APPENDIX C. SITE REPORTS Site: Doshisha University Department of Mechanical Engineering Kyoto 602, Japan Date Visited: December 9, 1992 Report Author: V. Karbhari ATTENDEES JTEC: V. Karbhari D. Wilkins HOSTS: Dr. Toru Fuji Chairman, Dept. of Mechanical Eng. RESEARCH & DEVELOPMENT ACTIVITIES 1. Fatigue of polymer matrix composites o Investigation of joints using a special rubber toughened epoxy o Effects of biaxial loading in fatigue on specimens with a hole o Fatigue of a woven glass composite with investigations on microstructureat the unit cell level o Effects of loading and unloading durations o Investigation of repeated tension-torsion loadings 2. Development of CVT belts o Use of composites in continuous variable transmission belts 3. Investigation of environmental effects o Acid rain -- specimens immersed in synthetic acid-rain-simulating bath and tested in fatigue -- results suggest that effect is insignificant. o Effects of vacuum, dry air and oxygen rich environment on fiber strength -- results indicate that a pure oxygen environment significantly decreases S2 glass strength. o Effects of marine environment on performance -- the main aim is to establish accelerated testing methods. Tests are in progress, pressure being the main variable being considered. 3. Tension/torsion testing of tubes o Fabricated by a wet rolling type process followed by grinding. Tests are for marine type applications. 4. Automotive transmission belts o Fatigue testing of belts reinforced with aramid layers SUMMARY Dr. Fuji switched completely from ceramic matrix composites to polymer matrix composites in the last two to three years because of increased industrial support and because of the need to obtain specimens. His research is heavily supported by Honda, Nitta, JSR, Teijin, Shin Caterpillar Mitsubishi, and other companies and organizations that lend him equipment for tests as well as fund his research. Composite materials are supplied by courtesy of Dai-Nippon Ink & Chemicals, Asahi Fiber Glass, Toray, and other companies. Site: Fuji Heavy Industries Aerospace Energy Division 1-1-11, Yonan, Utsunomiya Tochigi 320, Japan Date Visited: December 10, 1992 Report Author: B. Kramer ATTENDEES JTEC: M. Ashizawa D. Granville B. Kramer HOSTS: Mr. Masaomi Kadoya Deputy General Mgr., Utsunomiya Plant Mr. Takeshi Nakao General Mgr., Research & Laboratories Dept. Mr. Takashi Nagumo Manager, Material Research Section, Research & Laboratories Dept. Mr. Kenichiro Usuki Manager, First Airframe Design Section, FixedWing Engineering Dept. Mr. Toshio Sakakibara Manager, R&D, Production Engineering Dept. BACKGROUND Fuji Heavy Industries started in 1917 with the establishment of the Aircraft Research Laboratory, later Nakajima Aircraft Company. The company was broken up after World War II; five elements rejoined in 1953 as FHI. FHI has four manufacturing plants in the Tokyo area, in addition to an R&D Center and the home office. Six percent of company sales are in aerospace ($453 million), and 20% of employees (3,000) are employed in aerospace. In-house support is mainly provided for graphite/epoxy wing and fuselage structure fabrication, repair methods, and titanium-composite joint development in FHI's recent composite activity. From 1981 to 1988, MITI supported basic technology for future technologies of fiber-reinforced polymers, fiber-reinforced metals, and fabrication and design techniques for composites. RESEARCH & DEVELOPMENT ACTIVITIES The facility is highly production-oriented. SUMMARY FHI does not do CATIA simulations for the tape layer, but does simulations using its unique TLVRFY (tape layer verify) system. The facility is highly production-oriented, with the most actual production of any site visited. FHI is a Boeing subcontractor, and is required to use Boeing technology in many parts. They have learned a lot from Boeing but they now feel they could get better quality and the same technology themselves. Workers at FHI typically lay up parts according to operation sheets but they also do some memorization. Primary structures are made to layup according to operation sheets as well. They use throw-away nylon bags for autoclaving, because it reduces the expense. A laser- cut Kevlar component was shown, but water jet cutting is currently widely used since water jet cutting is considered superior. FHI rates its composites processing as excellent compared to other Japanese industries. They do not know much about U.S. companies; only a few FHI employees have seen the production line at Boeing. They rate co-curing and honeycomb structures as their best low-cost manufacturing technologies (they include honeycomb only if they can do both the design and production). They think that composite use in aerospace will expand, since more electronics are going into airplanes, requiring more weight savings. They feel that better design is needed; no more "black aluminum," and feel that Airbus Industries, a European company, seems to be ahead of the U.S. and Japanese companies in automated manufacturing techniques. FHI's integral wing structure is the most complex part in the world. It took five years to develop and will be co-produced with MHI (and General Dynamics). Development was done jointly, but production will be completely separate. The most difficult aspect was developing the required bladder bag technology. Four aspects were mentioned as having potential for breakthroughs in cost reduction: 1. Reduction in material cost from $36/lb. to $10/lb. 2. Design for low cost manufacturing, using the unique characteristics of composites, including the elimination of fasteners using co-curing and filament winding 3. Automation 4. New automated manufacturing technology to eliminate autoclaving and newresin systems The 777 co-cure horizontal stabilizer was jointly developed by FHI and Boeing. This co- cure technology is currently applied in Boeing's 777 program. FHI indicated that scrap and bag failures are very rare. The bag material is from the U.S. and is commercial grade (the best of three available commercial grades). Our hosts stated that stitched RTM is not a good idea for cost reduction and that thermoplastic composites may reduce cost, since material cost may decrease and manufacturing methods (especially in pultrusion) have tremendous room for improvement. They observed that in the past everyone in the U.S. was excited about thermoplastics; now everyone in the U.S. is giving up on thermoplastic composites. They think there is potential, because there is no cure time. Therefore, if good processing methods can be developed and material cost is reduced, manufacturing cost can be low. They rate, in order of importance in composites manufacturing: (1) people, (2) equipment, and (3) facilities. They are thinking about automated kitting, but only as an idea thus far. FHI would be interested in cooperative efforts with the U.S., if they prove to be mutually beneficial. REFERENCES Fuji Heavy Industries Aerospace Division. 1991. "Advanced Composite Technology in FHI" (pamphlet). Japan. Fuji Heavy Industries Ltd. 1992. "Aerospace FHI" (pamphlet). Japan. Fuji Heavy Industries. 1992. Annual Report, 1992. Site: JAMCO Corporation 6-11-25 Osawa Titaka Tokyo 181, Japan Date Visited: December 11, 1992 Report Author: D. Granville ATTENDEES JTEC: M. Ashizawa J. DeVault D. Granville V. Karbhari J. McDermott D. Wilkins HOSTS: Mr. Yoshiro Matsuo President Mr. Seiji Ogawa Executive Vice-President Mr. Osamu Terada General Manager, Second Manufacturing Div. Mr. Satoru Ogasawara General Manager, R&D Dept. Mr. Shigeo Suzuki Sales Manager, Marketing Dept. BACKGROUND JAMCO is the world's leading producer of aircraft lavatories, supplying units for Boeing 747 and 767, and McDonnell Douglas MD-80 and MD-11, and galleys for all models. Its current market share is 70% for lavatories, and 30% for galleys. In 1952 the company began doing aircraft repair, and in 1955, aircraft component fabrication. JAMCO holds the highest levels of certification for aircraft maintenance awarded by the Japanese government; these include structural, electrical, pneumatic, hydraulic and instrumentation repair. It began making aircraft galleys in 1970. They increased production to heat exchangers and aircraft lavatories. JAMCO has extensive testing laboratories to meet Federal Aviation Administration (FAA) and American Society for Testing and Materials (ASTM) standards. Computer-aided manufacturing includes autoclave production of sandwich skin composites. JAMCO is one of only two companies in the world capable of manufacturing jet aircraft air chillers made from thin stainless steel. RESEARCH & DEVELOPMENT ACTIVITIES JAMCO advanced pultrusion is used to manufacture curved T-stiffeners. This process is isobaric die roll-trusion manufacturing equipment (1-2 m/hr). Typical fabrication is two ply uni and two ply graphite fabric for each side and bottom, with PP/PET slip-sheets as separators between the split isobaric die and the product. Nylon rolls are used to guide 3" wide tape through the channel "chute" into the die, followed by variable radius takeup within the "oven" chamber. Compression press equipment is used for continuous sandwich skin laminate structures using a honeycomb core. Lavatory and galley expenditures are highest in the machining, trimming, and assembly costs. Current cost of a lavatory is approximately $30,000 to $40,000. The weight is approximately 250 lbs. JAMCO uses a "streamlined" assembly approach. Lavatory assembly stations are set up so that each worker has the responsibility for two or three assembly details. More experienced workers are at the end of the assembly cycle; they are skilled in all tasks and quality checks. Workers keep a running record of all engineering