Advanced Materials Solutions for Infusing Carbon Fibers & Thick ...
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Transcript of Advanced Materials Solutions for Infusing Carbon Fibers & Thick ...
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5/30/2012 Copyright: BASF Corporation 1
2012 Wind Turbine Blade Workshop May 31, 2012
Advanced Materials Solutions for Infusing Carbon Fibers & Thick Composite Parts
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5/30/2012 Copyright: BASF Corporation 2
Disclaimer
Data and pictures used in this presentation are either from public domain or from the sources as mentioned
Product specific data and benchmarks are average values and will vary with specific production conditions
Reflections on present and future market trends are presenter‘s personal opinions
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5/30/2012 Copyright: BASF Corporation 3
BASF - Introduction
Outline
Latent Cure Technology
Proven Benefits in Blade Production
Summary
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BASF – The Chemical Company We create chemistry for a sustainable future
Our chemicals are used in almost all industries
We combine economic success, social responsibility and environmental protection.
Sales 2011: €73,497 million (~$100 B)
EBIT 2011: €8,586 million (~$11.6 B)
Employees (as of Dec 31, 2011): 111,141
6 Verbund (integrated) sites and around 370 production sites worldwide
World-class, innovative, sustainable systems & solutions
R&D Expenditure (2011) : €1.6 B ( ~$2 B) #1 in chemical industry by Patent Asset IndexTM
World’s Most Admired Chemical Company : Fortune 2011, 2010 & 2009
4
Platzhalter für Bild
5/30/2012 Copyright: BASF Corporation
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5/30/2012 Copyright: BASF Corporation 5
Sales 2011 Employees
Production Sites R&D Sites
~$20 Billion 16,000 + 100 + 20
BASF in North America
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5/30/2012 Copyright: BASF Corporation 6
BASF in Wind Energy
Coatings
Construction Chemicals
Intermediates
Polyurethanes
Performance Polymers
Grouts & Admixtures
Adhesive
Blade Coatings
Epoxy Systems
Adhesive
Foams
Tower Coatings
Wind Turbine
Foams
in development
Commercial
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Infusion
Baxxodur® 5300 System (Latent)
Baxxodur® 5400 System
Laminating
Baxxodur® 5500 System
Baxxodur® 5503 System
Adhesive
Baxxodur® 4100 System
Baxxodur® 4200 System (Latent)
Tooling
Baxxodur® 3100 System (Infusion)
Baxxodur® 3601 System (Gelcoat)
BASF Epoxy Systems Portfolio for Wind Turbine Blades
5/30/2012 Copyright: BASF Corporation 7
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5/30/2012 Copyright: BASF Corporation 8
BASF Introduction
Outline
Latent Cure Technology
Proven Benefits in Blade Production
Summary
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Copyright: BASF Corporation 9
Chemistry in Rotor Blade Production
Fabric deposition
Prefab integration
Fabric deposition
Infusion
Curing Bonding Curing Precoating Coating
~40% of blade production cycle time is driven by chemistry... 5/30/2012
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Copyright: BASF Corporation 10
“Reaction Dilemma“ of VARTM (Epoxy Infusion)
Fast
Curing
Slow
Slow Infusion Fast
Slow
Curing
Fast
Curing
Customers look for a combination of… fast infusion with good fibre wetting through low reactivity fast polymerization / vitrification through high reactivity
Latent curing systems solves the „reaction dilema“.
