Advanced Materials. Composites technology for mass production. A global offer to the automotive industry

Transcription

1 Advanced Materials Composites technology for mass production A global offer to the automotive industry

2 A new step forward in composites mass production The brand enabling lightweight solutions in the worldwide composite industry for more than half a century Whilst the level of global business competition in automotive is high, manufacturers need solutions to help sustain their competitive edge and secure long-term growth. Production process improvement, innovation in design, weight savings, compliance to stringent safety and environmental standards, and low process costs have become vital to success. In this context, Huntsman Advanced Materials offers multiple innovative composite solutions including new process and simulation services dedicated to the automotive industry. Our specifi c range of composites solutions for the automotive industry meets your needs for both high performance and reduced production cycles. Rely on us with confidence As a global partner and innovator working in close collaboration with all major industries using fi ber reinforcement, we offer our customers a unique range of innovative high value thermosetting formulated systems combined with a strong technical support. Huntsman leverages its core strengths in synthesis and formulation to produce high performance materials that deliver improved mechanical and thermal performance in the area of composites. Our application engineers can support you with advice and practical recommendations on how to optimize the use of Huntsman s products in your chosen manufacturing process. We deliver more than just products Our process know-how and over 60 years expertise help us to develop standard products as well as custom-made solutions formulated to answer project requirements. Our worldwide team of experts is dedicated to : > identify with you the best system meeting your needs > develop when needed new material solutions > reduce manufacturing and production costs through process time reduction based on shorter cure cycles > help you to improve the quality, the durability and the performance of your products such as lightness but also mechanical, temperature, fi re, chemical or corrosion resistance and more > RTM, High pressure RTM > Wet compression molding > quickly bring your product to market through material and process optimization > Filament winding > Pultrusion > Prepreg 2 3

3 Solutions for body-in-white structures Solutions for leaf springs Araldite LY 3031 / Aradur 3032 (1) Araldite LY 3585 / Aradur 3475 (1) Araldite LY 3585 / Aradur 3831 (1) Araldite LY 3585 / Aradur 3834 (1) Very fast cure solution for WCM The new 30 sec. cure system has been developed to improve productivity and meet requirements of structural automotive parts made by Wet Compression Molding (WCM) and Dynamic Fluid Compression Molding (DFCM). Typical cure cycle 30 s at 140 C 2 min at 115 C Tensile modulus (2) MPa MPa Fast cure solution for HP-RTM / WCM The resin system offers enhanced processing, reduced curing cycle and improved toughness. It has also proved suitability for producing cosmetic parts thanks to its specifi c chemical network and shrinkage development. First generation system Proven leaf-spring system, shown to withstand real-world fatigue under severe hot/wet conditions. A cured Tg of 125 C covers most leaf-spring customer requirements. High Tg solution A second-generation solution based on innovative technology, offering a Tg in excess of 140 C together with increased fatigue resistance. Answering the need for a solution capable to endure the harshest hot/wet conditions, such as those encountered close to the vehicle engine. Tensile strength (2) MPa MPa Tensile elongation (2) 5-7 % 8-10 % DSC Tg midpoint (3) C C DMA Tg onset (4) C C ILSS (5) MPa MPa Fast curing resin solutions designed for highly structural applications. Their high toughness makes them ideal for the production of highly impact-resistant composite parts. In addition to providing the required process latency, the new solutions exhibit very fast demold stiffness development, enabling drastic reductions in cure time. Cosmetic parts can be achieved, even with the use of internal release agents. Araldite LY 3585 / XB 3458 (1) BMW «i» qualified system the fi rst generation solution offering proven reliability and robust processing since Cure time versus injection time / injection window Fast curing epoxy solutions with high thermo-mechanical properties and fatigue resistance ideal for the production of composite leaf springs. Suitable for fast robust HP-RTM processing allowing effi cient production of high-thickness composite parts. Araldite solutions have been shown to produce composite leaf springs in less than 5 minutes in-mold curing (105 C cure: > 98% cure conversion) able to withstand long-term dynamic loading even under severe hot/wet conwditions. Testing and simulation capabilities State-of-the-art fatigue testing and computer simulation capabilities mean that Huntsman can support customers developing their composite leaf spring technology. In-house expertise in mechanical coupon characterization (hot/wet fatigue testing up to 80 C and 90% humidity) provides relevant insight to the application requirements. In addition, our simulation expertise in fl ow and rheo-kinetics enables process optimization from the fi rst leaf-spring injection trials through to full qualifi cation and serial production. (1) Data generated with 1-2 phr internal release agent (2) ISO on neat resin (3) 5 C/min, ISO on CFRP (4) Torsion mode, 2 C/min, ISO 6721 on CFRP (5) 50K UD, TVf 50%, ASTM D2344 on CFRP (1) Data generated with 1 phr internal release agent S-N curve: UD GFRP flexural dynamic properties (ISO 14125) 4 5

