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Thermoplastic Composites and Processes

Klaus F. Gleich Senior Research Associate, Johns Manville Technical Center


www.acmashow.org www.acmashow.or g

February 21-23, 2012 Mandalay Bay Convention Center, Las Vegas, NV

Overview

Introduction into Thermoplastic Fiber Composites Semi-Finished Materials Manufacturing Processes

Economics
Applications

Introduction

Why Use Composite Materials ?


Specfic Tensile Properties of Polymer Matrix Composites
4.5

3.5

Continuous Unidirectional Carbon Composites

Specific Modulus (x10 8 in.)

2.5

Glass & Carbon LFT & Continuous Other Fibers Varying Fiber Orientations

1.5

LFT Carbon Composites

Metals
LFT Glass Composites Continuous Uni-directional Glass Composites

0.5

Plastics
0 0

Specific Strength (x106 in.)

One Reason For Using Composites

Charlestown Bridge Boston


5

Thermoplastic Composites
Benefits Unique properties Vibration dampening Light weight Potential for low cost Shelf life Recyclable Durability
Fatigue Corrosion Toughness

Limitations Cost
Materials Manufacturing Tooling

Design know-how Manufacturing knowhow Use temperature

Thermoplastic Composites
Thermoplastic composites can be tailored to meet the required properties. Many Polymer Options
Polyethylenes Polypropylenes Nylons Polycarbonates Acrylics Polyesters Polyimides Polysulfones Polyketones Polyurethanes the list continues

Fiber Options
Glass Fiber Carbon Fiber Natural Fiber Polymer Fiber Stainless Steel Fiber

Many Property Options


ultimate strain > 100% no micro cracking no delamination dampening no water uptake low dielectric properties melt formable weldable elastomeric - plastic - elastic behavior the list continues

Basic Properties of Fibers and other Engineering Materials


Material Type Tensile Strenght Tensile Modulus Typical Density Specific Modulus

(MPa)
Carbon HS Carbon IM Carbon HM Carbon UHM Aramid LM Aramid HM Aramid UHM Glass - E glass Glass - S2 glass 3500 5300 3500 2000 3600 3100 3400 2400 3450

(GPa)
160 - 270 270 - 325 325 - 440 440+ 60 120 180 69 86

(g/cm3)
1.8 1.8 1.8 2 1.45 1.45 1.47 2.5 2.5

(GPa)
90 - 150 150 - 180 180 - 240 200+ 40 80 120 27 34

Glass - quartz
Aluminum Alloy (7020) Titanium Mild Steel (55 Grade) Stainless Steel (A5-80) HS Steel (17/4 H900)

3700
400 950 450 800 1241

69
69 110 205 196 197

2.2
2.7 4.5 7.8 7.8 7.8

31
26 24 26 25 25

Source: www.netcomposites.com
8

Thermoplastic Composites Importance of Fiber Length


Models predict that over 90% strength of continuous fiber composite is achieved when fiber aspect ratio approaches 2000 This correlates to glass fiber lengths of ~1.3 and carbon fiber Lengths of ~0.6
9

Composite Performance versus Fiber Length for PP/Glass


1.2 1.0

Fillers

Short Fiber

Long Fiber Continuous

Relative Property Level

0.8 0.6 0.4 0.2 0.0 0.1 1 Length (mm) 10 100


Source: OCF

Modulus Strength Impact Processibility

Impact and Fiber Length

Source: Ticona

Key Factors
Fiber length Fiber dispersion Fiber impregnation processing conditions and technique

The Long Fiber Advantage


Stress is transferred to the fibers - the structural members of the composite Long fibers create a skeletal structure within the molded article that resist distortion and provide unmatched strength, toughness, and overall performance
Source: Ticona
1

High-Performance Thermoplastic Composites


Properties are fiber dominated Oriented long or continuous fiber reinforcement High volume fiber fraction (up to 65% by volume) Key benefits:
Reducing thermal limitations (e.g. creep) caused by the TP matrix system Reducing costs and weight and retaining toughness, formability, weldability, short cycle times, recycling are benefits of the thermoplastic matrix

Continuous Fiber Advantage

In continuous oriented fibers the load is ultimately fully transferred to the fiber As a result tensile creep is limited in fiber direction

History Of Low Cost Thermoplastic Composites

VW Passat front end carrier First front end in D-LFT

D-LFT Inj. Mold.

