Advanced Air Mobility & Composite Materials - VFS 2021 Electric VTOL Symposium Imad Atallah, Director, Strategic Marketing - UAMMI
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Advanced Air Mobility &
Composite Materials
VFS 2021 Electric VTOL Symposium
Imad Atallah, Director, Strategic Marketing
January 2021
1 ©2021 Hexcel. All rights reserved.
ABOUT HEXCEL
Leading composites manufacturing company
4 73
YEARS IN BUSINESS
CONTINENTS Founded in a California garage in
North America, Europe, Asia, Africa 1948
23
MANUFACTURING SITES
5,100+
PEOPLE 3
MAJOR MARKETS
Commercial Aerospace, Space
and Defense, and Industrial
2 ©2021 Hexcel. All rights reserved.
UNRIVALED PRODUCT RANGE
Everything from carbon fibers, reinforcement fabrics, and resins to prepregs, honeycomb core, tooling materials and more . . .
from raw materials to fly-away parts . . . vertical integration is a strength and a differentiator
PAN CARBON FIBER GLASS HONEYCOMB ENGINEERED
Polyacrylonitrile Continuous and Chopped PREPREGS Rotorcraft blades PRODUCTS
precursor
A320neo sharklets | F-35 wings | LEAP fan blades/case Wind turbine blades Aircraft flooring Structural assemblies
Aerospace secondary Nacelle structures Machine/shaped core
Carbon Fiber & Prepregs
structures Acousti-Cap® Tooling system
Engineered Products
Glass Prepregs
Honeycomb
ADDITIVE
MANUFACTURING
REINFORCEMENTS CARBON PREPREGS
Thermoplastic, carbon fiber
Aerospace primary and A350 fuselage and wings reinforced 3D printed parts
secondary structures GE90 fan blade for Aerospace
Free Webinars – www.hexcel.com/webinars
3 ©2021 Hexcel. All rights reserved.
COMPOSITE MATERIALS CRITICAL DRIVERS
TRADES
Additive Automated
Manufacturing Placement
Higher Build Rates Part Size
Complexity
Automation Optimize
Material &
Equipment Processing
Lower Cost
Performance
Technology
Resin Transfer Compression
Maintenance Molding Molding
Aerospace Grade & Quality
4 ©2021 Hexcel. All rights reserved.
COMPOSITE SOLUTIONS – OPTIMIZE FOR NEED
Parts & Processing
Thermoset
Prepregs Automated Placement & Layup
Liquid Composite Molding
Out-of-Autoclave Molding
Additive Manufacturing
Carbon Fiber | Reinforcements | Resins | Prepregs
Compression Molding
Thermoplastic Prepregs Pultrusion
with unsized HexTow® CF
Welding and Joining
Leverage material science & formulation with parts processing
5 ©2021 Hexcel. All rights reserved.
AAM MARKET TIMELINE – NOTIONAL PHASING
Horizon 4
Reduce Risk Certification First Service Larger Scale Operations
Meet Cert Timeline
Use Aero Grade
Today’s New Technology
Technology to support Rate, Cost & Efficiency
New Materials Qualifications
Innovation
Phase 1: Support Qual & Cert; Phase 2: Support Volume and Cost
6 ©2021 Hexcel. All rights reserved.
AVAILABLE HEXCEL PAN-BASED CARBON FIBERS
Hexcel develops & manufactures HS, IM & HM carbon fibers
7 ©2021 Hexcel. All rights reserved.
FASTER CURING PREPREGS – APPROACH
Target: Fast
Mechanical Performance
Aero cure & primary Reduce cure time Aero PS
Primary structure maintain performance Prepreg
Structure performance
Development based on
• reducing cure time of
Performance existing primary structure
Improve
prepregs
• Improving performance of
industrial fast curing
prepregs
M701/M901/
Industrial M77
Auto/Industrial
Prepreg
1 2 3 4 5 6
Cure Time (h)
Two strategies to develop fast curing primary structure prepregs
8 ©2021 Hexcel. All rights reserved.
