Post on 27-May-2020
Advanced Materials 1
Huntsman Advanced Materials
Advanced Materials 2
Compression Moulding – High Pressure RTM
Two complementary technologies for cost effective carbon
composites mass production in Automotive
Duncan Howland, Klaus Ritter
Advanced Materials 3
Table of Content
> Composites in Automotive: Applications, Liquid Composite Processes
> Resin-Transfer-Moulding Epoxy Solutions
> Standard low Pressure RTM
> High-Pressure RTM
> Comparison on latest Epoxy RTM Resin Technologies
> Compression-Moulding Epoxy Solutions
> Expandable Epoxy Systems (EES)
> Wet Compression Moulding for Structural Parts
> Mold-Technologies
> Influence of Accelerator Content
> Conclusion: Comparison HP RTM vs. Compression Moulding> Cycle-times and Material-Properties
> Outlook
Advanced Materials 4
Composites Applications in Automotive
Roof
Bonnet
Interior panelsEES technology
Drive shafts
Trunk panelEES technology
Chassis
Leaf springs
Wheels
Advanced Materials 5
Liquid Composites Processes in Automotive
Complexity vs. production speed
Advanced Materials 6
Resin Transfer Moulding Solutions
- Standard Low Pressure RTM
- High Pressure RTM
Advanced Materials 7
Resin Transfer Moulding Process
Main features and benefits
� Design freedom !!!
� Short cycle time
� Industrial process for medium-to-high volume car part production
� High quality – reproducibility
� Integrated function (eg. reduced number of parts, metallic insert integration…)
Advanced Materials 8
Standard Pressure vs. High Pressure RTM
Low pressure: static mixer
Low Pressure Mixing Head with courtesy of Cannon
Advanced Materials 9
Standard Pressure vs. High Pressure RTM
High pressure: mixing chamber
* HP-RTM requires the use of internal release agent, which can either be pre-dosed in the resin or mixed as a third component directly in the mixing chamber. FPL mixing head: with courtesy of Cannon
Advanced Materials 10
Standard Pressure vs. High Pressure RTM Epoxy Solutions
Production cycle comparison
(1) Out of the mould postcure often required
(2) Includes mould closure and vacuum
(3) Tg DMA obtained with 1% internal release agent
STANDARD RTM (1)
HP RTM SOLUTIONS
Araldite® LY 3585 / XB 3458
NEWAraldite® LY 3585 /
Aradur® 3475
= System 1
Preform set (2) 1 - 5 min 0.5 min
Mould Temperature 30 – 120°C 100°C 115°C
Injection 2 - 15 minup to 0.5 min
(small to medium part)up to 1 min
(small to large part)
Cure 10 - 60 min > 5 min > 2 min
Demoulding 1 - 5 min 0.5 min
Part production time(minimum)
14 - 85 min 6.5 min 4 min
DMA Tg onset (3) 100 – 190°C 93 – 103 °C 105 – 115°C
Advanced Materials
Cure Latency During Mold filling
System1 + 2 phr IRA
Unit
Mix ratio 100 : 21
Mix viscosity at 110ºC / 115ºC mPas < 50
Injection time at 110ºC / 115ºC s ca 60
0
500
1000
1500
2000
0 10 20 30 40 50 60 70
vis
co
sit
y i
n m
Pa
.s
time in seconds
XB 3585 / XB 3458 @ 100°C
XB 3585 / Aradur 3475 @ 110°C
XB 3585 / Aradur 3475 @ 115°C
Advanced Materials 12
BMW M3 roof parts with Araldite® XB 3523 / XB 3458
Araldite® Solutions / Case Histories
Benefits• Low weight, high stiffness and high dimensional stability• Fashion / aesthetics due to carbon look• Class A finish• Low shrinkage
Lamborghini Aventador LP700-4’s chassis with Araldite®XB 3518 / Aradur® 22962
BMW i3 - Life - Cell Araldite® LY 3585 / XB 3458
Benefits• Low viscosity during injection• Sufficient pot life• Low shrinkage (surface quality)• High mechanical properties (good balance Tg / Toughness)• Good hot / wet properties
Benefits• Fast curing • Versatile for RTM and Compression Molding• Low water pick up• high mechanical performance
Advanced Materials 13
Binder for Preform Manufacture
Typical preforming conditions: cold pressing after infra-red heating
Product Designation
Type Gel time Softening point
Tg Typical applications Recommended preforming cycle
Conditions 130°C DSC mid point
Unit sec °C °C
Resin
Araldite® LT 3366
Epoxynon reactive
na ca. 150 75 - 85 High pressure RTM 20 ±10 sec at 180 ±20°C+ cold stamping
Advanced Materials 14
Compression Molding Technology
- Expandable Epoxy Systems (EES) & Natural Fibre
- Wet Compression Moulding of Structural Parts
Advanced Materials 15
Expandable Epoxy Systems / Compression Moulding Process
Main features and benefits
� Possibility of extremely short cycle times (45-60 s at 150-160°C)
� Low density laminates (~ 0.7 g/cm3 with natural fibres)
� Moderate investment cost
� Easy and exact moulding of complicated shapes
� Closed cells (no water penetration)
� Monolithic laminates as well as sandwich structures
� Adjustable porosity for vacuum assisted covering
with decorative films
Cooling JigApplication of resin system
Wet-reinforcement
placement
Mould-closure and cure
De-moulding
Mould and press occupation time
Expansion of EES resin and fibre impregnation
Advanced Materials 16
Conti Duo™ Patented Processand Material Properties of EES
Main features and benefits
� Fully automated process with a low investment cost
� Cost competitive for large series production