change orders, drawing changes, sub-assembly changes, and fabricating, machining, and trimming errors. JAMCO hopes to further investigate self-extinguishing low-exotherm thermosetting resins, advanced pultrusion methods, and lightweight sheet molding compounds (SMC) for aircraft markets. SUMMARY JAMCO has excellent data processing, manufacturing, planning, and inventory control systems. It has 52 CAD terminals, eight for 3-D solid modelling, the remainder for 2-D. They do not use CATIA as Boeing does, but use another less sophisticated but compatible system. Their CAD is adaptable to CAM so that information is transferrable to the shop floor. CAD data files are essential for later maintenance of the lavatories, and as a record for Boeing. Engineering has an on-line communications network with Boeing. Manufacturing drawings are kept separately from design drawings but the skilled workforce has no trouble reading design drawings. Shop people are regarded eminently qualified to address quality issues and to assess better ways of building the product. Scrap is approximately 10% for all composite lavatories and ways to recycle scrap are being investigated since waste removal costs are very high. Three autoclaves are in operation, but no modern feedback controllers are used. Disposable vacuum bags are used but JAMCO is evaluating the newer re-usable elastomeric cauls and bags and bag sealing methods. Material (pre-preg and core) quality is "bought" (in specs) from the suppliers. No differential scanning calorimetry or other chemical characterization is used, but there are many tests and visual checks for the finished product quality after processing. REFERENCES JAMCO. 1992. Annual Report. JAMCO AMERICA. 1992. "Component Technology in Flight" (brochure). Site: Kawasaki Heavy Industries Aerospace Engineering Dept. 1 Kawasaki-chome, Kakamigahara-shi Gifu Prefecture 504, Japan Date Visited: December 8, 1992 Report Author: B. Kramer ATTENDEES JTEC: I. Ahmad M. Ashizawa J. DeVault D. Gill B. Kramer X. Spiegel HOSTS: Mr. Kohmei Kawaji Sr. Mgr., Aerospace Eng. Dept., Aerospace Group Mr. Kohki Isozaki Associate Dir., General Manager of Aerospace Eng. Div. & Space Systems Div., Aerospace Group Mr. Motoaki Yanase Mgr. of MR&D Section, Manufacturing Eng. Dept., Gifu Aircraft Div. Mr. Minoru Noda Mgr. of Materials & Process Engineering Section, Aerospace Eng. Dept., Aerospace Eng. Div., Aerospace Group Mr. Hirotoshi Nakayama Mgr. of Structures & Materials Research Section, Aircraft Research Lab., Gifu Technical Institute Mr. Hisao Sayanagi Manager of Structure Eng. Section, Aerospace Eng. Dept., Aerospace Eng. Div., Aerospace Group BACKGROUND Kawasaki started assembling aircraft in 1923. The company separated from the Kawasaki Dockyard as an independent company in 1937. The Aerospace Group consists of seven divisions (see Figure KHI.1). The principal composite products manufactured are shown in Figure 1.2 (Chapter 1, p. 6). KHI's major equipment for composites manufacturing is indicated in Table KHI.1. Figure KHI.1.Organization Chart (Courtesy of Kawasaki Heavy Industries, Ltd.) Graphic File ***.GIF Table KHI.1 KHI Facilities for Composite Products Autoclave Automatic Tape Layup Machine Automatic Prepreg Cutting Machine Filament Winder Honeycomb Core Cutting Machine Water-Jet Knife X-Ray Inspection Equipment Ultrasonic Inspection Equipment RESEARCH & DEVELOPMENT ACTIVITIES KHI has developed a low cost method for manufacturing an -type stringer, using a teflon rod insert and silicone rubber tooling. There is new technology for producing super-composite bolts (see Figure KHI.2). The unique feature is that the fibers bend into the thread space, vastly increasing shear strength. They have a 4.8:1 specific strength advantage versus high strength steel. Figure KHI.2.Super Composite Bolt -- expected for future use in the sea, ground, air, space and so on. KHI expects great activity in all fields. Graphic File ***.GIF KHI has developed technology for producing sine wave stiffeners using a low CTE, cast steel tool on the outside and silicone rubber on the inside. SUMMARY Our KHI hosts preferred not to rate their company relative to others due to a lack of information. They felt that composites raw material costs should be reduced by about 50%, and indicated that they tried to get structures business from the U.S. and Europe, but that their quotes were too high. When the JTEC team observed that KHI's parts were highly integrated by co-cure; our hosts agreed, but added that they needed excellent craftsmanship to get good yield. The team noted three items of particular interest: 1. The use of integral tool heating in the high temperature (450C), high pressure (20 kg/cm(2)) autoclave 2. The use of integral tool cooling (air and water) in the autoclave 3. The -stiffener manufacturing process The emphasis on new process development was on tough resins and high temperature resins. REFERENCES Kawasaki Heavy Industries Ltd., Aerospace Group. 1991. "Advanced Material Products in the Aerospace Field" (brochure). Japan. ------. 1992. "KHI's Capability for Composite Structure" (viewgraph). Kawasaki Heavy Industries, Ltd. 1992. "Gifu Works" Cat. No. 5V0071 (brochure). Japan. Site: Kyoto Institute of Technology (KIT) Matsugasaki, Sakyo-ku Kyoto 606, Japan Date Visited: December 9, 1992 Report Author: B. Kramer ATTENDEES JTEC: J. DeVault B. Kramer HOSTS: Dr. Zenichiro Maekawa Professor, Faculty of Textile Science Dr. Eng. Hamada HiroyukiAssoc.Professor, Faculty of Textile Science Mr. Akihiro Fujita Research Assoc., Faculty of Textile Science Gabriel O. Shonaike, Ph.DFaculty of Textile Science BACKGROUND Professor Maekawa's research group in composites is the largest in Japan, with 40 industry affiliates, seven doctoral candidates, nine masters candidates and 12 bachelors candidates. RESEARCH & DEVELOPMENT ACTIVITIES Professor Maekawa summarized the research projects in his laboratory (see Table Kyoto.1). The JTEC team was provided with an extensive collection of recent papers and research reports (mostly in Japanese). There is extensive work in braiding, with KIT performing braiding, industry conducting curing, and KIT doing characterization. A particular emphasis is on co-mingled yarn systems. They hope to organize an international symposium on fiber-resin interface studies in Japan in 1998, to complement an annual symposium on the subject in Japan. Table Kyoto.1 Research Programs in Dr. Maekawa's Department RESEARCH PROGRAMS Fabrication and mechanical properties of 3-D composite materials Reliability improvement on mechanical properties and fracture behavior of ACM Durability evaluation of composite materials under hot water and acidic environment Damping properties of FRP with modified resin and hybrid reinforcement Measurement of fiber orientation process in thermoplastic composites Evaluation of the interfacial properties in GFRP Melt flow analysis of injection molding Non-destructive evaluation by AE Static and fatigue properties of mechanically fastened CFRP Crushing properties of CFRP and GFRP SUMMARY KIT is conducting an impressive range of research activities, with strong modeling and characterization efforts and very strong and effective links to industry. The research group appears to be limited by a severe shortage of space and, particularly, of space that is of sufficient quality to perform the most demanding composites processing applications. REFERENCES Tokyo Institute of Technology. 1992. PM KIT. Site: Mitsubishi Electric Co. (MELCO) Sagami Works Materials & Electronic Devices Laboratory 1-1, Tsukaguchi-Honmachi 8-chome Amagasaki, Hyogo 661, Japan Date Visited: December 11, 1992 Report Author: B. Kramer ATTENDEES JTEC: M. Ashizawa J. DeVault D. Gill B. Kramer HOSTS: K. Murayama Materials & Electronic Devices Lab S. Yamashita Materials & Electronic Devices Lab T. Inoue Kamakura Works S. Utsunomiya Sagami Works K. Kawakami Sagami Works H. Shimodaira Sagami Works BACKGROUND MELCO started producing glass & fiber-reinforced radar domes in 1955 and began applying composites to satellites in 1970. The company is now one of the biggest satellite manufacturers in Japan. It develops all of its own composites technology for satellites. A synthetic aperture radar launched in 1992 has eight panels, 2.2 m x 1.4 m each with 1 mm form accuracy. The Intelsat VII, C-band antenna is 2.44 m diameter, with 0.15 mm accuracy. Heat pipe panels are produced up to 2.4 m x 2.8 m in size. Large solar panel arrays are also produced. RESEARCH & DEVELOPMENT ACTIVITIES Continuously Formed Graphite/Epoxy Composite Tubes for Large Space Structures (MITI research project -- approximate cost of $1 million for the machine) The machine combines filament winding and pultrusion with high E fiber and epoxy resin, achieving 60% fiber volume fraction. Production rate is 1-5 m/hr. It uses prepreg tape, approximately 50 meters on each tape spool. Reinforcement Architecture for Fiber-Reinforced Composites MELCO currently uses 2.5-D preforms. The 3-D composites research consortium was started five years ago with 10 researchers from five companies (NSC, Toyoda, Mitsubishi Rayon, and Arisawa and MELCO) and $16 million in funding for six years (70% government & 30% companies). Braiding It is believed that the most promising technologies are four-step braiding and four-axis and five-axis braiding. Mr. Murayama is very knowledgeable about braiding. MELCO has good capabilities in cylindrical braiding and has a parabola weaving machine that is patented. A 3-D knitting machine is under development by Asahi Kasei. SUMMARY Our MELCO hosts stated that they cannot rate their company relative to other companies, since they have not seen other companies. They use CAD/CAM, and their best manufacturing technologies are accurate filament winding (better than anyone else) and very lightweight structures. They think there may be a good future for composites, if applications can be developed. RTM is a potential breakthrough technology in the mid- volume area (not refrigerators). The main problem in 3-D weaving is production rate and no solution is in sight; 2.5-D might provide a partial solution. MELCO uses supplementary oil heating on autoclave tooling and produces very flat solar cell panels with excellent seams. Our hosts expressed the view that design for the total system of composites is very important, since conventional design systems are oriented towards metals. They feel the key element is more imaginative, creative people. Our hosts indicated that U.S.