D-LFT chopped fiber Compr. Mold. (CPI) VW Golf A4 front end carrier First front end in GMT LFT/Ticona Compression Molding

D-LFT Compr. Mold. LFT concentrates Twintex / Vetrotex

Azdel Superlite

GMT/Azdel

LFT /LNP Inj. Mold

1972

1980 1

1990

2000

Year

Economics

House Of Production

Successful Part Production

Internal / External Knowledge

Design

Part Requirements / Specification / VOC

Selection of the Manufacturing Process

Material Selection

House Of Production - Often Seen

Semi-Finished Materials

Commercial Semi-Finished Materials


GMT (Glass Mat Reinforced Thermoplastics)
Needled mat Extrusion process Slurry process (e.g. Azdel SuperLite)

Pultruded Products
LFT (Long Fiber Reinforced Thermoplastics) CFT (Continuous Fiber Reinforced Thermoplastics)

Wire coated products Commingled fibers Powder coated materials Film stacking Self-reinforced materials

GMT Needling of the Mat

Source: Symalit (Quadrant Plastics Composites)


2

GMT The Consolidation Process

Source: Symalit (Quadrant Plastics Composites)


2

Slurry Based Process The AZDEL SuperLite as an Example

Source: AZDEL
2

Short Fiber, Long Fiber and Continuous Fiber Composites

Typical short fiber thermoplastic material, granules with fiber length of approx. 2 to 4 mm, resulting fiber length in a part of approx. 0.4 mm

Long fiber thermoplastic material, pellets of and 1 fiber length, resulting fiber length in a part of approx. 4-6 mm in injection molding and approx. 20 mm in compression molding
2

Continuous reinforced thermoplastic material, tape used for woven sheets (thermoforming), filament winding or pultrusion

The Pultrusion Process

70% i s r P ocess Technol ogy 30% i s Pr oduct Com posi t i on


Cleaning Finishing Packaging
Glass

Block

Cooling

Haul-off/ Puller

Pelletizer

Courtesy of GEN

Typical Pultruded Prepregs


Fiber:
E-glass, S-glass, Carbon, Aramid, polymer fibers, metal fibers

Matrix:
PE, PP, PA (6, 6/66, 12, ), PET, PBT, PC, PEI, PPS, SMA, blends,

Fiber content:
20% - 60% standard, some up to 84%

Product forms:
Tape, pellets (0.5, 1), woven tapes more complex textile structures in development

Typical Use of GMT and LFT Today


Processes GMT compression molding LFT-pellet approach Direct LFT approach LFT mainly used in compression molding and injection molding Applications Semi-structural and non-structural applications

Twintex - Commingled Fiber Products


Extruder

TP

Glass

E Glass adapted sizing

Commingling Roving
Source: Vetrotex

Plastic filament Additives : - coupling agent - UV stabilizer - natural or black

Twintex Prepreg Temperature + Pressure


Source for all pictures: Vetrotex (OCV)
Source: Vetrotex

Twintex - Commingled Fiber Products

Today OCV and Fiber Glass Industries (license from OCV) Fiber/matrix combinations: E-glass/PP, E-glass/PET Fiber content: 53 % and 70 % by weight Product forms: Roving, fabric (1:1, 4:1), consolidated fabric, pellets

Specfic Tensile Properties of Polymer Matrix Composites


4.5

Continuous Uni-directional Carbon Composites

3.5

2.5

Twintex
LFT Carbon Composites Metals Twintex LFT Glass Composites Plastics

Glass & Carbon LFT & Continuous Other Fibers Varying Fiber Orientations

1.5

Continuous Uni-directional Glass Composites

0.5

0 0 1 2 3 4 5 6

Limitations: Matrix material must be usable for a fiber spinning process limitations in MFI/viscosity, additive type and additive content

