PREPREG System BX Low-temperature. Tooling Structural parts

Transcription

1 PREPREG System BX Low-temperature Tooling Structural parts

2 Overview on mold making Metal and fiber composite molds are used to manufacture components from PREPREG materials. Fiber composite molds are produced using wet lamination and PREPREG technologies. Glass fiber fabric and carbon fiber fabric can be used as reinforcement materials. Requirements to the mold The requirements on a high-quality serial tool are as follows: High contour accuracy under process conditions High surface quality Vacuum integrity Service life > 500 cycles High chemical resistance Low thermal mass Coefficient of thermal expansion similar to that of manufactured parts Short processing time Competitive price Contour accuracy Manufacturing molds with loose and change parts of the highest accuracy of fit requires the application of model materials that have a low coefficient of thermal expansion and a PREPREG material that has the lowest possible initial curing temperature. Therefore the subsequent post-curing cycle is optimized to minimize the shrinkage of the laminate mold. Surface quality The molds are made of PREPREG fabrics of various area-weights. The surface material is a PREPREG with a lightweight fine fabric. This enables finest contour impressions while maintaining high edge stability. This will also ensure high surface quality even after a large number of cycles. The following laminate structure is designed so that tracing of following fabric layers (which are necessary for a rapid build-up of the laminate) does not take place. Component manufacturing Testing laboratory & prototype construction 1.2

3 PREPREG System BX Service life The PREPREG material used provides heat resistance up to 185 C. Practical experience from producing fiber composite components with phenolic or epoxy resin matrix shows that they can run for more than 500 component cycles. The precondition for this is that the laminate is carefully arranged to comply with the intermediate compression steps while strictly avoiding overstretching. Thermal mass, coefficient of thermal expansion CFRP and GFRP laminates provide a lower thermal mass and a lower coefficient of thermal expansion when compared to metallic materials. Competitive price, cycle time The BX system cures at low temperatures. The required autocalve pressure for compacting the laminate is 5 bar. The recommended pressure for consolidation is 6 7 bar in order to achieve the highest surface quality of monolithic components, particularly in mold making. Curing temperature and pressure therefore allow the application of readily available, inexpensive and easily processable master forms. 3D measuring equipment Milling 1.3

4 Tooling PREPREG Glass fiber PREPREG GGBX Carbon fiber PREPREG KGBX Fields of application Common applications are laminating facilities, tools, gauging and fixing devices of high contour accuracy. Processing method Autoclave and pressing technologies. Features The low initial curing temperature between C allows the use of inexpensive master form materials. After initial curing on the master form, the BX laminate can be demolded and post-cured seperately. A very high contour accuracy will be ensured when the mold has sufficient back structure. An exceptional characteristics is the possibility to perform autoclave cycles at a low temperatures. This enables the use of low-cost model materials and procedures. It s recommended to use only epoxy block materials for the master form. Properties The BX system is based on a multifunctional, specifically modified epoxy resin with a curing system being latent at room temperature but highly reactive at elevated temperatures. The BX system has low shrinkage and can be used up to 185 C. Structural components with excellent mechanical properties can be manufactured by using glass, carbon or aramid fibers. The flexibility and tack of the PREPREG are adjusted to achieve outstanding drapability and to allow the facile production of complicated components. 1.4

5 PREPREG System BX Delivery forms of standard systems PREPREG glass fiber fabric PREPREG Carrier g / m² PREPREGweight g / m² Cured ply thickness mm GGBX 1109 Twill 1/ ,08 x1 47 GGBX 2808 Twill 2/ ,22 x1 44 GRBX 5806 Twill 2/2 or plain ,46 x1 38 Resin content % by weight x1 at 50 % fiber volume content PREPREG carbon fiber fabric PREPREG Carrier g / m² PREPREGweight g / m² Cured ply thickness mm KGBX 0909 Plain -1K ,1 x1 47 KGBX 2508 Twill 2/2-3K ,27 x1 44 KGBX 6006 Twill 2/2-12K ,67 x1 40 Resin content % by weight x1 at 50 % fiber volume content Weight loss Volatile components < 1,0 % (10 min / 160 C) Resin flow > 20 % Shelf life At +18 C to + 23 C 3 days At + 2 C to + 8 C 1 3 months At - 18 C 12 months It is necessary to maintain the cooling chain during transportation, because the prepreg already reacts at low temperatures. Best surface qualities will be achieved within a lay-up time of 2 days (maximum 3 days depending on ambitient temperature). 1.5

