High performance basalt fibers & products for next gerneration composites by Wojciech Dlugosz (Incotelogy)

High-Performance Basalt Fibers & Products for Next Generation Composites

INCOTELOGY GmbH Sachsstrasse 18 50259 Pulheim Germany

Phone: +49 2234 9882371 Fax: +49 2234 9882372 web: www.incotelogy.de e-mail: info@incotelogy.de

Company Profile •

Incotelogy GmbH is official distributor of advanced high performance basalt fiber and producer of basalt fiber products, composite materials or semi-finished products.

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We are the biggest supplier of basalt fiber and basalt fiber products in west Europe.

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Our philosophy is looking and development of new solutions for composites, automobile, aviation, building and other industries. We are working ongoing on improvement and optimization of our basalt fiber products in order to provide the best products quality and mechanical properties to our consumers.

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We are looking for new cooperation and developing innovative sustainable composite products of next generation.

What is Basalt? • Basalt is a common extrusive volcanic rock, which minerals share is composed of: SiO2 54,9%, MgO 4,4%, CaO 7,7%, Na2O 2,5%, Fe2O3 + FeO 11,3%, Al2O3 16,4%, TiO2 1,1%, K2O 1,6%, Li2O 0,1% • Color of basalt is usually grey to black and fine-grained due to rapid cooling of lava at the surface of a planet. • Basalt may be porphyritic containing larger crystals in a fine matrix, or vesicular, or frothy scoria. Unweathered basalt is black or grey. • The term basalt is at times applied to shallow intrusive rocks with a composition typical of basalt, but rocks of this composition with a phaneritic (coarse) groundmass are generally referred to as diabase or gabbro. • Basalt rock is the main and only one source for production of basalt fiber monofilaments.

Production Process Chemical control

Charging of stone onto furnace's conveyer

Melting of basalt stone and homogenization

Drawing through bushing

Sizing application

Winding of fiber on the cakes

Production of assembled roving

Cutting of wet fiber (moisture content 8-10%)

Cakes with wet fiber

Drying of cakes in drying oven (moisture content 0,1%)

Cutting of dry fiber

Comparison of Different Fiber Types Properties

Continuous Basalt

E-Glass

S-Glass

Carbon

Aramid

Density (g/cm³)

2.6- 2.8

2.5 - 2.6

2.5

1.8

1.5

Tensile Strength (MPa)

4100 - 4840

3100 - 3800

4020 - 4650

3500 - 6000

2900 - 3400

Elastic Modulus (GPa)

93.1 - 110

72.5 - 75.5

83 - 86

230 - 600

70 - 140

Elongation at break

3.1

4.7

5.3

1.5 - 2.0

2.8 - 3.6

Maximum Service Temperature °C

650

380

300

500

250

Technical data compare to steel, magnesium, aluminum 2,5 kg/cdm Basalt 80.000â&#x20AC;Ś110.000 MPa Basalt (= 1MPa)

3200 MPa Basalt Basalt 6x10*-7 1/K Basalt < (10x10*-6 1/K Glass fibers)

Classification of Basalt Fibers Products: E-Glass 2,61 g/cm3

S2-Glas 2,46 g/cm3

Basalt

1,74 g/cm3

1,85 g/cm3

Epoxy 1,2 g/cm3

2,60 g/cm3

2,70 g/cm3

4,51g/cm3

0,9 g/cm3

Aging of Rovings in a Concrete Matrix – SIC Test

The tests of rovings aging resistance in a concrete matrix were carried out in accordance with DIN EN ISO 2062 and DIN EN 14649 (SIC). The results show that our basalt fiber rovings BR130.2400.12RAA, BR170.240013RAA and BR170.240042RAA are in the top group and reach almost even after aging the values of alkali-resistant glass fibers.