Powder Impregnated Prepregs The Hexcel TowFlex-Technology

Fiber Creel Racks

Fluidized Bed Powder Coating Chamber

IR Oven

Puller

Take-up System To Weaving To Tapes To Pellets

Charged Resin Powder


Source: Hexcel

Hexcel TowFlex
Specfic Tensile Properties of Polymer Matrix Composites
4.5

Typical fibers:
Specific Modulus (x10 8 in.)

TowFlex
Glass Carbon
Glass & Carbon LFT & Continuous Other Fibers ` Varying Fiber Orientations

Carbon, E-glass, Sglass

3.5

Continuous Unidirectional Carbon Composites

2.5

Carbon Towflex

Typical resins:
PP, PA6, PPS, PEI, PEEK

1.5

LFT Carbon Composites Metals

Glass Towflex
LFT Glass Composites

Continuous Uni-directional Glass Composites

0.5

Plastics

Typical product forms:


Flexible Towpreg Woven fabric Braided Sleeving Unidirectional Tape

0 0 1 2 3
Specific Strength (x10 in.)
6

Film Stacking
Layers of fibers and thermoplastic film materials are placed above each other and consolidated in a double belt press with a heating and cooling zone (similar to the GMT process) Glass, carbon, aramid fibers and combinations are typically used Most of thermoplastic resins available Impregnation/wet out sometimes tricky Typically used as a semi-finshed material for thermoforming
3

Curv
Self-reinforced polypropylene Consists of hot compacted polypropylene fiber or tape
Surface of tape or fiber melts during compaction to form the matrix that binds the directional elements together

Oriented morphology provides over six-fold increase in tensile strength and nearly 5-fold increase in tensile modulus over isotropic polypropylene, with ~2% weight penalty Nearly doubles tensile strength of 40% random mat short glass polypropylene, with comparable modulus and 22% weight savings Elimination of glass reinforcement has several advantages:
Increased recyclability Reduced weight Lower temperatures and pressures for thermoforming High strain to failure, with good impact strength
3

Data from A New Self-Reinforced Polypropylene Composite Jones, Renita S. and Derek E. Riley

Manufacturing Processes

Manufacturing Processes for TP-Composites

Low volume manufacturing processes


Discontinuous processes
Thermoforming Thermoplastic S-RIM, RTM and VARTM Thermoplastic filament winding Vacuum bag molding

Manufacturing Processes for TP-Composites


High volume manufacturing processes
Discontinuous processes
Injection molding with
LFT-pellets and concentrates (high performance resin/fiber combinations) Inline compounding (high performance resin/fiber combinations) Back molding / local reinforcement

Compression molding
LFT-pellets and concentrates (high performance resin/fiber combinations) Inline compounding (high performance resin/fiber combinations) Back molding / local reinforcement

Stamp forming
Preheated preforms Matched metal tools Potential to manufacture very thin sections (0.5 to 1 mm) Drapable material required

Continuous processes
Pultrusion LFT-extrusion
3

Current Composite Materials and Processes


Process Type of Application

Injection Molding

Low-Structural Components

Compression Molding Semi-Structural Components Thermoforming

Hand Lay Up / Vacuum Bag / Autoclave


3

Structural Components

Low Volume Manufacturing Processes

Thermoforming

Heat in Oven

Thermoforming Operation

Finished Product

Thermoforming
Weight performance:
Good weight/performance ratio for fabric reinforced sheets due to continuous fibers Reduced weight/performance ratio for extruded sheets depending on the resulting fiber length

Design flexibility:
Limited, especially for complex geometries Simulation tools available

Processing:
Stabilization against oxidation necessary Fiber misalignments with continuous fibers possible depending on geometry, material, tooling and process conditions