4 Preforming solution Fire retardant solutions for battery housings Araldite LT 3366 epoxy binder Araldite FST / New development Softening point ca. 150 C DSC Tg mid-point C Typical preforming cycle Qualified for mass production of powdered fabrics and preforms (1) High softening point preventing ply-to-ply adhesion during storage and fi ber distortion during injection. Fast preforming cycle. 20 ± 10 s at 180 ± 20 C + cold stamping First generation system In addition to fi re resistance the system features a low mix viscosity and wide process window, allowing effi cient manufacture even of large parts such as battery packs, with in-mold cure times as low as 5 minutes at 150 C. UL94 CFRP (1) V1 V0 UL94 GFRP (2) V0 V0 Tensile modulus (3) MPa MPa High mechanical performance The most recent development pushes the capabilities even further, increasing structural properties and providing parts with UL94 V0 fi re resistance on both carbon and glass reinforcements over varying thicknesses. Tensile strength (3) MPa MPa Tensile elongation (3) 1-2 % 3-4 % K 1C (3) MPa. m MPa. m Solutions for automotive wheels G 1C (3) J/m J/m 2 DMA Tg onset (3) C C Araldite LY 1560 / Aradur / DY 079 Araldite LY 8615 / Aradur 8615 Cosmetic and toughened solution A new resin system featuring improved aesthetics for carbon-look parts, increased toughness for high part durability and optimized reactivity to achieve low moldcycle times. Typical in mold cure time 15 min 20 min Tensile modulus (2) MPa MPa Tensile strength (2) MPa MPa Tensile elongation (2) 4-5 % 1-2 % High thermal resistance system The fi rst generation system dedicated for the production of hybrid and full-composite wheels by RTM and HP- RTM. The system is OEM qualifi ed and has proven performance and reliability from several years of on-road service. Araldite solutions for battery housings are based on a unique halogen-free thermosetting chemistry to meet the fi re resistance requirements of electric vehicles. They are unfi lled, fast-curing and offer low reaction enthalpy, enabling fast and effi cient production of composites parts by HP-RTM, WCM or DFCM, including even thick parts. High thermo-mechanical properties ensure battery cells are fully protected, whilst providing design freedom, light weight and corrosion resistance. DSC Tg midpoint (3) C C DMA Tg onset (4) C C (1) Typical preforming conditions: cold pressing after infra-red heating (2) ISO on neat resin (3) 10 C/min, ISO on neat resin (4) Tensile mode, 2 C/min ISO 6721 on neat resin (1) Flame resistance screening test UL94 vertical burning mm thickness, 50% FVC (2) Flame resistance screening test UL94 vertical burning mm thickness, 50% FVC (3) Test on neat resin coupons cured for 5 min at 150 C + 2 h at 180 C 6 7

5 Scan to download the App on ipad Explore how to improve manufacturing performance using simulation. Exclusive composite process Simple and fast, the Dynamic Fluid Compression Molding process bypasses the injection step and brings composites production cycle to just 1 minute Advanced process simulation Simulation is used to determine suitable resin solutions and to design a production process tailored to each part Autoclave quality in 1 minute Combining a novel process and fast-cure Araldite epoxy solutions, highly structural parts with outstanding properties can be produced in 1 minute. This process is simple, fast and cost effective, requiring low pressure (typically 30 bar) and often removing the need for a fi ber preform. Exceptional benefi ts versus standard wet compression molding: outstanding mechanical performance thanks to fi ber volume content up to 65% in a low wastage process, simple processing, even with heavy-tow industrial reinforcements, void-free parts produced consistently straight from the mold. NEW exclusive DFCM process > Fiber volume content up to 65% > Void-free parts > Faster process vs. RTM > Simple processing of heavy-tow industrial fabrics > Pressure only 30 bar > Fiber wash eliminated > Low equipment investment > Reduced waste > Fiber preform not mandatory > Complex parts possible (medium draw or 2.5+D) > Consistent part quality Cure simulation can substantially reduce production times as well as part development times by simplifying process engineering and enabling selection of the correct resin system and process parameters. Flow simulation in liquid composite molding helps process engineers to evaluate injection strategies and fi nd optimum processing parameters leading to properly fi lled parts. Cure simulation > curing cycle Generation of material models Accurate rheokinetic data of the resin systems are used to generate material models which are projected onto CAD data. This enables the prediction of the material behavior during the injection and curing process at each point on a composite part. Flow simulation > fl ow front evolution and fi lling time > exotherm temperature > pressure evolution > evolution of Tg and conversion rate during cure > process induced fi lling variability (e.g. fl ow channels, inserts) inlet inlet HP-RTM Standard WCM New DFCM Prediction of cure progress (left) and exotherm (right) Impact of inlet geometry on the flow pattern Reduced production cycles and development times Consistent quality straight from the mold Resin system selection I Early stage process design I Process parameter determination I Process safety Improved fl ow patterns and injection concepts Low porosity, medium FVC (50%) High porosity, high FVC (60%) Low porosity, high FVC (60%) 8 9

