The strength of a composite component is dependent on the correct alignment of the fibres from which it is made; fibres which are laid incorrectly can result in a range of defects that affect the structural integrity of the final part. While quality checks during the lay-up process are vital they can take 70 per-cent or more of total machine time and is a huge cost.

Detecting such defects, from gaps and overlaps to the presence of foreign objects and debris, at the relatively early lay-up stage of production is much more efficient and cost effective than identifying unacceptable weak points in the material once it is part of a completed component.

The Composite Centre at the AMRC has researched what systems were being successfully employed in related applications which identified the capabilities of the Absolute Arm and its laser scanner options, products developed by Hexagon’s Manufacturing Intelligence division.

Hexagon has developed a composite inspection system especially for measuring fibre orientations, which we believed could be a potential candidate for solving some of our inspection problems. They were able to bring the system to the AMRC to perform a case study – an Absolute Arm with RS5 Laser Scanner and a Vision System 3D.

The Vision System 3D is a camera-based sensor that can accurately detect the orientation of composite fibres using pixel-based algorithms. The system uses a metrological Absolute Arm for position referencing and, combined with scans made using the arm’s laser scanner and camera functionalities, this fibre orientation data can be mapped onto a three-dimensional model of the part being inspected using the dedicated Explorer 3D software platform.

The system lets us validate the design and simulation work that we do at our desks to make sure our design intent is being manufactured, so it becomes a good validation step for our design and manufacture process.

The researchers are primarily using the system for weaving, braiding and preforming processes. Once they perform that initial manufacturing process, they can bring the part to the workstation and use the new inspection system to do a scan of the part to generate the 3D profile of the part.

Using some of the advanced algorithms that are built into the software, they are able to determine fibre orientations that can give an indication of some of the defects that are present in the part.

That information is then taken back into the design and analysis software to update the models with the data from the as-manufactured part in order to perform an analysis which can then be compared against the as-designed part. This provides valuable information for comparing both ‘real’ and ‘virtual’ environments.

This system is one of a number of solutions for composite fibre inspection that has been developed by Hexagon’s Vision and Composites product group in Aachen, Germany. The next stage of the project is to investigate how the technology can be further developed to make them robust enough to pick up some of the more complex defects that we’re hoping to achieve solutions for in the near future.

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The longterm aim of the venture is to manufacture high-pressure hydrogen carbon fibre cylinders for fuel cell vehicles in the Japanese market, a world leader in the transition to hydrogen-based energy.

The plan would integrate and leverage the high-pressure cylinder manufacturing technology of Hexagon Composites, a leading manufacturer of carbon fibre-reinforced high-pressure cylinders, the comprehensive capabilities of Mitsui, including its customer assets and marketing know-how, and the capacity of Toray to supply competitive, high-quality carbon fibre and develop new technologies.

The development of lighter parts and materials to reduce energy consumption by transportation equipment, especially in motor vehicles, is seen as an important approach to the solution of this problem. The market for lightweight materials, such as carbon fibre, is expected to expand rapidly.

Hexagon Lincoln, Mitsui, and Toray are motivated to contribute to the Japanese government plans to make the 2020 Tokyo Olympics the starting point for the creation of a hydrogen society by commencing domestic production of high-pressure hydrogen cylinders as functional components for these fuel cell vehicles.

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The company plans to invest a total of approximately 833 million in NOK(¥11.0 billion JPY) in Hexagon, which is the world’s biggest manufacturer of plastic-lined carbon fibre reinforced pressure cylinders.

For almost 20 years, Mitsui and Hexagon have built a strong partnership centred around the sales of composite cylinders. By drawing on this equity participation and business alliance, Mitsui will use its assets and global network to expand Hexagon’s business, while also contributing to the reduction of greenhouse gas emissions in the transportation sector.

This investment spans two of those key strategic domains: “mineral resources and materials”, and “mobility”. In April 2015, Mitsui signed an agreement concerning cooperation on composite materials research and an equipment lease agreement with the Innovative Composite Materials Research and Development Centre (“ICC”) of the Kanazawa Institute of Technology. Mitsui and ICC have since commenced collaborative development of new manufacturing methods for automotive parts and other products made of carbon fibre composite materials.

