composites future materials for high performance boats consultancy 150+ projects completed since...

© Copyright STRUCTeam Ltd Slide: 1

Composites – Future Materials for High Performance Boats

Hiper Conference

17-19/10/2016 – Cortona, Italy

Julien Sellier

Managing Director

STRUCTeam LtdCredit: Ozata Shipyard


S T R U C Te a m ( S T L )

Independent Composite Consultancy

150+ Projects Completed since 2010 across market sectors

We enable composite applications!

Composites Solutions Provider

We help our clients make better decisions, reduce costs, improve efficiency, select and develop appropriate technologies for their composite business. Credit: Atlantic Eagle Shipbuilding

Credit: Tri-Marine


I n t ro d u c t i o n

Objectives:

1) Brief Intro on Composites

2) Opportunities for Composites in Marine Sector

3) Method to Assess Opportunities


C o m p o s i t e s …

Is It Really Easy to Adopt?

Materials

Design Process

B787


Manufacturing Process

T h e E n g i n e e r ’s M a t e r i a l Pa l e t t e

Cores

ResinsFibres

Adhesives

What Materials Shall I Use?


M a n u fa c t u r i n g Te c h n o l o g i e s

Wet lamination Press Infusion

Pultrusion Prepreg Automation

What Process Shall I Use?


N e e d fo r D e d i c a t e d E x p e r t i s e a n d S o f t w a re S o l u t i o n s

Which Combination of

Materials & Processing

should I choose?


S O L A S Re g u l a t i o n s

Ship structures must be constructed with steel or other equivalent material

Equivalent material = non-combustible material

However it is possible to go through case-by-case certifications with certification bodies as DNV GL, Lloyd’s Register, Bureau Veritas…


N e e d fo r D e d i c a t e d E x p e r t i s e a n d S o f t w a re S o l u t i o n s

Large number of materials to choose from¤ Lots of Possibilities for Resin, Fibres, Core…

Lots of Manufacturing Processes Possible

Certification Can Be Difficult

Need of Dedicated Expertise

Different From Other Isotropic Material

Need for Dedicated Software Solutions

Not Easy &Can be Expensive


C o m p o s i t e M a t e r i a l Pe r fo r m a n c e

Specific strength (kPa.m^3/kg)

Specific stiffness (MPa.m^3/kg)

Indicative Material Cost (€/kg)

Specific Fatigue Strength at 10^7 cycles (kPa.m^3/kg)

CFRP GFRP Steel Aluminium

855 385 63 103


89 21 25 27


30 8 4.5 1.7


229 83 10 16

0

1

2

3

4

5

Specificstrength

Specificstiffness

Cost

Fatigueresistance

Corrosionresistance

Fire retardancy

Traditional Metals and Composites Comparison



Perf

orm

ance

Price

C o m p o s i t e s O p p o r t u n i t i e s

Regulated Products

Weight Driven

Optimised Products

Special Requirements

Low Regulated, High Strength & Stiffness Driven.

Production Products

Geometry, Cost and Weight Driven


Regulated Products

Weight Driven

Optimised Products

Special Requirements

Not Regulated, High Strength & Stiffness Driven.

Production Products

Geometry, Cost and Weight Driven

Perf

orm

ance

Price

C o m p o s i t e s O p p o r t u n i t i e s

SmallOutboard

RIB’s

Olympic ClassesSurfing

CatHobby

Competition

Cabin BoatsSailing, Cruiser

Power

Mega Power Yacht

Ocean RacerAC Yachts

Mega Sailing Yachts

Work Boats

Shipping And Components

FerriesMilitary

Power Racers

Performance & High Quality Cruisers


M a r i n e S e c t o r

Leisure Market %Market size €7 billion

Regional Share

Source: UCINA

Source: RINA

Commercial Market %Market size €29 billion


Re g u l a t e d P ro d u c t sE xa m p l e : H i g h S p e e d Fe r r i e s

Benefits of Composites

¤ Trade off between equipment and performance

¤ Increased Fuel Efficiency

¤ Up to 50% weight saving compared to steel

¤ Reduced need for maintenance

Perceived Entry Barriers

¤ Heavily Regulated Market

¤ Composites are expensive

Multihulls

HSC

Electric Ships


S p e c i a l Re q u i re m e n t sE xa m p l e : M i l i t a r y Ve s s e l s

Performance

¤ Stiffness (Weapons)

¤ Ballistics Protection

¤ Low Radar and Magnetic Signature

¤ Opportunity from specific regulations

¤ High Shock Resistance

¤ Increased Speed from Reduced Weight

Perceived Entry Barriers

¤ Repairability, Maintenance and new

¤ Is it really new?

¤ Will the staff be trained in composite?

¤ Is the experience there?

HSC

Ultra-efficient ships

Intelligent + connected ships

Military Vessels

Patrol Boats


H e av i l y Re g u l a t e d Ve s s e l sE xa m p l e : C o m m e rc i a l S h i p p i n g

Perceived Entry Barriers for composites¤ How do I cope with regulations?

¤ How do I maintain/repair vessels?

¤ What about the current fleet?


H e av i l y Re g u l a t e d Ve s s e l sE xa m p l e : C o m m e rc i a l S h i p p i n g

Lightweight

¤ Superstructures, Radar Masts, Rudders, Cargo Hatches Etc..

¤ Increased Payload OR Increased Fuel Efficiency

¤ Increased Stability from lower COG

¤ Reduced Maintenance

Example: Composite Cargo Hatches

¤ Easier crane handling and lighter motors

¤ No corrosion means better seal performance - reducing risk of cargo damage

Shipping


A s s e s s i n g O p p o r t u n i t i e s

Business Case: Patrol Boat ¤ 60 feet

¤ 40 knots

Material and Process Matrix (Reference Material : Aluminium)

Reinforcement material

Core material

Glass Carbon

Process

Infusion Prepreg

PET G/INF/PET C/INF/PET C/PP/PET

PVC-Balsa G/INF/ PVC-B N/A N/A

PVC G/INF/PVC C/INF/PVC C/PP/PVC

Credit: ARES Shipyard Inc.



Business Case: Patrol Boat¤ Weight vs material cost



Business Case: Patrol Boat¤ Return on investment

30-year budget for 50% utilization


C o n c l u s i o n

Opportunities Challenges

• Cost-effective on a Medium-term basis- Increase in fuel efficiency

- Increase in payload- Increase in stability• Low maintenance

• Large freedom from variables• Decrease total weight

• Shortage in traditional materials(Aluminium, Wood, Steel)

• Useful for niche markets/Special crafts

• Requires a well structured process for decision and design

• SOLAS Regulations on main components• Initial Cost of Materials


A ny Q u e st i o n s ?

Julien [email protected]

STRUCTeam Ltd

+44 1983 240 534

www.structeam-ltd.com

mailto:[email protected]

composites future materials for high performance boats consultancy 150+ projects completed since...

Documents