental and bench base, and also increase of level of preparation of experts in corresponding area.

The fact that in Russia works on PCM, lag behind the advanced foreign workings out and are in experiment stages, and also a number of other reasons, essentially constrains development of perspective techniques and development of new areas of the industry.

Proceeding from the spent analysis of scientific and technical development in the field of working out and use of composite materials and considering developed world tendencies, raw and resource possibilities - a problem of working out of a complex of base technological decisions for creation of new generation of the composite materials reinforcing fibrous fillings, highly strain binding, and also development of some allied industries of manufacture of chemical components and auxiliary materials, with creation of new approaches to modeling of technological processes and designing of products with application PCM is rather actual.

The short description of the markets and economy sectors on which influence of the technologies developed within the limits of a technological platform is supposed

Prospects of formation of the new hi-tech markets of production (services), developments of the new industries on the basis of essentially new technologies

The success in application of composite materials is promoted by increasing requirements to preservation of the environment and reduction to energy consumption, and also search of various environments easier and steadier against influence and conditions of materials. Now the world volume of the market in sector of composite materials comes nearer to 60 billion euro. Taking into account annual world rate of increase of 5-10 % - it can reach to 2015 80 billion euro. Today the total amount of world production PCM makes more than 8 million tons, and the sales volume does not exceed 40 billion euro, thus the contribution of manufacture of products from PCM makes practically half of this market.

The basic consumers of polymeric composite materials in the Russian Federation are the nuclear industry, the aviation industry, whereas abroad most heavy users - building, mechanical engineering, power, the sport industry; now, capacities on consumption are increased by motor industry, aviation. In Russia in building branch polymeric composite materials practically are not applied, while this branch is represented as one of the most important in market PKM creation. Composite materials can be used for manufacturing of armature for concrete designs, as strengthening and repair overlays, also application of polymeric composite materials effectively at building of bridges, inhabited and industrial buildings in seismically dangerous areas of the Russian Federation.

Today application of composite materials allows many companies to create conditions for growth of profitability of production, and tendencies of development of technologies steadily expand area of their application. On the other hand, modern market mechanisms lead to consolidation of the basic players of the given segment – to creation of the groups of companies investing large means in research and development of new generation of polymeric composite materials.

The bases for wide introduction of polymeric composite materials in various segments of the market are caused by a complex of their unique properties defining possibility of wide application: the high it is stress-strain characteristics, corrosion firmness in natural atmospheric conditions, and also good stability to influence of acid and alkaline environments, chemically active substances, a number of other operational characteristics. In a combination to high durability composite materials provide to power designs high operational reliability and durability that besides traditional scopes (aircraft and astronautics) is the extremely actual in designs of a building and road infrastructure and, in particular, bridge constructions, and also in other sectors of the industry (shipbuilding, a fuel and energy complex, motor industry, the sport industry, consumer goods, etc.).

It is possible to notice that the weight of the plane without fuel and a pay load approximately twice is less than weight of the equipped plane, including about 30 % it is necessary on various designs of a glider. Weight reduction of these designs thanks to polymeric composite materials allows to reduce engine dimensions, the sizes of plumage and etc. that leads to decrease in weight of the plane, and accordingly, and the fuel expense. Decrease in weight of constructional materials of all on 1 kg leads to decrease in lump of the plane on 3-7 kg. Use of composite materials in manufacture of planes allows to vary flexibly designing conditions, and also to lower a total cost of a product on 20-30 % at the expense of reduction of power inputs, increases capacity ratio, reduction of total of operations, decrease in expenses at machining (details are made practically at size), etc.

Working out of rather cheap methods of mass production will lead in the near future to that various composite materials, and, first of all, carbon fiber composites, will receive wide application in motor industry. Thanks to already designated advantages by decrease in weight of the car first of all, the economy of fuel, and accordingly, and increase of ecological compatibility of motor transport is reached. For increase of profitability of the car on 0,0042 km/l it is necessary to lower its weight approximately on 7 kg. By means of replacement of details from a steel and pig-iron on a detail from carbon fiber composites, fibreglasses and other constructional polymeric materials probably to lower weight of cars approximately on 320 kg.

