Toho Tenax America October 19th, 2015
Advanced Composites Fundamentals
Seminar
“From Carbon Fiber to Carbon Fiber
Reinforced Thermoplastic”
Rodrigo Cesar Berardine
Sales and Marketing Manager
South America
São Paulo - Brazil
Page 1
Part 1 Carbon Fiber Material Fundamentals
• Carbon Fiber production and properties overview
• Carbon Fiber Market in Brazil
Part 2 Thermoplastic Composites Fundamentals
• Thermoplastics versus Thermosets
• Importance of sizings for Thermoplastics
• Thermoplastic UniDirectional Tapes (TPUD)
• Thermoplastic Woven Fabrics (TPWF)
• Thermoplastic Consolidated Laminates (TPCL)
• Commingled Yarn Technology
Content
Page 2
PART 1 – CARBON FIBER MATERIAL FUNDAMENTALS
Page 3
Solvent Acrylonitrile
(Monomer)
Polymerization
Filtration
SPINNING
Washing Surface Treatment Drying Stretching Packing
Precursor (PAN) Production Process
Page 4
Stretching Oxidation Carbonization Surface Treatment Winding
LT HT
LT
Carbon Fiber Production Process
Complex chemical plant: nitrogen, energy, toxic exhaust fumes
Substantial plant size 200m length, 18m height
Three shift, 24 hours production process on 360 day/year
2kgs of PAN for 1kg of carbon fiber
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Tenax carbon fiber production line
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Reinforcement Products
IMS65
HTS40
S-Glass
E-Glass
Aramid
Steel
Standard
Modulus
IMS40
HMA35
IMS60
UMS40 UMS45
UMS55
Tenax® Carbon Fibers
Glass Fiber
Aramid Fiber
Steel
Tensile Modulus (GPa)
HTR40
UTS50
High
Modulus
Ultra High
Modulus
Intermediate
Modulus
Ten
sile
Str
en
gth
(M
Pa
)
690
1380
2070
2760
3450
0
4140
4830
5520
6210
69 138 207 276 345 414 483 552
Blue – Aerospace Grade
Red – Industrial Grade
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Continuous Filaments
Chopped Fiber
Milled Fiber
Carbon Fiber Supply Forms
Page 9
SHORT FIBERS
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PERFORMANCE OF METAL COATED
CARBON FIBER
Page 11
PERFORMANCE OF METAL COATED
CARBON FIBER
Page 12
PERFORMANCE OF METAL COATED
CARBON FIBER
Page 13
CARBON FIBER MARKET IN BRAZIL
Carbon Fiber Market in Brazil
Last 4-years Outlook
• GE48.5m Wind Blade Production brought strong demand from 2012 until 2014
• Market Decrease in 2015 – GE blade out of production effect
Carbon Fiber Market in Brazil
Next 5-years Forecast
2011
2012
2013
2014
2015
2016
2017
2018
2019
2020
Tons Millions of US$
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PART 1 CONCLUSIONS
• Variety of carbon fiber grades and supply forms enable versatile
composite design;
• New generation of Carbon Fibers bring multi-functional characteristics –
not just mechanical performance but also lightning strike performance;
• Carbon Fiber market in Brazil under development / expansion –
strong emphasis in Oil&Gas, Wind Energy and Aerospace
PART 2 – THERMOPLASTICS
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Thermoplastics versus Thermosets
Page 18
*more difficult
THERMOPLASTIC RESINS
PERFORMANCE PYRAMID
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Source: http://wiki.zero-emissions.at/index.php?title=Information_about_the_chemical_industry
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IMPORTANCE OF CARBON FIBER SIZINGS FOR
THERMOPLASTICS
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Thermoplastic Unidiretional tapes comparison
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SEM Pictures
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Page 25
Tenax® TPUD: Part making
TPUD
Hand Lay-up + Local welding
(HLY)
Automated Tape Laying
(ATL)
Automated Fibre Placement
(AFP)
Vacuum bagging
Oven
Autoclave
Static Press
5-30 min
(consolidation time) Without debulking
(time saving vs. TS)
Similar to Thermoset Prepreg
Lay-up Consolidation
using heat & pressure
Filament Winding
(FW)
(semi)-Continuous
Press Forming (CPF)
Page 26
Tenax® TPUD
1mm
TPUD PEEK-HTS40 laminate
out of 8 plies (+/- 45°)
136 µm
Tenax®-E TPUD PEEK-HTS40
TPUD PEEK-HTS40
Press consolidated laminate
• Press and vacuum consolidation possible
• Low sensitivity of cristallinity to cooling rate 35 +/- 3 %
• Low void content in TPUD and Laminate < 2 %
TPUD Mechanical Properties
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TPUD Mechanical Properties
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Thermoplastic Woven Fabric
Page 30
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TPCL: Part Making
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TPCL Part Making
Page 33
Page 34
TPCL Technical Characteristics
Glass Fabric surface ply for Corrosion Protection
Page 35
Bronze Mesh for LSP
Page 36
TPCL: Mechanical Properties
Page 37
Page 38
Thermoplastic Consolidated Laminates
Page 39
Thermoplastic Consolidated Laminates
Page 40
Thermoplastic Consolidated Laminates
Page 41
Technology Readiness Level
Page 42
COMMINGLED YARN TECHNOLOGY
Page 43
COMMINGLED YARN TECHNOLOGY
Page 44
Source: Concordia Fibers
COMMINGLED YARN TECHNOLOGY
Page 45
Source: Concordia Fibers
COMMINGLED YARN APPLICATIONS
Page 46
Carbon / Nylon 6
Racket Frame
Source: Concordia Fibers
COMMINGLED YARN APPLICATIONS
Page 47
Carbon / PEEK
YF-22 Structural Parts
Source: Concordia Fibers
COMMINGLED YARN – SEM PICTURES
Page 48
CARBON / NYLON BRAID CARBON / PPS BRAID
Source: Concordia Fibers
COMMINGLED YARN – SEM PICTURES
Page 49
CARBON / PEEK FABRIC
Source: Concordia Fibers
Page 50
PART 2 CONCLUSIONS
• Thermoplastic composites market growth driven by short cycle processing,
recycling and logistics advantages.
• New sizing technologies for Carbon Fibers allow excellent fiber/resin
bonding
• Excellent impact and fracture toughness properties
• Processing temperatures and high viscosity are challenges
Page 51
Rodrigo Cesar Berardine
Sales and Marketing Manager
+55 11 5070-3862
+55 11 98706-1766