6 Curing cycles The BX system provides three different curing cycles for mold making and component production, which vary in temperature. BX 60 For manufacturing multi-piece molds with high contour accuracy. Construction of molds on wet laminate forms and epoxy block materials. Initial curing, curing cycle BX 60 Post-curing cycle without master form Vac. (%) P (bar) T ( C) T ( C) h 2h 2h 3h 2h 2h 4h min. 30 min. 30 min. 30 min. 30 min. 30 min. 120 min Vac. (%) P (bar) T ( C) T (h) T (h) BX 65 For manufacturing single-piece molds with high contour accuracy. Use for production of laminates preferably on forms with good heat conductivity and low thermal expansion coefficients. Initial curing on master form, curing cycle BX 65 Post-curing cycle without master form Vac. (%) P (bar) T ( C) T ( C) h Vac. (%) P (bar) T ( C) T (h) h 2h 2h 3h 2h 30 min. 30 min. 30 min. 30 min. 30 min. 30 min. 120 min h T (h) 1.6

7 PREPREG System BX BX 80 Structure of thin-walled laminates (< 3.5 mm) for templates and devices. Suitable for producing components in reasonably priced molds. Initial curing on master form, curing cycle BX 80 Post-curing cycle without master form Vac. (%) P (bar) T ( C) T ( C) h Vac. (%) P (bar) T ( C) T (h) h 2h 2h 2h 30 min. 30 min. 30 min. 30 min. 30 min. 30 min. 120 min h T (h) After initial curing on the master form or in the mold, the laminate can be demolded and post-cured to the desired heat deflaction temperature. To ensure that the post-curing is free of distortion, the stated cycles must be strictly adhered to. Dimension stability up to 185 C is attained by post-curing at 180 C. If a lower heat deflection temperature is sufficient, a heat deflection temperature can be achieved by post-curing at lower temperatures. The heat deflaction temperature will be approximatlely 10 C below the applied post-curing temperature. 1.7

8 Laminate structure Lamination of molds The BX system utilizes fabrics with twill or plain weave. These fabrics are symmetrical to the median plane and therefore makes the symmetrical laminate construction easier. These fabrics are optimized with regard to their resin content and resin flow. A great reduction in thickness leads to a sliding of PREPREG layers and can result in a relocation or a local overstretching. The design of cuts is important, too. Local overstretching can be avoided by small overlaps beween adjacent layers. In case of too large overlaps, friction will prevent the relative sliding of adjacent layers. The overstretching of only one layer can result in costly reworking, insufficient vacuum integrity or internal rejects. Intermediate compression of the first layer improves the better surface quality. The intermediate compression steps specified in the layout plan must be observed in sequence and length. Performing intermediate compression at elevated temperatures will worsen the ventilation of the laminate. The intermediate compression can be retained longer than stated, though. The auxiliary materials must be chosen to ensure a good airflow and to avoid overstretching. Avoiding overstretching The most frequently occurring error is the local overstretching of the fabric. This results in an inadequate compression of the composite. This also leads to porosity, insufficient vacuum integrity and limited durability of the mold laminate. Overstretching should also be avoided when positioning an air-conveying layer ( AIRWEAVE ), especially when peel plies are used. The material of the air-conveying layer needs a good drapability to exclude local overstretching. 1.8