6 We value your challenge By providing unique, certifi ed or patented technologies, combined with high quality and reliability, our chemists and experts bring enhanced value to our customers, ensuring their success. With innovation Every day, all over the world, our Technical Competence centers engage in intensive research and development focusing on one goal : to deliver innovative solutions by working hand-in-hand with our business partners. Together through a continual exchange of ideas, supported by an experienced team of sales and technical specialists, we strive to deliver innovative and regulatory compliant (eg REACH compliant) solutions. We track both new market expectations and changing regulations. Protection of the environment, as well as health and safety are paramount concerns, playing an integral part in our development projects. With customer intimacy We market a unique product portfolio and a broad range of forward-looking solutions for our customers. Customers and partners benefi t from an advanced level of service in: > product selection and quality > product trials in-house and with customers > customer seminars and trainings > technical service and solution-providing Partnership with our customers is more than simply «putting them fi rst». It requires long-term commitment to forging close relationships that create synergies of knowledge, security and adaptability to create a successful, shared future. With care Sustainability is a fundamental part of our corporate and business strategy. We see a better world in which our innovations help reduce consumption of natural resources and improve the quality of life for people everywhere. We are identifying the long - term trends that affect our markets and looking to see how products and applications can play a part in supporting and providing solutions to the challenges those markets face

7 Huntsman Advanced Materials Our Advanced Materials division is a leading global chemical solutions provider with a long heritage of pioneering technologically advanced epoxy, acrylic, phenolic and polyurethane-based polymer products. Our capabilities in high-performance adhesives and composites, delivered by more than associates, serve over global customers with innovative, tailor-made solutions and more than products which address global engineering challenges. We operate synthesis, formulating and production facilities around the world For more information advanced_materials@huntsman.com Europe, Middle East & Africa Huntsman Advanced Materials (Switzerland) GmbH Klybeckstrasse 200 P.O. Box 4002 Basel Switzerland Tel Fax Asia Pacific & India Huntsman Advanced Materials (Guangdong) Co., Ltd. Room , Maxdo Centre, 8 Xing Yi Road, Shanghai , P.R.China Tel Fax Americas Huntsman Advanced Materials Americas Inc Woodloch Forest Drive The Woodlands Texas USA Tel Fax Legal information All trademarks mentioned are either property of or licensed to Huntsman Corporation or an affi liate thereof in one or more, but not all, countries. Sales of the product described herein ( Product ) are subject to the general terms and conditions of sale of either Huntsman Advanced Materials LLC, or its appro priate affi liate including without limitation Huntsman Advanced Materials (Europe) BVBA, Huntsman Advanced Materials Americas Inc., or Huntsman Advanced Materials (Hong Kong) Ltd. or Huntsman Advanced Materials (Guangdong) Ltd. ( Huntsman ). The following supercedes Buyer s documents. While the information and re com mendations included in this publication are, to the best of Huntsman s knowledge, accurate as of the date of publication, NOTHING CONTAINED HEREIN IS TO BE CONSTRUED AS A REPRESENTATION OR WARRANTY OF ANY KIND, EXPRESS OR IMPLIED, INCLUDING BUT NOT LIMITED TO ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE, NONINFRINGEMENT OF ANY INTELLEC TUAL PROPERTY RIGHTS, OR WARRANTIES AS TO QUALITY OR CORRESPONDENCE WITH PRIOR DESCRIPTION OR SAMPLE, AND THE BUYER ASSUMES ALL RISK AND LIABILITY WHATSOEVER RESULTING FROM THE USE OF SUCH PRODUCT, WHETHER USED SINGLY OR IN COMBINATION WITH OTHER SUBSTANCES. No statements or recommendations made herein are to be construed as a representa tion about the suitability of any Product for the particular application of Buyer or user or as an inducement to infringe any patent or other intellectual property right. Data and results are based on controlled conditions and/or lab work. Buyer is responsible to determine the applicability of such information and recommendations and the suitability of any Product for its own particular purpose, and to ensure that its intended use of the Product does not infringe any intellectual property rights. The Product may be or become hazardous. Buyer should (i) obtain Material Safety Data Sheets and Technical Data Sheets from Huntsman containing detailed information on Product hazards and toxicity, together with proper shipping, handling and storage procedures for the Prod uct, (ii) take all steps necessary to adequately inform, warn and familiarize its employees, agents, direct and in direct customers and contractors who may handle or be exposed to the Product of all hazards pertaining to and proper procedures for safe handling, use, storage, transportation and disposal of and exposure to the Product and (iii) comply with and ensure that its employees, agents, direct and indirect customers and contractors who may handle or be exposed to the Product comply with all safety information contained in the applicable Material Safety Data Sheets, Technical Data Sheets or other instructions provided by Huntsman and all applicable laws, regulations and standards relating to the handling, use, storage, distribution and disposal of and exposure to the Product. Please note that products may differ from country to country. If you have any queries, kindly contact your local Huntsman representative Huntsman Corporation. All rights reserved. Ref. No. Composite technology for mass production 03.18_EN_EU Concept and design by Zygmund SARL