-Japanese cooperation could help increase the use of composites and they are interested in continued cooperation. They have good cooperation with their suppliers, but communications with other manufacturers is on a person-to-person basis only. For widespread use, low fiber cost is not critically needed. It is more important to reduce finished cost to 2-3 times raw material cost, instead of 10-50 times. REFERENCES Mitsubishi Electric Co. 1992. "The Sagami Works 1992 Corporate Profile." ------. "Space Activities" (brochure). Site: Mitsubishi Heavy Industries Research Division Nagoya Aerospace Systems Factory 10 Oyemachi, Minato-ku Nagoya-shi, Aichi-ken 455, Japan Date Visited: December 8, 1992 Report Author: B. Kramer ATTENDEES JTEC: D. Wilkins M. Ashizawa J. Devault D. Gill I. Ahmad X. Spiegel HOSTS: Mr. T. Tanioka Director, Eng. Research Dept. Mr. T. Ikeda Asst. Dir., Aircraft Engineering Dept. Mr. Y. Yamaguchi Asst. Dir., Engineering Research Dept. Mr. K. Ogasawara Manager, Production Dept. Mr. T. Yamamoto Manager, Engineering Research Dept. Mr. Shiraishi BACKGROUND The Nagoya works employs 4,593 people. Mr. Shiraishi indicated that almost anything could be discussed at this meeting, except areas related to Japanese Defense Agency projects. Mr. Ogasawara indicated that advanced composites work at MHI started in 1969. As a result, MHI is the world leader in co-curing technology, which is needed to reduce assembly cost. General applications include the co-curing of very large and complex parts, including a new fighter wing torque box which is 160" by 80". It took 5 years to develop the technology to produce the wing torque box by co-curing. The part is autoclaved in the biggest unit in Japan: 18' diameter, 51' long, within 200 psi, 800F capability. RESEARCH & DEVELOPMENT ACTIVITIES 1. 3-D composites. Efforts are to improve interlaminar shear strength. They do the weaving for the project in-house. 2. Resin-transfer molding (RTM). It was indicated that they were investing "almost significant" research resources in the project. When asked what the biggest challenge in RTM was, they indicated that it was the resin. The JTEC team indicated that it thought weaving was the biggest challenge. However, our hosts replied that they have a low-cost method for manufacturing the preform. They also have many specialty weavers in Japan working on preforms. U.S. companies are coming to Japan for weaving technology. 3. Film infusion. 4. Material development. The emphasis is on thermoplastics and high temperature resins. MHI representatives listed five key approaches to co-curing technology: 1. Finding the applicable range of co-curing. MHI engineers calculate the design/manufacturing/quality assurance (QA) trade-off for each part in order to optimize resources. When asked how the scrap rate is estimated for the model, they indicated that they assumed zero scrap. They have an effective repair method for fixing the defects they get. When asked about bag leakage, they indicated it almost never happens. For instance, only one failure in 240 speed brakes. 2. Assuring the strength of the co-cured interface for in-plane shear, tension and peel. 3. Minimizing thermal deformation. Finite element methods (FEM) analysis is used to adjust parts deformation. 4. Assuring achievable tolerance. 5. Assuring effective repair methods. MHI employs five key methods for improving co-curing: 1. Each detail part is compacted before co-curing the assembly to remove air and water, to adjust the resin viscosity and to control the dimension and/or shape of the part. The parts are non-destructive evaluation (NDE) inspected by ultrasound after hot compaction. 2. A reliable, leak-free bagging system is used. The MHI system is made from unreinforced silicon rubber, reusable for 20 cycles. The company used to buy bagging rubber from a U.S. material supplier, but now makes its own. It has developed its own zip-lock system for bagging. 3. Dimensional stability is assured to minimize warpage. MHI uses invar tooling. 4. Pressure is transferred directly to the part using a molded bladder bag that has the same shape as the part. 5. Temperature uniformity is assured by uniform gas flow in the autoclave. The MHI staff feels that 80% of their success is in the tool, but indicated that this assumes the use of high quality labor. For tooling research, film pressure transducers are used in the autoclave. MHI is engaged in the following cost reduction activities: 1. Cooperation between research, design, manufacturing, and Q/A 2. Manufacturing development incorporating a zero-defect goal and emphasizing step- by-step development 3. Low cost manufacturing technology including: a. Automated cutting and nesting b. Automated layup c. Computer-controlled cure with temperature and pressure sensing but no supplemental tool heaters d. Net trim before cure with an NC trimming machine SUMMARY MHI representatives indicated that prepreg cost is important, that filament winding, pultrusion and thermoplastic composites are not used in production, and that CATIA data are shared by designers, automated layup, and tool fabricators. Our hosts expressed the view that a 50% decrease in cost could be attained with accumulated minor improvements, that no major breakthroughs were on the horizon, and that MHI has a special device (an intensifier) to prevent bleeder mark-off, but that they cannot discuss it. The method involves the use of carbon fiber slip-sheets. They indicated that MHI wingbox technology has been transferred successfully to General Dynamics and that they do not use long, discontinuous fibers. Composite organizations mentioned included JSCM and JSAMPE. Professor Maekawa of Kyoto Institute of Technology was mentioned as one of the leading university researchers. Site: Mitsubishi Kasei Corp. (MKC) Research Center 1000, Kamoshida-cho Midori-ku, Yokohama 227 Japan Date Visited: December 7, 1992 Report Author: D. Granville ATTENDEES JTEC: J. DeVault D. Granville J. McDermott D. Wilkins HOSTS: Dr. Yasuhiro Ohmura General Manager, Material Science Research Sector Mr. Takao Uematsu Chief Research Scientist, Advanced Composite Materials Laboratory Mr. Shigeki Tomonoh Research Scientist, Advanced Composite Materials Laboratory Dr. Tohru Imanara Sr. Research Scientist, Advanced CompositeMaterials Laboratory Mr. Junichi Goto Manager, Research Planning Dept. BACKGROUND Mitsubishi Kasei is involved in six basic areas of technology: carbon chemistry, inorganic chemistry and metallurgy, organic chemistry, polymer chemistry, electronics, and biotechnology. MKC services civil engineering and the sporting goods markets as well as the pharmaceutical, agricultural, and communications markets. This is an innovative corporation with diverse interests from superconductors to carbon fiber and biotechnology. A joint venture with U.S. company Fiberite/ICI dissolved in October of 1992. RESEARCH & DEVELOPMENT ACTIVITIES MKC's research activity in advanced polymer composites includes materials-pitch based carbon fiber, formulations of thermoset resins, thermoplastics resin and prepreg (pan-based CF, pitch based CF, GF, aramid fiber). In pitch carbon fiber development, MKC markets "Dialead" (500 tons/year), to make prepregs and printing press rolls. It is one of the three largest manufacturers of pitch based carbon fiber in Japan. They start at the raw feedstock level with coal tar (pitch coke, needle coke, dialead) which is incorporated into metals, plastics and cement. Several application technologies were developed or are being developed for civil engineering and architecture: curtain wall, rod for prestressed reinforcement, smoke stack reinforcement, slab retrofitting reinforced with CF UD tape and also special resin systems for reinforcement. The Kyushu Prince Hotel has cement walls using graphite-reinforced cement. Another innovation is in smoke stack applications where the top 1/3 is reinforced with pitch-based graphite. Pre-preg uni-tape is laid down along the stack axis, then overwrapped with wet strand reinforcement at a low temperature cure. Other applications include 8 mm diameter carbon fiber reinforced plastic (CFRP) rods (thermoplastic) for anchors in construction (often prestressed) and hexagonal honeycomb pontoons. Structural RIM has applications for electric motor scooters and also for large parts with high strength at high speeds. From near net-shape parts (30% Vf) using epoxy/acrylic hybrid resins, a scooter frame was developed which replaced a steel frame and fairings with a 40% weight savings. Other applications are being pursued for sporting goods (lamination technology for golf shafts and fishing rods) and industrial markets (roll manufacturing technology and railway components). Not much work is being done on automotive applications, but they are doing work on trains. SUMMARY Business units fund 80% of MKC research activities, specifically in pitch-based carbon development, pre-preg, chopped fiber etc. MKC