Customer need
Latent Curing
5/30/2012
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Copyright: BASF Corporation 11
Advantage Longer pot life, Faster infusion Better process control
During infusion at temperatures below 55°C the Baxxodur 5300 system reacts slowly allowing long open time (pot life)
The lower viscosity at e.g. 40°C with the slow reactivity enables fast infusion and improved fiber wetting
Novel infusion system reduces infusion time around 40%
0100200300400500600700800900
1000
0 50 100 150 200
Standard System
BASF Latent System Longer Pot Life Faster Infusion
Infusion at 30°C Viscosity [mPas]
Time [min]
5/30/2012
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Copyright: BASF Corporation 12
Advantage Faster Curing Cycle Time Reduction
Once the temperature inside the laminate rises to 70°C, the latent curing mechanism “kicks in”
At this temperature System cures much faster than the standard system
Curing at 70°C Δ Reverse Heat Capacity [mJ/°C]
0
1
2
3
4
5
6
0 100 200 300 400Time [min]
Standard System
BASF Latent System Faster Curing
Latent infusion system reduces curing time by 30-40 % 5/30/2012
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Crosslinking / Tg Development at 70°C
0%10%20%30%40%50%60%70%80%90%
100%
0 100 200 300 400 500 600Time [min]
Tg/T
g m
ax Standard systemLatent system
Latent Baxxodur® system allows faster curing and higher Tgmax (~85 C)
Latent Baxxores® ER 5300 / Baxxodur® EC 5310
Copyright: BASF Corporation 5/30/2012
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5/30/2012 Copyright: BASF Corporation 14
BASF Introduction
Outline
Latent Cure Technology
Proven Benefits in Blade Production
Summary
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Cycle time reduction in rotor blade production
Baxxodur epoxy systems with latent but fast curing agents enable
fast infusion at low viscosity with inactive reactants at low temperatures
fast curing above temperature threshold with activated reactants
Infusion 30-40 %
Curing 30-40 %
5/30/2012 Copyright: BASF Corporation
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0 4 8 12 16 20 24 4 8 12 16 20 24
0 4 8 12 16 20 24 4 8 12 16 20 24
Produce 2 Root Rings per mold set instead of 1
Produce 1.5 sets of Spar Caps per mold set instead of 1 set
Current production
Potential with BASF resin
Current production
Potential with BASF
Mold set 1 Mold set 2
hours
hours
Taking advantage of cycle time reductions
Reduced tooling costs
5/30/2012 Copyright: BASF Corporation 16
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Copyright: BASF Corporation 17
Proven benefits in blade production High Quality Structural Parts
Latent Baxxodur® systems produce high quality composites
Reduced Spring In
No Waves
X
X
5/30/2012
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Copyright: BASF Corporation 18
Lower viscosity and longer stability of latent system allows direct infusion of root ring in shell molds
Successfully adopted in production
Proven benefits in blade production Direct Infusion of Root Ring
Thickness: 22 cm (~9 inch) No. of layers: 270 Fabric type: TRIAX 1200 g/m2
5/30/2012
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Baxxodur® Latent System
Typical Cure Profile for 200 layers fiberglass laminate
0
10
20
30
40
50
60
70
80
90
100
8:06
8:30
9:00
9:30
10:0
010
:30
11:0
011
:30
12:0
012
:30
13:0
013
:30
14:0
014
:30
15:0
015
:30
16:0
016
:32
17:0
017
:30
18:0
018
:30
19:0
019
:30
20:0
020
:30
21:0
021
:30
22:0
022
:30
23:0
023
:30
0:00
0:30
0:52
Tem
pera
ture
Time
Curing Cycle for 200 layer thick part
Table temp °C
Bottom °C
Middle °C
Top °C
Top (outsidebag) °C
Source: Data generated in BASF lab 5/30/2012 Copyright: BASF Corporation 19
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Copyright: BASF Corporation 20
Proven benefits in blade production Infusion of Carbon Fiber Spar Cap
Lower viscosity & better stability of latent system allows infusion of carbon fibers at higher temperature
Only epoxy infusion system in commercial production of carbon spars
90 layers of UD carbon fabric in 1000 X 600 mm laminate; thickness 55 mm Infusion time: 100 minutes @ 35C Curing time 2 hours @ 50 C + 2 hours @ 75C
5/30/2012
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Summary
Significant scope for innovations in blade production through creative use of chemistry
BASF’s Latent Cure Technology enables cycle time reductions and quality improvements
Several blade producers are successfully using latent system for direct infusion of root ring and for infusing carbon spars
Latent system offers substantial opportunity for capital and operational cost reduction
5/30/2012 Copyright: BASF Corporation 21
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5/30/2012 Copyright: BASF Corporation 22