Types of Materials Worn By Crew Members

This afternoon, I ventured onto the deck to take some seawater samples. Last night, we had to navigate through a transition zone of winds with stormy weather. Luckily, the crew members on watch at that time had several layers of clothing from their durable, if limited wardrobe.

Polyester fleece is the main material for jackets and gloves worn by the members of the Camper crew. It is durable, resists moisture, and dries quickly. Polyester is the product of terephthalic acid and ethlyene glycol combined together at high temperatures, cooled, and forced through tiny holes in order to form thin, long fibres. The fleece retains heat as a result of its structure, which allows for air pockets. If the fleece is blended with natural fibres, this increases its strength and resistance to scrapes and scratches.

Microfibres, such as Kevlar, are used for the shirts and trousers in the wardrobe. They are lightweight and resistant to damage from outside forces. In order to produce Kevlar, poly-para-phenylene terephthalamide has to be produced through the polymerization process, where molecules are combined into extensive chains. The resulting liquid is then spun into fine threads and then woven together to form the fabric.

Nylon and spandex are the most common materials used for rash guards and vests worn by the boat crew. Both are lightweight and resistant to abrasion as well as staining. This makes them easy to clean, which is useful when the crew is travelling for long periods of time without access to most amenities. Two chemicals are combined together under high temperatures to form molten nylon, which is then spun into thin fibres and exposed to air, causing it to harden. Nylon is usually heat-set after manufacturing. A heat treatment is used to “relax” any leftover deformities in the fabric, which provides near-permanent stability so that shrinkage and wrinkling are less likely to occur. When two pre-polymers are mixed together, they form the raw material for spandex fibres. Stabilizers, such as antioxidants, are then added to the fabric to implant resistant properties.

Our diver, Guy Endean, who is responsible for keeping the boat while it is in water, will also have a wetsuit in his wardrobe. The primary component used in Camper wetsuits is neoprene rubber, which is buoyant, waterproof, and traps heat between the wetsuit and wearer’s skin. It also has high elasticity: the rubber becomes deformed when a strong force is applied to it, but when the force is removed, the material returns to its original state. Neoprene rubber starts out as a powder, polychloroprene, with several other chemicals added to create specific properties. The mixture is then put under extreme heat and pressure, which creates thin sheets of rubber that provide the raw material for the suit.

References

Woodward, Angela. "Polyester Fleece." How Products Are Made. Advameg Inc, 9 Jul 2011. Web. 2 May 2012. <http://www.madehow.com/Volume-4/Polyester-Fleece.html>.

Woodford, Chris. "Kevlar." Explain That Stuff. N.p., 2008. Web. 15 April 2012. <http://www.explainthatstuff.com/kevlar.html>.

Block, Ira. "Manufactured Fiber." AccessScience. McGraw Hill Companies, 2008. Web. 30 May 2012. <http://www.accessscience.com/content.aspx?searchStr=nylon&id=404050>.

Perry Romanowski. Dry-spinning Process. 2005. Graphic. How Products Are MadeWeb. 5 May 2012. <http://www.madehow.com/images/hpm_0000_0004_0_img0149.jpg>.

Maier, Karyn. "What is Neoprene Rubber." Wise Geek. Conjecture Corporation, n.d. Web. 21 April 2012. <http://www.wisegeek.com/what-is-neoprene-rubber.htm>.

Partridge, Edward G. , and John Leucken. "Rubber."AccessScience. McGraw Hill Companies, 2008. Web. 30 May 2012. <http://www.accessscience.com/content.aspx?searchStr=rubber&id=594800>.

Kiernan, Denise, and Joseph D'Agnese. Science 101: Chemistry. First Ed. New York: HarperCollins Publishers, 2007. Print.

Chemical Components of Boat Materials and Purposes

Before the Volvo Ocean Race began, I was discussing the construction of the boat with our boat builder, Adrian Grey, and our sailmaker, Richard Kiff. Although the materials we could use were limited by the official handbook, we still had to make wise choices. The various components of the Camper must be durable and long-lasting to withstand the extreme weather conditions of the Volvo Ocean Race. 

The sails of the Camper are responsible for its propulsion and control its movement. Bowmen and pitmen on the boat are responsible for hoisting, dropping and controlling the sails to move the vessel. The sails are constructed from carbon fibre, which can withstand tough weather but weighs little, so it won’t impair the boat's movement. The fibres are also used in masts, ropes and cords, as they are non-corrosive and durable. The material can last for most of the race’s legs without needing to be replaced, which saves time, effort, and money for the crew. 

The raw material for carbon fibre is polyacrylonitrile, an organic polymer. Carbon fibre is formed when polyacrylonitrile strands are heated to high temperatures, causing the molecules to move faster and vibrate. This process expels most of the non-carbon atoms and results in a long chain of tightly bonded carbon crystals. The fibre surfaces are then immersed in specific liquids and gases for minor oxidization, which improves their chemical and mechanical bonding properties. After, the fibres are coated with protective resin, wound onto bobbins, and spun into threads.

