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Painel Aeroespacial -2017
Compósitos em SMC- Sheet Molding Compound :
Estrutura , propriedades e Aplicações
Palestrante: Everton Sterzo
A.Schulman Inc. in the World
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A. Schulman operate facilities in the Americas, Europe and Asia-Pacific regions. Its plants, offices and technical centers are strategically located to serve customer needs in markets throughout the world.
Rio Claro Plant
– Plant Size: 43.665,29 m²
– Built area: 8.821,13 m²
– Location: Meridian, 55
Distrito Industrial
Rio Claro – SP, Brasil
13505-610
– Inaugurated Date: 1997
– Associates: 65
Rio Claro Plant / Internal Area
Materials Engineered Tetrahedron
Chemical Structure
PropertiesProcess
Products / End Market
Chemical Structure - SMC & BMC
SMC & BMC Formulation
• Thermosetting resin - Unsaturated Polyester , Vinyl Ester , Epoxy, Phenolic
• Catalyst
• Inhibitor
• Mold Releases
• Crosslink Agents
• Reological additives
• Fillers
• Reinforcement ( Glass Fiber, Carbon Fiber ,etc)
Polymer Matrix
• Thermosseting Resin
• Basic Component that will be cure process
• Unsaturated Polyester
• Vinyl Ester
Chemical Structure - SMC & BMC
• Epoxy
• Phenolic
Chemical Structure - SMC & BMC
Polymer Matrix
• Thermosseting Resin
• Basic Component that will be cure process
Catalyst
• Increase reaction speed, Decrease activity energy , same Free Energy
Chemical Structure - SMC & BMC
• Inhibitor
Others Additives
• Mold Release
• Fillers = (o + A)eBP
Chemical Structure - SMC & BMC
• For SMC , BMC and Pultrusion, the reinforcement can be used in Chopped Strand,
continuous or mat shape.
Ingredientes %
Sílica (SiO2) 52 – 56
Óxido de Cálcio (CaO) 16 – 25
Alumina (Al2O3) 12 – 16
Óxido de Boro (B2O3) 5 – 10
Mágnésia (MgO) 0 – 5
Óxidos Alcalinos (Na2O e K2O) 0 – 2
Dióxido de Titânio (TiO2) 0 – 0.8
Óxido Férrico (Fe2O3) 0.05 – 0.4
Fluoreto (F2) 0 – 1.0
Composição do Vidro -E
• Reinforcement (Glass and Carbon Fiber)
Interface
Chemical Structure - SMC & BMC
BMC SMC Pultrusion Compression Mold Injection Mold
Process
WHAT IS BMC?
• Bulk Molding Compound (or Composite)
• Polyester resin, glass-fiber and fillers reinforced
thermoset molding compound
• Used on hot-tool press molding
• Specifically formulated for each end-use
application
• Contains 5 % to 30 % chopped strand
• Can be injection, compression or transfer
• Sheet Molding Compound (or Composite)
• Chemically-thickened, glass-fiber/Carbon-
reinforced thermoset molding compound
• Used on hot-tool press molding
• Specifically formulated for each end-use
application
• Contains ½ to 2 inch chopped glass roving
• Can be compression
WHAT IS SMC?
Press
WHAT IS PULTRUSION?
Pultrusion is a manufacturing process for producing continuous lengths of reinforced polymer structural shapes with constant cross-sections. Raw materials are a liquid resin mixture (containing resin, fillers and specialized additives) and flexible textile reinforcing fibers.
Properties
• Physical-chemical
• Thermal
• Mechanical
• Electrical
• Optical
What is a Thermoset?
A thermosetting polymer is a prepolymer in a soft solid or viscous
state that changes irreversibly into an infusible, insoluble polymer
network by curing.
.A thermoplastic polymer is a polymer that becomes pliable or
moldable above a specific temperature, and returns to a solid state
upon cooling. Most thermoplastics have a high molecular weight,
whose chains associate through intermolecular forces; this property
allows thermoplastics to be remolded because the intermolecular
interactions spontaneously reform upon cooling. In this way,
thermoplastics differ from thermosetting polymers, which form
irreversible chemical bonds during the curing process.
