Application of novel A.S.SET epoxy resin in batch manufacturing process of CFRP

Transcription

1 Faculty of Mechanical Science and Engineering / Friedrich List Faculty of Transport and Traffic Sciences Application of novel A.S.SET epoxy resin in batch manufacturing process of CFRP Werner Hufenbach, Maik Gude, Andrzej Czulak, Ryszard Pilawka*, Tomasz Gajda, Bartłomiej Przybyszewski, Herman Hilse *Instytut polimerów, Zachodniopomorski Uniwersytet Technologiczny w Szczecinie Technische Universität Dresden Institute of Lightweight Engineering and Polymer Technology Prof. Dr.-Ing. habil. Prof. E. h. Dr. h. c. W. Hufenbach Holbeinstr. 3, Dresden, Germany Tel.: +49 (0) Fax: +49 (0) ilk@ilk.mw.tu-dresden.de Web: tu-dresden.de/mw/ilk

2 What is an ASSET? Powdered epoxy resin: - Manufactured from any powdered epoxy resin. - Storage at room temperature for min. 12 month - Easy to modified (change curing temperature and time) - One component resin - 3 types of modyfications 2

3 Thermoanalysis Result of differential scanning calorimetry: melting point at 40 C (peak 48 C) curing starts at 95 C (peak 140 C) glass transition at 84 C (middle 108 C) Differential scanning calorimetry (DSC) Curing in 120 C for 32 mg optimal time is ~4 min. Differential scanning calorimetry (DSC) in 120 C 3

4 Curing temperature White resin White resin Blue resin Blue resin Storage and loss modulus Viscosity of A.S.SET Resin Viscosity and curing temperature can be modyfied and adopted to specified process conditions. 4

5 Thermoanalysis Thermal gravimetric analysis (TGA) High thermal resistant in comparision to thermoplastics. 5

6 CFRP manufacturing technology ADVANTAGES of A.S.SET resin application: simple resin preparation process (one component) short-time resin curing solid form low viscosity Resin Reinforcement Resin preparation process Reinforcement preparation process Infiltration Process (forming) Product Resin powder moulding Resin Reinforcement Resin preparation process Reinforcement preparation process organo-sheet Forming (infiltration process) Product Thermoset sheet forming 6

7 Resin powder moulding product A.S.SET powder RESIN POWDER MOULDING (RPM) - new technology developed for batch manufacturing based on hot pressing. RESIN POWDER MOULDING any reinforcement Parameters: Pressure up to 40 kpa Curing temp C Process time: 8-10 min Curing time: 4-6 min With and without vacuum 7

8 Thermoset sheet forming A.S.SET powder product THERMOSET SHEET FORMING THERMOSET SHEET FORMING (TSF) - new technology developed for batch manufacturing based hot press forming of premanufactured organo-plates. any reinforcement A.S.SET sheet Parameters: Pressure up to 40 kpa Curing temp C Process time: 8-10 min Curing time: 4-6 min With and without vacuum 8

9 RPM Technology Preparation Preparation Product Benefits: Very simple process and system technology Excellent variability in terms of resin selection Very short cycle times possible Simple storage of A.S.SET POWDER at roomtemperature. Avoids fibre displacement (advantage over infusion techniques) Excellent surface quality and low pore content of RPM components Additives ensure outstanding fire safety (DIN EN fire protection standards of railway industry can be reached) One temperature of process (no cooling) 9

10 TSF Technology Preparation Preparation Heating Product BENEFITS: Simple, energy- efficient process management Excellent mechanical and thermal properties, especially when compared with thermoplastic composites Simple storage of A.S.SET SHEET at roomtemperature. Very short cycle times Excellent variability in terms of fibre and resin selection Ease of trimming and handling (comparable to thermoplastic organic sheets) Excellent variability in terms of processing characteristics, multiple reshaping possible Excellent surface quality and low pore content of TSF components One temperature of process (no cooling) 10

11 Quality analysis of manufactured plates via TSF A TSF technology A.S.SET epoxy resin 2D-CF Vf ~ 55% 180 C/6min/6kN/vacuum(foil) B C Result: Using vacuum (foil) aggravate surface and structure quality Pressure force and form quality are critical for product quality Structure of CFRP: a) ultrasonic, c) microscopy 50x, d) microscopy 200x 11

12 Mechanical properties of manufactured plates via TSF TSF technology A.S.SET epoxy resin 2D-CF Vf ~ 55% 180 C/6min/6kN/vaccum(foil) stress in MPa Tensile test: avr. 566 MPa strain in % Linear deformation Good mechnical properties despite to manufacturing time Results of tensile test 12

13 Quality analysis of manufactured plates via RPM Results: excelent surface and structure quality no pore content higher fiber content RPM technology A.S.SET epoxy resin 2D-CF Vf ~ 60% 120 C/6min/20kN/no vaccum C A B Structure of CFRP: a) microscopy 50x, b) microscopy 200x, c) CT analysis 13

14 Mechanical properties of manufactured plates via RPM stress in MPa RPM technology A.S.SET epoxy resin 2D-CF Vf ~ 60% 120 C/6min/20kN/no vaccum strain in % Tensile test: avr. 861 MPa Linear deformation Very good mechnical properties despite to manufacturing time Simple process and technology Results of tensile test 14

15 Technologies comparision time RPM TSF A resin/reinforcement or organo-sheet preparation B forming/curing C press opening Fast RTM* A resin/reinforcement preparation - infiltration B curing C press opening *source: Felix N.Nguyen, Kenichi Yoshioka : FAST-CYCLE CFRP MANUFACTURINGTECHNOLOGIES, Toray Composites (America), Inc., Washington, USA 15

16 RPM vs TSF RESIN POWDER MOULDING THERMOSET SHEET FORMING very simple storage at room temperature for min. 12 months more complicated shapes of product possible need spraying/sieve-based dosing technology low cost of components simple storage at room temperature up to 12 months easy of trimming and handling short preparation time low cost of technology High quality product with excelent thermo-mechnical properties and low poor content manufactured in short-time process. 16

17 Thank you 17