Confirmed Presentations

Transcription

1 Confirmed Presentations Enhancing the Operating Costs and Revenue Generation with Composites: A Ten Year Interiors Market Outlook CHRIS RED, Principal, Composites Forecasts and Consulting LLC Current market for advanced composite components and materials in use on commercial aircraft, specifically in interiors Competitive landscape for the suppliers of those components PVDF Foam Applications for Aircraft Interiors: Offering Reduced Weight vs. Composites and Silicone Rubber, FAR Compliance and Cost Reduction JACK DERUYTER, Vice President Business Development, Technifab Inc. How the chemistry works How the material physics work The fabrication process The success of the fabricated parts Environmentally Benign Nanocoatings that Create a Flame-retardant Gas Blanket for Aircraft Interior Foams, Fabrics, Etc. JAIME GRUNLAN, Assistant Professor and Gulf Oil/Thomas A. Dietz Development Professor, Department of Mechanical Engineering, Texas A&M University 500 nm intumescent nanocoatings reduce pkhrr more than 50 % 30 nm chitosan/polyvinylsulfonic acid stops burn on foam with gas blanket Total heat release reduced by as much as 65 % on cotton fabric Transparent, water-based nanocoatings are environmentally benign Light-weight Structure Material and Process CLINT NEWELL, Direct Digital Manufacturing, Stratasys Inc. Ultem 9085 Flame/Smoke/Toxicity (FST) material Additive manufacturing Fused Deposition Molding (FDM) process

2 Thermoplastic Composites Processes for Aircraft Interior Applications MIKE FAVALORO, Business Development Manager, Cutting Dynamics, Inc. Why thermoplastic vs thermoset composites Continuous compression molding process description and examples Tubular structures molding process description and examples Injection over-molding process description and examples Advantages of Flexible Thermoplastic Composite Materials and Advanced Preforming Techniques ROBERT DAVIES, CEO, Fibrtec Introduction to Fibrflex - a new thermoplastic composite material Tailored Fiber Placement combined with drapable woven and braided Fibrflex Consolidation methods Future developments using nanocomposites Nomex XF: New Lightweight, Thin Flame Barrier for FAR and Applications BILL PARDO, Global Marketing Manager Performance Materials, DuPont Protection Technologies Nomex XF Intrinsic Properties Nomex XF in Composites Current Applications Future Applications Process Conversion from Vacuum Bagged Layup to Compression Molding: Thermoset to Thermoplastic NICK BUSCH, R&D Engineer, Triumph Composite Systems Reason to switch materials and process Material selection Process development Benefits of new process Low OSU/FST Epoxy Prepreg Matrix for Aircraft Interior Components JOHNNY LINCOLN, President, Axiom Materials, Inc. RAJ DHAWAN, Axiom Materials, Inc. In response to increasing demand for higher strength, lower toxicity materials for aircraft interiors, Axiom Materials, Inc. has developed and characterized a line of OSU/FST compliant prepregs based on epoxy resin chemistry. Conventional interior prepregs have become a less attractive option for new programs due to increased concern about their toxicity, and a legacy of inconsistent quality, complicated processing cycles, and low strength in both laminar and sandwich structure properties. Epoxy-based, low OSU/FST systems represent a