Recycling:
High rate of production scrap (fixation) No direct recycling Use in other processes like plastication or regranulation
4

VARTM / RTM / S-RIM


Process VARTM 1 bar RTM 5 bar S-RIM 50 bar

Typical Injection Pressure Tooling

Single sided tool Double sided tool Double sided steel tool Mixing vessel Pressure vessel, most cases no mixing heat 40 % Separate tanks for each component, mixing head 55%

Injection Unit

Typical Achievable Fiber Volume Content

40%

Reactive Thermoplastic VARTM/RTM/S-RIM


Similar the thermoset process Reaction of at least two components creates a thermoplastic resin that can be melted, preshaped, welded, Low viscosity is required Possible materials: Nylon, TPU, C-PBT (Cyclics)

Process Technology Of The Anionic Polymerization Of Caprolactam


Explanations Flowchart

1. 2.

Storage vessel for caprolactam Reactor for caprolactam with activator Reactor for caprolactam with catalyst Mixing head Mold, heated Flexible tube Mixing head, valve

3.

4. 5. 6. 7.

Source: Brueggemann Chemical U.S., Inc.

TP S-RIM, RTM, VARTM


Weight/performance:
Excellent

Design flexibility:
Limited to preforming capability, flow length and flow behavior of the resin

Processing:
Reaction can be sensitive to moisture and fiber sizing

Recycling:
Production scrap due to preforming step depending on preforming method No direct recycling; can be used in other processes

Materials Used For Liquid Molding Processes


Materials used for liquid molding processes
Cyclics Reactive Nylon Fulcrum

Requirement for these materials


Viscosity less than 3000 mPa.s (cP) (better less than 1000 mPa.s (cP)) Viscosity influences achievable fiber content
4

Cyclics
Cyclic form of PBT, PET, PC and others Only PBT commercial available Based on a ring shaped cyclical form One or two part systems Solid at room temperature low viscosity resin at elevated temperature (approx. 150 cP) Polymerize into the Polymer using a catalyst Isothermal process Typical process temperature: 180 200 oC

Cast Polyamide 6 vs. Polyamide 6


There are differences between Cast Polyamide 6 and Polyamide 6 chips. Production: Use of simple inexpensive molds possible High part weights with various thickness Efficient for low quantities

Material:

Improved mechanical properties Better wear resistance Better crystalline structure, higher crystallinity
Source: Brueggemann Chemical U.S., Inc.
4

Basic Principles Of Nylon Casting Raw Materials


-Caprolactam: AP-Quality (Anionic Polymerization) water content < 200ppm

Catalyst:

Sodium-Caprolactam used in concentration of app. 1.2- 3.0%

Activator:

Caprolactam blocked isocyanate or similar used in concentration of app. 1.0-2.5%

Cast Polyamide 6 vs. Injection Molded Polyamide 6


Examples of mechanical properties
70 60 50
N/mm
N/mm

TENSILE STRENGTH
4000

MODULUS OF ELASTICITY

3000

40 30 20 10 0
Nylon 6 Cast Nylon 6

2000

1000

0
Nylon 6 Cast Nylon 6

Source: Brueggemann Chemical U.S., Inc.


4

Fulcrum
ISOPLAST matrix (Dow proprietary engineering thermoplastic polyurethane)
Thermoplastic viscosity issues addressed by ability to reverse polymerization in the melt stage, reducing viscosity to ensure good impregnation Repolymerizes upon cooling, retaining traditional thermoplastic composite advantages
High impact resistance Recycling High elongation to failure (~2.5%, versus ~1-1.5% for thermosets) Zero-emissions processing

Fulcrum is the combination of ISOPLAST and pultrusion, with specific hardware design Provides 10-fold line speed improvement over typical thermoset pultrusion lines Allows thermoforming, welding, and overmolding of finished pieces

Thermoformed Fulcrum Components

Figures from Fulcrum Thermoplastic Technology; Making High-Performance 5 Composite via Thermoplastic Pultrusion Dow Plastics, J anuary 2000