developed the SRIM process with special hybrid resin systems, and successfully applied the modeled product to the structural body of an electric scooter, the design and assembly of which were performed at Tokyo R&D. MKC is the developer and supplier of pitch carbon fiber (chopped and continuous) and epoxy/acrylic resins. It is developing the processing science in structural RIM, as well as the processing science and product development in CFRPs (PC, PBI, TP molding compounds), scooter frames, golf shafts, composite rolls, cement walls, and composite rod for construction anchors. REFERENCES Mitsubishi Kasei Corporation. "DIALEAD CFRC (Carbon Fiber ReinforcementCement)" (brochure). ------. "DIALEAD - Coal Tar Pitch Carbon Fiber". Mitsubishi Kasei Corp. andMitsubishi Kasei America Inc. California Office (viewgraphs). ------. "I am MITSUBISHI KASEI" 1991-92 Annual Report (brochure). ------. "Mitsubishi Kasei - CFRP LEADLINE Carbon Fiber Rod" (brochure). ------. "Mitsubishi Kasei DIALEAD:Coal Tar Pitch-Based Carbon Fiber" (brochure). ------. "Mitsubishi Kasei, Ohbayashi Corporation - New Method with New Materials - Carbon Fiber Reinforced Earthquake-Resistant Retrofitting" (brochure). ------. "Mitsubishi Pitch Carbon Fiber - Application: Carbon Fiber Reinforced Thermosetting Plastics" (brochure). ------. "Mitsubishi Pitch Carbon Fiber - Application: Carbon Fiber Reinforced Thermo Plastics" (brochure). ------. "Mitsubishi Pitch Carbon Fiber - Application: Carbon-Carbon Composite" (brochure). ------. "Mitsubishi Pitch Carbon Fiber - Application: Metal Matrix Composite"(brochure). ------. "RESEARCH & DEVELOPMENT - Mitsubishi Kasei Corporation," with Corporate Data enclosed, as of July 1, 1990 (brochure). Reprint of "Advanced Materials for Future Industries: Needs and Seeds." from Proceedings of The Second Japan International SAMPE Symposium and Exhibition, Chiba, Japan, December 11-14, 1991 by the Society for the Advancement of Material and Process Engineering," Abstract by Shoichi Sato, Tohru Imanara, Naomi Iketani, and Takao Uematsu, "A New Resin System for S-RIM," pp. 44-50. Site: Mitsui Toatsu Chemicals, Inc. 2-5, Kasumigaseki 3-chome Chiyoda-ku, Tokyo 100 Japan Date Visited: December 7, 1992 Report Author: D. Granville ATTENDEES JTEC: J. DeVault D. Granville J. McDermott D. Wilkins HOSTS: Mr. Moto Kawamata Assistant Dir., Corp. R&D Administration Dept. Dr. Akihiro Tamaki Deputy Dir., Central Research Institute Mr. Sadayuki Esaki Manager, TPI Development Dept. Mr. Norifumi Ito Director, Polymer Research Laboratory Mr. Masahiro Masutani Chief Research Coordinator, R&D CoordinationOffice, Central Research Inst. BACKGROUND Mitsui Toatsu Chemicals is a privately owned company with 55.4% of their business in commodity products (plastics, fabricated plastics, industrial chemicals, and industrial fertilizers), 15.4% in fine chemicals (pharmaceutical, agrochemicals, and dyestuffs), and 22.3% in specialty products (urethanes, industrial resins, building materials, electronic materials, and performance polymers). The company started R&D work on advanced thermoplastic prepregs with hot melt impregnation in 1983. Twenty-five percent of the workforce is in R&D. The goal of the company is to expend 60% of the R&D budget in specialty chemicals and materials. They participate in joint R&D with other Pacific rim counties, and have collaborative programs with universities in the U.S. (MIT, Wisconsin, and Univ. of Washington), as well as with Fuji Heavy Industries and the Society of Japanese Aerospace Companies. Work for the High Speed Civil Transport (HSCT) program is with BASF and Boeing. Their program with Fuji Heavy Industries (FHI) for the National Aerospace Laboratory (NAL) is in molded PIX/T-800 pre-preg for fatigue testing; they also have another program for a fusion bonding system with FHI sponsored by SJAC. RESEARCH & DEVELOPMENT ACTIVITIES Mitsui Toatsu Chemicals is developing catalysts for epoxy synthesis, aromatic polyimide special plastic lens monomers (refractive index 1.6), heat-sensitive coated papers, and amorphous silicon solar cells. They have developed PIX (TP Polyimide) CF pre-preg tape for automated composite materials (ACM), and will also make molding compounds for injection molding (388C melting point and good moldability). At the time of the JTEC team's visit, they were in the process of developing PP, PS, AS, ABS, Barex 210 (acrylonitrile barrier resin), PES, PEEK processors, and urethanes; they were planning to develop compact discs by April 1993. They have developed TPI adhesive for fusion bonding at Mitsui and constructed panels for aircraft fuselages at Fuji, and have developed an improved interface GF/PP pre-preg with special surface treatments for low cost applications (well suited for automotive applications). Professor Seferis of the University of Washington is working on PIX development. SUMMARY This is an excellent company structure for commodity plastics, engineering resins (TP & TS), and composites using primarily carbon and glass. They are backed by well-staffed analytical, characterization, and testing laboratories. The in-house analytical research department has an excellent modeling capability. Their customer base is broad (aerospace, industrial, construction, automotive, sporting goods, and marine). There are extensive international agreements of cooperation with U.S. companies and universities. Training and extensive cooperation is practiced with both their customers and partners. REFERENCES Mitsui Toatsu Chemicals, Incorporated. "Mitsui Toatsu Chemicals, Inc. AnnualReport, April 1991-March 1992." ------. "Mitsui Toatsu Chemicals, Inc. Tokyo, Japan," as of March 1992. ------. "Research & Development - Mitsui Toatsu Chemicals, Inc." Site: MITI Headquarters Bureau of Machinery and Info. Industries Aircraft and Ordnance Division 3-1, Kasumigaseki 1 chome, Chiyoda-ku Tokyo 100, Japan Date Visited: December 7, 1992 Report Author: B. Kramer ATTENDEES JTEC: M. Ashizawa D. Granville V. Karbhari B. Kramer X. Spiegel HOSTS: Mr. Keisuke Saito Deputy Dir., Aircraft Ordnance Division BACKGROUND The Ministry of International Trade and Industry (MITI) was originally established as the Ministry of Commerce and Industry in 1949 with the mission of developing the Japanese economy and industry. Figure MITI.1 shows an organizational chart. In brief, it indicates that 12,447 people do the work for MITI. Within MITI, the Machinery and Information Industries Bureau (one of seven internal bureaus, employing a total of 2,263 people) handles the manufacturing- related aspects of composites, while the Basic Industries Bureau handles the materials aspects. Figure MITI.1.Organization of MITI - "MITI is organized so as to facilitate the effective implementation of concrete measures in line with the Ministry's basic policies (MITI, pp. 6 & 7)." Graphic File ***.GIF The Machinery and Information Industries Bureau employs about 200 people. Within this bureau is the Aircraft and Ordnance Division, which employs 12 people. RESEARCH AND DEVELOPMENT ACTIVITIES Mr. Saito is a policy expert. Therefore, his presentation emphasized policy matters. SUMMARY Utilization of dual-use technologies. Dual-use technologies means that the export of a technology is allowed if it has been designated for civilian use, or is being used already by the Japanese industry for civilian purposes. Otherwise, export of technology is decided on a case-by-case basis by the International Trade Administration Bureau, Export Division, indicated in Figure MITI.2. Figure MITI.2. International Trade Administration Bureau (MITI, p. 10) Graphic File ***.GIF When asked which part of MITI organized cooperative projects, it was indicated that each bureau has its own R&D budget. In addition, the Agency of Industrial Science and Technology (3,700 people) runs 16 regional institutes (see Figure MITI.1), the majority of which are located in Tsukuba City. Four years ago, for the first time, foreign companies were invited into an aircraft engine project (GE, Pratt and Whitney, SNECMA and Rolls Royce) and these four received Japanese funds. It was indicated that the aircraft industry in Japan is 75% military, with a declining defense budget (see Tables MITI.1 - MITI.3); therefore, output is decreasing in 1992. Regarding MITI projects in aerospace, funds are only available for international cooperation: Japanese companies cannot get funding unless they have foreign partners. Current projects include the Boeing 777, the V2500 hypersonic (Mach 4-5) engine (with P&W, Rolls Royce, Fiat, and MTU [Germany]). Plausible future projects include a 600- 800 passenger super-jumbo jet, an SST, or a small, 50-100 passenger aircraft. Table MITI.1 Military/Civil Demand ( billion) YEAR TOTAL MILITARY CIVIL RATIO OUTPUT (A) (B) (B/A) ===== ========= ======= ====== ===== 1988 661 523 138 79.1% 1989 731 558 173 76.3% 1990 802 601 201 74.9% 1991 851 639 212 75.1% =========================================== * The ratio is around 35% in the U.S. and 65% in England. We asked what was MITI's policy in dealing with excess capacity in composites and were told that the official policy is that composites are very important. Table MITI.2 New Contracts for Combat Equipment (Defense Agency) ( billion) 1990 1992 GROWTH RATE ==== ==== ======== 1,073 865 -19.4% (Related to Aircraft) 360 270 -24.9% =========================================== Table MITI.3 Output in the Japanese Aircraft Industry YEAR OUTPUT GROWTH EMPLOYEES ( billion) RATE ==== ========= ====== ========== 1988 661 1.2% 27,913 1989 731 10.5% 28,913 1990 802 9.7% 28,810 1991 851 6.2% 29,160 1992 800 -6.0% 29,160 =========================================== REFERENCES Ministry of International Trade and Industry. "MITI." Japan. Site: National