ROHACELL Triple F. Complex shaped PMI Foam Cores for highly efficient FRP Composite

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1 Complex shaped PMI Foam Cores for highly efficient FRP Composite ROHACELL Triple F Sandwich Fabrication for low to - A Novel Particle Foam high volume applications SAMPE tesdr. Kay Brazil Conference nd October 2015, Sao Jose dos Campos, Brazil Fabio Tufano Technical Sales & New Business Development South America Evonik Degussa Brasil Ltda. M. Alexander Roth, Dr.-Ing. Director ROHACELL Americas & Vice President Evonik Foams Inc.

2 1. Sandwich Cores Requirements and Overview 2. Manufacturing Process of PMI Rigid Foams 3. Advantages of PMI In-Mold Foaming (IMF) SAMPE Brazil Conference 2015, 22nd October, São José dos Campos Seite 2

3 Definition and Layup of Sandwich Structure A structural SANDWICH is a special form of a composite that combines at least two different materials by bonding them to each other so as to utilize the properties of each separate component to the structural advantage of the entire assembly. Fibers, e. g. CF, GF Resin, e. g. EP FRP Face Sheet Core, e. g. PMI-Foam Resin, e. g. EP Fibers, e. g. CF, GF FRP Face Sheet Source of image: 08/31/2015 SAMPE Brazil Conference 2015, 22 nd October 2015, Sao Jose dos Campos, Brazil Slide 3

4 The Sandwich Effect Sandwich Structures are very suitable for bending & axial compressive loaded parts to increase: Bending stiffness and strength Buckling and crash performance Lightest Solution! Source of image: 08/31/2015 SAMPE Brazil Conference 2015, 22 nd October 2015, Sao Jose dos Campos, Brazil Slide 4

5 Function of Core Material Mainly: Keep Skins at Distance Stabilization of Skins (FRP Layers) Transferring Shear Forces from one Skin to the other Skin But also: Absorption of Impact Loads Thermal Insulation Acoustic Insulation Vibration Dampening SAMPE Brazil Conference 2015, 22 nd October 2015, Sao Jose dos Campos, Brazil Slide 5

6 Requirements for Sandwich Cores Composite sandwich construction is an emerging option to meet innovation demands coming from many industries, from automotive up to sport industry. It leads to the lightest available final parts and can also offer significant cost reduction in mass production. Requirement Lightweight design High surface quality Fast cycle times Processability Core properties High mechanical strength at low density Fine and closed cell foam High temperature & high compression resistance Easy to shape ROHACELL is a PMI-based structural foam core that meets all requirements for fast curing processes. SAMPE Brazil Conference 2015, 22nd October, São José dos Campos Page 6

7 Biggest Hurdle for more Composites: Manufacturing Costs Overall cost Requirements from OEMs: Competitive costs for composites 100 % 0 % current composite costs requested costs Source of image: 08/31/2015 SAMPE Brazil Conference 2015, 22nd October, São José dos Campos Page 7

8 Biggest Hurdle for more Composites: Manufacturing Costs Overall cost Requirements from OEMs: Competitive costs for composites 100 % 0 % current composite costs requested costs Production process has the biggest potential to decrease costs! Source of image: 08/31/2015 SAMPE Brazil Conference 2015, 22nd October, São José dos Campos Page 8

9 Production Processes Production process Fast Trend toward mass production HP-RTM, Press Moulding (Prepregs, Organosheets, Dry Fabrics/Liquid Resins, Foam Cores) Slow Hand Lamination, Autoclave- Technology (Prepreg, Honeycomb) Number of Parts SAMPE Brazil Conference 2015, 22nd October, São José dos Campos Page 9

10 Production Processes Dry-Compression Prepreg Core IR Press 180 C IR Press Wet-Compression IR Epoxy Press 140 C Core IR Press shorter production cycle time of composite parts SAMPE Brazil Conference 2015, 22nd October, São José dos Campos Page 10