Problems Connected With Reactive Thermoplastic Molding


Reaction can be stopped or made incomplete by
Moisture Chemicals in fiber sizing
Most of the thermoplastic compatible sizings are not developed for such type of processes Availability of compatible sizings in form of fabric is very limited

Oxygen
5

TP Filament Winding
Typically done with pre-impregnated fibers Weight/performance:
Excellent

Design flexibility:
Limited to symmetric parts that can be wound on a mandrel

Processing:
Higher oxidative stabilization required

Recycling:
Low rate of production scrap No direct recycling Scrap can be used in other processes
5

Vacuum Bag
Weight/performance
Excellent due to continuous fiber reinforcement

Design flexibility
Limited to drapability and to the possibility of manually lay up

Processing
Higher void content due to low pressure consolidation Using autoclave to reduce void content Often fiber dealignments

Recycling
High rate of production scrap possible depending on the size of the material sheets and the part geometry No direct recycling Scrap can be reused in other processes

High Volume Manufacturing Processes

Extrusion /Compression Molding

Shot exiting extruder / plasticator

Molded part
Tool in press

Shot placed on tool


5

Manufacturing Processes Using LFT-Pellets


Injection Molding
Injection and injection compression molding Low pressure molding

Compression Molding
Plasticator Continuous extrusion
Flying knife and belt plunger
Source: C.A. Lawton
5

Problematic General Purpose Screw

Source: Krauss-Maffei

Compression Molding of Thermoplastic Composites


GMT
manufacturing of mats (manufacturing of PP-film) extrusion of matrix and consolidation using a double belt press

LFT
pultrusion of the semi-finished product

ILC

Semi-finished Material

(cutting of the GMT-sheets)

Part production

heating in GMT-oven material handling compression molding

plastication material handling compression molding

in-line compounding material handling compression molding

Resulting Fiber Length in a Part

Inline-Compounding
Processes using chopped fibers only
CPI Binani JCI (slurry process (Fibrolen, plastication process)

Processes using rovings (most of them capable for chopped fibers)


Compression Molding
Berstorff Coperion Dieffenbacher Lawton LMG PlastiComp

Injection Molding
Husky Krauss Maffei PlastiComp

Process Technologies For LFT


Compression (GMT) little fiber damage small fiber orientation high impact strength LFT-D IMC
Fiber length in the part

GMT
LFT-D

LFT-G/P

LFT-G/P

Compression (LFT-D, LFT-G/P) reduced cost for intermediate product thin wall thickness possible variability of fiber content Injection Molding reliable and stable process technology good surface quality variability of fiber content no finishing work necessary

Compression

Injection Molding

Source: Krauss Maffei


6

ILC Injection Molding

Pictures: KraussMaffei

Proprietary Compounding System


Overhead View

***All materials are gravimetrically fed for precise content***

The Dieffenbacher-System

Picture: Rieter
6

The Dieffenbacher System

Source: Dieffenbacher
6

The Coperion System

1 Polymer pellets 2 Gravimetric feeder 3 Rovings 4 Motor and gearbox

5 Twin-screw compounder ZSK 6 Devolatilizing 7 Cutting unit

8 Separating unit 9 Robot 10 Press

Source: Coperion
6

The Berstorff System

Source: Berstorff
6

The Lawton System


Conveyers

Control Panel Flat Sheet Die

Roving System Reciprocating Screw Plasticator Four-Component Gravimetric Feeder

Single Component Gravimetric Controlled Vibrational Feeder

Twin Screw PrePlasticator

Vibratory Track

Vacuum Feeder from Octabin

Source: Lawton
6

PlastiComp Pushtrusion Injection Molding

Source: PlastiComp

PlastiComp Pushtrusion Compression Molding

Source: PlastiComp

Material For D-LFT Processes


Polymer
PP (most cases) PA Other technical thermoplastic resins

Fiber reinforcements
Roving Chopped Fibers
6 8mm, 12 mm, long chopped fibers

Additives
Process and heat stabilization Coupling UV stabilization Color Flame Retardants

