Why Turkey Should Focus on Materials Technology in Industry (Part-2)

METALLURGICAL AND MATERIALS ENGINEERING IN THE WORLD

The name of the materials and metallurgy sectors commonly used in Turkey has been changed to MATERIALS SCIENCE and ENGINEERING in many countries. Materials Science and Engineering basically receives support from the following branches of science and engineering and at the same time supports them in terms of materials and acts as a catalyst with this structure.

The main branches of science and engineering from which it receives and provides support;

Chemistry, Physics, Biology, Environment, Crystals, Monomers & Polymers Sciences

Civil, Chemical, Plastic, Mechanical, Aircraft, Ship, Automotive Engineering

Engineering, Architectural Product Designs

The industrial sectors it supports are;

Metal industry (Iron-steel, non-ferrous metal production and casting industry)

Ceramic industry (Advanced technology ceramics, traditional ceramics and glass)

Polymer industry

Semiconductor industry

Coating industry

Defense industry

Machine manufacturing industry

Automotive and automotive supply industry

Aircraft and ship manufacturing industry

Welding materials manufacturing industry

Metal forming and processing industry

Surface treatment and coating industry

Electrical-electronic material production

Magnetic material production

Biomedical material production

Quality control and inspection companies

Non-destructive testing

Aluminum, which is the most produced material in the world after steel, is used extensively in the construction sector, especially in roof and facade cladding, doors and windows, stairs, scaffolding and greenhouse construction. It is also used in automotive, aircraft and wagon construction, electricity, packaging, vehicle components, wire and cable production, machinery and machine elements and metallurgy. As a result of R&D research, it is now also used in the defense industry. Aluminum consumption in the world is mostly in the transportation vehicle manufacturing sectors. This is followed by packaging, construction, machinery, electricity and other fields. 

MATERIALS SCIENCE, ENGINEERING AND INDUSTRY IN TURKEY

Due to time and space constraints, only the production status of major industrial materials in Turkey will be examined.

Aluminum Industry in Turkey

Turkey was introduced to aluminum in the 1950s and aluminum applications started in the second half of the 20th century with the construction of building joinery, kitchen utensils and conductors used in the transmission of electrical energy.

Compared to developed countries, aluminum has a short history in Turkey. Since the 1960s, the production of durable consumer goods and developments in the automotive sector, especially after the 1970s, have increased the demand for aluminum. The only facility where primary raw aluminum is produced is Eti Alüminyum A.Ş.'s Seydişehir Production Plant. Other aluminum producing companies produce semi- or end products (processed aluminum). In other words, apart from the Seydisehir Aluminum plant, there is no other company that produces aluminum directly from its raw material (bauxite).

Crude Steel Production

Turkey ranks 7th in the world with 40.4 million tons in 2021. The total production of 27 countries in the European Union is 152.6 million tons. Germany produces the highest production in the European Union with 40.1 million tons. In other words, Turkey has the highest production capacity in the European region. In 2021, Turkey exported 22.1 million tons of steel products and imported 16.2 million tons. It ranks 8th in the world with a net foreign trade surplus of 5.9 million tons.

Boron Production

Turkey has 73.6% of the known world boron reserves. Although world boron reserves are concentrated in 4 regions, Turkey, USA, Russia and South America, the boron sector has an oligopolistic structure. A large part of the sector is managed by 2 main producers, Eti Maden and a rival company based in the USA. If we try to count in which sectors boron has application areas, it would be the subject of a separate article and would not fit here. But as an "aircraft maintainer", I can easily say that it is an element with critical application areas even in jet airplanes and jet engines.

By the way; the foundation of Turkey's first Ferrobor (a ferro alloy composed of iron and boron, used to produce boron steels), Boron Carbide (a boron product with high hardness, resistant to corrosion types and resistant to high temperatures) production facility was laid in Balıkesir Bandırma district. The value of Boron Carbide increases the added value of Boron raw material up to approximately 2 thousand times depending on its category. This is a tremendous added value.

