RPM and TSF New processes to manufacture thermoset composite parts - In cooperation with

Page created by Terry Carr
 
CONTINUE READING
RPM and TSF New processes to manufacture thermoset composite parts - In cooperation with
RPM and TSF
New processes to manufacture
thermoset composite parts

                               In cooperation with
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
RPM and TSF New processes to manufacture thermoset composite parts - In cooperation with
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
RPM and TSF New processes to manufacture thermoset composite parts - In cooperation with
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
RPM and TSF New processes to manufacture thermoset composite parts - In cooperation with
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
RPM and TSF New processes to manufacture thermoset composite parts - In cooperation with
Process impressions ‐ RPM

                                        Video RPM
                      (http://www.youtube.com/watch?v=YxUeRvvmN1g)

In cooperation with                                                  6
RPM and TSF New processes to manufacture thermoset composite parts - In cooperation with
Spray application – A.S.SET‐Powder

In cooperation with                  7
RPM and TSF New processes to manufacture thermoset composite parts - In cooperation with
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
RPM and TSF New processes to manufacture thermoset composite parts - In cooperation with
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
RPM and TSF New processes to manufacture thermoset composite parts - In cooperation with
Process impressions ‐ TSF

                                        Video TSF
                      http://www.youtube.com/watch?v=MLXWBX4E_DA

In cooperation with                                                10
Advantages 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                                                                11
Material 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                                                   12
Example 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                                                                        14
Example 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                                                         16
Frame‐Manufacturing impressions

                     No Bridging  No resin rich areas!
In Kooperation mit                                        17
Process 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                                                                 18
Example 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                                                                 20
Chance: 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                                                                       21
Prospect

• 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!

In cooperation with                         23
You can also read