high performance basalt fibers & products for next gerneration composites

High-Performance

Basalt Fibers & Products for

Next Generation Composites

INCOTELOGY GmbH Sachsstrasse 18

50259 Pulheim

Germany

Phone: +49 2234 9882371

Fax: +49 2234 9882372

web: www.incotelogy.de

e-mail: [email protected]

© 2014 Incotelogy GmbH. All rights reserved.

http://www.incotelogy.de/

mailto:[email protected]

Company Profile

• Incotelogy GmbH is official distributor of advanced high performance basalt fiber and producer of basalt fiber products, composite materials or semi-finished products.

• We are the biggest supplier of basalt fiber and basalt fiber products in west Europe.

• Our philosophy is looking and development of new solutions for composites, automobile, aviation, building and other industries. We are working ongoing on improvement and optimization of our basalt fiber products in order to provide the best products quality and mechanical properties to our consumers.

• We are looking for new cooperation and developing innovative sustainable composite products of next generation.


What is Basalt?

• Basalt is a common extrusive volcanic rock, which minerals share is composed of: SiO2 54,9%, MgO 4,4%, CaO 7,7%, Na2O 2,5%, Fe2O3 + FeO 11,3%, Al2O3 16,4%, TiO2 1,1%, K2O 1,6%, Li2O 0,1%

• Color of basalt is usually grey to black and fine-grained

due to rapid cooling of lava at the surface of a planet. • Basalt may be porphyritic containing larger crystals in a

fine matrix, or vesicular, or frothy scoria. Unweathered basalt is black or grey.

• The term basalt is at times applied to shallow intrusive

rocks with a composition typical of basalt, but rocks of this composition with a phaneritic (coarse) groundmass are generally referred to as diabase or gabbro.

• Basalt rock is the main and only one source for production of basalt fiber monofilaments.


Production Process

Chemical control

Charging of stone onto furnace's

conveyer

Melting of basalt stone and

homogenization

Drawing through bushing

Sizing application

Winding of fiber on the cakes

Cakes with wet fiber

Drying of cakes in drying oven

(moisture content 0,1%)

Cutting of wet fiber (moisture content 8-10%)

Production of assembled roving

Cutting of dry fiber

Production of twisted yearn


Comparison of Different Fiber Types

Properties Continuous Basalt E-Glass S-Glass Carbon Aramid

Density (g/cm³) 2.6- 2.8 2.5 - 2.6 2.5 1.8 1.5

Tensile Strength (MPa)

4100 - 4840 3100 - 3800 4020 - 4650 3500 - 6000 2900 - 3400

Elastic Modulus (GPa)

93.1 - 110 72.5 - 75.5 83 - 86 230 - 600 70 - 140

Elongation at break 3.1 4.7 5.3 1.5 - 2.0 2.8 - 3.6

Maximum Service Temperature °C

650 380 300 500 250


Technical data compare to steel, magnesium,

aluminum

(= 1MPa) 3200 MPa Basalt Basalt

80.000…110.000 MPa Basalt

6x10*-7 1/K Basalt < (10x10*-6 1/K Glass fibers)

2,5 kg/cdm Basalt


Classification of Basalt Fibers Products:

E-Glass 2,61 g/cm3 S2-Glas 2,46 g/cm3

Epoxy 1,2 g/cm3 PP 0,9 g/cm3

45

1,74 g/cm3 2,60 g/cm3 2,70 g/cm3 4,51g/cm3

Basalt

1,85 g/cm3


Aging of Rovings in a Concrete Matrix – SIC Test

The tests of rovings aging resistance in a concrete matrix were carried out in accordance with DIN EN ISO 2062 and DIN EN 14649 (SIC). The results show that our basalt fiber rovings BR130.2400.12RAA, BR170.240013RAA and BR170.240042RAA are in the top group and reach almost even after aging the values of alkali-resistant glass fibers.


Green Product

National Directives on end-of life vehicles strongly recommend to car

manufacturers to use end-of-life management principles during car

development and production.