Green Product  National Directives on end-of life vehicles strongly recommend to car manufacturers to use end-of-life management principles during car development and production.  To fulfill such recommendations, car manufactures have to look for new "green" materials which could  Help them to meet environmental requirements and to ensure maximum recycling when the vehicles reach end-of-life stage

LCA Study Basalt vs. Glass Fiber

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Basalt fibers are natural product with less impact on environment Easy recycling ensure the sustainability Basalt fibers improve the energy and CO2 balance of end product Reducing of recycling costs and negative environmental effects The monofilament diameter > 9 µm is not carcinogenic

Summary of Basalt Fiber Properties  5 % higher density to conventional E glass fiber,  15 % higher tensile strength, higher compressive strength and rigidity (modulus of elasticity).  Extremely high thermal stability, begin to melt at 1450 °C  Best flam stop of all fiber composites

 Chemical endurance, especially against strong acids, lye's and solvents  Protected, so to speak by nature, again UV radiation, organic effects and corrosion  10% higher absorption of electromagnetic radiation  Classified as non-poisonous and non-carcinogenic.  100 % natural Basalt fibers are  Suitable for compounds with resin epoxy, melamine vinyl ester, polyester, PP, PA  High wettability and adhesion based of new facing technology  High resistance to heat stressed joining (Flowdrill, spot weld)  Integration of function /inteligence  Price relevance CFK Linen 30,00€/sqm to BF 4,00€

Basalt Fiber Product Protfolio Roving, Yarns, Chopped Strands

Fabrics

Multiaxial Fabrics

UD Tapes

Tapes

Mats

Prepregs

Non-Woven

Mesh

Bars

Laminates

Basalt Fiber Raw Materials Rovings

Yarn/Core Yarn

Chopped Strand Monofilament diameter:

Monofilament diameter:

10 – 20 μm

10 – 13 μm

Linear density: 68 – 4800 tex

Linear density: 68 – 2400 tex

10 – 13 μm

Length of cut: 3, 4, 6, 12, 24 mm

Basalt Fiber Fabrics Plain

Twill

Weight:

150, 200, 400, 500, 600, 800 g/đ?&#x2019;&#x17D;đ?&#x;?

220, 345, 370, 700 g/đ?&#x2019;&#x17D;đ?&#x;?

Elastic Knitted Fabrics

Hybrid Knitted Fabric

Weight on request

Metallic coating Plain: 150, 200, 400 g/đ?&#x2019;&#x17D;đ?&#x;? Twill: 220 g/đ?&#x2019;&#x17D;đ?&#x;?

Concealed Fabrics

Weight on request

and fiber share

and kind of weave

Hybrid Fabrics Basalt-Carbon Basalt-Aramid

Tapes Width: 30, 40, 50, 70 mm Thickness: 0,21 mm

UD & Multiaxial Fabrics DU-Fabrics

Hybrid DU-Fabrics

Biaxial Fabrics

Triaxial Fabrics

Width, Weight and kind of fixing materials on request, Impregnation: Epoxy resin, PVAc possible

Width, Weight, share of fibers and kind of fixing materials on request, Impregnation: Epoxy resin, PVAc possible

The fibers are crossed over each other and the alignment of fibers can be 0/90 °, + / -45 ° Different weights are available.

The fibers are composed of three overlapping layers and the fiber orientation can be 0 ° / +45 ° / -45 °.

Quadriaxial Fabrics

The fibers are composed of four layers and can be aligned e.g. 0 ° / +45 ° / -45 ° / 90 °.

Matts, Non-Woven & Prepregs Matts Thickness: 6 mm, 550 & 780 g/đ?&#x2019;&#x17D;đ?&#x;? Thickness: 8 mm, 850 g/đ?&#x2019;&#x17D;đ?&#x;? Thickness: 10 mm, 1500 g/đ?&#x2019;&#x17D;đ?&#x;? Thickness: 12 mm, 1200 g/đ?&#x2019;&#x17D;đ?&#x;? lamination with PET, Aluminum foil and self-adhesive film possible

Non-Woven

Prepregs

Pre-impregnated UD-Tapes Pre-impregnated fabrics:

Weight: 60, 80, 100 g/đ?&#x2019;&#x17D;đ?&#x;?

