toho tenax america...toho tenax america october 19th, 2015 advanced composites fundamentals seminar...
TRANSCRIPT
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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
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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
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PART 1 – CARBON FIBER MATERIAL FUNDAMENTALS
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Solvent Acrylonitrile
(Monomer)
Polymerization
Filtration
SPINNING
Washing Surface Treatment Drying Stretching Packing
Precursor (PAN) Production Process
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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
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SHORT FIBERS
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PERFORMANCE OF METAL COATED
CARBON FIBER
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PERFORMANCE OF METAL COATED
CARBON FIBER
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PERFORMANCE OF METAL COATED
CARBON FIBER
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CARBON FIBER MARKET IN BRAZIL
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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
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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
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PART 2 – THERMOPLASTICS
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Thermoplastics versus Thermosets
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*more difficult
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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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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)
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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 %
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TPUD Mechanical Properties
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TPUD Mechanical Properties
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Thermoplastic Woven Fabric
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TPCL: Part Making
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TPCL Part Making
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TPCL Technical Characteristics
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Glass Fabric surface ply for Corrosion Protection
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Bronze Mesh for LSP
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TPCL: Mechanical Properties
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Thermoplastic Consolidated Laminates
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Thermoplastic Consolidated Laminates
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Thermoplastic Consolidated Laminates
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Technology Readiness Level
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COMMINGLED YARN TECHNOLOGY
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COMMINGLED YARN TECHNOLOGY
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Source: Concordia Fibers
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COMMINGLED YARN TECHNOLOGY
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Source: Concordia Fibers
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COMMINGLED YARN APPLICATIONS
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Carbon / Nylon 6
Racket Frame
Source: Concordia Fibers
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COMMINGLED YARN APPLICATIONS
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Carbon / PEEK
YF-22 Structural Parts
Source: Concordia Fibers
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COMMINGLED YARN – SEM PICTURES
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CARBON / NYLON BRAID CARBON / PPS BRAID
Source: Concordia Fibers
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COMMINGLED YARN – SEM PICTURES
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CARBON / PEEK FABRIC
Source: Concordia Fibers
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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
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Rodrigo Cesar Berardine
Sales and Marketing Manager
+55 11 5070-3862
+55 11 98706-1766