To fulfill such recommendations, car manufactures have to look for new

"green" materials which could

Help them to meet environmental requirements and to ensure

maximum recycling when the vehicles reach end-of-life stage


LCA Study Basalt vs. Glass Fiber

• Basalt fibers are natural product with less impact on environment

• Easy recycling ensure the sustainability

• Basalt fibers improve the energy and CO2 balance of end product

• Reducing of recycling costs and negative environmental effects

• The monofilament diameter > 9 µm is not carcinogenic


Summary of Basalt Fiber Properties

5 % higher density to conventional E glass fiber,

15 % higher tensile strength, higher compressive strength and rigidity (modulus

of elasticity).

Extremely high thermal stability, begin to melt at 1450 °C

Best flam stop of all fiber composites

Chemical endurance, especially against strong acids, lye's and solvents

Protected, so to speak by nature, again UV radiation, organic effects and corrosion

10% higher absorption of electromagnetic radiation

Classified as non-poisonous and non-carcinogenic.

100 % natural Basalt fibers are

Suitable for compounds with resin epoxy, melamine vinyl ester, polyester, PP, PA

High wettability and adhesion based of new facing technology

High resistance to heat stressed joining (Flowdrill, spot weld)

Integration of function /inteligence

Price relevance CFK Linen 30,00€/sqm to BF 4,00€


Basalt Fiber Product Protfolio

Multiaxial Fabrics

Fabrics

Mesh

Laminates

Roving, Yarns,

Chopped Strands

Mats

Prepregs

Non-Woven

Tapes

UD Tapes

Bars


Basalt Fiber Raw Materials

Rovings

Monofilament diameter:

10 – 20 μm

Linear density: 68 – 4800 tex

Chopped Strand


10 – 13 μm

Length of cut:

3, 4, 6, 12, 24 mm

Yarn/Core Yarn


10 – 13 μm

Linear density: 68 – 2400 tex


Basalt Fiber Fabrics

Weight:

150, 200, 400, 500,

600, 800 g/𝒎𝟐

Plain

Weight:

220, 345, 370, 700

g/𝒎𝟐

Twill

Plain: 150, 200, 400

g/𝒎𝟐

Twill: 220 g/𝒎𝟐

Metallic coating

Basalt-Carbon

Basalt-Aramid

Hybrid Fabrics

Weight on request

Elastic Knitted Fabrics

Weight on request

and fiber share

Hybrid Knitted Fabric

Weight on request

and kind of weave

Concealed Fabrics

Width: 30, 40, 50, 70

mm

Thickness: 0,21 mm

Tapes


UD & Multiaxial Fabrics

Width, Weight

and kind of

fixing materials

on request,

Impregnation:

Epoxy resin,

PVAc possible

DU-Fabrics

Width, Weight,

share of fibers

and kind of

fixing materials

on request,

Impregnation:

Epoxy resin,

PVAc possible

Hybrid DU-Fabrics

The fibers are

crossed over

each other and

the alignment of

fibers can be 0/90

°, + / -45 °

Different weights

are available.

Biaxial Fabrics

The fibers are

composed of

three

overlapping

layers and the

fiber orientation

can be 0 ° / +45 °

/ -45 °.

Triaxial Fabrics

The fibers are

composed of four

layers and can be

aligned e.g.

0 ° / +45 ° / -45 ° /

90 °.

Quadriaxial Fabrics


Matts, Non-Woven & Prepregs

Matts

Thickness: 6 mm, 550 & 780

g/𝒎𝟐

Thickness: 8 mm, 850 g/𝒎𝟐



lamination with PET, Aluminum

foil and self-adhesive film

possible

Prepregs

Pre-impregnated UD-Tapes

Pre-impregnated fabrics:

Plain/Twill

Pre-impregnated multiaxial tapes

Non-Woven

Weight: 60, 80, 100 g/𝒎𝟐

Mesh, Bars & Laminates

Mesh

Asphalt reinforcement mesh for

open structures

Asphalt reinforcement mesh with

meshes fill

Reinforcement for building

industry

Laminates

Basalt fiber sheet – black

Thickness and kind of surface on

request

Bars

Different diameter are

available


Field of Applications

Basalt Fibers

Sport & Leisure Military

Automotive &

Aerospace

Engineering Networks

Construction &

Building


Basalt Fiber Applications

• Among existing fibers basalt fiber with its dark color is the closest to carbon fiber

by color. Much less expensive basalt is used as either a replacement for carbon or

in combination with it. By using carbon and basalt together you can significantly

reduce the cost of finished products without losing attractiveness of its

appearance.