Research Institute of Materials and Chemical Research (NIMC) Structure Technology Dept. MITI/AIST 1-1-4, Higashi, Tsukuba-shi Ibaraki-ken 305, Japan Date Visited: December 10, 1992 Report Author: D. Granville ATTENDEES JTEC: D. Granville V. Karbhari HOSTS: Ryuichi Hayashi Director, Structure Technology Dept. BACKGROUND A major reorganization of MITI labs and overhaul/reexamination of objectives in all technology/industrial projects funded by MITI was planned for 1993. Projects typically run approximately eight years. At the half-way point of the project, a full evaluation occurs (a major review) to warrant further funding. Also, two reports are given per year as part of the review process. In addition, a symposium is held annually to review all projects, with papers published in the proceedings. MITI receives proposals from universities, national institutes, and industry for review and selection by Technical Committees for each technology (six year cycle). RESEARCH & DEVELOPMENT ACTIVITIES Two national projects: 1. R&D on Composite Materials, 1981-1988 2. R&D of Hi-Performance Materials for Severe Environments, 1989-1996; approximately 200 researchers are involved, includes work with c/c, intermetallics, and fiber-reinforced IMC matrix composites. Table NIMC.1 Budgets ( Million) 1989 1990 1991 1992 National Research Institute 50 104 135 - New Energy Development Org. 251 897 1,564 - Japan was the host of the Joint Symposium of Japan-Euro Exchange on Composite Materials and High Performance Materials for Severe Environments in June 1993. Fiber reinforced TiAl IMC composites at NIMC are now using Textron SiC (CVD) fibers and in the future will use Japanese Nicalon or Tyrano fibers to optimize prop's in composite development. Research work is also done in cooperation with American universities and institutions such as Georgia Tech. NIMC has the VAMAS Projects (polymer composites) with ISO and JIS, including o Gas sensors project for environmental monitoring using nano-composites o EMI-shielding materials in composites o Polymer conductive paints, use of carbon fiber & mica SUMMARY Most of the discussion covered the organization's background and structure, and its university and industrial participants. Present funded work covers much of the fundamental characterization, surface analysis work, and testing of c/c and intermetallics, as well as the evaluation of carbon fiber reinforced TPs. A tour was provided of their mechanical test lab, where a crack propagation and compliance experiment was in progress on an Instron machine to evaluate T800/epoxy & PEEK laminates (materials to be used on the Boeing 777). Also, a robotics lab, olfactory lab, and depth perception lab were briefly presented to demonstrate their interest in addressing artificial means of developing human sensory perception. A processing lab with a Japanese-made autoclave (up to 350C, 300 psi pressure) and a 2' x 2' compression press capable of very fast cool-down rates (for evaluating crystallinity growth and size of TPs) was also visited. REFERENCES Bathias, Claude and Masuji Uemura, editors. "Advanced Composite Materials: New Materials, Applications, Processing, Evaluation and Databases," Proceedings of the 1st France-Japan Seminar on Composite Materials, Paris-Le Bourget (March 13- 14, 1990). Paris:SIRPE Publishers. Site: National Research Institute of Materials and Chemical Research (formerly Research Institute for Polymers & Textiles) Polymer Composites Laboratory MITI/AIST 1-1-4 Higashi, Tsukuba-shi Ibaraki-ken305, Japan Date Visited: December 10, 1992 Report Author: D. Granville ATTENDEES JTEC: D. Granville V. Karbhari HOSTS: Dr. Takeshi Kitano Director, Polymer Composites Laboratory Dr. Takashi Tamaki Sr. Officer for Research Planning BACKGROUND From 1993 onwards, a large group of laboratories at Tsukuba, including the Research Institute for Polymers and Textiles, will be divided into two major groups: 1. Biomaterials, with approximately 200 researchers 2. Materials (including plastics and composites), with 300-500 researchers RESEARCH & DEVELOPMENT ACTIVITIES Excellent Braiding Studies Functional Gradient Materials a. Controlling heat-resistance (fibers) and conductivity of materials b. Controlling the distribution of fiber materials, in chopped mat form c. Varying the polymer alloys used d. Varying the fiber shape (profile) e. Tension variability f. Fiber orientation/control/gradient distribution g. 2-D and 3-D braiding of composites with up to 3 reinforcements (3 attached articles by Dr. Kitano relate to this subject) h. Water jets used to force short fiber reinforcement into mats so as to givethrough- thickness reinforcements Chopped Strand Experiments a. Effect of fiber length distribution before and after mixing/compounding b. Influence on the number of filaments in chopped strand vs. mechanicalproperties SUMMARY The 3-D braiding machine was viewed in the lab, along with a number of braided prototypes. The possibilities of using the 3-D braider as a low-cost process to produce truss structures and cores for composite structures was discussed. Site: Mizuno Corporation R&D Department, Product Development Div. 12-35, 1-chome, Nanko-kita Suminoe-ku, Osaka, Japan Date Visited: December 9, 1992 Report Author: B. Kramer ATTENDEES JTEC: J. DeVault V. Karbhari B. Kramer D. Wilkins HOSTS: Mr. Kazuhiro Ohmori R&D Dept, Product Development Division Mr. Toshihiro Inubushi Manager, Eng. & Development Dept., Product Development Div. Mr. Takeshi Naruo Section Chief, R&D Dept., Product Development Division Mr. Takashi Ito Deputy Mgr., Product Engineering Development Section Mr. Rick Tsuruoka Manager, International Marketing Ms. Chikako Kamimukai R&D Div., Product Development Div. BACKGROUND Mizuno, founded in 1906, is a leading manufacturer of general sports equipment. They manufacture all of their sports equipment internally. The JTEC team had discussions in the new headquarters building, but did not visit the production facility. The discussions at Mizuno were largely limited to a question and answer period. SUMMARY Concerning golf shafts, U.S. shafts are 10% carbon fiber, while Japanese shafts are 50% carbon fiber. Mizuno produces golf shafts by sheet rolling. They use graphite in skis, tennis rackets, baseball bats, and sports shoes. They use 20 different kinds of carbon fiber, both PAN and pitch types. They have used graphite springs in shoes for five years and usage is not growing. They are not producing carbon-fiber bicycle frames now, but may be developing them. When asked why they decide to use composites in a given product, they indicated that it is very strong when compared to wood or steel. Mizuno compression molds skis and blow molds graphite baseball bats (they consider themselves to be the leader) and tennis rackets with an expanding rubber bladder. They use computer analysis extensively, particularly for skis and golf shafts. Manufacturing is highly automated, with both robots and in-process sensing. Total waste amounts to only 2-3% of the composite sheet. Mizuno considers SRIM (structural reaction injection molding) for tennis rackets to be a key technology for the future because it is a non-solvent process, and is completely automated and repeatable. They claim 60% by weight fiber content in SRIM and indicated that cross-linked polyesterimide is the best SRIM resin. All of their professional tennis rackets (20% of total production of 100,000 per year) are SRIM; the remainder are blow- molded. Mizuno uses all kinds of hybrid fibers, preformed by braiding. Their process development emphasized steady improvement, rather than breakthroughs. They pick new products by looking for applications where high performance composites give real benefits. For example, large head tennis rackets cannot be fabricated from wood or metal because of their relatively lower stiffness. REFERENCES Mizuno Corporation. 1992. "Mizuno The World of Sports" (Japan). Site: National Aerospace Laboratory (NAL) 6-13-1 Ohsawa Mitaka, Tokyo 181, Japan Date Visited: December 7, 1992 Report Author: F. Xavier Spiegel ATTENDEES JTEC: M. Ashizawa D. Granville V. Karbhari B. Kramer F. Spiegel HOSTS: Dr. Takashi Ishikawa Section Head, Composite Structure Section, Airframe Division Mr. Yasuo Tada Director, Airframe Division BACKGROUND The National Aerospace Laboratories (NAL) has four divisions concerned with composites. NAL is not involved in manufacturing or fabrication but emphasizes testing with three divisions involved with mechanical testing. NAL's total 1991 budget was $85.5 million and they employed 439 people. Its capital investments in test and non-destructive testing (NDT) equipment were very impressive. Dr. Ishikawa was full of enthusiasm and was quite proud of a CF/thermoplastic wing box model which was fusion bonded; he continued his enthusiasm as he discussed the characterization of CF/polyimide (in support of NASDA's Hope Project), testing machines with environmental chambers (up to 9 m x 5 m x 3 m), high temperature composites of SiC - SiC, tailoring of composites for space with zero coefficient of thermal expansion, a bi-axial testing machine (1 m x 1 m capacity with fully programmable load actuators), impact test systems, a thermal conductivity analyzer, and a mainframe and submainframe testing system. Their NDE efforts include an ultrasonic scanning system (robotic) using pulse-echo and back scatter (10 Mhz to 50 Mhz), thermal imaging, acoustic-emission, x-ray, and CT scanner. The priority areas of research are chosen by NAL, not the fabricators. There is a thorough understanding of the problems of the fabricators and there are many domestic conferences for interaction. NAL pays for co-operative research and does the testing for all of its fabricators. There is a consistent budget and the manufacturers of the materials are funded for long-term research, typically 10-15 years. They are very patient and understand that failures will occur in research. The tour of the facility was very impressive. The JTEC team saw many systems including thermal imaging, impact, a large environmental chamber, fracture toughness, ultrasonic imaging enhancement, and the random loading platform. The random loading platform was testing a C/PIX tape wound tubular main spar (see Fig. 4 in Ishikawa et al. 1991b). SUMMARY Dr. Ishikawa considers manufacturing costs as the main barrier to the use of composites. He anticipates advancements in high temperature resins and thermo- plastics. Research on fibers must be conducted to reduce their cost rather than improve their quality. Improvements must be made in RTM tooling, preforms, and most importantly, resins. There are many specialty weavers in Japan. NAL rates Toray as the best pre-preg manufacturer, Mitsui the best at high-temperature and tough resins, and Shikibo the best at fabric manufacture. Dr. Ishikawa is not satisfied with the quality of the pre-preg. The carbon fiber market in Japan has not been significantly impacted by the slowdown in Japan's defense spending. REFERENCES Ishikawa, T., Y. Hayashi, M. Matsushima, and T. Noguchi. 