RPM and TSF New processes to manufacture thermoset composite parts - In cooperation with
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RPM and TSF
New processes to manufacture
thermoset composite parts
In cooperation with
Partner LZS and NEM
• Polish Start-Up of the Uni Stettin • German development supplier for
• Innovative thermoset systems light weight technology
• Inventors of new thermoset resin • International costumer network
system A.S.SET • Process-know-how
Work share
Development/Sale
Development of A.S.SET-process
innovative thermoset
technologies (RPM, TSF)
systems (A.S.SET)
In cooperation with 2
A.S.SET Technology
Adjustable Simple Thermoset
• Epoxy Resins with thermoplastic processing properties
• Multiple melting/softening, fast curing
• Storage at room temperature
First Presentation
• Producible with various Epoxy Resins Hanover trade fair
• Modifiable (e.g. fire prevention, temperature resistance) 2014
In cooperation with 3
Characteristics A.S.SET Material
Temperature Temperature
120°C 120°C
60°C 60°C 60°C 60°C
RT
Viskosity Viskosity
(Powder)
solid solid
liquid liquid
Curing Curing
Time Time
In cooperation with 4
Resin Powder Moulding ‐ RPM
Powder application
• Spray gun / Sieve / conveyor
belt
• No mixing of Resin
• No cooling chain
Pressing
• Classic press/ membrane
• Short cycle times
• Low process pressures
Comparable to preform‐ and binder
process!
In cooperation with 5
Process impressions ‐ RPM
Video RPM
(http://www.youtube.com/watch?v=YxUeRvvmN1g)
In cooperation with 6
Spray application – A.S.SET‐Powder In cooperation with 7
Fixation of A.S.SET Powder
Fabric on a
heating plate
Applying A.S.SET
Powder
Fixating the Powder
(30 sec at 70°C)
CFRP-ply with fixated A.S.SET-Powder
In cooperation with 8
Thermoset Sheet Forming ‐ TSF
Pre-heating
• To handle like thermoplastic organic
sheets
• Heating field or oven
Pressing • Classic press/ membrane-press
• Pressing without vacuum
• Short cycle times
• No variothermal process
• Low process pressures
Processing analogue to thermoplastic organic sheets!
In cooperation with 9
Process impressions ‐ TSF
Video TSF
http://www.youtube.com/watch?v=MLXWBX4E_DA
In cooperation with 10Advantages of RPM and TSF
• Simple process technology
• Short cycle times
+ • Multiple forming possible +
RPM (before final curing) TSF
• Large Resin variety
• Excellent surface finish
• Very good fire prevention
• Simple Handling
• Demoulding out of the hot mould
In cooperation with 11Material Properties
Decomposition
Resin Curing cycle Tg max.
temperature
5 min at 140°C
A.S.SET 125°C 350°C
+ 15 min at 140°C
RTM6 2 h 180°C 196°C 290°C
4 h at 80°C
LY 556 155°C 310°C
+ 8 h at 160°C
L‐Harz 15 h at 100°C 90°C 320°C
Glass Thermal
transition degradation
In cooperation with 12Example Panel Material A.S.SET-Powder / CF fabric Process RPM Parameters 130° (constant), no vacuum, 1.8 bar pressure Cycle time 8 minutes pressing time, 10 minutes tempering In cooperation with 13
Mechanical Analysis
a) b) c)
a) Ultra sonic scan, b) Microscopy, c) Computer tomography
Static tensile test
CF-A.S.SET-Fabric
• Small pore content, even without
Vf ~ 60% vacuum
Load direction 0°
Stress [Mpa]
• Fibre volume content at
approx. 60 vol.%
• Strength in and perpendicular to fibre
direction comparable to common CF-
ER-laminates
Strain [%]
In cooperation with 14Example Panels [Wood-CF]S [Decor layer-Wood-GF]S [Wood-GF]S [Wood-BF]S [GF-Balsa-CF]S [Hemp-Balsa-CF]S In cooperation with 15
Example CFRP‐Frame
Material A.S.SET-Powder / Aviation Fabric resp. Non-crimp Fabric
Process RPM with autoclave or vacuum bag without autoclave
Parameters 60°C pre-heating, 120°C autoclave, 3 bar for 15 min
Tempering 20 min at 140°C outside the mould
Properties Probably passes Airbus fire prevention standard
In cooperation with 16Frame‐Manufacturing impressions
No Bridging No resin rich areas!
In Kooperation mit 17Process comparison – Example Frame
Process times
Cutting Laminating Bagging Curing Tempering
Conventional Frame
manufacturing with
Prepreg
Frame
manufacturing with
A.S.SET-Powder
Additional advantages Challenges
• Cost‐effective Preform • Automated Powder application
• No cooling chain • Slipping of Layers
• Better fire prevention
• No pores
• No resin richness
In cooperation with 18Example Sandwich‐Seat Material A.S.SET-Sheets / GF-Fabric Process TSF with membrane press Parameters 120° (constant), no vacuum Cycle time 8 minutes pressing time, 15 minutes tempering Properties Passes fire prevention standards of railway industries In Kooperation mit 19
Example Repairing
NASA
Damaged Part A.S.SET-Sheet-Patch Repairing Repaired Part
Material A.S.SET-Sheets
Process „Ironing Process“
Parameters 140°C (constant), no vacuum
Cycle time 10 Minuten „ironing“, optimization possible
In cooperation with 20Chance: Repairing wind turbines
Boats and cars
wind-energie.de boot-service.at
Today: Repairing trough wet laminating Future: Repairing with A.S.SET Sheets?
• Dirty work, at max. 80 days a year possible • Clean
• Long curing times • Repaired structure loadable after few
• Low fibre volume content minutes
• High quality of the patches
In cooperation with 21Prospect • Further development of RPM and TSF • Data sheets available for selected reinforcement materials • Starting Series production of A.S.SET • Starting Series production of the railway-seat • Developing A.S.SET-Parts together with industrial partners In cooperation with 22
Thank you
for your attention!
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