Polymeric composite materials allow to create case designs seldom supported with a set modern, including high-speed courts, combining the same advantages, as to aviation designs. Besides, creation of large-sized elements in shipbuilding from PCM does not demand welding application that also reduces cost of manufacturing of products not less than on 10 % and raises reliability of their operation. Creation of modern bathymetrical off-shore means is almost impossible without use of composite materials. The analysis of dependence of possible depth of immersing from constructive characteristics of the device reveals advantages high-strength and high-modulus composites. High shock-absorbing ability of last, combined with high physic-mechanical characteristics, leads to reduction of overloads of such difficult technical systems. The small density of materials at maintenance of fire safety allows to apply them in architecture of a surface part of courts of all types that promotes stability improvement, reduction of a radar-tracking visibility of courts, simplification of operation of the case.

Presently the power problem connected with use of classical kinds of the electric power which development demands considerable raw expenses has globally become aggravated and causes deterioration of an ecological situation in the world. In this connection also necessity of development of independent energy sources constantly grows. Inexhaustible wind power can become a part of the decision of a global power problem. During the last years the quantity of the developed energy with application of the given technology has increased in tens times. However at present in the world with use of wind turbine than 1 % of the electric power though according to the experts this figure should reach 15 % is developed only a little more.

Besides, for last 15 years at manufacturing of blades of turbines for wind turbine its sizes about 23 m to 45 m and even to 90 m have essentially increased, the longest blades weigh today to 18 tons everyone that causes of application of new materials for manufacturing of blades so that they became much easier and thus stronger and durable in operation. PCM, applied at manufacturing of "wind-driven generators" satisfy, etc. to the important requirement – their cost less in comparison with traditionally used alloys of metals.

Energy of wind turbines has the lowest cost in comparison with cost of energy of all renewed sources. Foreign experts (the British Association of wind energy) have calculated that modern cost of development of energy of 1 kW makes approximately 2,5 pence (0,50 RUB) that corresponds to cost of energy from the stations working on coal. Transition to development of the electric power with the help of wind turbine with the general capacity 1,75 mW, providing with an electricity approximately 1000 houses, will lower emission in atmosphere СО₂ on 2000 tons.

High stability PCM to corrosive attacks, the equal and dense surface of products received at formation allow to refuse in some cases coloring and in the near future will define the leading part of these materials in the building industry. Already today abroad from total amount of manufacture PCM (about 8 million tons/years for the sum about 59 billion Euro) 30 % go for use in building. On the average volume weight PCM in 2 times is less, than aluminum and in 5-8 times has less, than at a steel, copper, lead. Strength at compression and stretching PCM are high enough and surpass in this respect many building materials of silicate group (a brick, concrete). As a whole the complex of properties of building materials can be described in factor of constructive quality which for a bricklaying makes 0,02 (lowest of all building materials), at cement concrete of mark 150 - 0,06, there were Item marks 3 - 0,5, pines - 0,7, duralumin - 1,6, composite designs - 2,2. Thus, on factor of constructive quality polymeric composite materials are unsurpassed till now. Introduction in building of materials with high factor of constructive quality predetermines the correct decision of one of its basic problems - weight reduction of buildings and constructions, increase in terms of their operation and between-repairs service.

On an example of bridge constructions it is possible to notice that application PCM does them much easier Ferro-concrete is allows to erect them quickly and practically without breaking a traffic. At rather higher cost (now) initial materials on expenses for all period of operation the bridge from PCM to become is more competitive, than traditional. Usual bridges demand major repairs through 15 — 20 years while the bridge made with application PCM is ideal for long-term use. By expert estimations term of operation of such constructions will make till 50 years without repair as the used material is not subject to corrosion.