1990. "Comparison of Tensile and Compressive Properties of Some Structural Elements Between Carbon/PEEK and Carbon/Epoxy Composites." Reprint from Proceedings of the Fifth Japan-U.S. Conference on Composite Materials, Tama-City, Tokyo (June 24- 27, 1990). Held by Japan Society for Composite Materials. 445-452. Ishikawa, T., Y. Hayashi, H. Fukunaga, M. Matsushima, M., and T. Noguchi. 1991a. "Experimental Examination of Theory of CTE (Coefficient of Thermal Expansion) Control Technology." In JSME International Journal, Series I, 34 (2):178-186. Ishikawa, T., Y. Hayashi, M. Matsushima, K. Takasawa, and T. Sato. 1991b. "Structural Concept of Main Wings of High Altitude Unmanned Aerial Vehicle and Basic Properties of Thermoplastic Composites as Candidate Material." Reprint from Proceedings of International Pacific Air & Space Technology Conference and 29th Aircraft Symposium Proceedings, Gifu, Japan (October 7-11, 1991). Society of Automotive Engineers, Inc. 677-685. Ishikawa, T., T. Yamamura, T. Hirokawa, Y. Hayashi, Y. Noguchi, and M. Matsushima. 1992. "Strength Properties of 3D-Woven Si-Ti-C-O (TYRANNO)/SiC High-Temperature Composites for Future Space Transportation." In Proceedings of The Eighteenth International Symposium on Space Technology and Science (Kagoshima). 437-442. National Aerospace Laboratory, 1991-1992. "Annual Report". Japan. National Aerospace Laboratory, Science and Technology Agency. 1992-1993."Composite Structure Testing Facilities" (brochure). Tokyo. Site: Nippon Steel Corporation Advanced Materials & Technology Research Laboratories Technical Development Bureau 1618 IDA, Nakaharu-ku, Kawasaki 211 Japan Date Visited: December 6, 1992 Report Author: V. Karbhari ATTENDEES JTEC: V. Karbhari D. Wilkins HOSTS: Dr. Kenji Kubomura Chief Researcher Hironori Maikuma Senior Researcher BACKGROUND Nippon Steel is the world's largest producer of crude steel with production figures of 28.6 million tons in 1991. However, they have been aggressively pursuing the advanced composites market for a while with the long term goal of being the leaders in materials that would replace steel. Research is conducted through the Technical Development Bureau, which consists of six divisions, one of which, the Advanced Materials and Technology Research Laboratories, deals with composites. Corporate R&D controls funding of resources and personnel. However, only 40% of the budget is decided by this group, the remaining 60% being based on specific recommendations from business groups. This makes their research activities very applied in nature. There are 35-40 researchers working on PMCs under Kubomura and 25-30 more working in the area of polymer processing. RESEARCH & DEVELOPMENT ACTIVITIES 1. Joint development projects with the automotive industry o Carbon fiber reinforced drive shafts, centrifuges, and body panels o Activities in fabrication, process development, materials characterization 2. Filament winding o Large cylinders of 1" thickness o Research to look at issues related to cracking o Mostly done through experimentation since there was insufficient time forthe use of models, although they did attempt to use Springer's model.Used sensors and controls in experimentation. 3. Honeycomb type prepreg o Developmental project for inspection and quality control (QC) 4. Effect of holes and bolted joints in composites using pitch based carbon fibers o Characterization and analysis o This has been a major area of research in the recent past with specialemphasis placed on the comparison of behavior and design of boltedjoints in pitch carbon reinforced composites. 5. Use of Carbon fibers in construction o Use of chopped fiber and continuous fiber for increased ductility andtoughness o Small scale models tested in bending o Use of filaments in precast blocks o Applications in precast and modular structures, including for prestressedconcrete o Reinforcement of caissons to be used for initiation of bores (C is easier tocut through than steel). This is marketed as a novel materialshield-cuttable tunnel wall system (NOMST) and has been used fortunnels in Japan. o Developmental work on use of glass for the Japan-France monument (This seems to be a major applications area) 6. Surface Treatment o Use of oxidizing layers on fibers for interfacial strength augmentation 7. Hybrid composites o Investigation of layered pitch/PAN based laminated structures SUMMARY Nippon Steel uses filament winding, autoclave cure, stamping of thermoplastic sheets, and is developing a modification of RTM for high fiber volume structures. Their main target areas for the use of composites are in the automotive, construction and engineering machinery sectors. Although recycling is an issue, they do not believe that it will kill the thermoset market. Cost, quality control and speed of fabrication are still major issues. They viewed MITI led projects to be useful as catalysts for the extended internal funding of projects. Marketing, even of R&D activities, is done through the presentation of generic research to potential customers. The customers are then allowed to come up with applications for the materials systems and processing techniques. This then leads to the establishment of a joint research project or a developmental project at Nippon Steel. Projects in construction applications and in the transportation sector are viewed as having potential for future growth. The key to the initiation of projects was a full blown cost analysis, which presupposed success. Site: Shimizu Corporation Seavans South No. 2-3, Shibaura 1-chome, Minato-ku, Tokyo 105-07, Japan Date Visited: December 11, 1992 Report Author: D. Granville ATTENDEES JTEC: D. Granville V. Karbhari J. McDermott X. Spiegel D. Wilkins HOSTS: Dr. Toshiaki Fujimori Deputy Director, Technology Div. Executive V.P., S. Technology Mr. Minoru Sugita General Manager, Technology Div. Mr. Takatoshi Ueno Manager, Planning Dept., Technology Div. Mr. Kenichi Sekine Manager, Sales Dept., NEFCOM Corp. Mr. Mohi U. Ahmed Planning Dept., Technology Div. BACKGROUND Shimizu Corp., one of the largest architect/engineering/construction firms in Japan, is the leader in the application of composites in the construction industry. Shimizu was founded in 1804 and provides architecture, property development (living and working environments), engineering, and construction. They employ 4,500 architects and engineers. Examples of their accomplishments include the New Tokyo Metropolitan Building complex, Kansai International Airport, dams, Tokyo Gas Works, Kashiwazaki Nuclear Power Plant, and the Great American Plaza and Resort Hotels. In 1987, Shimizu established a space construction office for NASA. This endeavor will include concept design and construction materials. They are considering circular dams for the ocean and desert living sites. Shimizu's composite construction products include "NEFMAC," a reinforcement for concrete (carbon, glass and aramid formed as an integrated mesh), which is resistant to the chemicals in concrete and therefore corrosion. This system is dependent on the mechanical interfacing of the grid to the concrete, but can reduce the volume of concrete required for strength. NEFMAC is non-magnetic but is most importantly, light weight. It can be layed in and held using air-powered staple guns. Although the cost is three to five times that of re-bar, it requires one-third the labor cost, has lower transportation and lower maintenance costs. "NESTEM," an FRP geogrid, is produced for road reinforcement and stabilization as well as embankments, retainments and foundations (especially useful in arctic regions because its low weight transportation costs are drastically reduced). It also has many marine applications, e.g., for oil platforms, underwater structures, and pontoons. RESEARCH & DEVELOPMENT ACTIVITIES Shimizu is engaged in R&D efforts in a wide variety of fields, including materials research ranging from underground to space construction applications, intelligent buildings, and more. See the JTEC report on construction technology in Japan (1991) for further information. Activities described below and elsewhere in this report relate only to applications of polymer composites. NEFMAC and NESTEM grids have specifications for graphite and Kevlar. Both use continuous forming. Batch forming can be accomplished by manual layup for any size grid. Shimizu is forming design committees for building construction to develop "Design Codes" by setting up a consortium with goals and newly updated property tests. R&D activities include FEA structural analyses using computer controlled structural member testing for new construction materials, modeling and simulation codes. The development of vibration damping/dissipation composites of multi-layered rubber and then metal plates in building foundation is being pursued. SUMMARY Discussions during the JTEC team's visit included the Shimizu suppliers (Asahi, Toray, and Nippon Steel) and new market opportunities. Shimizu's current market for NEFMAC is about $2 million/year. New opportunities include the development of automated materials handling and dispensing equipment for fabricating, transporting, and installing NEFMAC and NESTEM composite grids for underground tunnels, storage tanks, building walls, etc. REFERENCES Shimizu Corporation. 