Lightweight Composite Materials: How Far and How Fast?Lightweight
composite materials, composed of polymers reinforced by advanced fibres
made of carbon, glass and polymers, have come a long way since they
were first introduced in the US space industry in the 1960s. Today, we
have substantially carbon fibre composite passenger aircraft (Boeing
Dreamliner, Airbus A-350, Bombardier C-Series), electric/hybrid
automobile bodies (BMW i-series), and super yachts with composite masts
of more than 90m height. High performance composites are used for the
blades of wind and tidal turbines, as well as for human bone and spinal
fixation devices. The main drivers for the lightweight composites
revolution are the need to increase fuel efficiency and reduce
greenhouse-gas emissions in transport, to generate renewable energy more
cost-effectively and to increase performance and personal protection in
security, defence, sports and leisure applications.
The speed
and limits of composites penetration into transport, energy,
infrastructure and consumer sectors will depend on development of lower
cost, higher-volume manufacturing processes and on improved
fire-resistance, repair and end-of-life strategies for these complex
materials. There may be limits on the mechanical properties that can be
industrially achieved with advanced microscale fibres, while the
much-vaunted nanoscale reinforcements (e.g. carbon nanotubes) have so
far failed to deliver on their promise of a step-change in strength and
stiffness. Lower embodied energy and less reliance on fossil fuels for
polymer and fibre feedstocks will also be necessary for long-term
sustainability of composite materials.
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