Composite technology development in Italy

Composites Sctence and Technology 31 (1988) 81-85

Guest Editorial

COMPOSITE T E C H N O L O G Y DEVELOPMENT IN ITALY* In order to clarify our view of the present state of development of composite technology In Italy, we first outline the framework within which the economical parameters of the Itahan mdustrial and production worlds move in the light of recent reports from industrial, political and labour representatives. The analysis should identify the role of the principal decision-making factors for or against the advance of composite technology in past years as well as prospects for the future. There has been a strong growth in the Italian economy m the last four years, and the country may now be ranked as the fourth economic power in the world, ahead of France. The main reasons for this growth are to be found in the favourable international situation resulting from the drop in the price of oil, m the relatively unusual pohtical stability, and in a new outlook on the part of Italian industrialists on the production system. These general features are confirmed this year by a large and unusual surplus m the foreign balance of payments. However, it is not uncommon in Italian economics to meet the idea that there is real danger of an inversion of the economic trend as a result of monitoring signals from both international and internal industrial situations. In spite of the good foreign payments situation, exports have fallen 7% in value and 2% in quantity in the early part of 1987, by comparison with 1986. Larger penetration In Europe of items 'Made in Italy' has not completely accounted for the loss of markets in the USA and OPEC *This paper was presented at a meeting of the European Composites Forum, held m Cambridge, UK, July, 1987. 81

Composttes Sctence and Technology (31) (1988)--© 1988 Elsevier Apphed Science Publishers Ltd, England Printed m Great Britain

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countries, where Italy has mostly suffered in terms of competitiveness and profits. In relation to the internal industrial situation, a qualitative &fference exists, as in other European countries, between large- and medium- or smallsized industries and we shall later present explanations, particularly in the field of composites. We should hke to stress that the second type of industry suffers from difficulties encountered during reorgamsatlon intended to modernise and increase the efficiency of production systems. Obstacles are represented by the continuing high cost of borrowing, and, particularly, by the difficult choice between the need for reorgamsation and for enlargement of production potentml. One further point to mention in this context is that the labour cost is still increasing twice as fast as the inflation rate, which has rapidly decreased in the period. Although an increase in the production base ~s seen as a prerequisite for economic growth, it is thought that the practical con&tlons to move towards a larger industrial production potential, owmg to the cost of borrowing and to the insufficiently high internal demand, do not exist m Italy. A trend in this direction could therefore be dangerous m the long-term, producmg a decrease in the rate of innovation and reorganisation of technological cycles with the risk of being ill-prepared, financially and technologically, for 1992, a critical date for the European Economic Community. It is not difficult to foresee the role of innovative technologies in the picture of the Italian economy just briefly presented. New technologies are in fact considered as powerful means of influencing industrial behavlour in the search for new dimensions in the international markets. The approach to the use, knowledge, and exploitation of composites is however very &versified between different types of industries and it is appropriate to make a comparison between large- and small-sized industries, while noting that 2 or 3% of the 450 producers, with some 6500 employees, transform more than 1000 tonnes of GRP a year, while more than 70% transform less than 50 tonnes a year. The composite world has been of interest to all large Italian chemical groups, and, more recently, to some large mechanical engineering groups. The s~tuation is confused by the fact that some of the industries intend to remain raw materials producers, while others also intend to become active in fimshed products. No advanced reinforcing fibre is produced in Italy, only glass and orgamc fibres with modest mechanical properties. Conversely, there is within the sector large-scale production of high-performance polyester, epoxy and phenohc resins, as well as thermoplastics. The most important chemical groups involved with composites are Montedison, Enichem and SIR (Soclet~ Italiana Resine). Montedison is probably the most typical example of the phenomenon, because of the route followed in