1992. "R&D Research and Development" (brochure). Shimizu annual report and corporate data till March 31, 1992. Site: Toray Industries, Inc. Ehime Plant 1515 Tsutsui, Masaki-cho Iyogun, Ehime 791-31, Japan Date Visited: December 12, 1992 Report Author: F. Xavier Spiegel ATTENDEES JTEC: J. DeVault D. Granville J. McDermott F. Spiegel D. Wilkins HOSTS: Mr. Akira Takeo Assistant General Manager, ACM TechnologyDept., Head Office Mr. Hiroshi Ohnishi Manager, LSS Development Dept., Technology Center, Ehime Plant Mr. Hideo Komatsu Dir., General Manager Large Scale StructureProject & Composite Materials ResearchLabs, Ehime Plant Mr. Hiroyoshi Tanaka Deputy General Manager, Composite Materials Research Labs, Ehime Plant Mr. Koji Kozuka Manager, Composite Fabrication Dept., Advanced Composite Materials Div., Shiga Plant Mr. Minoru Kitanaka General Manager, LSS Development Dept. Technology Ctr., Ehime Plant Mr. Nobuyuki Odagiri Sr. Research Chemist, Composite MaterialsResearch Labs, Ehime Plant BACKGROUND Toray is the number one Japanese company in quality and quantity for the manufacture of carbon fiber. Ten percent of Toray's composites business is structures. Toray's composite related organization is composed of the following four divisions: Composite Materials Manufacturing Research and Development Technical Center and Administration The Manufacturing Division is composed of the Shiga Plant (composites) and the Ehime Plant (carbon fiber, prepreg). The Research and Development Division contains the Composite Materials Laboratories. The Composites Materials Division is composed of carbon fiber, carbon sports goods, composite materials, ACM technology, and the administrative departments. The technical center contains the Large Scale Structures Project Group. Net sales (April 1, 1990 - March 31, 1991) were $6.5 billion, with the following distribution: Synthetic Fibers 48.4% Plastics and Chemicals 26.3% Housing & Engineering 15.8% New Products & other* 9.5% *New products and other business activities are listed by Toray as: carbon fiber, reverse osmosis membranes, printing plates, plastic glasses, artificial kidneys and pharmaceuticals. The Toray Group (domestic and overseas subsidiaries and affiliated companies) includes 119 domestic and 58 overseas companies. The parent company has 10,116 employees, the domestic subsidiaries have 8,393, and the overseas subsidiaries have 7,502. Toray forecasts the worldwide pan-based carbon fiber capacity to be 11,505 tons/year. Worldwide consumption in 1991 was estimated at 6,170 tons. Toray forecast pitch based carbon fiber capacity to be 2,054 tons/year in Japan. Toray's approach to business is the market/demand system. They enter a market where management expertise is available, where there is a market demand, and where the host government or industry requests their expertise. The Toray Group was the first company to qualify carbon/epoxy for the Boeing 777. In 1991, they announced APG 2000, their long-term corporate vision, which sets out the Group's aims by the year 2000. The "G" in the name denotes the three concepts that guide their business strategies: Growth, Group Management, and Globalization. RESEARCH & DEVELOPMENT ACTIVITIES Although Toray's R&D activities are numerous, emphasis is placed on automatic filament winding, pultrusion, and resin transfer molding. Toray is determined to develop a structures business. Its major efforts in resin development are aimed at toughened PI and BMI resins. However, not much work is being done on thermoplastic resins. In RTM, they believe that the main challenge lies in the preform rather than the resin. Currently, automotive efforts in Japan appear to be limited to drive shafts only. They answered a set of questions sent by the panel, which are attached for reference. REFERENCES Toray Industries. Incorporated. "Toray Outline of the Ehime Plant" (brochure).1/4 - 4/4. ------. 1992. "Toray - TORAYCA Quality Carbon Fiber" (brochure). Japan. ------. 1992. "Toray - TORAYCA - TORAYCA Carbon Fiber - Quality Plus Stability" (brochure). ------. 1992. "Toray - Toray Industries, Inc. Annual Report 1992", April 1, 1991 - March 31, 1992 (brochure). Toray Industries Incorporated, Carbon Fibers Department. "Toray - TORAYCA Compendium of Recent Advances in Torayca Technologies - Review ofToray's Technical Papers, 1989" (booklet). ------. "Toray - TORAYCA Technical Reference Manual" (booklet). Site: Toyota Motor Corp. Higashifuji Technical Center 1200, Mishuku, Susono Shizuoka 410-11, Japan Date Visited: December 8, 1992 Report Author: D. Granville ATTENDEES JTEC: D. Granville V. Karbhari J. McDermott HOSTS: Dr. Masatoshi Matsuda Project Manager, R&D Development Div. II Mr. Yoshiki Murashima Project Manager, R&D Planning Div. BACKGROUND This plant makes SMC rear covers for the MR-2 engine and side air housings, sun roof housings, and spoilers with SMC molding (1500-2000 ton machines). RESEARCH & DEVELOPMENT ACTIVITIES They are evaluating carbon/epoxy drive shafts made by GKN (French company) on the MARK II (Cressida) in Japan. They are evaluating RTM for structural body parts and SMC for exterior body parts. Recent research has been conducted on batteries for electric cars, on leaf springs, and suspension components. Toyota has evaluated composite wheels but found them to be unreliable. Other activities include LCPs, surface glazing materials (high abrasive resistance), and new TPs with high modulus. REFERENCES Toyota Motor Corporation. 1989. "Toyota Higashi Fuji Technical Center" (pamphlet). "Sun God or UFO," Plastics News 4 (38). Site: Nikkiso Co., Ltd. 43-2, Ebisu 3-chome, Shibuya-ku, Tokyo 150-91, Japan Date Visited: December 9, 1992 Report Author: D. Granville ATTENDEES JTEC: M. Ashizawa D. Granville J. McDermott HOSTS: Mr. Masahiko Hatano Pres. & Chief Operating Officer [now Vice Chmn.] Mr. Toshiaki Noda General Manager, Central Research Ctr.*, Licensed Technical Translator Mr. Takashi Ohsaki Leader, Central Research Center Dr. Kazuo Miyamichi Central Research Center Mr. Shinya Asada Manager, Engineering Dept., Advanced Materials Factory, Shizuoka Plant Mr. Fumio Kida Manager, Advanced Materials Factory Mr. Kohichi Imai Chief Staff, Central Research Ctr. *As of Dec. 1993, the central Research Center was renamed the "R&D Center" BACKGROUND Mr. Masahiko Hatano, President of Nikkiso Co., Ltd. at the time of the JTEC team's visit (now Vice Chairman), used to work at Toho Beslon Co., Ltd. as a vice president in charge of establishing a carbon fiber (CF) manufacturing technique. Mr. Hatano has now succeeded in the commercialization of some of the major constituent components of airplanes utilizing CFRP, and also in the development of a brand new production technique of graphite whisker. Nikkiso continues to grant its CF production technique by licensing. RESEARCH & DEVELOPMENT ACTIVITIES Nikkiso has an advanced materials factory to develop and produce high quality complicated composite parts for the aerospace and industrial markets, such as thrust reverser cascades (in production), precooler inlet scoop (BMI, FAA certified), a fairing track for thrust reversers (with epoxy), unmanned helicopter frames, steering wheels, and racing motor frames. They have developed their own automated layup machine and RTM technology, and have filament winder, autoclave, hot press, and water jet cutter. Full characterization, NDE (super soft x-ray) design and analysis, and FEA are done in-house. Special features of the carbon fiber manufacturing process (licensed to the Boeing Company and Tae Kwang Industrial Co., Ltd.) include comonomers with a suitable oxidation speed, continuous solution polymerization (high molecular weight and its narrow distribution), incorporating a salt solution for spinnability, dry/wet spinning at high speeds, oiling agent for lubricating to separate filaments, and high-stretch carbonization for high strength. Nikkiso has developed a low cost but high quality graphite whisker (GRASKER) for commodity applications including friction and wear materials, electroconductive materials, and battery electrodes. Nikkiso has recently developed continuous fiber-reinforced ceramic composites (CFCC) for high temperature application. SUMMARY If the cost of carbon fiber were reduced to less than $10/kg., then it is believed that greater commodity use of carbon fibers and pre-pregs would occur despite the assembly and fabrication costs. They are working with major battery makers to develop high energy storage batteries using GRASKER anodes, as well as electroconductive inks for flexible circuit boards and TPs/TSs for wear resistance materials. REFERENCES Nikkiso Company, Ltd. "Nikkiso Outline & Products," 1992 annual report. ------. "GRASKER," at Nikkiso Shizuoka Plant, December 9, 1992 (viewgraphs) ------. Technical Information, "GRASKER Graphite Whiskers" No. 1. Site: University