Plain/Twill Pre-impregnated multiaxial tapes

Mesh, Bars & Laminates Mesh

Bars

Laminates

Asphalt reinforcement mesh for open structures Asphalt reinforcement mesh with meshes fill

Different diameter are

available

Basalt fiber sheet â&#x20AC;&#x201C; black Thickness and kind of surface on request

Reinforcement for building industry

Field of Applications

Basalt Fibers Sport & Leisure

Military

Automotive & Aerospace

Engineering Networks

Construction & Building

Basalt Fiber Applications •

Among existing fibers basalt fiber with its dark color is the closest to carbon fiber by color. Much less expensive basalt is used as either a replacement for carbon or in combination with it. By using carbon and basalt together you can significantly reduce the cost of finished products without losing attractiveness of its appearance.

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Coating and concealing of basalt fiber fabrics allow to reach not only better fire protection performance and higher mechanical properties but also new design surface optic.

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New range of elastic knitted and hybrid knitted fabrics can be used as filtering materials. Additional high thermal resistance allows application of these fabrics in many places where other materials would be destroyed.

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Due to high E-Modulus and tensile strength of basalt fibers find basalt fiber fabrics applications by manufacturing of sport equipment e.g. snowboards , wind surfboards and tuning parts.

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Comparable temperature coefficient of expansion with carbon fibers allows applications in sandwich constructions especially by direct tooling.

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Non-Conducting properties of basalt fibers allow applications by construction of battery boxes by cars.

Applications for Automotive Industry

 Headliners  High pressure cylinders for CNG and H2

 Break pads and clutch plates  Thermo insulation for exhausting systems  Muffler’s fillers

 Interior end exterior parts  Thermoplastic parts

Basalt Fiber Chops for Friction Applications Basalt chopped strands are used as an alternative to asbestos in production of brake pads and provides the following advantages to final products:  2-3 times longer service life  Extended working temperature range •Resistance to chemically aggressive conditions

•Eco friendliness

Thermo-Insulation for Exhaust System  Basalt fibers are used for production of the thermo insulating sleeves, braids, and fabric for car's exhaust system.  The flexible knitted sleeve, when installed on vehicle exhaust pipes, prevents exhaust gases from losing their high temperature as they flow through the exhaust system.  The technology enables more complete conversion of gases and particulates, such as CO2 and unburned carbon, in the catalytic converter; the result is better engine effectiveness and less environmentally damaging exhaust effluents

Muffler’s Fillers Basalt fiber advantages compared to traditional materials:  Much higher operating temperature

 High resistance to thermal cycling  Greater noise reduction  Lower moisture absorption  High chemical resistance

Interior and Exterior Parts ď&#x192;&#x2DC; Fabrics for interior and exterior parts Many interior and exterior parts of cars are made of fabrics and basalt fiber is used by some car producers in this application because of its attractive dark-brown color, high mechanical properties, fire-resistance and competitive price. ď&#x192;&#x2DC; Thermoplastic parts and components Today auto manufacturers widely use thermoplastic fiber composites as alternative to metal to reduce vehicles' weight and cost of production. With its outstanding mechanical properties, resistance to high temperature and "green" advantages, basalt

fiber also can be successfully used for this application.

Innovative Applications – Direct Tooling  Use of conventional carbon, glass and basalt fiber fabrics,  Mould is constructed with a sandwich design, insulation integrated,  Basalt fiber mat as mould surface layer

 Light moulds with low inherent thermal capacity  Agreement of the heating surface close to the surface, very short heat pathways - optimum utilization of energy

 Heating panels can be individually designed  Free geometric design of the heating panels  Additional functions are possible as desired

 Precise temperature control and heating processes  Simple programming of the temperature

Basalt Fiber Products – In Building & Construction Industry

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Reinforcement Direct Tooling Protection Separation Filtering Drainage Erosion Control Fire Protection Thermal Insulation Acoustical Insulation Electrical Insulation

Basalt Fiber Geogrid Basalt fibber geogrid with special polymer impregnation is the most resistant to high temperatures when laying asphalt layers, superstable to chemically aggressive environments, as well as to the effects of biochemical factors. The material has high strength properties at break in warp and weft and good adhesion to asphalt concrete. Scope Material used as reinforcement layer on the fractured layers of asphalt concrete pavement before placing the upper layers, and as a means of inhibiting the formation of "the rut." Due to the unique properties of basalt, basalt fiber geogrid increases stiffness modulus asphalt concrete strength up to 80% coverage. Strengthening earthen slopes accompanied by a number of complex construction activities. Poor reinforced slope can bring a lot of problems and lead to a landslide or collapse. Strengthening of slopes, embankments, shorelines necessary to prevent wind and water erosion.

