DevelopmentDevelopment of Preforming Process of Preforming Process in PCM*in PCM* TechnologyTechnology

Koichi AkiyamaToyohashi Research LaboratoriesComposite Material Development Center

* Prepreg Compression Molding

PCM TechnologyPCM Technology

High cycle process based on compression molding Rapid cure prepreg

2 minutes cure at 150 ℃ (302°F)Carbon Fiber SMCDeveloped for high volume Carbon Fiber Reinforced Plastic (CFRP) applications

PCM (Prepreg Compression Molding)Newly developed rapid curing prepreg is preformed, and then cured in heated steel tool.Short mold cycle times.

Laminate Heat Preforming Charge Compression De-molding

Prepreg for PCMPrepreg for PCMResin Properties

Resin type Gel time @ 140 C min.

Minimum cure time @140 C min.G'-Tg ℃

tanδ ℃

Notes

Prepreg Properties

CF reinforcement1)

FAW g/㎡ Resin Content wt%

CF Vf vol% Specific Gravity

1) TR50S carbon fiber from Mitsubishi Rayon Co., Ltd. is used for all prepregs Tensile strength; 4900 MPa, Modulus; 240 GPa, Elongation; 2.0%2) Plain, twill and Satin fabric can be used.

1.54 1.47

30.0 40.059 49

UD Fabric2)

250 or 125 200.0

Properties Ttypical grade

167

Good SurfaceHigh Tg

High TgGood Surface154 186 190

R 05

Bisphenol A typeEpoxy resin

2.75.05.0 3.0

Resin Formulation R 02 R 03

Bisphenol A typeEpoxy resin

Bisphenol A typeEpoxy resin

2.0 1.3

125 165

Compression Molding ProcessCompression Molding Process

By Courtesy of

Automotive Body PanelsAutomotive Body Panels

Class A surface is achievable with UD prepregBody panels can be produced by bonding PCM outer panel and CF-SMC inner panel

Outer Panel PCM

Part size; 600X600X1.1mm

UD prepreg with body color paint

CF-SMC

Part size; 600X600X1.5mm

Inner Panel Fabric prepreg with clear coat

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Automotive Structural PartsAutomotive Structural Parts

PCM process application on floor partMolded parts have high mechanical properties due to continuous fiber materialCo-molding of prepreg and CF-SMC allows complex three dimensional shapes

Rapid Curing MaterialRapid Curing Material

Prepreg compression molding significantly reduces time to convert PREPREG to COMPOSITE

Traditional ProcessCycle time; 240 minutes

AutoclaveAutoclave PressPress

High Cycle ProcessCycle time; 5 Minutes

Rapid Preforming ProcessRapid Preforming ProcessConventional preforming process is inefficient compared to high-cycle PCM process

Manual lay-upVery slow

Large variationHuman error

Conventional Preforming

Conventional Preforming

Advanced Preforming Process

Advanced Preforming Process

Fast enough for PCMConsistent

Less manual laborAutomated

Preforming process for PCM must be…

Preforming process for PCM must be…

RapidRapid Preforming ProcessPreforming Process

Pattern cutting, preforming and compression molding are consecutive processes.Cycle times of each process must match for high capacity production.

5minutes5minutes5minutes

Heating PreformingLaminating

Net shapepreform

CuttingPatterns

Prepreg

CompressionMolding

Composite

Development of Development of RRapid apid PPreforming reforming PProcessrocess

Preforming large and complex shapesDeep drawn shapesShapes that cannot be preformed by stretching materialThree dimensional shapes such as ribs and bosses

Optimization of preforming parametersHeating temperature and time, press pressure, etc.

Automated process for rapid preforming system

Prepreg Curing AnalysisPrepreg Curing AnalysisTemperature of prepreg quickly rises after charged on heated steel toolCuring reaction starts immediately after prepreg is heated to tool temperature.

Preforming cannot be done with compression molding tool.Preforming cannot be done with compression molding tool.