Polymer
PP most common
All major PP supplier Some PP supplier have their own additive package as a concentrate Typical MFI 30 80, sometimes higher Homo- and Copolymers used

Nylons and others


Viscosity must allow wet out and impregnation
Similar or lower viscosity used as for PP

Heat and process stabilization is much more an issue


7

Glass Fiber Roving


Glass Melt Bushing Water Spray Fiber

Applicator Gathering Shoe Finishing Packaging

Dryer

Winder

Chopped Strand
Glass Melt Bushing Water Spray Fiber

Dryer / Separator

Applicator

Densification

Gathering Shoe Chopper


7

Winder

Sizing The Interface


Sizing = coating of the fiber Often applied as a water based solution during the fiber forming process Can be a complex mixture of chemicals including coupling agents, film forming polymers, lubricants, anti-foaming aids, dispersants, fillers, stabilizers, and others

Function of a Sizing
Protection of fibers
during manufacture during shipment during processing by customers

Easy to meter and feed


no fuzz

Easy to disperse Improve wet out Chemical coupling of fiber and resin
7

Sizing and Properties


Some functions of sizings are contradictory
easy to disperse and easy to feed

Mechanical performance of the final composite part


is controlled by the coupling agent other sizing chemicals are neutral or reduce mechanical performance

Fiber dispersion in a final part is important for


consistency of mechanical performance surface quality

Chemical Coupling
Polypropylene and fiber glass can be chemically coupled by using
Aminosilane functionality in the sizing Maleic anhydride grafted polypropylene in the resin

The matrix polypropylene is crystallizing around the MaH-PP that is coupled to the fiber Interface is a combination of chemical and mechanical coupling
7

Influence of Additives
Pigmentation
Carbon black changes flow and wet out characteristics Pigments with sharp edges damage fiber All pigmentation can influence crystallinity Impact

Flame retardants
Higher processing temperatures in the LFT processes (compared to short fiber TP) can start the reaction of the flame retardant already during the process High influence on Dynatup impact in most cases: 5% flame retardant can reduce impact by 20% and more.

Comparison of LFT-Processes
Process Average Fiber Length Warpage / Fiber Orientation Low medium Throughput

Injection Molding of Short Fiber Compounds Injection Molding of LFT-Pellets (12.7 mm) Injection Molding of LFT (ILC) Compression Molding of LFT-pellets (25 mm) In-Line Compounding Compression Molding

0.4 mm

High

4 mm

High

High

4 - 10 mm

High

High

20 mm

Medium

Medium; concentrates: low High

15 to 35 mm

Medium

Increasing Properties on LFT Parts


Sizing developments / Optimization Co-molding with unidirectional or multidirectional inserts
Compression and injection molding LFT-extrusion with continuous reinforcement (including braiding) Co-Thermoforming

Increase/design orientation of fibers


by flow design By reactive resin approach

Changing fiber/resin combination

Effects on Material and Equipment


Most of the engineering thermoplastic resins are more sensitive to degradation due to heat, air and moisture as polypropylene Processing equipment and compounding additives has to compensate for this sensitivity If material is exposed to air, the stabilization has to be adjusted for the exposure time
All compression molding lines need higher stabilization levels compared to injection molding lines If material is deposited continuously on a belt, an additional amount of stabilization is recommended
8

Effects on Material and Equipment


Moisture sensitive resins:
Resins should be dried before use
A hopper dryer is recommended for all types of D-LFT equipment when running moisture sensitive materials

A high volume vacuum degassing system can be used

The Co-Molding Concept:


Integration of Frame for a Bus Seat

Carbon fiber ribs (depth exaggerated)

Insert

Source: FTA-AL-26-7001.1

SEAT TOOL WITH INSERTS

Source: FTA-AL-26-7001.1
8

MANUFACTURING CONCEPT
Compression molding with LFT-pellets

Compression back molding of carbon-fiber reinforced inserts with long glass fiber reinforced pellets
Insert will be preheated (if necessary) in an oven and placed in the tool immediately before the compression molding step