Buildings & Construction Applications Layer in a cracked layer of asphalt concrete pavement

1 – Sand subbase; 2 – The base layer; 3 – Existing asphalt coating fracture; 4 – Basalt fiber geogrid 5 – Planarization layer; 6 – asphalt coating

Basalt Fiber Fabrics in Construction We are providing different types of basalt fiber fabrics such as plain, twill, panama, quer-rips, hybrid fabrics, coated fabrics with polyurethane, silicone, aluminum, PET, adhesive film. The main application field is not only reinforcement for composites but also for thermal and acoustical insulation and fire protection. Basalt fiber hybrid fabrics with silicate fiber have found place as applications for fire protection for civil engendering.

Excellent resistance to acid and alkali medium allows applications to reinforcement of concrete sheets and pillars.

New Applications Produced Samples “Organo Sheets with Solid Core structure “

Basalt Fiber Chopped Strand Basalt fiber chopped strands have an wide field of applications. On the one hand as reinforcement of Mortar and concrete matrix and on the other hand can be used as thermoplastic compounds to produce of pipes for civil engineering and chemical industry. West European countries increasingly put attention to sustainability of environment friendly construction materials and promote new solutions for building and construction industry. In this way has starting German Government some projects of harbor repairing e.g. Kiel

Basalt Fiber Bars Basalt fiber bars are made in pultrusion process and available in different length and diameter. Due to corrosion and UV resistance are basalt fiber bars excellent suitable to reinforcement of concrete constructions. High tensile strength and resistance to acid & alkali medium prolongs life cycle of concrete constructions. SIC tests have shown that basalt fiber rovings are in the top of group other rovings such as AR-Glass fibers by competitive price compared to AR-Glass fibers. Basalt fiber bars allow robust light concrete constructions by ensuring their stability.

New Application & Perspectives Integrated sensor techniques for lightweight material constructions –Organo Sheets:

Back-Lighting-Foil , low voltage to glue on OS or integrated inside in OS on the Basalt fibre matte , flies or woven and integrated in Acryl-, Silicon-, Epoxy resin to glue „behind“ the Basalt-fibre mat or transparent wood furniture light foils and to put into effect of transparency win different colours and intensity Back-Light-Foil without electrical contact, activate trough electrical frequency (micro waves) Application & Optic effects: • OS-in cabin room, covering in living rooms, ship cabins, container, waggons, car, plane, furniture • OS-on outdoor illumination of buildings, cruise ships, vehicles • OS-trade fair, sales booth, etc. • OS-particular illumination for medical places

Our Future Developing Stage  Class A Surface

 Tinge of yarn and fabrics  Developing of non-woven fabrics for automotive industry  Developing of new hybrid fabrics

 Developing of basalt fiber fabrics with steel core for better fire protection  Fabrics with high high temeprature and heat resistance for fire protection and insulation

Politician & Market Future Tendencies  Political Stage The Association of Automotive Industry (Annual Report 2013) provides the main factors, which will have strong impact on production in automotive industry in the next years e.g. efficiency and saving of used input, change to lightweight design, easier recycled and downsizing components, introducing of ecological innovations. These factors are strong on resource efficiency oriented.  Market Prediction Place 12th of McKinsey study about “15 important things in the future” take “high performance composites” e.g. light and steady components made from carbon, basalt or

glass fiber for automotive and aviation industry. The characteristic of high performance composites is especially high temperature resistance. The influence of GDP 2025: 25 M €; GDP-Share: 0,6%; no/less impact of employment; competitiveness in Germany: very strong.

www.incotelogy.de â&#x20AC;&#x153;High-Performance Basalt Fibers & Products for Next Generation Compositesâ&#x20AC;? - presented by Wojciech Dlugosz Contact: wojciech.dlugosz@incotelogy.de