11 Production Processes Textiles Core Epoxy Pressure Finished part Pre-formed Sandwich Positioning in mold Vacuum (optional) Injection A fast curing process requires a core to withstand: temperatures of C pressures of bars SAMPE Brazil Conference 2015, 22nd October, São José dos Campos Page 11

12 Production Processes Requirements of the Core Materials: Resistance to Process Pressure Resistance to Process Temperature Creep Resistance Compatibility with any Matrix System Closed Cells Source of image: 08/31/2015 SAMPE Brazil Conference 2015, 22nd October, São José dos Campos Page 12

13 Applications Requirements of the Core Materials: High Strength High Stiffness Fatigue Behavior Buckling Behavior Crash Performance Low Weight = Low Density Low Uptake of Resin Adhesion to Cover Layers Source of upper image: 08/31/2015 SAMPE Brazil Conference 2015, 22nd October, São José dos Campos Page 13

14 Medley of a few Applications with ROHACELL inside Aerospace Radome & Antennas Automotive Ship Building Wind Energy Consumer Electronics Medical Sports Source of images: The Use of PMI Foams for Sandwich Applications in the Aerospace Industry, 2 nd BCCM, Sao Jose dos Campos, Brazil, 17 th of September 2014 SAMPE Brazil Conference 2015, 22nd October, São José dos Campos Page 14

15 1. Sandwich Cores Requirements and Overview 2. Manufacturing Process of PMI Rigid Foams 3. Advantages of PMI In-Mold Foaming (IMF) SAMPE Brazil Conference 2015, 22nd October, São José dos Campos Seite 15

16 Conventional Production of ROHACELL 2. Co-Polymer Sheet SAMPE Brazil Conference 2015, 22nd October, São José dos Campos 1. Liquid Monomer Solution Page 16

17 Conventional Production of ROHACELL 4. Cut-to-Size Foam Sheets 3. Raw Foam Block 2. Co-Polymer Sheet SAMPE Brazil Conference 2015, 22nd October, São José dos Campos 1. Liquid Monomer Solution Page 17

18 Conventional Production of ROHACELL 6. Sandwich structure Customer 5. Net-Shaped cores 4. Cut-to-Size Foam Sheets 3. Raw Foam Block 2. Co-Polymer Sheet SAMPE Brazil Conference 2015, 22nd October, São José dos Campos 1. Liquid Monomer Solution Page 18

19 Production of ROHACELL Triple F 2. Co-Polymer Sheet SAMPE Brazil Conference 2015, 22nd October, São José dos Campos 1. Liquid Monomer Solution Page 19

20 Production of ROHACELL Triple F 3. Co-Polymer Granules 2. Co-Polymer Sheet SAMPE Brazil Conference 2015, 22nd October, São José dos Campos 1. Liquid Monomer Solution Page 20

21 Production of ROHACELL Triple F 4. Pre-foamed beads 3. Co-Polymer Granules 2. Co-Polymer Sheet SAMPE Brazil Conference 2015, 22nd October, São José dos Campos 1. Liquid Monomer Solution Page 21

22 Production of ROHACELL Triple F 4. Pre-foamed beads 3. Co-Polymer Granules 5. IMF Complex Core SAMPE Brazil Conference 2015, 22nd October, São José dos Campos 2. Co-Polymer Sheet 1. Liquid Monomer Solution Page 22

23 Overview ROHACELL Triple F Standard production of ROHACELL foam sheets The newest product ROHACELL Triple F core Granules Beads Filling the mold Foaming ( C) Cooling & Demolding Ready-to-use cores SAMPE Brazil Conference 2015, 22nd October, São José dos Campos Page 23

24 1. Sandwich Cores Requirements and Overview 2. Manufacturing Process of PMI Rigid Foams 3. Advantages of PMI In-Mold Foaming (IMF) SAMPE Brazil Conference 2015, 22nd October, São José dos Campos Seite 24

