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Title: Global Carbon Fiber Composites Supply Chain Competitiveness Analysis

Abstract

This study identifies key opportunities in the carbon fiber supply chain where the United States Department of Energy's Office of Energy Efficiency and Renewable Energy resources and investments can help the United States achieve or maintain a competitive advantage. The report focuses on four application areas--wind energy, aerospace, automotive, and pressure vessels--that top the list of industries using carbon fiber and carbon fiber reinforced polymers and are also particularly relevant to EERE's mission. For each of the four application areas, the report addresses the supply and demand trends within that sector, supply chain, and costs of carbon fiber and components, all contributing to a competitiveness assessment that addresses the United States' role in future industry growth. This report was prepared by researchers at Oak Ridge National Laboratory and the University of Tennessee for the Clean Energy Manufacturing Analysis Center.

Authors:
 [1];  [1];  [1];  [2]
  1. Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States)
  2. Univ. of Tennessee, Knoxville, TN (United States)
Publication Date:
Research Org.:
National Renewable Energy Lab. (NREL), Golden, CO (United States)
Sponsoring Org.:
USDOE
OSTI Identifier:
1260138
Report Number(s):
NREL/TP-6A50-66071; ORNL/SR-2016/100
DOE Contract Number:
AC36-08GO28308
Resource Type:
Technical Report
Country of Publication:
United States
Language:
English
Subject:
32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATION; 42 ENGINEERING; carbon fiber; CEMAC; manufacturing; clean energy; Oak Ridge National Laboratory; wind; aerospace; auto; pressure vessels; industry; supply chain

Citation Formats

Das, Sujit, Warren, Josh, West, Devin, and Schexnayder, Susan M. Global Carbon Fiber Composites Supply Chain Competitiveness Analysis. United States: N. p., 2016. Web. doi:10.2172/1260138.
Das, Sujit, Warren, Josh, West, Devin, & Schexnayder, Susan M. Global Carbon Fiber Composites Supply Chain Competitiveness Analysis. United States. doi:10.2172/1260138.
Das, Sujit, Warren, Josh, West, Devin, and Schexnayder, Susan M. Sun . "Global Carbon Fiber Composites Supply Chain Competitiveness Analysis". United States. doi:10.2172/1260138. https://www.osti.gov/servlets/purl/1260138.
@article{osti_1260138,
title = {Global Carbon Fiber Composites Supply Chain Competitiveness Analysis},
author = {Das, Sujit and Warren, Josh and West, Devin and Schexnayder, Susan M.},
abstractNote = {This study identifies key opportunities in the carbon fiber supply chain where the United States Department of Energy's Office of Energy Efficiency and Renewable Energy resources and investments can help the United States achieve or maintain a competitive advantage. The report focuses on four application areas--wind energy, aerospace, automotive, and pressure vessels--that top the list of industries using carbon fiber and carbon fiber reinforced polymers and are also particularly relevant to EERE's mission. For each of the four application areas, the report addresses the supply and demand trends within that sector, supply chain, and costs of carbon fiber and components, all contributing to a competitiveness assessment that addresses the United States' role in future industry growth. This report was prepared by researchers at Oak Ridge National Laboratory and the University of Tennessee for the Clean Energy Manufacturing Analysis Center.},
doi = {10.2172/1260138},
journal = {},
number = ,
volume = ,
place = {United States},
year = {Sun May 01 00:00:00 EDT 2016},
month = {Sun May 01 00:00:00 EDT 2016}
}

Technical Report:

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  • The objective of this study is to identify key opportunities in the carbon fiber (CF) supply chain where resources and investments can help advance the clean energy economy. The report focuses on four application areas—wind energy, aerospace, automotive, and pressure vessels—that top the list of industries using CF and carbon fiber reinforced polymers (CFRP) and are particularly relevant to the mission of U.S. Department of Energy’s Office of Energy Efficiency and Renewable Energy (DOE EERE). For each of the four application areas, the report addresses the supply and demand trends within that sector, supply chain, and costs of carbon fibermore » and components.« less
  • This analysis identifies key opportunities in the carbon fiber supply chain where resources and investments can help advance the clean energy economy. The report focuses on four application areas — wind energy, aerospace, automotive, and pressure vessels — that top the list of industries using carbon fiber and carbon fiber reinforced polymers. For each of the four application areas, the report addresses the supply and demand trends within that sector, supply chain, and costs of carbon fiber and components.
  • The goal of the project was to develop a greater understanding of the key factors determining wind energy component manufacturing costs and pricing on a global basis in order to enhance the competitiveness of U.S. manufacturers, and to reduce installed systems cost. Multiple stakeholders including DOE, turbine OEMs, and large component manufactures will all benefit by better understanding the factors determining domestic competitiveness in the emerging offshore and next generation land-based wind industries. Major objectives of this project were to: 1. Carry out global cost and process comparisons for 5MW jacket foundations, blades, towers, and permanent magnet generators; 2. Assessmore » U.S. manufacturers’ competitiveness and potential for cost reduction; 3. Facilitate informed decision-making on investments in U.S. manufacturing; 4. Develop an industry scorecard representing the readiness of the U.S. manufacturers’ to produce components for the next generations of wind turbines, nominally 3MW land-based and 5MW offshore; 5. Disseminate results through the GLWN Wind Supply Chain GIS Map, a free website that is the most comprehensive public database of U.S. wind energy suppliers; 6. Identify areas and develop recommendations to DOE on potential R&D areas to target for increasing domestic manufacturing competitiveness, per DOE’s Clean Energy Manufacturing Initiative (CEMI). Lists of Deliverables 1. Cost Breakdown Competitive Analyses of four product categories: tower, jacket foundation, blade, and permanent magnet (PM) generator. The cost breakdown for each component includes a complete Bill of Materials with net weights; general process steps for labor; and burden adjusted by each manufacturer for their process categories of SGA (sales general and administrative), engineering, logistics cost to a common U.S. port, and profit. 2. Value Stream Map Competitiveness Analysis: A tool that illustrates both information and material flow from the point of getting a customer order at the manufacturing plant; to the orders being forwarded by the manufacturing plant to the material suppliers; to the material being received at the manufacturing plant and processed through the system; to the final product being shipped to the Customer. 3. Competitiveness Scorecard: GLWN developed a Wind Industry Supply Chain Scorecard that reflects U.S. component manufacturers’ readiness to supply the next generation wind turbines, 3MW and 5MW, for land-based and offshore applications. 4. Wind Supply Chain Database & Map: Expand the current GLWN GIS Wind Supply Chain Map to include offshore elements. This is an on-line, free access, wind supply chain map that provides a platform for identifying active and emerging suppliers for the land-based and offshore wind industry, including turbine component manufacturers and wind farm construction service suppliers.« less
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  • Individual axial tensile specimens of AS4/3501-6 and T300/934 unidirectional carbon fiber reinforced polymer composite laminate systems are characterized microstructurally. Fiber volume, fractional fiber volume, fiber uniformity, void volume, and variations in laminate thickness are acquired using automated quantitative image analysis (QIA). The sample preparation methods and QIA system procedures are fully explained. The problems in determining average or batch fiber contents in composite laminates using current methods are discussed. Possible problems in using micrometer thickness data in fiber content calculations are discussed when variations in specimen thickness due to surface contours are present. Variations in microstructure exhibited within a singlemore » fabricating company, between several fabricating companies, and between two different fiber-resin systems are demonstrated. Overall, QIA was determined to be a precise means of determining fiber and void contents and uniformity in individual test specimens prior to or after mechanical testing.« less