3 significant step forward in the development of environmentally-benign, high-strength, fireresistant composite products for aircraft interiors. Basic chemistry and driving factors in the development of the prepreg systems are reviewed. Data are presented with respect to physical, mechanical, and flammability properties of the epoxy systems on fiberglass and carbon reinforcements in both laminar and sandwich structures. Data sets indicate performance levels similar to those of traditional phenolic systems with regard to flammability, and superior with regard to strength. Material transition implications and future material designs were also explored. Thermoplastic Composites for Interior Structures DAVID MANTEN, President, DTC Progress of using thermoplastics in seating Interior brackets using press forming and welding Using CFRTP scrap to use in injection molding of interior brackets High Elongation Glass Fibers for Aircraft Interior Applications JUAN C. SERRANO, Business Development Manager JAMES C. PETERS, Associate Director Science and Technology, PPG Industries. Fiber reinforcement cost/benefit analysis Global supply and availability trends Technical performance metrics Low velocity impact testing of various composites made with these fibers Impact prone aircraft interior components such as overhead stowage bins, aircraft flooring/ceiling panels and galleys are traditionally made with honeycomb cored sandwich structures that incorporate fabric based face sheets (made with glass or carbon fibers). This paper will highlight the benefits of recently developed low density/high performance glass fiber reinforcements designed to achieve increased impact performance and lower weight making them ideally suited for these applications. As part of this presentation, fiber reinforcement cost/benefit analysis, global supply and availability trends, and technical performance metrics. Mechanical properties highlighted will include low velocity impact testing of various composite materials produced with these fibers as well as basic static mechanical properties of the reinforcement suitable for aircraft design engineers and prepreg producers. A Comparative Study of High Performance Infusion-grade Thermosetting Resins with Various Advanced Reinforcement Fibers RICK PAUER, Market Manager, CCP Composites Infused laminate property data comparing high performance epoxy resin to both a rubber-modified vinyl-ester and a urethane-ester Infused laminate property data comparing carbon fiber to E-Glass and H-Glass fiber DMA Tg of infused epoxy as compared to vinyl-ester and urethane-ester

4 Out-of-autoclave processing advantages of infused thermosetting resins Reduced Weight Aircraft Interior Structures via Optimized Reinforcements FREDRIK OHLSSON, Product Development Director, Oxeon AB MARK SHIOLENO, Aerospace Sales Manager - North America, Oxeon Inc. Case histories of TeXtreme Spread Tow carbon reinforcements to reduce weight in aircraft structures will be discussed, including design theory, optimization techniques and current research. Spread tow reinforcements Reinforcement optimization Current research Customer case studies Polyarylethersulfone-based Long Fiber Thermoplastics (LFT) for Metal Replacement in Aircraft Interior Applications RALPH D. MAIER, Manager, Aerospace Technologies, BASF Corporation RAJ MATHUR, VP & Director, Technology & Business Development, PlastiComp BASF aerospace materials Polyarylethersulfones PlastiComp Long Fiber Thermoplastics (LFT) based on polyarylethersulfones A Comparison of Various Flammability Test Methods used in Aerospace, Marine and Rail Markets. CARL F. VARNERIN, Vice President Research & Development, Barrday Composite Solutions Advanced composite prepreg materials are used in various applications where flame resistance, reduced smoke and toxicity are requirements in order to protect the public. Most of these applications involve interiors in some way, shape, or form in aircraft, ship or rail cars. All three of these markets have varying flame resistance requirements as well as the test methods used to verify a material s compliance. In some cases, the same composite material could be used in any of these markets, which can create confusion for the design engineer. This paper will review the various flammability test methods by market as well as how these tests differ from one another. Commercial Aircraft Interior FST Compliant Foam Core Materials Past and Future CHRIS KILBOURN, Global Aerospace Manager, DIAB Inc. Presentation of a commercially available foam core material made for thermoplastic resin of PES Polyethersulphone as an alternative to honeycomb. PES foam advances the technology envelope for core material that exceeds the FST, heat release and burn thru requirements for Commercial Aircraft Interiors. Foam cores have been used for many years for interior

5 components in lieu of or in conjunction with honeycomb. PVC based chemistries were used in the 70 and 80 s and later regulated out of usage when the heat release regulation was adopted by the FAA in Current changes in regulations are requiring a move to Heat Release compliance on all interior structures and a new burn thru requirement for the interior shell. This is driving even more materials out of the Commercial Interior Environment. PES and other thermoplastic resins are used to produce Heat Release compliant structures at reduce weight and installed cost over traditional honeycomb sandwich constructions. Weight reduction leads to reduce fuel burn and CO2 emissions. Foams are much easier to make free form structures with than rigid thermoset impregnated honeycombs. This lends itself to use of more free-form shapes instead of flat panel constructs for interior components yielding enhanced passenger experience.