25 Mechanical/Thermal Properties of PMI foam compared to other polymer foams SAMPE Brazil Conference 2015, 22nd October, São José dos Campos Page 25

26 Mechanical Properties of conventional PMI foam compared to TripleF SAMPE Brazil Conference 2015, 22nd October, São José dos Campos Page 26

27 Properties of In-Mold Foamed Cores Thermal properties as good as convential PMI material Mechanical properties slightly lower slight increased density Able to withstand fast processes because of high temperature and compressive creep resistance No open pores less resin up-take, less adhesion but lower weight and class A surface Design: High degree of freedom SAMPE Brazil Conference 2015, 22 nd October 2015, Sao Jose dos Campos, Brazil

28 Advantages of In-Mold Foaming Why foaming in a closed Mold? Get a final shaped Foam Cores with less production steps and less material consumption but way faster Create Complex Shapes in one step technology Utilize high degree of integration to eliminate further assembly steps Minimize Waste More for Less: Save Time & Money Meet Requests for High Volume Applications SAMPE Brazil Conference 2015, 22 nd October 2015, Sao Jose dos Campos, Brazil Slide 28

29 Glass Transition Temp. [ C] Improve your process with ROHACELL Triple F core 250 Use the full temperature performance of the resin The T g of ROHACELL Triple F (~200 C) is significantly higher than the T g of all common used resins ROHACELL Triple F X A Density [kg/m³] SAMPE Brazil Conference 2015, 22nd October, São José dos Campos Page 29

30 Comp. Strength [N/mm²] Glass Transition Temp. [ C] Improve your process with ROHACELL Triple F core 250 Use the full temperature performance of the resin The T g of ROHACELL Triple F (~200 C) is significantly higher than the T g of all common used resins ROHACELL Triple F X A Density [kg/m³] 4 A strong, but extremely lightweight core. 3 Depending on the part / process requirements, cores can be produced in a customized density range between kg/m³ or more 2 1 ROHACELL Triple F X A Density [kg/m³] SAMPE Brazil Conference 2015, 22nd October, São José dos Campos Page 30

31 Comp. Strength [N/mm²] Glass Transition Temp. [ C] Improve your process with ROHACELL Triple F core 250 Use the full temperature performance of the resin The T g of ROHACELL Triple F (~200 C) is significantly higher than the T g of all commonly used resins ROHACELL Triple F X A Density [kg/m³] 4 A strong, but extremely lightweight core. 3 Depending on the part / process requirements, cores can be produced in a customized density range between kg/m³ or more 2 1 ROHACELL Triple F X A Density [kg/m³] Speed up the curing process. ROHACELL Triple F can be processed up to 140 C and up to 6 MPa SAMPE Brazil Conference 2015, 22nd October, São José dos Campos

32 Create geometrically complex parts with very tight tolerances - No need for evacuation due outgassing - High Surface Finishing due fine cell structure (no potting and sanding is required) and no outgassing - Helps to reduce manufacturing costs related to time, materials and processing - The core is directly foamed in a mold and complex geometries can be produced Tight tolerances - Inserts can be easily integrated into the part during the core foaming process - No outgassing due to residual chemical reactions that can restrict adhesion of layers ROHACELL Triple F cores are ready to use. Integrated inserts SAMPE Brazil Conference 2015, 22nd October, São José dos Campos Page 32

33 Conclusion Processes need to be faster Materials need to be faster Sandwich Technology is not cost effective for Large Scale Production Time Efficient Process Cost Efficient Process Sandwich Technology is one of the best Design Concepts to achieve Weight Reduction High Quality Lightweight In-Mold Foamed PMI Triple F is a great opportunity to meet these conditions SAMPE Brazil Conference 2015, 22nd October, São José dos Campos Page 33

34 Thank You! Integrate a bit of Magic A kind of Magic for complex automotive part design!!! It s not Rocket Science ask our Experts!!! Page 34

35 Slide 35

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