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Overview
Economics
Applications
Introduction
3.5
2.5
Glass & Carbon LFT & Continuous Other Fibers Varying Fiber Orientations
1.5
Metals
LFT Glass Composites Continuous Uni-directional Glass Composites
0.5
Plastics
0 0
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
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
(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
Fillers
Short Fiber
Source: Ticona
Key Factors
Fiber length Fiber dispersion Fiber impregnation processing conditions and technique
In continuous oriented fibers the load is ultimately fully transferred to the fiber As a result tensile creep is limited in fiber direction
D-LFT chopped fiber Compr. Mold. (CPI) VW Golf A4 front end carrier First front end in GMT LFT/Ticona Compression Molding
Azdel Superlite
GMT/Azdel
1972
1980 1
1990
2000
Year
Economics
House Of Production
Design
Material Selection
Semi-Finished Materials
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
Source: AZDEL
2
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
Block
Cooling
Haul-off/ Puller
Pelletizer
Courtesy of GEN
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
TP
Glass
Commingling Roving
Source: Vetrotex
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
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
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
IR Oven
Puller
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
3.5
2.5
Carbon Towflex
Typical resins:
PP, PA6, PPS, PEI, PEEK
1.5
Glass Towflex
LFT Glass Composites
0.5
Plastics
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
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
Injection Molding
Low-Structural Components
Structural Components
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
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
40%
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.
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
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
Material:
Improved mechanical properties Better wear resistance Better crystalline structure, higher crystallinity
Source: Brueggemann Chemical U.S., Inc.
4
Catalyst:
Activator:
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
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
Figures from Fulcrum Thermoplastic Technology; Making High-Performance 5 Composite via Thermoplastic Pultrusion Dow Plastics, J anuary 2000
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
Molded part
Tool in press
Compression Molding
Plasticator Continuous extrusion
Flying knife and belt plunger
Source: C.A. Lawton
5
Source: Krauss-Maffei
LFT
pultrusion of the semi-finished product
ILC
Semi-finished Material
Part production
Inline-Compounding
Processes using chopped fibers only
CPI Binani JCI (slurry process (Fibrolen, plastication process)
Injection Molding
Husky Krauss Maffei PlastiComp
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
Pictures: KraussMaffei
The Dieffenbacher-System
Picture: Rieter
6
Source: Dieffenbacher
6
Source: Coperion
6
Source: Berstorff
6
Vibratory Track
Source: Lawton
6
Source: PlastiComp
Source: PlastiComp
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
Dryer
Winder
Chopped Strand
Glass Melt Bushing Water Spray Fiber
Dryer / Separator
Applicator
Densification
Winder
Function of a Sizing
Protection of fibers
during manufacture during shipment during processing by customers
Easy to disperse Improve wet out Chemical coupling of fiber and resin
7
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
15 to 35 mm
Medium
Insert
Source: FTA-AL-26-7001.1
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
PROCESSING OF INSERTS
good bonding
PROCESSING OF INSERTS
PP rich area
Prototype
Opimized Version
Calculated
Existing
Source: FTA-AL-26-7001.1
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
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
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
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
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
125 % 100 % 85 % 60 % 75 %
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
Quality Costs
Related to receiving inspection test
GMT and LFT-pellets:
testing done by material supplier only limited testing is necessary
Quality Costs
Related to production problems and stability
material development problems:
flow problems long term properties mechanical properties
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
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
Consumer / recreational
Orthotics, safety shoes, sporting goods, helmets, personal injury protection, speaker cones, enclosures, bed suspension slats
Transportation
Railcar structure, body structure and closures
Outlook
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
Questions ?