Plastic Products Production

The plastics industry is one of the most important actors of the Turkish economy. Today, with a total production of more than 10 million tons, a turnover of around 40 billion dollars, direct exports of more than 7 billion dollars and an annual growth exceeding the GNP growth in the last 10 years, the contribution of the plastics industry to the country's economy is gradually increasing. With the production capacity it has reached, our plastics semi-finished products sector ranked second in Europe and sixth in the world.

One of the most important problems of the sector is its inability to provide sufficient added value. There are two main ways to provide higher added value in production and exports. These are to manufacture innovative products with high added value and/or to increase the profit margin by reducing costs without compromising on quality. In order for the sector to increase its competitive production and export opportunities in global markets without compromising on quality, it is inevitable for it to produce at European standards and in harmony with the environment.

Polymer Matrix Composite Products Manufacturing

Turkey's composites industry is developing rapidly and long-term in parallel with global economic developments. Developments in the composites sector play an effective role in the development of many sectors, especially carbon fiber applications, GRP pipe applications, automotive and transportation, renewable energy, marine, building-construction and engineering plastics. The composite materials market has reached a global volume of €66 billion and 8.7 million tons, while in Turkey it has reached a volume of €1.4 billion and 265,000 tons.

Lightweighting and cost reduction factors will continue to drive innovation in the aerospace, automotive and wind energy sectors. We could see more manufacturers using carbon composites in the future due to the prospect of reduced fuel consumption, especially for car manufacturers. In the aerospace industry, we will see composite parts currently used being replaced by carbon nano-reinforced polymers (CNRP). CNRP composites are stronger and 30% lighter. Wind energy producers will prefer carbon fiber material in wind blades. Blade lengths and turbine capacities will increase. As resin becomes more important, longer blades can be manufactured. Increasing interest in green technology will increase the use of high-strength fibers in production. It will also affect other industries in response to the greening of world markets, such as nano resins and bio resins. Regulations in Europe allowing the use of composites in rail vehicle designs will have an impact. The weight of railway wagons can be reduced by 30% through the use of composite materials. This means that 30% more cargo can be transported on the same train.

In the manufacture of transportation vehicles (aircraft, automobiles, yachts, ships, trains, etc.), composite materials are the solution to the need for more lightness without compromising safety. The superior properties of composites compared to traditional materials can be listed as follows:

- More lightness,

- High impact resistance,

- High thermal stability,

- Resistance to metal fatigue and corrosion,

- Lower material cost,

- Invisibility to radar (important in radar stealth-jet aircraft),

- Creating aerodynamic shapes not possible with wood or metal,

- Simplifying the assembly process by reducing the number of parts.

The need for lighter but stronger materials will continue to increase in vehicles, where energy cost is a very important input.

In this development process led by aviation;

The early use of composite materials in aircraft began in the late 1950s with aircraft such as the Boeing 707 and DC-9. Glass Fiber Reinforced Polymer (GFRP) was the first composite material used in aircraft. Due to the high safety standards of aircraft, the widespread use of composites took place in three stages. Initially, they were used in tertiary structures not directly related to flight safety, such as interiors, side walls, overhead cabinets and galleys. In the late 1960s, after proving successful in interiors, composites were incorporated into secondary aircraft structures such as spoilers, rudders, ailerons and flaps. The most critical applications of composite materials in commercial aviation began to be seen in the 1980s on primary structures such as stabilizers, wings and fuselage. The first example of this was the use of composite materials in the Boeing 737 horizontal stabilizer in 1984. Carbon Fiber Reinforced Polymer (CFRP), which has been widely used since the 1990s with advances in production techniques, has been a revolutionary material for the aviation industry. The carbon fiber vertical stabilizer used in the Airbus A310, which reduced weight by more than 250 kg, is considered the first successful example of this. Today, 50% of the structural weight of the next-generation Boeing 787 commercial airliner is made of composite materials, including stabilizers, wings and fuselage. Similarly, Airbus' groundbreaking A350 XWB is made of 53% composites, saving 25% in fuel consumption. 25% fuel savings is a huge efficiency improvement in a wide-body passenger aircraft.