� Minimum material waste associated with high quality consistency
� Resin consumption minimised as there is no over-spray (clean process vs. spray)
Maximum Tg Density of composites (1) Comments
Unit °C g/cm3
Araldite® LY 5310 /Aradur® 1135-1B
135 - 145 0.65 - 0.85 High Tg, extremely low emission (for interior use)
(1) With natural fibre mats density : ~ 1.4 g/cm3 ; epoxy resin ~ 35 % by weight
Advanced Materials 17
CSL C218 indoor panel, produced by Bushoku Automotive Europe GmbH (Europe) with Araldite® epoxy system and natural fibres
Benefits
� Very short production cycle, less than 1 min (45 s at 150°°°°C)
� Parts with high impact-strength
� Rigid, very light and dimensionally stable parts
Araldite® EES Solution for Mercedes Benz
Advanced Materials 18
Wet Compression Molding Processfor Structural Parts
Main features and benefits
� Very short cycle time
� No injection step
� Lower investment vs. high pressure RTM
with courtesy of Cannonwith courtesy of Cannon
Cooling JigFibre-stack placement
Mould-closure and cure
De-moulding
Mould and press occupation time
Resin application
Advanced Materials 19
Wet Compression Moulding ProcessTooling- Technology
Classic Compression Mold Concept with controlled
“Overflow” Channel
Compression Chamber Technology Vacuum assisted
Benefits: - Simple mould technology
- Cost of mould
- Slightly faster (no vacuum)
-> For simple parts
Benefits: - significantly higher part quality
- void free parts / highest
composite quality
- higher design freedom
- less waste
Advanced Materials 20
Wet Compression Moulding Processfor Structural Parts
1. Fabric stack prepared
2. Resin applied
3. Wetted stack in mouldMould closed and vacuum applied
4. Cure in press 60s
Advanced Materials 21
Wet Compression Moulding Processfor Structural Parts
Composite part quality: parts straight out of mould, untrimmed
Advanced Materials 22
Wet Compression Moulding vs. HP RTM“Parts in Minutes”
Production cycle comparison on same epoxy system
HP RTM SOLUTIONS WET COMPRESSION MOULDING SOLUTIONS
NEWEP- System 1
NEWEP-System1
Preform Normally required Optional
Preform / fabric lay-up set (1) approx. 30’’ approx. 30’’
MouldTemperature
110°C 130 - 150°C
Injection up to 1 min
(small to large part)-
Cure > 2 min 1 min
Demoulding approx. 30’’ approx. 30’’
Part production time (minimum)
appr. 4 min appr. 2’ min
(1) Includes mould closure and vacuum
Advanced Materials
Neat-resin-dataEP- System1 +
2 phr IRA
Standard Unit
Curing cycle time (1) min 2 min 115ºC 2 min 115ºC
HP-RTM – neat resin data 4 mm DRY 7 days H2O @ 23ºC
Tensile Modulus
ISO 527-2/1B
MPa 2742 2645
Tensile Strength MPa 78 76
% 9.7 13.8Tensile Elongation
Cure conversion (2)
ISO 11357-2% 100
DSC Tg onset (2) ºC 122
DMA Tg onset (3) ISO 6721-4 ºC 131 127
G1C ISO 13586 J/m2 267 285
CTE ISO11359 10-6 / K 54
(1) Based on a 12 sec injection time, (2) 10ºC / min, (3) Tensile mode, 2ºC / min, 10 Hz
Material Properties
CFRP –Data (1)
HP-RTM – CFRP 2 mm 2 min 115ºC
DMA Tg onset (2) ISO 6721-4 ºC 111
ILSS ASTM D2344 / UD MPa 60.2
(1) Based on a 12 sec injection time, (2) Torsion mode, 2ºC / min, 1 Hz
Advanced Materials
Influence of Temperature and Accelerator-Content on Curing-Speed (Conversion)
24
0 50 100 150 200 250 300 350 400 450 5000
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
1100XB3585-23LME10950-with10percacc
Time (s)
convers
ion (-)
80°°°°C100°°°°C120°°°°C140°°°°C Araldit LY 3585 – Hardener 2----- high accelerator level low accelerator level
Optimizing Formulations for Compression-Moulding
Advanced Materials 25
Conclusion
RTM:
� Advantage - Design Freedom !
� Pressure during injection up to 150 bar
� Proper preform mandatory to avoid fibre misalignment
RTM
Preforming Placement
Mould-closure
and
Vacuum
Demoulding
Mould and Press Occupation Time ( +/- 4 min)
Preforming Injection Cure
Compression Molding
Wet Fabric-Placement
Mould-closure
and Vacuum
Demoulding
Mould and Press Occupation Time (1’30 - 2’30’’)
Preforming
Not mandatoryCure Cooling Jig
Compression Moulding (Vacuum-Assisted):
� Preform not mandatory due to vertical
impregnation
� Higher fibre volume content possible
� Much faster process vs. RTM
� Pressure max. 30 bar
� Design freedom higher than classical compression moulding
Advanced Materials 26
Outlook
With process optimized epoxy systems for wet
compression molding, we expect cure-times of 30’’ ,
processing times of 1’-1’30’’ respectively, will very soon
be possible.
Advanced Materials 27
For more information
www.huntsman.com/advanced_materials
advanced_materials@huntsman.com
Europe
Huntsman Advanced Materials (Switzerland) GmbH
Klybeckstrasse 200
P.O. Box - 4002 Basel
Switzerland
Tel. +41 61 299 20 41
Fax +41 61 299 20 40
Advanced Materials 28
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Advanced Materials 29
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Advanced Materials 30
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Advanced Materials 31
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