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reaching its present state of development. The enterprise began with the acquisition of part of the financial empire of the Bonomi family, in particular a small group of some four to five small-sized industries active in the fabrication of composites articles, in textiles, and in similar activities. The small group has recently been enlarged by the inclusion of Intermarine, a large firm producing large military vessels in GRP, such as minehunters and minesweepers, which possesses an interesting technology for thick sections and automatic lamination. The will to promote a global strategy in the field of composites, with the creation of an international centre for Research and Development, is therefore quite recent within Montedlson. The final goal will then be to sell raw materials, final products, and technologies, apparently not in the aeronautical sector. The Enlchem case represents the situation related to the most important state-owned chemical group. Composites are very recent among the various interests of the group but already within the last three or four years a certain degree of experience has been acquired, as represented by interests in applications of high-performance composites, including those for aeronautical applications of interest to Aerltaha and Agusta, which are the most important aeronautical groups producing high-technology parts in advanced composites. With this target, Enichem has started a significant number of collaborative contracts with Universities and Research Centres in order to increase knowledge of design and fabrication technologies, thought to be of basic importance for developments in composites applications. The third example is SIR, a well-known chemical group, initially privately owned, but now governed by a four-person committee which reports directly to Italian ministries. The new situation of the SIR group, following a dark period some 10-15 years ago, is now financially attractive, and, like Enlchem and Montedlson, SIR is looking to diversification, with the principal current aim being to increase and accredit the present production which is essentially centred on epoxy and phenolic resins. In so doing SIR will be following a different strategy from Montedison and Enichem. It must be noted that these three examples, Monte&son, Enichem and SIR, refer to large chemical groups with outstanding knowledge and traditions in polymer chemistry, that made the decision to invest in the field of composites because of a conviction of the strong future of this industrial sector. However, it has been recognlsed, although only after a certain time, that the chemical base alone is not sufficient to satisfy all the requirements for achieving the best understanding of the composites world, particularly in the areas of design, testing, quality control, and fabrication technologies, which are now recognised as key-factors in composite application developments. Therefore, an interesting phenomenon is now occurring

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within the chemically-based groups, consisting of the presence of new staff with mainly mechanical engineering knowledge rather than chemical backgrounds. The results expected are thus related to the symbiotic relationships between different groups in a traditionally chemical environment In conclusion, it must be added that other important groups like Fiat or Aeritaha are not at all leading forces, for different reasons. Fiat is traditionally adverse to the use or testing of innovative alternatives, and looks for consolidated technologies before advancing any real interest. Aentalia, on the other hand, possesses substantial know-how, experience, hardware and software gained in years of production of advanced composites components. Furthermore, being a state-owned firm, it should have the duty to transfer all Its experience to other, particularly small-sized, Italian industries in order to increase the average level of industrial applications of composites. The total absence of this technology transfer is indicative of the isolation of Aerltaha from the Italian industrial context. In order to understand the state of development of medium- and smallsized industry m the field of composites, it must be realised that this type of industry occupies an important role in the Italian economy because of the peculiar character of the private, industrial Italian. There are various ways in which small industries pursue profit. However, it could be said that Italian medium- or small-sized industry is distinctive in being able to respond rapidly to all kinds of needs for innovation by comparison with larger industries. For this reason all activities that can introduce advantages, both in efficiency and in marketing, are often approached and pursued quickly and with great enthusiasm. This situation is of course balanced by a lower degree of independence as far as technical knowledge, and general hardware availability are concerned. But there is also a large degree of creativity that can, in some cases, be well utlllsed to exploit new ideas. Although Italian laws offer large incentives to industry in general, It is often said that greater attention should be paid to the problems of small industries, and recently old laws have been recast just to give more opportunities to small industries to reorganise in terms of technological innovation and research. By contrast with what happens in other European countries, among innovative technologies relatively little attention is officially paid to composites technology. But In spite of this difficult environment, Itahan small industriahsts have shown a growing interest m composites as confirmed by the daily increasing number of requests for information, requests for help and direction, the desire to increase composites knowledge, and complete feasibility studies and the transfer of prototype experience into initial production. A m o n g the participants in the technical actlwties of the Centro Materiali Compositl, which is the only specialist society in Italy in the field of composites, the majority come from small- and medium-sized

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industries. This movement of deep interest dates back only a few years and it is only recently that the term 'composite' has begun to assume a precise meaning. However, practical results begin to appear on the Italian scene of small- and medium-sized industries. Three examples may be mentioned to illustrate this point. (a)

(b)

(c)

The largest Itahan graphite fibre consumer is a small industry producing fishing rods by wrapping techniques Following consolidation of this 'traditional' production the owners are now planning investments m other industrial fields, using the same or similar technologies. Apart from the unique case of Intermarine, belonging to the Montedlson group, almost all the activities in the field of marine and naval production in composites are carried out in small industries. In this field great progress has been made in recent years in terms of automaUon of composites production and new composites apphcatlons. An important p r o o f of the utility and necessity of material and technology innovation m this field is represented, in Italy, by the large numbers of small-sized industries forced to close down as a result of not having the will or the abdlty to follow the paths dictated by the new technologies. The sporting goods industry has never been, in general, an important voice in the foreign balance of payments. With the advent and knowledge of composite materials, starting from the first graphite composite skis made for the Sapporo Olympic Games m 1972, an increasing number of small industries are now forecasting good internal and foreign activities, as is the case for b~cycles, tennis racquets, snow skis and racing boats I. Crivelli Visconti

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