To summarize

- Our bauxite reserves are sufficient to cover 70 years of alumina production from 2022 onwards, and we have a strategic production facility, the apple of our eye, to process these reserves.

- We are Europe's largest tonnage crude steel producer.

- We are Europe's second largest producer of plastic semi-finished products. We are also good at polymer matrix composites, which is a value-added product, but we are not yet at the levels we desire. If we can utilize the natural gas from the Black Sea in the production of petrochemical products, we will be the first in Europe. Moreover, the gas coming out of here will reduce energy costs, which is a very serious input in manufacturing.

- We have a monopoly on the World Boron Reserves. 

- Thorium, Hydrogen, Natural Gas and Crude Oil reserves will not be discussed due to time constraints.

General Assessment (SWOT Analysis) of Turkey's Materials (Aluminum, Steel, Boron, Plastic, Composite) Industry

A. Strengths (S-Strength):

- Turkey has world-class rich resources in terms of bauxite reserves, which is the most important raw material of aluminum (in fact, we have 1% of the world's bauxite reserves, but this reserve is sufficient for our 70 years of primary aluminum production (conversion of Bauxite (Aluminum ore) into Aluminum), and other reserves will be identified. 

- We are the largest producer of Crude Steel in Europe.

- We have the largest manufacturing capacity after Germany in Europe (Germany, Turkey, Italy) in the production of general industrial plastic semi-finished products (sheet, rod, pipe, film, etc.).

- Having a petro-chemical company and facilities capable of manufacturing General Industrial Plastics raw materials (PE (HDPE, LDPE), PP, PVC) (PETKİM).

- We have a monopoly in the world in boron raw material reserves. ETIBOR is the world's largest in the primary processing of raw material ore, it has only one competitor (American), the construction of the necessary facilities for the production of secondary Boron products with very high added value has started and production will start in the near future.

- With European countries moving away from the aluminum processing industry due to environmental and labor costs, Turkey has a significant potential in the market. 

- Relatively cheap and educated labor force compared to Europe.

- Proximity to Europe and to markets in the Middle East, Eastern Europe and Africa, which are likely to develop.

B. WEAKNESSES (W-Weakness):

- High energy and financing costs.

- While scrap resources, which is the raw material for secondary aluminum, are insufficient, the existing aluminum scrap is exported without creating added value.

- Since capacity increase and modernization investments are not made in the plants, 70-75% of the steel raw material need is met through imports.

- Unfortunately, we do not think "SIMPLE" in the production of goods, materials, tools, equipment, etc., we think "COMPLEX", and if we do it, we want it to be "BIG BANG". However, we should think simple and lean, let us make the simple one first if it is enough for us, then we will gradually make the more complex one. Because manufacturing requires a background and experience, experience cannot be gained from books, it can only be gained by doing.

C. OPPORTUNITIES (O-Opportunities):

- The discovery of natural gas resources in the Black Sea will reduce our energy costs in the short term, and the naphtha to be obtained from this resource in the medium term will provide cost-effective raw material input to the Turkish Plastics Industry. Of course, either PETKİM's petrochemical production capacity should be increased and/or the establishment of new petrochemical plants (e.g. in Zonguldak Filyos) should be encouraged and supported.

- Our country's idle coal mines (e.g. Zonguldak) should be made functional again, thermal power plants with appropriate chimney systems and modern technology should be built, those that are not should be modified, electricity should be generated from coal and especially industrial electricity costs should be reduced to levels that will increase the competitiveness of Turkish Industry. 

- The commissioning of our nuclear power plant should be accelerated, and new power plant installation agreements and processes should be accelerated.

- The number of hydro-electric power plants should be rapidly increased and the wasteful flow of water, our natural resource, should be prevented. Measures that protect the environment and the agricultural sector can be taken easily while building hydroelectric power plants.