Geometry of plasticated material as a result of flow simulation


8

PROCESSING OF INSERTS

PP/fiber tapes back molded with LFT


Insert at tool side LFT will not melt the insert enough to get good bonding

Insert at top of the LFT charge

good bonding

Insert should be preheated directly before processing

PROCESSING OF INSERTS

Fibers of the inserted tape, cut against fiber direction

PP rich area

LFT, random fiber orientation


Source: FTA-AL-26-7001.1

ECONOMIC ANALYSES SUMMARY

Prototype

Opimized Version

Calculated

Existing
Source: FTA-AL-26-7001.1

100.00% 80.00% 60.00% 40.00% 20.00% 0.00%

Pultrusion
Weight/performance
Good to excellent due to continuous reinforcement

Design flexibility
Low design flexibility Limited to constant cross sections, but can be shaped (pull/press)

Processing
Only limited experience available Depends on stabilization of the material as well as used material form

Recycling
Low rate of production scrap expected No direct recycling Can be used in other processes

LFT-Extrusion
Weight/performance
Medium weight performance Depends on retaining fiber length

Design flexibility
Low design flexibility Limited to constant cross sections Can be post shaped or pull formed

Processing
Not a lot of experience A stable process is expected using the right die design

Recycling
Low rate of production scrap Can be reused in the same process

Simulation - Comparison of Filling Behavior and Flow Simulation

Result of flow simulation

Short shot shows filling behavior

Source: FTA-AL-26-7001.1

Joining

With the increase of mechanical properties, joining techniques play a more important role and are part of system design

Economics

Cost Challenge

Typical Aerospace Structure $50 - $100/lb and more

Materials: Carbon Fiber / Epoxy, Carbon Fiber / BMI, Carbon Fiber / PEEK Processes: Hand Lay Up

Costs in $/lb

Apply Materials and Processing Techniques being Developed for Automotive Applications to Aerospace Applications

Innovative Materials and Processes $5 - $20/lb Automotive Structures $1 - $3/lb

Materials: Thermoplastic Woven Sheets, Glass, Carbon and Kevlar Fiber, Engineering Polymers Processes: Co-Compression Molding, CoInjection Molding, Thermoforming

Materials: Glass Fiber / Polypropylene, SMC/BMC Processes: Compression Molding, Injection Molding

Economics
Process Thermoforming TP S-RIM, RTM, VARTM Cycle Time Medium Medium to long, up to several minutes Tooling Costs Low VARTM: low, single sided tool RTM: low to medium S-RIM: Medium Low to medium Low, single sided tool High; steel tools with ejector pins and slides High; steel tools with ejector pins and slides Medium Medium to high
9

Scrap Rate High Depends on preforming technique; often high for complex shaped parts Low Medium to high Very low

Overall Economics Good for low volume production with no or limited thickness variation Good for low volume production

TP Filament Winding Vacuum Bag/ Hand Lay-up Injection Molding -LFT -ILC Compression Molding -GMT -LFT -ILC Pultrusion Extrusion

Medium to long, depending on number of tapes and heating system Long; manual preparation can be hours for a part Short cycle times; typically 50 80 sec. Short cycle times; typically 35 60 sec.

Good for symmetrical parts in low to medium volume production Good for prototyping. Not recommended for production scale. Excellent for high volume production Excellent for high volume production of large components

Low medium depends on cut outs. Scrap can be reused Low Low

Continuous process; not enough experience on throughput Continuous process; throughput mainly limited by cooling capacity of calibration die

Limited experience available Expected to be cost effective for profiles

Cost Factors for High Volume Component Production


Direct costs:
Material costs Labor costs Cycle Time Energy and water Quality costs

Indirect costs:
Equipment costs / depreciation Floor Space Maintenance Overhead Costs

Other costs:
Development costs Tooling costs

Material Costs
All material costs are based on PP and 30% glass fiber

GMT LFT-pellets LFT-concentrates Direct-LFT (raw materials) Short fiber granules

125 % 100 % 85 % 60 % 75 %

Material Costs Including Recycling


All material costs are based on PP and 30% glass fiber and 20% recycled scrap, costs for shredder included. 100% = LFT-pellets without recycling.