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Saertex will pay NOK 115 million for the transaction plus any net change in equity in fourth quarter 2013, for equity and internal long-term debt. The total cash effect for Hexagon Composites is estimated to be approximately the same. The transaction is estimated to give a small profit (from book value) after transaction costs. A long-term external debt in Hexagon Devold’s subsidiary in Lithuania of NOK 16.8 million will be transferred to the new owner.

Saertex is a market leader in multiaxial fabrics with main markets in wind energy, aerospace, civil engineering, automotive and shipbuilding. The company is privately owned with a turnover of EUR 250 million. Their head-quarters are located in Saerbeck, Germany, with production facilities in Germany, France, Portugal, US, Brazil, South Africa, India and China. SAERTEX will keep Devold AMT as a parallel brand and continue present operations in Lithuania, US and Norway.

Senior Vice President Tore J. Fjell said on the deal;

We are very satisfied that the transaction with Saertex is concluded. Saertex is one of the leading players in the multiaxial fabrics industry and the transaction will give Hexagon Devold and its employees a strong industrial owner. The transaction will enable Hexagon Composites to focus on its core business areas within the strongly growing high pressure and LPG-cylinder segments.

Hexagon Devold had turnover during the first three quarters of 2013 of NOK 133 million, EBIT of NOK 4.9 million, assets of NOK 206 million and liabilities of NOK 194 million. The company has 125 employees.

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The Board of Hexagon Composites ASA has discussed the situation and future prospects for the North American market. Against the background of these growth opportunities and Hexagon Lincoln’s market-leading position, the Board has decided in principle to invest in a further increase in capacity in Lincoln. The planned production line is expected to once again double the production capacity for CNG cylinders for the bus and truck market compared with the second half of 2013. This corresponds to four times the capacity in 2012. The new production line is expected to be operational towards the end of 2014.

Initial calculations indicate an investment of around NOK 150 million. This investment will give Hexagon Lincoln an automated and dedicated production line aimed specifically at the production of pressure cylinders for larger vehicles.

Tore J. Fjell, CEO of Hexagon Composites said;

Because of the great market potential for pressure cylinders for larger vehicles in the USA, we wish to take the lead with essential investments so that we can meet customer needs. We wish to establish an automated and cost-effective production line, so as to achieve the greatest possible competitive effect. We are therefore pleased that the Board has taken this decision in principle.

The Board of Hexagon Composites has also approved a bond issue to finance this investment and other possible investments linked to development of the high-pressure area. DNB Markets and Swedbank First Securities are appointed joint lead managers in connection with the issuance of bonds.

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The opening ceremony was attended by the Governor of the Nizhny Novgorod region Mr. Valery Shantsev, Deputy Head of Mission at the Norwegian Embassy Mr. Bård Ivar Svendsen, Chairman of Autocomponent Mr. Yuriy Belyaev, Chairman of Hexagon Composites Mr. Knut Flakk, together with other representatives from the authorities, owners and customers.

Rugasco was formed in 2012 as a joint venture between Hexagon Composites ASA and Autocomponent, a large Russian manufacturer of plastic parts for the automotive and construction industry. The plant has a capacity to produce 200,000 LPG cylinders annually. The establishment has initially created 25 positions in Nizhny Novgorod.

Mr. Knut Flakk, Chairman of Hexagon Composites.

The opening of the plant in Nizhny Novgorod marks a new era in the development of composite cylinders in the Russian market. The establishment of the plant is a result of successful cooperation between Russia, Sweden and Norway

The automated production line has been transferred from Hexagon’s subsidiary Composite Scandinavia AB in Sweden which was closed down in 2012.

Russia is one of the world’s largest producers of natural gas and has implemented a policy to better utilise its natural gas resources domestically. The opening of the LPG cylinder plant is therefore seen as very positive by the Russian authorities. It is also expected that this will generate sales of Hexagon’s high-pressure composite cylinders for storage and transportation of natural gas to the Russian market.