- The number of facilities and equipment for the use of wind and solar energy should be increased. Especially the installation of solar energy panels on factory buildings should be supported.

- Due to the low added value and labor-based nature of the aluminum casting sector, the EU and other developed countries do not make new investments in this sector and prefer to supply their needs from countries such as Eastern Europe, Turkey, China and India.

- The growth potential of the domestic market in the automotive, white goods and construction sectors. Increase in the use of aluminum due to the growth potential in sectors such as construction, automotive, consumer durables, rail transportation, ships, construction, packaging and defense industries.

- We have the youngest average age in Europe that can be directed to manufacturing. We cannot make the desired utilization of our young people in industrial production. However, the technical education and training of our young people suitable for industry should be supported and made attractive. The planning, design, testing and development, mass production, etc. of industrial production should be entrusted to a qualified Engineering Group workforce.

How should the Education and Training of the Engineering Group be?

Engineering Group: Lead & Managing Engineer, Engineer, Technologist, Technician, Technician, Expert Master, Assistant Master, Helper

Leader & Managing Engineer: A certain amount of engineering experience and success followed by management training.

Engineer: 5 Years of Technical High School + 5 Years of Engineering Faculty, 2 Years of Master's Degree and Practical Training (salaried with government and university support in an industrial organization in the ISO 1000 List)

Technologist: 5 Years Technical High School and Industrial Vocational High School + 4 Years Faculty of Technology + 1 Year Field Practice (gaining experience in an industrial organization in the ISO 1000 list with a salary from the state)

Technician 5 Years Technical High School and Industrial Vocational High School + 2 Years Faculty of Technology

Technician 5 Years Technical High School and Industrial Vocational High School + 2 Years Faculty of Technology

Master Expert Industrial Vocational High School and On The Job Training & Experience (OJT-On The Job Training & Experience)

Assistant Master Industrial Vocational High School and On The Job Training & Experience (OJT-On The Job Training & Experience)

Helpers: Manual dexterity and On The Job Training (OJT)

D. THREATS (T-Threats):

External competition will try to prevent us, to force us to remain within their industrial and market monopoly spheres of influence at a level that does not threaten them. We will struggle, we will resist. We will say, we will say that it will come and go. Yes, the industrial revolution came to us late, it entered our commercial life late... Nevertheless, we now exist in industrial and commercial life. No stopping, keep going... We will not be afraid of falling, but we will know how to get up.

Unfortunately, we are insufficient in directing our young people, our most valuable strategic power, to manufacturing and utilizing their dynamism. Young people find it more attractive to be employed in service sectors rather than industrial sectors. This is unfortunately the case across the world and our young people are also affected. We will look for ways to make working in the manufacturing industry attractive to our youth.

Conclusion

Turkey is one of the industrial giants of EMEA. If we can utilize the next "three decades (30 years)" by placing great importance on materials science and focusing on value-added materials manufacturing, Turkey will be the South Korea of this region in 10 years, Japan in 20 years and Germany in 30 years. In this period, the world will talk about the "Turkish Miracle", not the miracle of these countries. Because the one who is strong in materials will be able to make everything that flies, walks and swims in the air, land and sea cost-effectively. Cost-effective, branded, high quality, reliable tools and equipment will be the "value multipliers" of all sectors.

Abbreviations:

EMEA (Europe, The Middle East and Africa/Avrupa, Orta Doğu ve Afrika).

AR-GE (Araştırma-Geliştirme).

TOKİ (Toplu Konut İdaresi Başkanlığı).

OSB (Organize Sanayi Bölgesi)

SWOT (Strengths, Weaknesses, Opportunities, Threats - Güçlü yönler, Zayıf yönler, Fırsatlar, Tehditler)

TPAO (Türkiye Petrolleri Anonim Ortaklığı).

BIG BANG (Büyük Patlama).

HES (Hidro-Elektrik Santrali).

ISO (İstanbul Sanayi Odası).

OJT (On The Job Training-İş Üzeri Eğitim).

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