Curing property of Prepreg

20

40

60

80

100

120

140

0 50 100 150 200 250 300

Time (second)

Tem

per

atu

re (

C)

Cure time

Gel time

Temperature at the center of prepreg was measured by a thermocouple.(Measuring Condition)Material; R05 UD prepreg, cross plyThickness of prepreg; 4mm (2mmX2sets)Tool temperature; 140 ℃

Magnified chartExothermal behavior of prepreg

Preforming with PressPreforming with Press

Heating temperature must be below 80 ℃during press-preforming process.

Resin viscosity decreases by heating and prepreg becomes flexible and drapableCuring occurs when temperature is over 80 ℃

1.E+00

1.E+01

1.E+02

1.E+03

1.E+04

0 1 1 2 2time (min)

55℃

60℃

65℃70℃

80℃90℃

90 1206030

Vis

cosi

ty I

ndex

1

10

100

1000

10000

100000

0 50 100 150Temperature(℃)

Vis

cosi

ty I

ndex

Stability of Resin at Elevated TemperatureTemperature Dependence of Resin Viscosity

Resin formulation; R02Measured by TA Instruments AR-G2 RheometerTemperature ramp up rate; 2℃/min

Resin formulation; R02Measured by TA Instruments AR-G2 Rheometer

Preforming with PressPreforming with PressThicker laminates need longer heating time.

Longer time is needed for inside to reach to appropriate temperature (50-75℃)Low heater output allows longestworking time.

IR Heater output; Low (11mA)Material; R05 (Thickness of Laminate; 1, 2, 3mm)

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pera

ture

(℃

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Thickness 3mm

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0 60 120Time (sec)

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pera

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Thickness 2mm

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0 60 120Time (sec)

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pera

ture

(℃)

Thickness 1mm

TopMiddleBottom

Good temperature rangeWorking rang (Preform is possible)

BottomMiddleTop

IR Heater

About 15cm

Thermocouple

Preforming with PressPreforming with Press

Higher heater output shortens heating time, but working time is shorter.

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TopMiddleBottom

60 1200 60 1200 60 1200Hea

ter;

Mid

dle

Hea

ter;

Hig

h

Thickness; 1mm Thickness; 2mm Thickness; 3mmMaterial; R05 (Thickness of Laminate; 1, 2, 3mm)

Typical Preforming ProcessTypical Preforming ProcessNear net shape preform can be produced at low temperature and low pressure.

Low cost equipment can be used (chemical wood tool, air cylinder driven press, IR heater, etc.)

1) Heat laminate to 70 ℃ex) 30 seconds by IR heater for 1mm thick

2) Press for 1 minute to cool downTypical pressure is lower than 0.1 MPa (1 bar)

3) Debulk for 1 minute by vacuum(if necessary)

1) Lay up several prepreg sheets2) Debulk for 2 minutes by vacuum3) Cut patterns

Heat PreformLaminate

Net shapepreform

CutPatterns

Prepreg

Preforming Demonstration UnitPreforming Demonstration Unit

Preforming demonstration unit was builtPressing by tool stretches prepreg like manual lay-up in few minutes.

Press unitHeating unit

Preforming ProcessPreforming Process

Preforming of Complex ShapePreforming of Complex Shape

Advanced procedures to produce near net shape preform for complex shape

Apply tension to stretch laminate.Optimal for forming round or deep drawn shape

Divide into smaller sections.Preform each section with press.Sections are combined into an integrated near net shape preformOverall short process time.

Combine prepreg and CF-SMC for three dimensional complex shape.

Prepreg based design for mechanical properties with CF-SMC only for three dimensional complex shape.CF-SMC based design for design flexibility with prepreg as local reinforcement.

