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Top 10 CompositesWorld articles of 2023

Through a variety of editorial content, CW explored the trends and topics that are rapidly flourishing in the industry. Based on Google Analytics, these top 10 articles were considered the most popular.  

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CW top 10 articles of 2023

Photo Credit: CW

10. Jeep all-composite roof receivers achieve steel performance at low mass

Jeep all-composite roof receivers
Photo Credit: Stellantis

Traditionally, the belief has been that longer fiber reinforcement leads to stronger composites. However, the introduction of nanocomposite additives has somewhat challenged this idea. Now, a new type of ultrashort carbon fiber-reinforced thermoplastics (CFRTP) designed for injection molding is proving to outperform both short and long fiber thermoplastics, whether glass or carbon. These materials, known as KyronMax and produced by Mitsubishi Chemical Advanced Materials Inc.(MCAM, Mesa, Ariz., U.S.), excel especially in complex shapes where achieving good fiber penetration is challenging. They not only surpass conventional thermoplastic composites but also outperform metals. A prime example is their use in the roof receivers of 2021 Jeep Wrangler SUVs and Gladiator pickups by Stellantis. This is the story behind how this application came to fruition. Read the full article

8.  A new era for ceramic matrix composites

ceramic matrix composites applications
Photo Credit: (top left, clockwise): GE Aerospace, MATECH, Hypersonix and ©DLR-WF via the Ceramic Network

Ceramic matrix composites (CMC) use ceramic fibers in a ceramic matrix to create strong structures that perform exceptionally well at high temperatures. GE Aerospace (previously GE Aviation, Evendale, Ohio, U.S.) produces a CMC for LEAP engines that withstands extreme heat, enabling higher efficiency and reduced fuel consumption compared to metal alloys. CMC are becoming essential in aerospace for supersonic and hypersonic vehicles due to their ability to handle these extreme temperatures. Research is underway to develop ultra-high temperature CMC for even hotter environments. Beyond aerospace, CMC are gaining traction in power generation. Limited supply of certain fibers has been a challenge, but companies are ramping up production to meet the demand. Despite challenges in production time, ongoing research aims to improve manufacturing methods and sustainability in CMC development. This article will further explore these advancements and the expanding applications of this material. Read the full article

6. Manufacturing the MFFD thermoplastic composite fuselage

lower shell skin
Photo Credit: STUNNING project, GKN Fokker

The Multifunctional Fuselage Demonstrator (MFFD) program, initiated in 2014 under the Clean Sky 2 (now Clean Aviation) initiative, aims to innovate aircraft technologies and sustainability in Europe. One of its goals was to construct an 8-meter-long, 4-meter-diameter fuselage section entirely from carbon fiber-reinforced thermoplastic polymer composites, reducing fuselage weight by 10% and recurring costs by 20%, potentially enabling faster aircraft production. Airbus Research & Technology (Bremen, Germany) led the project, issuing multiple calls for proposals and engaging more than 40 companies to work on various aspects, from automated assembly to testing methods. The completed lower shell has been sent for final assembly, with plans to use laser and ultrasonic welding techniques. This article summarizes completed manufacturing steps and highlights the laser-based co-consolidation process for fuselage joints. Read the full article

4. Plant tour: Albany Engineered Composites, Rochester, N.H., U.S.

fan blades
Photo Credit: Albany Engineered Composites

Albany Engineered Composites (AEC) (Rochester, U.S.), has been at the forefront of high-quality, automated composite manufacturing since 2013, producing carbon fiber composite components like fan cases, blades and spacers for CFM International’s (Cincinnati, Ohio, U.S.) LEAP aircraft engine. These parts play a crucial role in Airbus, Boeing and Comac aircraft, making the LEAP engine a standard choice for narrow-body aircraft. Safran, the engine’s developer, revealed at an event that LEAP engines hold a significant share in the global market, with a substantial backlog of orders indicating its prominence as the largest consumer of composite fan blades worldwide. AEC’s journey from startup to an industrialized, high-volume production facility showcases the aerospace industry’s future, emphasizing the critical link between manufacturing scale and top-notch quality. The company’s success story holds valuable insights for the entire aerocomposites supply chain. Read the full article

2. Cryo-compressed hydrogen, the best solution for storage and refueling stations?

cryo-compressed hydrogen tank
Photo Credit: Cryomotive

Hydrogen stands pivotal in the shift toward cleaner energy, vital for curbing CO2 emissions amid the escalating climate crisis. The Hydrogen Council’s “Hydrogen Insights 2022” report underscores this, spotlighting 680 global large-scale projects funneling $240 billion into hydrogen by 2030, marking a 50% surge from 2021. Cummins’ (Columbus, Ind., U.S.) executive chairman Tom Linebarger emphasized the necessity for diverse solutions to achieve a zero-emission future, citing hydrogen’s pivotal role. Adaptable solutions within the hydrogen sector are imperative, catering to varied needs like storing and fueling different vehicles and aircraft. Recent articles have explored diverse storage options such as Type IV compressed hydrogen gas (CGH2) tanks, liquid hydrogen (LH2) tanks for heavy transportation and the emergence of cryo-compressed hydrogen (CcH2) for mobility applications. Read the full article

Read more of CW’s most-viewed content from 2023:

Top 10 CompositesWorld news items of 2023

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Toray Advanced Composites hi-temperature materials
ELFOAM rigid foam products
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