Cost Efficient Processes for high performance composite structures

Riccardo Gennaro

2

Alessia – First recyclable thermoplastic boat

•Material:PP reinforced with continuous glass fibres

•Process: vacuum bagging - Length: 4.78m

Since 2003 CETMA develops innovative solution for marine applications:

• recyclable materials• renewable materials (bio-based resin and natural fibres) • innovative manufacturing process

33

Materials: pre-preg for high performances composites

•high cost •low volume production

Innovative processes developed by CETMA

Development and optimization of cost efficient out-of-autoclave manufacturing processes for prepregs.

Consolidation pressure on the pre-preg is achieved using the different coefficients of thermal expansion of mould materials

TOOL

PRE-PREG

SILICON RUBBER

TEMPERATURE

p

Thermal Expansion Cores for OoA (Out-of-Autoclave) processing of pre-preg materials

CARBON TUBE by CETMA

Thermal Expansion Cores for OoA processing of pre-preg materials

• steel ~ 1.2x10-5 (k-1)•aluminium ~ 2.3x10-5 (k-1)•silicone rubber ~ 7.7x10-5 (k-1)

Coefficients of Linear Thermal Expansion

Thermal Expansion Cores for OoA processing of pre-preg materials

0 100 200 300 400 500 600 700-1x106

-9x105

-8x105

-7x105

-6x105

-5x105

-4x105

-3x105

-2x105

-1x105

0

Pre

ssu

re [

MP

a]

Time [s]

Alluminium Steel

Process Simulation by FEM

comparable pressure with AUTOCLAVE process

Low cost processes developed by CETMA

High performance components by CETMA

Thermal Expansion Cores for OoA processing of pre-preg materials

complex shape variable sectiondifferent geometries closed geometries

Low cost processing of pre-preg materials

Advantages of thermal expansion processing

•Complex components

• Net shape components

•High mechanical properties

•Wieght reduction

•Low cost process

•Fast process

Low cost processing of pre-preg materials

Components for sailing boat

Mast

Rudder

Steering Wheels

Batten

Tiller

boom

Bando AIUTI A SOSTEGNO DEI CLUSTER TECNOLOGICI REGIONALI PER L’INNOVAZIONE

CETMA supports companies in the following phases::Technical coordination in the preparation of the proposalIdentification of partners Support for technical activities during the projectSupport for management activities during the project

for more details and sharing of the project:Ing. Alessandro Marseglia – alessandro.marseglia@cetma.it

tel- 0831 440408 - 333 2620456