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Modified cost effective fibre based structures with improved multi-functionality and performance

Periodic Reporting for period 2 - MODCOMP (Modified cost effective fibre based structures with improved multi-functionality and performance)

Reporting period: 2017-10-01 to 2019-03-31

What is the problem/issue being addressed:

The challenges that MODCOMP addresses are the following:
New approaches to improve functionality are important
Fibre based material for high value, high–performance products at reasonable prices with
improved functionality and safety, represent a challenge for materials science and engineering
Sustainability, recyclability, safety, energy
Cost effectiveness and commercial potential of innovativeness compared to state-of-art
Market needs for composite materials

Why is it important for society?

MODCOMP will increase the competitiveness and sustainability of EU multiple sectors industry through innovative high value products and manufacturing processes. Moreover, it will offer employment and training through engagement in cutting edge technologies in various sectors, e.g. transport, construction, sport and leisure etc.
Specifically, MODCOMP's demonstators, such as the SecureShel designed by GSG will have societal impacts. SecureShel (Humanitarian Assistance) and manufacturing process also could develop onsite manufacture right in the heart of the affected territories using containerized factories. This will allow a sustainable programme of production using local labour, local resources where available and therefore stimulating local economic activity. With a predicted life expectancy in excess of twenty five years, the SecureShel concept is a unique, long term and re-usable transitional secure shelter system option. It has evolved to incorporate core values of affordability, easy installation, comfort and security for the end-user, ease of maintenance, resistance to adverse weather conditions, cost efficient transportation and trouble free storage.
Another societal impact comes from the memory devices developed by THALES. With the growing volume of global trade and travel, government and international agencies have to respond to the proliferation of new types of risks and threats, such as illegal immigration, cybercrime and terrorism. The new standards define security features, electronic components and biometric data formats to ensure the interoperability that is a basic requirement in a more connected world. Governments rebuilding their institutions after conflicts or major disaster see identity management programmes as an opportunity to prepare for the future by issuing new ID documents and developing their identity databases. At the same time, governments have a duty to protect the privacy of their citizens by guaranteeing the security of the systems used to issue and control a whole range of documents including national identity cards, e-ID cards, voter registration cards, passports, e-passports, visas and driving licences. In addition, since ID documents are increasingly used to bring citizens access to basic rights and services (elections, employment, banking, etc.), identity management programmes have come to play a critical role in social and economic development. The emergency of new technologies to improve the security of ID card, and of smart card in general, in an interconnected world is a priority and will impact our everyday life guaranteeing our personal security, safety and protecting our identity.

What are the overall objectives:

MODCOMP aims to develop novel engineered fibre-based materials for technical, high value, high performance products for nonclothing applications at realistic cost, with improved functionality and safety. Demonstrators will be designed to fulfill scalability towards industrial needs and focus on TRL5/TRL6. End users from a wide range of industrial sectors (transport, construction, leisure and electronics) will adapt the knowledge gained from the project and test the innovative high added value demonstrators. An in-depth and broad analysis of material development, coupled with dedicated multi-scale modelling, recycling and safety studies will be conducted in parallel for two types of materials (concepts):
CF-based structures with increase
• A continuous EPD prototype was designed, manufactured and verified, which can be patented (process has started at SICOMP) and up-scaled for production of CNTs (or other conductive nanomaterials such as CNFs, graphene, metal nanoparticles) functionalized carbon reinforcement and resulting composites reaching TRL 5-6
• A methodology – modelling of CNT concentration as a function of viscosity, to measure the concentration of CNT suspension during EPD was developed in order to maintain the suspension concentration in continuous EPD process, which can significantly reduce the cost due to the disposal of CNT suspension and environmental impact.
• Combinations of MWCNTs/GnPs give rise to CFRP composites having higher electrical and mechanical performance
• Treatments such as electrochemical and electropolymerization appear to convey increased surface roughness of the fibre with respect to associated plasma treatments.
• Characterisation of single fibre treatments has identified a number of candidates offering optimised results in terms of wettability and tensile stress testing.
• CFRP composites have been successfully manufactured by using CNT coated CF fabrics via EPD method.
• Unmodified and modified CFRP composites have been successfully prepared by impregnation strategy.
• MODA fiches prepared for all the models covered by WP4.
• Different mechanical and thermal properties have been characterized from the MD simulations for the carbon fillers, the polymer matrix (neat resin) and the nanocomposites. Effects of different parameters (sensibility analysis) as CNTs lengths, diameters, cross-linking degree, type of hardener, etc, have been investigated.
• Generation of a brochure and distribution to all MODCOMP partners, including general guidelines of Safety issues, regarding the use of CF based materials and nanomaterials.
• Distribution of a questionnaire for safety issues from the use of nanomaterials in the innovation processes of MODCOMP.
• Development and distribution of surveys regarding safety risks and hazards (HAZOP).
Current technological demands are increasingly stretching the properties of traditional materials to expand their applications to more severe or extreme conditions, whilst simultaneously seeking cost-effective production processes and final products. The aim of this project is to demonstrate the influence of different surface enhancing and modification techniques on carbon fibre (CF)-based materials for high value and high performance applications. These materials are a route to further exploiting advanced materials, using enabling technologies for additional functionalities, without compromising structural integrity. CF based materials have particular advantages due to their lightweight, good mechanical, electrical and thermal properties. Current generation CFs have extensively been used in a multitude of applications, taking advantage of their valuable properties to provide solutions in complex problems of materials science and technology. The limits of the current capability of such materials, however, have now been reached. MODCOMP will develop the next generation of CF-based materials for structural and electronics applications. The benefits of fibre-based materials have clearly been shown in aerospace applications which require lightweight, high strength, high stiffness, and high fatigue-resistant materials.