• Coating and concealing of basalt fiber fabrics allow to reach not only better fire

protection performance and higher mechanical properties but also new design

surface optic.

• New range of elastic knitted and hybrid knitted fabrics can be used as filtering

materials. Additional high thermal resistance allows application of these fabrics in

many places where other materials would be destroyed.

• Due to high E-Modulus and tensile strength of basalt fibers find basalt fiber

fabrics applications by manufacturing of sport equipment e.g. snowboards , wind

surfboards and tuning parts.

• Comparable temperature coefficient of expansion with carbon fibers allows

applications in sandwich constructions especially by direct tooling.

• Non-Conducting properties of basalt fibers allow applications by construction of

battery boxes by cars.


Applications for Automotive Industry

Headliners

High pressure cylinders for CNG and H2

Break pads and clutch plates

Thermo insulation for exhausting systems

Muffler’s fillers

Interior end exterior parts

Thermoplastic parts


Basalt Fiber Chops for Friction Applications

Basalt chopped strands are used as an alternative to asbestos in

production of brake pads and provides the following advantages to

final products:

2-3 times longer service life

Extended working temperature range

•Resistance to chemically aggressive

conditions

•Eco friendliness


Thermo-Insulation for Exhaust System

Basalt fibers are used for production of the thermo

insulating sleeves, braids, and fabric for car's exhaust

system.

The flexible knitted sleeve, when installed on vehicle

exhaust pipes, prevents exhaust gases from losing their

high temperature as they flow through the exhaust

system.

The technology enables more complete conversion of

gases and particulates, such as CO2 and unburned

carbon, in the catalytic converter; the result is better

engine effectiveness and less environmentally damaging

exhaust effluents


Muffler’s Fillers

Basalt fiber advantages compared to traditional

materials:

Much higher operating temperature

High resistance to thermal cycling

Greater noise reduction

Lower moisture absorption

High chemical resistance


Interior and Exterior Parts

Fabrics for interior and exterior parts

Many interior and exterior parts of cars are made of fabrics and

basalt fiber is used by some car producers in this application

because of its attractive dark-brown color, high mechanical

properties, fire-resistance and competitive price.

Thermoplastic parts and components

Today auto manufacturers widely use thermoplastic fiber

composites as alternative to metal to reduce vehicles' weight and

cost of production. With its outstanding mechanical properties,

resistance to high temperature and "green" advantages, basalt

fiber also can be successfully used for this application.


Innovative Applications – Direct Tooling

Use of conventional carbon, glass and basalt fiber fabrics,

Mould is constructed with a sandwich design, insulation integrated,

Basalt fiber mat as mould surface layer

Light moulds with low inherent thermal capacity

Agreement of the heating surface close to the surface, very short heat

pathways - optimum utilization of energy

Heating panels can be individually designed

Free geometric design of the heating panels

Additional functions are possible as desired

Precise temperature control and heating processes

Simple programming of the temperature


Basalt Fiber Products – In Building &

Construction Industry

• Reinforcement • Direct Tooling • Protection • Separation • Filtering • Drainage • Erosion Control • Fire Protection • Thermal Insulation • Acoustical Insulation • Electrical Insulation


Basalt Fiber Geogrid

Basalt fibber geogrid with special polymer impregnation is the most resistant to high temperatures when laying asphalt layers, superstable to chemically aggressive environments, as well as to the effects of biochemical factors. The material has high strength properties at break in warp and weft and good adhesion to asphalt concrete. Scope Material used as reinforcement layer on the fractured layers of asphalt concrete pavement before placing the upper layers, and as a means of inhibiting the formation of "the rut." Due to the unique properties of basalt, basalt fiber geogrid increases stiffness modulus asphalt concrete strength up to 80% coverage. Strengthening earthen slopes accompanied by a number of complex construction activities. Poor reinforced slope can bring a lot of problems and lead to a landslide or collapse. Strengthening of slopes, embankments, shorelines necessary to prevent wind and water erosion.