of Tokyo 7-3-1 Hongo Bunkyo-ku 113, Japan Date Visited: December 7, 1992 Report Author: F. Xavier Spiegel ATTENDEES JTEC: M. Ashizawa D. Gill V. Karbhari B. Kramer F. Spiegel HOSTS: Dr. Isao Kimpara Professor, Dept. of Naval Architecture and Ocean Engineering Mato Heder, M.Sc., Ph.D. Dept. of Naval Architecture and Ocean Engineering BACKGROUND The Kimpara-Kageyama Laboratory in the Department of Naval Architecture and Ocean Engineering is concerned primarily with the characterization of the mechanical properties of graphite and Kevlar composites. Their testing is performed on coupons supplied by industry; they do little fabrication of their own. Non-destructive evaluation is emphasized. Delamination is studied using C-scan and acoustic emission. Vibration pattern images are also used for damage evaluation, and some fatigue testing is conducted. Dr. Kimpara believes the trends in composites are identical in Japan and the United States. He sees future new applications in civil engineering (especially concrete structure repair), and in transportation, if costs can be reduced. In manufacturing technology Dr. Kimpara considers production improvements are needed in resin transfer molding, vacuum bag molding, and room temperature curing. He considers Aramid fiber use other than in the aerospace industry to be crucial. The main problems in naval use of composites lie in the damage tolerance of composites to impact. Dr. Kimpara noted the difference in the educational systems of Japan and the U.S., mentioning that the universities of Japan are quite independent. Coordination is not unified. Their funding is from the Ministry of Education, not MITI. The visit concluded with a brief tour of the Kimpara-Kageyama Laboratory where the JTEC team met Dr. Mato Heder. The equipment was typical of a small university laboratory -- modest but adequate. The research at this facility is primarily in the area of mechanical testing. REFERENCES Chang, W.T., I. Kimpara, K. Kageyama, and I. Ohsawa. 1990. "New Data Reduction Schemes for the DCB and ENF Tests of Fracture-Resistant Composites." Developments in the Science and Technology of Composite Materials. Proc. ECCM-4, September 25-28, 1990, Stuttgart-F.R.G. Kageyama, K., and Kimpara, I., 1991, "Delamination Failures in Polymer Composites." Materials Science and Engineering, A143. Kageyama, K., I. Kimpara, T. Suzuki, I. Ohsawa, and S. Kabashima. 1990. "Mode II Interlaminar Fracture Toughness Under Impact Loading." "Benibana" International Symposium on how to Improve the Toughness of Polymers and Composites, Yamagata, Japan (October 8-11, 1990). Kimpara, I., K. Kageyama, E. Tsushima, J. Takayasu, and K. Inoue. 1990. "On the Micromechanical Failure Process of Single Carbon Fiber and Strand in a Matrix." Achievement in Composites in Japan and the United States. A. Kobayashi, Ed., Proc. Japan-U.S. CCM-V, Tokyo. Kimpara I., and T. Ozaki. 1988. "Study on Reliability Assessment System of Composite Materials." J.S.N.A. Japan, Vol. 158, Dec. 1985, Vol. 159, June 1986, Vol. 161, June 1987, and Vol. 163, June 1988. Kimpara, I. "Mechanics and Design of Composite Materials and Structures." Theoretical and Applied Mechanics 37. Kimpara, I., I. Ohsawa, M. Kawashima, T. Horikawa, and T. Mori. 1986. "Characterization of Crack Resistance Performance of Continuous Glassfiber Reinforced Polyurethane Foam by Acoustic Emission." Progress in Acoustic Emission III. The Japanese Society of NDI. Kimpara, I., Kageyama, T. Suzuki, and I. Ohsawa. 1992. "Acoustic Emission Monitoring of Damage Progression of CFRP Laminates under Repeated Tensile Loading". Progress in Acoustic Emission VI. The Japanese Society for NDI. Kimpara, I. 1989. "Effect of Interfacial Strength on Tensile Behavior of Unidirectional Pitch Based Carbon Fiber Composite." 21st International SAMPE Technical Conference (September 25-28, 1989). Kimpara, I., K. Kageyama, T. Suzuki, and I. Ohsawa. 1991. "Fatigue and Impact Strength of Aramid/Glass Hybrid Laminates for Marine Use." In Proceedings of the 8th International Conference on Composite Materials (ICCM/8) (Honolulu, July 15-19, 1991). Kimpara, I. 1991. "Use of Advanced Composite Materials in Marine Vehicles." Marine Structures 4. Kimpara, I., and Tsuji, N., 1988, "Failure Process and Strength of CFRP Structural Joints." In Proceedings of the Fourth Japan - U.S. Conference on Composite Materials (June 27 - 29 , 1988). Ohsawa, I., I. Kimpara, K. Kageyama, and T. Suzuki. 1992. "Acoustical Analysis of Transverse Lamina Cracking in CFRP Laminates Under Tensile Loading." In Proceedings of the 4th International Symposium on Acoustic Emission From Composite Materials (AECM-4) (Seattle, July 27-31, 1992). ASNT, Inc. Outline of Kimpara-Kageyama Lab. NAOE CoMET. Kimpara-Kageyama Lab. Department of Naval Architecture and Ocean Engineering, Faculty of Engineering, University of Tokyo, 7-3-1 Hongo, Bunkkyo-ku, Tokyo, 113, Japan. Ozaki, T., and M. Okumura, M., 1991, "Nondestructive Evaluation of Composites by Elastic Wave Propagation Analysis." In Proceedings of the 8th International Conference on Composite Materials (ICCM/8) (Honolulu, July 15-19, 1991). Sun, F., I. Kimpara, K. Kageyama, T. Suzuki, and I. Ohsawa. 1991. "Failure Modes and AE Characteristics of Carbon Fabric Composites." In Proceedings of the 8th International Conference on Composite Materials (ICCM/8) (Honolulu, July 15-19, 1991). Site: Yamaha Motor Co., Ltd. 2500 Shingai, Iwata, Shizuoka 438 Japan Date Visited: December 8, 1992 Report Author: D. Granville ATTENDEES JTEC: D. Granville V. Karbhari J. McDermott HOSTS: Mr. Kohtaro Horiuchi Dir., Sr. General Manager, Marine Div. Mr. Akira Kubota Manager, Eng. Div., Marine Operations Mr. Hisao Aono Manager, Production Dept., Marine Operations Mr. Takashi Motoyama Assistant Manager, Horiuchi Lab Mr. Osamu Hashimoto Chief Engineer, Production Eng.Dept., Marine Operations Mr. Masao Yokouchi Assistant Manager, Production Eng.Dept., Marine Group BACKGROUND Yamaha developed human-powered and solar-powered racing boats for competition along with an America's Cup racing boat. The construction of the America's Cup boat is urethane paint, unidirectional carbon fibers/epoxy pre-preg and honeycomb core. They use low temperature cure pre-preg and vacuum bag molding methods on plywood tools. On the other hand, the construction of ocean-going boats is unidirectional T-glass epoxy, Kevlar woven cloth, and PVC foam. They use room temperature cure and vacuum bag molding methods, with reinforcement fibers laid up and impregnated by hand with resin on plywood tools. A new product is a remote-controlled agricultural helicopter sprayer. Yamaha began working with composites in 1960 (boats). Yamaha instructs suppliers to satisfy resin/feedstock quality as specified by its engineers, and inspects these materials when received. It also has its own educational program that includes apprenticeship education and training in manufacturing methods, rendered by senior and junior engineers. Yamaha specializes in "one-off" custom designed boats and low-rate production boats. There is no automated equipment except for chopper gun and gel coat paint spraying equipment. They use glass fiber reinforced plastics mold for production boats and plywood tools for trials and "one-off" custom designed boats. RESEARCH & DEVELOPMENT ACTIVITIES America's Cup yacht -- use of low temperature pre-preg in sandwich/skin construction on plywood tools with vacuum bags. Designed using "rule-based" design guide based on consensus hydrodynamic design by a technical committee composed of design experts from universities and industrial partners. Then "building simulation" is completed by fabricating sub-scale components and finite element materials (FEM) study and panel tests (small and large). Their NDE testing procedure is not fully developed. Racing sculls are composed of two-ply graphite uni-tape, "Klegecell" foam and two-ply graphite uni-tape, fabricated manually. Their solar-powered one-man racing boat and human-powered racing boat are also fabricated manually. They are currently marketing a radio-controlled helicopter for agricultural spraying applications called the R-50. The helicopter has a fuselage of 2655 mm, with a main rotor of 3070 mm diameter, and a 98 cc engine. The blades and body enclosure are fiberglass and layed-up by hand. Weight is 67 kg. SUMMARY "Hobby-shop" type activity was displayed during the tour of the Yamaha plant. This is a factory for trials and "one-off" custom designed boats only. They have six factories for production of boats located throughout Japan (Shizuoka and other prefectures). When asked if this facility is also used to build custom or prototype composite parts/assemblies for Yamaha's other activities (motorcycle shrouds/enclosures) the answer was yes, but to a limited extent. This division mainly makes trials and "one-off" custom-designed boats where automation has no advantage since each boat is unique or made in small quantity. They make it a rule to have discussions with suppliers of composite feedstocks and resins beforehand, so that they can receive materials that have been altered according to specifications. Other than thermocouples, no processing feedback monitoring/control was observed, and they had only visual NDE capability. Yamaha's greatest cooperative effort is extensive design and modeling with Japan's technical universities and industry in support of the America's Cup effort. Yamaha uses a push-pull system for styrene emissions. REFERENCES Booklets and Brochures: "Invitation to Yamaha." "Yamaha R-50." "Yamaha Marine Line-Up," 1992. Magazine: Japan's First Challenge to America's Cup 1992, edited and produced by Shippingand Trade News, Published by Tokyo News Service, Ltd., Part 1, April 1991.