A vital part of navigation on the Camper is the use of large LED lights of high brightness placed on the vessel. Red lights are usually mounted on the "port" (left) side of the vessel, while green lights are mounted on the "starboard" (right) side. Conventional, low-power LEDs are used as light sources for numeric displays and indicator lights in instrumental panels. Both uses suit the LED, whose design maximizes external efficiency. The lights are made up of semiconductors: poor conductors that have atoms of another material, usually metal, added. These additional atoms change the balance of the material, adding free electrons or creating holes through which electric current can be conducted. The most common material used for LEDs is aluminum-gallium-arsenide (AlGaAs). When the compound is in its pure form, all of the atoms bond to another neighbour with no spaces between. Once additional elements (impurities) are added, they change the "balance" of the substance. 

As a result of the intensity of the Volvo Ocean Race, all parts of the Camper, down to the winches and fittings, have to be mostly resistant to outside forces. 

Alloys are used for several key components because they have more advantages than pure metals. They are usually stronger and stiffer, because the atoms of each metal are different sizes. When they are bonded together, it becomes more difficult for them to move at the same time when a force is applied. 
For example, aluminum alloys are used for the steering system and deck equipment because of their resistance to corrosion. In response to a number of reactions with the environment, an oxide covering forms over the metal, protecting it from exposure to the weather and most chemicals. Aluminum alloys also increase their strength at low temperatures while remaining pliant. Stainless steel alloys form a similar oxide skin. When the surface of the metal is scratched, more oxide will quickly form and re-cover the exposed area, preventing it from corroding. They are used for fasteners and lifelines. Lead alloys have a high density and dampening capacity, which makes them useful for internal structures by isolating them from mechanical vibrations. 


Although metal is the primary component for most of the vessel, certain areas are made of moulded plastic. Plastic parts are lighter in weight as well as quicker and cheaper to produce than their metal counterparts. In addition, plastic doesn't experience corrosion at all, so it is best suited  for areas that are constantly exposed to moisture. 

Plastics are polymers: molecules that consist of long chains of atoms that repeat themselves in a specific pattern. Each repeating structure is called a “monomer”, which shares a covalent bond with adjacent monomers. Most polymer chains have carbon as one of their elements, because it has the rare ability to bond in four different directions with four other atoms. 

Injection moulding is a process used to create plastics suited for a specific purpose. Molten plastic is inserted at high pressure into a cast (an inverse of the features) where they solidify into the desired shape. This method saves time because several parts can be solidifying at the same time. 

The boat hull and rudders are also coated with liquid polyester resin to protect against corrosion. The resins are used because of their resistance to water and UV rays. Resins can be blended in with numerous reinforcing fibres (e.g. glass, carbon) to fit high strength and stiffness requirements.

If the boat is constructed properly, than fewer repairs and modifications will need to be made during the race, which could save time and mean the difference between sailing into port victorious or dead last. However, rest assured that the Camper is in good hands with the shore crew.

References

 "The Volvo Open 70 Rulebook." Volvo Ocean Race. Volvo Car Corporation, 1 Jan 2011. Web. 29 March 2012. <http://www.volvooceanrace.com/static/assets/content/media/files/m3082_volvo-open-70-    rule-v3-including-amendment-3.pdf>

Hooper, Hamish. "CAMPER WITH EMIRATES TEAM NEW ZEALAND IN THE VOLVO OCEAN RACE." Camper.com. Camper Store, 2012. Web. 20 Mar 2012. <http://www.camper.com/en/news-volvo-ocean-race>.

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Chu, Herman. "Aluminum Alloys." eFunda: Online Resource for Engineers. eFunda Inc. , 2012. Web. 5 April 2012. <http://www.efunda.com/materials/alloys/aluminum/aluminum.cfm>.

Linda Nguyen. Aluminum Oxide. N.d. Graphic. GRIN SolutionsWeb. 3 May 2012. <http://www.grin.com/object/external_document.23194/ef054ae11293e93ea3542563abc3df91_LARGE.png>.

"Lead and Lead Alloys." Key to Metals. Key to Metals AG, 2010. Web. 17 April 2012. <http://www.keytometals.com/Article10.htm>.

"The Chemistry Encyclopedia: Plastic." Chemistry Daily . ChemistryDaily.com, 25 Jan 2012. Web. 10 April 2012. <http://www.chemistrydaily.com/chemistry/Plastic>.

 "Composites Basics: Materials." MDAComposites. American Composites Manufacturers Association , 1 Jun 2004. Web. 12 April 2012. <http://www.mdacomposites.org/mda/psgbridge_CB_Materials2_Resins.html>.

Goodman, Sidney. "Plastics Processing." Access Science. McGraw Hill Companies, 2008. Web. 4 May 2012. <http://www.accessscience.com/content.aspx?searchStr=plastic&id=526800>.

Injection Molding Process. N.d. Graphic. Injectingmoldingprocess.net

Brunelle, Daniel. "Polyester Resins." Access Science. McGraw Hill Companies, 2012. Web. 3 May 2012. <http://www.accessscience.com/content.aspx?searchStr=polyester&id=534200>.

 George Dinwiddle. Hull Deck. 2005. Photograph. Alberg30.orgWeb. 3 May 2012. <http://www.alberg30.org/maintenance/HullDeck/SmallBoatPatch/06-FirstLayerOfMat.jpg>.