Buildings & Construction Applications

1 – Sand subbase;

2 – The base layer;

3 – Existing asphalt coating fracture;

4 – Basalt fiber geogrid

5 – Planarization layer;

6 – asphalt coating

Layer in a cracked layer of asphalt concrete pavement


Basalt Fiber Fabrics in Construction

We are providing different types of basalt fiber fabrics such as plain, twill, panama, quer-rips, hybrid fabrics, coated fabrics with polyurethane, silicone, aluminum, PET, adhesive film. The main application field is not only reinforcement for composites but also for thermal and acoustical insulation and fire protection. Basalt fiber hybrid fabrics with silicate fiber have found place as applications for fire protection for civil engendering. Excellent resistance to acid and alkali medium allows applications to reinforcement of concrete sheets and pillars.


New Applications

Produced Samples “Organo Sheets with Solid Core structure “


Basalt Fiber Chopped Strand

Basalt fiber chopped strands have an wide field of applications. On the one hand as reinforcement of Mortar and concrete matrix and on the other hand can be used as thermoplastic compounds to produce of pipes for civil engineering and chemical industry. West European countries increasingly put attention to sustainability of environment friendly construction materials and promote new solutions for building and construction industry. In this way has starting German Government some projects of harbor repairing e.g. Kiel


Basalt Fiber Bars

Basalt fiber bars are made in pultrusion process and available in different length and diameter. Due to corrosion and UV resistance are basalt fiber bars excellent suitable to reinforcement of concrete constructions. High tensile strength and resistance to acid & alkali medium prolongs life cycle of concrete constructions. SIC tests have shown that basalt fiber rovings are in the top of group other rovings such as AR-Glass fibers by competitive price compared to AR-Glass fibers. Basalt fiber bars allow robust light concrete constructions by ensuring their stability.


New Application & Perspectives

Integrated sensor techniques for lightweight material constructions –Organo Sheets:

Back-Lighting-Foil , low voltage to glue on OS or integrated inside in OS

on the Basalt fibre matte , flies or woven and integrated in Acryl-, Silicon-, Epoxy resin

to glue „behind“ the Basalt-fibre mat or transparent wood furniture light foils and to put

into effect of transparency win different colours and intensity

Back-Light-Foil without electrical contact, activate trough electrical frequency (micro

waves)

Application & Optic effects:

• OS-in cabin room, covering in living rooms, ship cabins, container, waggons, car,

plane, furniture

• OS-on outdoor illumination of buildings, cruise ships, vehicles

• OS-trade fair, sales booth, etc.

• OS-particular illumination for medical places


Our Future Developing Stage

Class A Surface

Tinge of yarn and fabrics

Developing of non-woven fabrics for automotive industry

Developing of new hybrid fabrics

Developing of basalt fiber fabrics with steel core for better fire

protection

Fabrics with high high temeprature and heat resistance for fire

protection and insulation


Politician & Market Future Tendencies

Political Stage

The Association of Automotive Industry (Annual Report 2013) provides the main

factors, which will have strong impact on production in automotive industry in the next

years e.g. efficiency and saving of used input, change to lightweight design, easier

recycled and downsizing components, introducing of ecological innovations.

These factors are strong on resource efficiency oriented.

Market Prediction

Place 12th of McKinsey study about “15 important things in the future” take “high

performance composites” e.g. light and steady components made from carbon, basalt or

glass fiber for automotive and aviation industry. The characteristic of high performance

composites is especially high temperature resistance. The influence of GDP 2025: 25 M

€; GDP-Share: 0,6%; no/less impact of employment; competitiveness in Germany: very

strong.


www.incotelogy.de

“High-Performance Basalt Fibers & Products for Next

Generation Composites” - presented by Wojciech Dlugosz

Contact: [email protected]

high performance basalt fibers & products for next gerneration composites

Documents

mpa basalt basalt

basalt stone

basalt rock

51gcm3 basalt

kgcdm basalt

color of basalt

unweathered basalt

term basalt