AEROSPACE MATRIX DEVELOPMENT FOCUS
OHC Performance (180°F W) vs CAI Strength (270 in-lb)
60 Key Chemistry Platforms:
CAI Strength, ksi (270 in-lb)
Focus 1:
55
IM8/M91 IM8/M91X
Balanced • Epoxy Resins
50 IM7/8551-7 toughness – High toughness options
compression
45 IMA/M21E
– Wet Tgs up to 320°F
– OOA prepregs
40
IM7/FC100 – Flexible cure
35 Focus 2:
High Comp, Flex Cure, OOA Driving HW-
M56/IM7 OOA OHC
30 IM7/8552
AS4/M65 BMI • BMI Resins
25 AS4/8552
IM8/M73
– M65
20
– Long-term service at 400°F
15 – Full range of ancillary products
30 35 40 45 50 55
QI OHC Strength, ksi (180°F wet)
Significant OHC improvement and balanced toughness and compression
9 ©2021 Hexcel. All rights reserved.
FAST CURE MATRIX SOLUTIONS - HexPly® M901
• High volume manufacturing • Designed for applications exposed to
– 4min @ 170°C hot/wet conditions
– Post cure option for outstanding Tg – Outstanding strength at 120°C
– Excellent retention of modulus
Option 1 Option 2 Option 3 Strength Modulus Strain at
[MPa] [GPa] failure [%]
Cure temperature 160°C 170°C 170°C
Cure time 5 min 4 min 2 min Room temp. (RT) 1400 38 4,0
Dry Tg* 180°C 165°C 130°C 120°C 1280 (-8%) 40 3,2
Post Cure - - 2h / 180°C
Dry Tg* after PC - - 190°C RT; hot/wet ** 990 (-30%) 41 2,4
*Table (left): Isothermal Cure Properties by HexPly® M901 in Prepreg Format, Press Cure (10bar); Measured by DMTA according to ASTM E1640-09 @3°C/min, Maximum Loss Modulus (G’’)
**Table (right): 3-point bending measurement set-up, hot/wet*: sample immersed in water at 70°C for 2 weeks; Data based on M901/29%/UD1200/G laminate
Provides flexibility and quick cure where needed
10 ©2021 Hexcel. All rights reserved.LIQUID COMPOSITE MOLDING – EXPECTED BENEFITS
Primary Structure
Cost Focus Rate Ready
Performance
✓ OOA ✓ Third gen. prepreg ✓ Next-gen. AFP machine
✓ Part integration performance ✓ Drape / low bulk
✓ Raw material ✓ Toughness / G1C ✓ Adjustable reactivity
✓ Storage / transportation ✓ High Tg & wet retention ✓ Bi-component available
HiMax® HiTape® HiFlow™
Hexcel LCM materials – robust solution for COST & RATE requirements
11 ©2021 Hexcel. All rights reserved.HEXCEL THERMOPLASTIC CARBON UD TAPES
Designed to meet low-cost HexPly® PEKK UD tape range
& high-rate targets growing various fiber types, not
limited to PEKK
Optimum performances
NCAMP qualification targeted
Press, Autoclave,
Stamping, OoA processing,
injection, Overmolding Environmental sustainability,
Innovative Welding process recycling and potential reuse
Production line ready and samples available with HexTow® AS7 and IM7 fibers
12 ©2021 Hexcel. All rights reserved.ARKEMA IN SPECIALTY POLYMERS 13 ©2021 Hexcel. All rights reserved.
QUALIFIED MATERIALS AND DATABASES
• AAM/UAV vehicle certification UNIVERSITY COLLABORATIONS &
TECHNICAL CONSORTIUMS
– Reduce cost and risk
– Use of materials with long history and available data
– Public databases or supplier provided data
• Hexcel available materials at NCAMP
– HexTow® IM7 & AS4 fibers (intermediate modulus & high strength)
– HexPly® 8552 high performance tough epoxy matrix
– Unidirectional tape and reinforcement fabric
• Hexcel-produced data can also be made available
• Flexible cure systems in-work for future NCAMP qualifications
Hexcel materials long history & data availability – reduce risk
14 ©2021 Hexcel. All rights reserved.COMPOSITE MATERIALS CHALLENGES FOR UAM – SUMMARY
Different solutions are available for different missions & different
mechanical properties specifications
Hexcel is a global leader in advanced composites technologies in
aerospace and automotive; we are investing in Urban Air Mobility
Engage with us on this exciting challenge
Hexcel is your trusted partner for Urban Air Mobility
15 ©2021 Hexcel. All rights reserved.THANK YOU
LET’S HAVE A BREAKTHROUGH
Contact Information:
Imad Atallah
Director, Strategic Marketing
Imad.Atallah@hexcel.com
16 ©2021 Hexcel. All rights reserved.You can also read
