Production Process of Non Crimp Fabrics [NCF] for aviation applications. Composites without borders Moskau Rainer Seuß
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1 Production Process of Non Crimp Fabrics [NCF] for aviation applications Composites without borders Moskau Rainer Seuß
2 Content Company profile Multiaxial structures Spreading technology MAX 5 technology Application 2
3 KARL MAYER Group KARL MAYER GB, Shepshed KARL MAYER, Obertshausen KARL MAYER MALIMO, Chemnitz LIBA Textilmaschinenfabrik, Naila NIPPON MAYER Japan, Fukui KARL MAYER Nord Amerika, USA, Greensboro KARL MAYER Schweiz, Uzwil Verkauf, Service, Produktion Verkauf, Service Service Produktion (ab 2014 in Indien) KARL MAYER ROTAL Italien, Mezzolombardo KARL MAYER Indien, Mumbai 3 Ca employees KARL MAYER Hongkong KARL MAYER China, Changzhou
4 Company Profile 1945 Foundation of LIBA Maschinenfabrik 1948 production of first tricot machine 1983 start development multixial technology 2014 Acquisition by Fa. KARL MAYER 2014 Foundation of KARL MAYER subsidiary KARL MAYER LIBA Textilmaschinenfabrik GmbH NAILA Located in Naila, Germany 330 employees in Naila 50 employees in R&D 4
5 Milestones 1983 Start multiaxial technology development 2004 Start spread technology development 2007 Product launch Offline spreading machine UD Product launch MAX Product launch MAX Product launch MAX Product launch MAX 5 automotive 5
6 Competence More than 30 years experience with multiaxial technology More than 25 years experience of processing carbon, glass and aramid fabric More than 10 years experience in spreading of high performance fibers e.g. carbon fibers, class fibers More than 15 years experience as a development partner in automotive, aerospace and wind energy industries Over 200 multiaxial machines installed worldwide 6
7 Competence Woven fabric NCF Spread tapes Braiding Etc. Produced on Karl Mayer LIBA machines Carbon fiber Textile reinforcement Preforming/ Tayloring Structural part Fiber reinforced composites : process chain
8 Multiaxial fabric Multiaxial fabric consists of one or more layers of differently aligned held in place by a stitching yarn 8
9 Multiaxial fabric Why multiaxial fabrics??? Multiaxial fabric Yarns remain straight, no crimp Direct linear utilization of fiber strength Different angles / more then two angle directions in one fabric possible Combination with additional material due to the in-line process Woven fabric Yarns bend over each other (= web crimp) Indirect utilization of fiber strength Only 0 /90 directions possible 9
10 Production of multiaxial structures Endless weft insertion [MAX 4] processing of rovings Finite weft insertion [MAX 5] processing of tapes One weft insertion system for each angle position 10
11 Production of of multiaxial structures structures Process flow 11
12 Production of multiaxial structures Weft insertion 12
13 Production of multiaxial structures Tape quality inspection system Inspection system for monitoring the tape structure regarding tape width an detecting defects in the tape like gaps. 13
14 Production of multiaxial structures Insertion additional material Let off system Non woven structures Core material Grid structures Weft insertion for thin yarns Glass yarn 34 tex and 68 tex Bottom ply for wide 0 plies Insertion of thermoset yarn / hotmelt yarn 14
15 Production of multiaxial structures Walking needle system Minimum load and tension = reduced wear on the needle system Reduced stitch holes = improved fabric quality Reduced friction = high production speed 16
16 Production of multiaxial structures Vario stitch tailored patterning tailored stitchlength 17
17 variable Production of multiaxial structures Vario stitch variable 18
18 Production of multiaxial structures Coating and batching Powder scattering system with infrared heating zone 19
19 Production of multiaxial structures Results new opportunities Vario stitch Tailored Vario stitch Multiaxial fabric with core material 20 Multiaxial fabric with thermoplastic ply
20 Production of multiaxial structures Results new opportunities 21 Quasi organic tension curves
21 Production of multiaxial structures Summarize main topics Modular machine concept Available working width 50 / 101 / 130 Processing of finite Tape structures Weft insertion for pre spread tape structures 14 wide Weft insertion for online spread tape structures 12 wide Processing angle direction up to 20, standard execution +/- 45 and 90 For each ply one individual weft insetion system necessary Feeding of 0 ply, arranged between weft insertion station or close to the stitching area Clamping system to keep the tape structures in the right alignment Production up to 180 m/h by using 14 wide tapes Variable patterning in production direction and also transversal to that Connecting the laid plies by warp knitting technology Drapility is adjustable by using the vario stitch technology Apply powder to the multiaxial fabric for preforming pupose 22
22 Production of spread tape structures Why spreading carbon fiber tows??? not spread (regular) carbon fiber tow spread carbon fiber tow spreading Carbon fiber tows are available in different sizes (size unit: 1K = thousand filaments in tow s cross-section) Low K tows (1K to 6K): High K tows (12K to 50K): - better impregnation - expensive - worse impregnation - low priced Spreading = Manufacturing of low areal weight unidirectional tapes from low priced carbon tows (>=12K) 24
23 Production of spread tape structures Offline spreading machine Online spreading system 25
24 Production of spread tape structures Process flow 26
25 Production of spread tape structures Offline spreading machine Tangential draw off Spreading zone Omega roller system Batching spread tape 27
26 Production of spread tape structures Online spreading system Direct feeding of spread tapes 29
27 v [m/min] Production of spread tape structures Online spreading system 50,00 40,00 Speed of online creel Speed of gripper Spreading speed 30,00 20,00 10,00 0,00-10,00-20,00 laying cycle Compensation of non-linear weft insertion speed by controlled creel motion 30
28 Production of spread tape structures Results Carbon fiber spread tape Carbon fiber spread tape with grid Glass fiber spread tape with grid Carbon fiber spread tape with powder 31
29 Production of spread tape structures Summarize main topics Modular machine concept Spreading of carbon fibers, glass fibers, aramid fibers Production of semifinished tape structures or also for enduser applications Different creel systems avaiable, twist free unwinding Individual spreading zones for 12K / 24K and 50K Carbon fibers Tape width 800mm or 2x 355mm (14 ) Max. production speed 25 min -1 Sectional beam for batching up to 40 Area weights from 75 gsm up to 400 gsm, depends of the fiber Spec. Adding functional materials like powder or grid structures as top and/or bottom plies Constant spreading speed for offline and online system Spreading princip by vibration, yarn deflection and heat 32
30 Applications for the industry Wind power Lightweight construction Transportation Aerospace Sports 33
31 Thank you for your attention! Nachdruck, auch auszugsweise, sowie fotomechanische Reproduktion nur mit ausdrücklicher Genehmigung der Firma KARL MAYER LIBA Textilmaschinenfabrik GmbH, Naila Oberklingensporn 1 Deutschland 35
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