Research and development for industry: Advanced ... - CSIR

ENABLING TECHNOLOGIESNatural fibres such as flax (pictured here) are being used in biocomposites.CSIR facilities geared to supportthe Biocomposites Centreof Competence“The processes involved in thepilot production line includefibre blending and opening;carding and cross lappingfor web formation; needlepunching;hydro-entanglement;foam impregnation; hot airbonding; the curing and dryingprocess; and hot calendaringand winding,” he explains.“The pilot plant facility isalso supplemented by acomprehensive range of testinginstruments to characterisenonwoven materials for a varietyof properties.”These instruments can test for airand water permeability; filtrationefficiency, dynamic contact angle;surface tension; pore size andits distribution; water-vapourpermeability; universal tensiletesting with attachments forpull-out force and punctureresistance measurement;hydraulic transmissivity; aswell as abrasion and peeling. Inaddition, digital image processingand microscopy analysis are alsodone.Composites and biopolymers“Composites are prepared usingnatural fibres such as flax, hemp,kenaf and agave; thermoplasticand thermoset resins; as well asbiopolymers such as soy protein,polylactic acid and polyfurfurylalcohol,” Anandjiwalacontinues. “The mechanical,thermal, thermo-mechanicaland fire-retardant propertiesof fibre-reinforced compositesare optimised for application inthe automotive and aerospaceindustries.”These two sectors are keen toincreasingly use composites in themany parts needed in aircraft andcars, but materials used have tobe strong as well as heat and fireresistant.Developing new biopolymersand resins is an importantactivity in the development ofbiocomposites. For this, theCSIR’s fully integrated compositeprocessing facility includes a2 700 kN compression mouldinghydraulic press, vacuum-assistedresin transfer moulding, twinscrewextruder and an injectionmouldingmachine.The composites laboratory housesstate-of-the-art equipment formeasuring the mechanical andthermal properties of composites.A weathering chamber wasrecently installed to studythe influence of temperature,humidity and sunlight oncomposite materials, which arecrucial for components that areused in outdoor environments.Fire testing laboratoryAnandjiwala says that the facilityalso supports fire-retardancyClient and partnershipsAirbusBombardierVolkswagenExpericoWoolworths and suppliersDe Gama, Frame, Brits TextilesUniversity of DelawareBIRNIDCSustainable Fibre SolutionsThe House of Hemp andHemporiumtesting. “The fire testinglaboratory is being upgradedwith the purchase of a rate-ofheat-releaseapparatus and asmoke density chamber.”According to Anandjiwala, plansare afoot to seek approval forthe fire testing laboratory fromthe Civil Aviation Authority. Thiswill allow the CSIR to undertakefire testing according to FederalAviation Administrationstandards. It will be the onlyfacility of its kind on the Africancontinent.Not just researchApart from research anddevelopment, this centre is alsocharacterised by elements ofindustry seeking assistance withInitiativesInterior panels for airplanesInterior panels for train carriagesParcel trayPackagingCharacterisasionNatural fibre compositesBiopolymers for housingInternational BiocompositesNetworkSisal fibre productionKenaf processingEstablishment of hemp industryBiocomposites for constructionChemcityindustryTable: Examples of high-profile clients/partners and research initiativesproblem-solving, quality control,and guidance on maintainingecological standards. In addition,the centre conducts hands-ontraining sessions for universitystudents and the industry.Anandjiwala concludes: “TheCSIR’s world-class researchersand well-equipped laboratories inPort Elizabeth have a valuable roleto play in growing South Africa’snatural fibre-reinforced compositesindustry, in close partnershipwith role players from academia,government and industry.”– Kelly-Anne MatthewsEnquiries:Dr Rajesh Anandjiwalaranandi@csir.co.za| 50 |Over the past few years, the CSIR has madea significant investment into fibres andbiocomposite research and infrastructure atits Port Elizabeth campus. The Department ofScience and Technology (DST) has investedapproximately R10.8 million in new equipmentto complement this research. With the hub of thecountry’s newly created Biocomposites Centre ofCompetence situated in Port Elizabeth, the CSIR isideally positioned to provide optimum support.The majority of researchdone at the CSIR’s facilities in PortElizabeth focuses on nonwovenproducts and the more traditionalfibre processing route. Fibremodification (where chemicalsand techniques are applied tofibres to change their properties)also remains a strong focus,with continued support given toindustry on fibres and textiles.Research production areaThis 4 300 m 2 facility includesextensive infrastructure forprocessing and analysing naturalfibres and natural fibre-basedcomposites along the whole valuechain, from fibre extraction andprocessing, through intermediateproducts such as nonwovens, to finalnatural-fibre composite products andcomponents. It is, essentially,a complete pilot production line.According to principal researcherDr Rajesh Anandjiwala, the CSIR’sworld-class nonwoven platformoffers a unique, custom-madecombination of several technologiesfor the production of a wide rangeof nonwoven fabrics and otherrelated products.Developing natural fibre-based composites for industrial applicationsCurrent research programmes focus on the development of natural fibre compositesfor various industrial applications. An interesting product that has been developedis a natural fibre-reinforced sandwich panel for aircraft interiors. For the first time,natural fibre-based panels for aerospace applications have been developed using anenvironmentally benign flame-retardant treatment to comply with flame, smoke andtoxicity (FST) requirements. The major advantages of these panels include beinglightweight (leading to energy savings), environmentally friendly, fully degradableand sustainable. They are, therefore, truly ‘green’. Other advantages includeimplementation of REACH (registration, evaluation, authorisation and restriction ofchemicals) guidelines and alignment with the European Union’s Clean Sky Initiative.A natural fibre-reinforced compositeis shown after fire testing.| 51 |