GMT LFT-pellets LFT-concentrates Direct-LFT (raw materials) Short fiber granules


1

125 % 85 % 70 % 48 % 62 %

Labor Costs
Injection Molding:
1 worker / shift can run multiple lines

Compression Molding:
Labor costs directly correlated with the degree of automation No automation: average 2 to 3 workers / shift (depending on the component) High automation: 1 worker / shift

Equipment Costs
Corrected for same throughput and a typical part size and including post operations, if necessary

GMT LFT-pellets LFT-concentrates Direct-LFT Injection molding D-LFT injection molding


1

100 % 100 % 103 % 115 % 60 % 80 %

Quality Costs
Related to receiving inspection test
GMT and LFT-pellets:
testing done by material supplier only limited testing is necessary

LFT-concentrates and ILC:


different material supplier no material supplier will take over responsibility more test effort material development responsibility

Quality Costs
Related to production problems and stability
material development problems:
flow problems long term properties mechanical properties

non-stable process bad part design


flow problems warpage

Development Costs
Material development and material testing Part and tool design Prototype tool Prototyping and testing

Reduction of development costs by Process simulation (for long fiber) Flexibility of a process in terms of
charge placement versus injection nozzle material characteristics

Manufacturing Decisions
Decisions on Pellet-LFT D-LFT and type of equipment depends on multiple factors, such as
Volume and part size Experience Location and labor costs Company and cost structure Development capabilities

Has to be calculated for every case/company

Applications

Applications
Type of applications Metal Replacement (integration and design possibilities) Replacement of unfilled, filled and short-fiber reinforced TPs Corrosion resistance Shielding (metal fiber or carbon fiber reinforced) Typical areas Automotive Leisure and sporting goods Infrastructural and housing Electrical Office Furniture Others Most of the applications today are in high volume segments such as automotive

Applications For High-Performance Thermoplastic Composites


Aerospace and defense:
Radomes, wing and fuselage sections, anti-ballistics

Infrastructure and construction


Window profiles, rebar, beams, structures, composite bolts

Consumer / recreational
Orthotics, safety shoes, sporting goods, helmets, personal injury protection, speaker cones, enclosures, bed suspension slats

Auto and truck


Bumper beams, skid plates, load floor, seat structures

Transportation
Railcar structure, body structure and closures

Energy production and storage


Oil and gas structural tube, wind turbines
1

Outlook

The Future of Thermoplastic Composites


Will go to more structural applications using different technical thermoplastics in combination with glass, carbon and synthetic fibers. Will replace metal applications and reduce weight. Improved processing methods will be developed and applied.

Future of LFT
LFT will expand into more structural applications and in applications that require higher surface quality This will be realized by using engineering thermoplastic resins additional to PP The major volume of LFT production will still be based on PP for the next few years Roving and chopped fibers will each have their applications due to different part requirements Combinations of LFT with in-mold decoration or painting will expand Other fiber combinations (e.g. natural fiber) will get a bigger share on the market Fabric reinforcement in combination with compression molding of LFT is providing new applications for thermoplastic composites. The process of local reinforcement creates a lot of new opportunities by combination of a cost effective process and high performance.

Acknowledgements
Federal Transit Administration SRI - Southern Research Institute UAB University of Alabama at Birmingham Allan Murray, Ecoplexus Inc. Ed McDade, BrueggemannChemical US Inc. All materials and equipment companies referred in the presentation

Contact Information

Klaus F. Gleich Johns Manville Technical Center 10100 W. Ute Ave Littleton, CO 80127 Phone: 303-978-2286 Email: gleichk@jm.com

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