High-potential niches in mechanical engineering

Whether gripper systems, cones, connecting rods, walking beams and rotor arms, blades, robot arms, springs, drive shafts, rollers or components for textile and machine tools - there are already many applications in mechanical engineering that are realized with the help of GFRP or CFRP. "There are currently no high volumes or large series, but a large number of different niches with high potential," according to the study "Series production of high-strength fiber composite components - prospects for German mechanical and plant engineering", which was published in 2012 by Roland Berger Strategy Consultants and the VDMA Composite Technology Forum. The experts forecast moderate growth and see technical necessities as well as efficiency and cost-effectiveness aspects as drivers.

More recent studies support this forecast. In its current survey of key figures on the market for fiber-reinforced plastics, Composites Germany surveyed all member companies of the four major supporting associations AVK, CCeV, CFK-Valley and VDMA Working Group Hybrid Lightweight Technologies and published the results at the beginning of the year in the "10th Composites Market Survey". According to the survey, mechanical engineering is increasingly being named as one of the user industries in the composites market from which significant growth impetus is expected.

The VDI Center for Resource Efficiency also sees a large and growing market for lightweight construction solutions in mechanical and plant engineering in its 2015 report "Stocktaking lightweight construction in Germany". For example, production for the energy sector and for medical technology applications is showing great momentum. "The largest lightweight construction markets in mechanical engineering in the short to medium term are for high-strength steel, aluminum and fiber-reinforced plastics (GFRP, CFRP, etc.)," the authors write.

Age-appropriate working with lightweight materials

The materials are increasingly being used for moving components in particular. "One research focus, for example, is the development of highly damping lightweight composite materials, which can be used to increase machining accuracy and speed, increase service life and reduce tool wear," the report states. Furthermore, the experts have identified not only technical but also social benefits for the use of composite materials in mechanical engineering: "Lightweight construction also provides a technology for age-appropriate working, as lighter production machines can reduce workloads," they state.

Within composites, the areas of application and therefore the market prospects for the individual fiber composites vary. GRP is used in plant engineering primarily in the form of profiles or as pipes and tanks manufactured using the centrifugal or winding process. However, the segment is "the only declining one in the European GRP market", according to the "Composites Market Report 2017". Nevertheless, the potential for pipes, for example, is huge because GRP only accounts for 3 to 5% of the overall market, especially for large diameters.

Great growth prospects for CFRP

Small market share, great growth prospects - this also applies to CFRP. Although plant and mechanical engineering companies are still hesitant to use them, the experts at Carbon Composites e.V. believe that these materials are increasingly convincing decision-makers. This is because "the material properties of these materials provide mechanical engineering with many advantages, such as their high innovation potential", according to a market analysis. For example, highly damping lightweight composites enable a considerable reduction in moving masses in various applications. This and a high level of vibration damping are extremely advantageous for a high-precision machine tool. This means that smaller drives and a design for reduced machining forces can be realized. As a result, accuracy and therefore quality increase. The service life of the machine and the service life of the tools are also increased.

Composite materials in mechanical engineering are mainly used as sandwich and profile constructions in the form of CFRP sheets and profiles, CFRP semi-finished products are increasingly being joined by adhesive bonding. The components are suitable for very rigid constructions that still allow high positioning accuracy even when enormous acceleration forces are applied. Through the targeted selection of fibers and a corresponding layer structure, advantageous moduli of elasticity are achieved at a very low weight, which are almost twice as high as those of steel. CFRP components can also be designed to minimize thermal expansion.

Composites Europe, November 6-8, 2018, Stuttgart