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Hexagon Devold (previously Devold AMT) founded in 2007 is an international supplier of stitched, multiaxial composite reinforcements of glass and carbon fibre. The majority of the volume goes to the wind industry and the production of wind turbine blades.

The acquisition of PPG’s share takes place according to an earn-out model where future operating profit (EBIT) is divided equally between the parties until 50% of equity as of 31.12.2012 is paid to PPG. The earn-out period is limited to five years.

Hexagon Devold will continue to produce composite reinforcements at the factory in the U.S to supply the U.S. market. Kåre Dybvik, Managing Director of Hexagon Devold said;

The acquisition will fully consolidate the company in Hexagon Devold’s strategies and plans. We will also increasingly be in a position to exploit synergies and resources between companies and act as one unit under the company name Hexagon Devold

Managing Director of the joint venture company, Herb Elder, will continue as head of the wholly owned subsidiary. At the same time, the company changes its name to Hexagon Devold USA.

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Starting from the 4th March 2013, Hexagon will emerge as a unified group with Ragasco, Lincoln Composites, Hexagon Raufoss and Devold AMT continuing as strong sub brands in the new identity.

The new visual identity has been based on the group’s previous identity and logo symbol, the hexagon. The solid and distinct hexagon is motivated by the company’s history, unique technology expertise and leading market position.

The Hexagon symbol is made up of lines that form 60 degree angles. This is the way fibre is both knit and wound and provides a reinforcing effect on the composite products we manufacture. This is precisely what makes the symbol so important for our identity.

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Through its wholly-owned subsidiary Lincoln Composites, Hexagon Composites has been awarded a new contract to supply 55 lightweight Titan transport modules to SC Group in Thailand. This represents the largest single Titan contract to date for Hexagon Composites worldwide.

SC Group is an integrated logistics services in Thailand. The Thai state-owned oil and gas company PTT Public Company Limited has recently contracted SC Group to transport CNG (Compressed Natural Gas) using the lightweight Titan transport modules.

The contract will generate strong activity in Lincoln Composites for Q3 2012.

On a global scale, Thailand represents the largest market for road transportation of natural gas from pipeline-connected mother stations to NGV fuelling daughter stations. Over 1,500 steel trailers presently operate in the country. With its significantly lighter weight and substantially larger transport capacity, the Titan has proven to reduce fuel consumption by more than 60% compared with conventional steel trailer technology.

The Titan tank is based around a Filament wound epoxy-carbon fibre composites shell with a Polyurethane coating applied to the outer surface to enhance the abrasion and scuff resistance of the container, as well as acts as a moisture protection layer. The tank is designed to transport compressed natural gas, hydrogen, nitrogen and helium and can be mounted to a ISO 1496 shipping container. The module weighs 14,500 kg unpressurised and can be transported via rail, truck or ship.

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The decision is based on the deficit the business unit has had for several years. The company is experiencing positive growth, however the margins on the products that the company supplies have further fallen following the financial instability of the last few years. Devold AMT has therefore been compelled to adjust its cost level to the market conditions in which it operates.

Kåre Dybvik, Managing Director at Devold AMT says;

This is a regrettable, but necessary decision, There will be a substantial gain from assembling all our production facilities in Lithuania and the company is reliant upon improving its margins in order to reverse the negative development.

The company’s wants to be the market leader in the supply of composite reinforcements and the move is part of positioning the company for growth in Europe. Further increases to the production capacity in Lithuania are planned for the future. By making deliveries from Lithuania, the company will come closer to its customers in the European market.

In addition to the factories in Langevåg and Lithuania, Devold AMT has a subsidiary in North Carolina that manufactures and supplies composite reinforcements to the American market.

Hexagon Composites ASA is a publicly listed group with its head office located in Ålesund, Norway. The group has 371 employees and had a turnover of NOK 846 million in 2010. The group develops and manufactures composite containers for the storage and transport of various gases under pressure, and stitched composite reinforcements that make windmills, boats and structures lighter and stronger.

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