Thermoplastic
Heat
Thermosetting
What is a Thermoset?
Cooling
What is a Thermoset?
Thermoplastic Thermosetting
Mechanical Properties – BMC/SMC
0
50
100
150
200
250
300
350
400
450
10 15 20 25 30 35 40 45 50 55 60 65
Tensile PropertiesTe
nsi
leSt
ren
ght
(Mp
a)
Fiber content(%)
BMC
SMC
Special Materials
-CF SMC
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Materials properties Comparision
*This table uses steel as a standard by which all other processes are compared. **Costs may vary.
Propriedades x
MateriaisStamped Steel SMC/BMC Thermoplastic CF SMC Aluminum
Part
ConsolidationBaseline Excellent Excellent Excellent Very Good
Comparable
Mass100 60-75% 70% <60% >80%
Corrosion
ResistanceBaseline Superior Superior Superior Poor
Tooling Cost 100% 40% 60% 40% 115%
CLTE 100% 100-130% 600-1000% 100-130% 170-200%
HDT N/A Baseline Poor Baseline N/A
Thermoset Composite Materials
70
140
280
350
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*This table uses steel as a standard by which all other processes are compared. **Costs may vary.
CF SMC TDS
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CF SMC TDS
*This table uses steel as a standard by which all other processes are compared. **Costs may vary.
A.Schulman Laboratory
What is the SMC advantages?
• High Heat Resistance- HDT and Tg
• Dimension Stability– Lower CLTE
• Flame Retardant
• Low Smoke Emission
• Excellent Chemical Resistance
• Excellent Creep Resistance – Little to No Creep
• Tailored Glass Transition Temperatures
• Formulations which are Easily Customizable to your Application
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Why SMC?
• Part Consolidation
• High yield
• Easy handling
• Excellent properties
• Formulations which are Easily Customizable to your Application
• Low Cost
AppliancesMotorcycle AutomotiveIndustrialAgricultural Electrical AerospaceTruck
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Products/ End Market
• BMC Applications
BMC (Headlamps)
Products/ End Market
Valve Cover
Products/ End Market
• BMC Applications
BMC - Sewing Machine
Products/ End Market
• BMC Applications
Electrical Parts
Products/ End Market
• BMC Applications
SMC - Sheet Molding Compounds
Products/ End Market
Electrical
SMC - Sheet Molding Compounds
Products/ End Market
GrillGrill
SMC - Sheet Molding Compounds
Products/ End Market
Ford Troller – Structural SMC
SMC - Sheet Molding Compounds
Products/ End Market
Ford Troller – Class A SMC
SMC - Sheet Molding Compounds
Products/ End Market
Rear Floor - Renault
SMC - Sheet Molding Compounds
Products/ End Market
Empilhadeira - Nacco
SMC - Sheet Molding Compounds
Products/ End Market
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Quantum Composites material is usedextensively in tertiary and secondary
structure applications where net shape
compression molding can provide cost
and weight reduction benefits over
aluminum and other metals including cost
reduction over prepreg materials.
Aircraft companies have increased their
reliance on compression molded Lytex®
components as overall composite usage
has increased in the next generation
aircraft with higher carbon and glass fiber
composite content.
UnderGwingThermalpanel
Inboard trackfairing
Flap trackcones
LYTEX® 9063
Inboard fanduct fairing
Trailingedge fairing
Lytex is usually chosen because of its much lower part cost versus a prepreg part. A key benefit that Lytexoffers is the ability to easily mold in ribs, bosses and changes in thickness.
Hundreds of part numbers are compression molded using Lytex materials in complex geometries for
commercial aircraft
Lytex® Parts used on Commercial Jets
Products/ End Market
Seat Components
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Products/ End Market
Oxygen Canister Container for Long Haul(Boeing and Airbus) and other Regional Aircra0
Aerospace
Products/ End Market
ISO/ TS 16949:2009 ISO 9001:2008
Certificates
Certificates : ISO 140001:2004
Thank you !!!!
Everton SterzoQuality & Development ManagerEngineered Composites
A. Schulman, Inc. ║ T: 55 (19) 35261229 // C: 55 (19) 9 98172600