For example, as has shown foreign experiment of creation and operation of bridge designs from polymeric composite materials, their efficiency is defined by reduction of terms of building, the big warranty periods and increase in reserve maintenance periods. Use of polymeric composite materials in bridge constructions will ensure qualitatively new durable designs that will be reflected in the general condition of a road and city infrastructure.

Besides, by expert estimations at replacement, for example, pig-iron protections from PCM cost of installation works is reduced to designs with 13 200 to 2 500 rubles for running meter, shipping expenses – with 880 to 50 rubles/items of m, expenses at operation – with 8 200 to 1 300 rubles/items of m. In comparison with similar metal pipes, pipes from a composite material have also a number of advantages: service life without major repairs in 2-2,5 times longer, than at metal pipes; small relative density of a composite material and high factory readiness of designs allows to simplify essentially installation and to reduce its duration several times; absence of corrosion processes in the conditions of a tropical climate and in environments of exhaust gases at any modes and fuel kinds; Water resistance, and also low heat conductivity of a composite material allow to reduce working costs at the expense of period increase between renewal of coloring of a surface in comparison with metal pipes.

Composite materials will find more and more application in land building. Repair of bridges (a carbon fabric, lamellas), building of lamella bridges (anchor roost), reinforcing of constructions in quake-prone regions, strengthening of high-rise constructions and difficult engineering designs. Considering numerous advantages – ease of a design, durability of operation, non-exposure corrosion, ecological compatibility, the big freedom for designing – becomes Russia obvious requirement for composite materials of a domestic production.

In short-term prospect realization of actions of operating federal target programs is supposed, including: development existing and creation of new capacities (a full cycle) on release of carbon fibrous materials with indicators of durability of a fiber at a stretching to 4,5-5 hPa; creation of new generation of highly nonrigid binding on working temperatures to 180С; development of modern base technological processes (calibrated prepregs, nonautoclave technologies, mechanical processing and connection). And also creation of an educational, scientific and test infrastructure, standard base for carrying out of researches, qualifications of polymeric composite materials according to the international requirements; definition of "perspective shape» sectors on long-term prospect (20-30 years); modeling and study of the concept of perspective projects.

In intermediate term prospect (for 2011-2015) – working out of the concept of full life cycle PCM; creation of large-capacity manufacture of carbon fibers with maintenance of competitive prices and characteristics; working out of new technological and design approaches; development of an industrial infrastructure; development at designing and in the industry of new digital technologies and IT decisions at manufacturing of designs from PCM; introduction in the industry of new technologies and materials; creation of manufacture and the market of consumption PCM of the wide nomenclature.

As long-term results (for the period till 2020) realizations of a national technological platform should be noted: full-scale introduction in manufacture of products of new materials and technologies; maintenance of support of full life cycle of products from PCM; development of manufacture and the market of consumption PCM; creation of a scientific and technical reserve, formation and development of the industrial critical and base technologies providing manufacture of perspective products (military and civil appointment) the various industries corresponding to world level 2020-2025

Besides, it is supposed to provide the complex approach in the organization of educational activity by preparation and retraining of profile experts of engineering, scientific structure, professional working and administrative shots on lines of activity of the Technological platform.

As a result of realization of the Technological platform «New polymeric composite materials and technologies» new principles of activity and interaction of the educational, scientific organizations, the industrial enterprises and the business structures directed on creation of essentially new generation of polymeric composite materials, technologies of their manufacture and the organization realization is planned for territories of the Russian Federation of new workplaces at modernization existing or creation of the new manufacturing enterprises using offered technologies. Thus level of planned results at the first stage assumes liquidation of backlog from world level in the field of polymeric composite materials at the expense of the decision of local technological problems to similarly works spent at world level, and further maintenance of competitiveness of Russian production in the world market, with leadership on separate technologies. Production principal views, on working out which (perfection) activity of the Technological platform is directed assume their application in various branches of economy, providing reception of direct and indirect social and economic effect.

The basic expected result of the Technological platform «New polymeric composite materials and technologies» – a gain of 10-15 % (instead of current 3 %) the world market of manufacture and sale of details and designs from polymeric composite materials.