1/2 Scale Seat Back Demonstration1/2 Scale Seat Back Demonstration

Complex deep drawn shapeNormally preformed manually by skilled operator

By Courtesy of

400mm(15.7”)

300mm(11.8”)

85mm(3.3”)

Preform Capability AnalysisPreform Capability Analysis

Fiber distortion was observed in simple press-preforming by matched tool.

By Courtesy ofAnalysis by FiberSimAnalysis by FiberSim

Fiber Direction; 0/90

Fiber distortion

Fiber Direction; 45/-45

Actual Preforming ResultsActual Preforming Results

3K Plain Fabric PP ; 0/90

Shear deformation angleB; 0-15° PossibleY; 15-30° DifficultR; over 30°impossible

3K Plain Fabric PP ; 45/-45

Shear deformation angleB; 0-15° PossibleY; 15-30° DifficultR; over 30°impossible

Fiber distortion

Preforming Deep Drawn ShapesPreforming Deep Drawn Shapes

Apply tension to stretch material and fit on tool surface without fiber distortion.

Jigs are used to simulate manual lay-up

Jigs for press preforming- Apply tension during preforming- 10 minutes

Traditional Manual Preforming- Heat and stretch by hand- 60 minutes

By Courtesy of

Tension ApplicationTension Application

Automatic chucking unit applies tension and stretches prepreg during preforming

By Courtesy ofPreforming Unit

Chucking unit Heating unit

Press unit

Trim

Automatic System for Complex ShapeAutomatic System for Complex Shape

By Courtesy of

Sectional Preforming ProcessSectional Preforming Process

Divide large complex shape to smaller sections.

Each section can be preformed by press in only a few minutes.

Layer A

Section #1

Layer B

Section #3

Section #2 Section #4

Sectional Preforming ProcessSectional Preforming Process

Design sections so their edges are not at same position and do not overlap.

Section edges must not be where significant load is applied, as mechanical strength is lower

Layer B

Section #1

Layer A

Section #2 Section #3 Section #4

Sectional Preforming ProcessSectional Preforming Process

Preformed sections are merged into a net shape preform.

Each section is stacked, layer by layerSection #1

Section #2 Section #4

Section #3

Sectional Preforming ProcessSectional Preforming Process

A near net shape preform is debulked by vacuum.

Debulking is completed in a few minutesReady to mold by compression molding

Two each of Layer A and B are stacked alternately

Debulk by vacuum for 3minutes

Three dimensional net Shape preform

Sectional Preforming ProcessSectional Preforming ProcessHigh cycle preforming is also possible for large complex shaped part by automated process.

Combined Unit

Near Net Shape Preform

Compression Molding Press

Prforming Line C

Prforming Line A

Prforming Line B

Prforming Line D

Hybrid Hybrid Molding of Prepreg and CFMolding of Prepreg and CF--SMCSMCPrepreg for mechanical properties and CF-SMC for complex shapes

Curing properties of both materials were matched for co-moldingCF-SMC flows in the tool cavity and molds into complex structures

PrepregSMC Compressionmolding

PCM/SMCHybrid Part

Tool

CF-SMC was charged onthe net shape preform

Molded part

SummarySummaryAutomated preforming process for PCM technology has been developed.

Short preforming process by press matches compression molding of rapid cure prepreg.

Large complex shape also can be preformed quickly by using following procedures.

Apply tension to stretch prepreg and fit to parts shape.Divide part to several smaller sections.

Sections can be preformed by pressThey are consolidated and form a near net shape preform ready for compression molding.

PCM/CF-SMC hybrid moldingCo-molding of prepreg and CF-SMC can provide high mechanical properties with three dimensional complex shape

Thank youThank you

AcknowledgmentAcknowledgment

Special Thanks to; Yajima Industry Co., Ltd.

Cooperation on the quarter engine hood development.

Challenge Co., Ltd.Cooperation on devide-preforming process development.

The other authorsY. Kazehaya, Y. Kakimoto, Y. Fukuharaand T. TakanoComposite Material Development CenterMitsubishi Rayon Co., Ltd.