9 PREPREG System BX Overstretching can be avoided by an overlap between stripwise cuts. An overlapping length of approximately 4 10 mm has proven to be effective. Also the overlap area should shift from layer to layer by approximately mm. Similar to the PREPREG, air-conveying non-woven fabrics and peel plies should be cut into strips and arranged with an overlap to avoid overstretching. Formation of edges, corners and tight radii 1) Laminate structure Layer No. Orientation Material Note 1.1 ± 45 KGBX 0909 Internal corner reinforcement 1.2 ± 45 KGBX 0909 Strip extendeing over the full width of the recess with overlap to the corners 1.3 ± 45 KGBX 0909 Strip with overlapping to adjacent areas 1.4 ± 45 KGBX 0909 Internal corner with overlapping to 1.2 and adjacent area 1.5 ± 45 KGBX 0909 Internal corner with overlapping to 1.2 and adjacent area 1.6 ± 45 KGBX 0909 Strip with overlapping to ± 45 KGBX 0909 Strip with overlapping to 1.1 and ± 45 KGBX 0909 Strip with overlapping to 1.3 and ± 45 KGBX 0909 Strip with overlapping to 1.3 1) Manufacturing recommendation based on laminate structure LC3. Analogous approach applies to other laminate structures. 1.9

10 LC1 laminate structure with carbon fiber fabric for mainly flat or continuously curved forms 1 KGBX / 90 Intermediate compression: at least 90 minutes. 2 KGBX / 90 3 KGBX / 90 turned 4 KGBX / 90 5 KGBX / 90 turned 6 KGBX / 90 7 KGBX / 90 turned 8 KGBX / 90 9 KGBX / 90 turned 10 KGBX / KGBX / 90 turned 12 KGBX / KGBX / 90 turned Easy cut / Little trim waste 1.10

11 PREPREG System BX LC2 laminate structure with carbon fiber fabric for moulds with curved contours 1 KGBX 0909 ± 45 Intermediate compression: at least 90 minutes. 2 KGBX 2508 ± 45 3 KGBX 2508 ± 45 turned 4 KGBX 6006 ± 45 5 KGBX / 90 turned 6 KGBX / 90 7 KGBX / 90 turned 8 KGBX / 90 9 KGBX / 90 turned 10 KGBX / KGBX 6006 ± 45 turned 12 KGBX 2508 ± KGBX 2508 ± 45 turned Good standard structure / Higher waste volume 1.11

12 LC3 laminate structure with carbon fiber fabric for moulds with highly curved contours 1 KGBX 0909 ± 45 Intermediate compression: at least 90 minutes. 2 KGBX 2508 ± 45 3 KGBX 2508 ± 45 turned 4 KGBX 6006 ± 45 5 KGBX 6006 ± 45 turned 6 KGBX 6006 ± 45 7 KGBX 6006 ± 45 turned 8 KGBX 6006 ± 45 9 KGBX 6006 ± 45 turned 10 KGBX 6006 ± KGBX 6006 ± 45 turned 12 KGBX 2508 ± KGBX 2508 ± 45 turned Good standard structure / Higher waste volume 1.12

13 PREPREG System BX LG1 laminate structure with glass fiber fabric for mainly flat or continuously curved forms 1 GGBX / 90 Intermediate compression: at least 90 minutes. 2 GGBX / 90 3 GGBX / 90 turned 4 GRBX / 90 5 GRBX / 90 turned 6 GRBX / 90 7 GRBX / 90 turned 8 GRBX / 90 9 GRBX / 90 turned 10 GRBX / GRBX / 90 turned 12 GRBX / GRBX / 90 turned 14 GGBX / GGBX / 90 turned Easy cut / Little trim waste 1.13

14 LG2 laminate structure with glass fiber fabric for moulds with curved contours 1 GGBX 1109 ± 45 Intermediate compression: at least 90 minutes. 2 GGBX 2808 ± 45 3 GGBX 2808 ± 45 turned 4 GRBX 5806 ± 45 5 GRBX / 90 turned 6 GRBX / 90 7 GRBX / 90 turned 8 GRBX / 90 9 GRBX / 90 turned 10 GRBX / GRBX / 90 turned 12 GRBX / GRBX 5806 ± 45 turned 14 GGBX 2808 ± GGBX 2808 ± 45 turned Good standard structure / Higher waste volume 1.14

15 PREPREG System BX LG3 laminate structure with glass fiber fabric for moulds with highly curved contours 1 GGBX 1109 ± 45 Intermediate compression: at least 90 minutes. 2 GGBX 2808 ± 45 3 GGBX 2808 ± 45 turned 4 GRBX 5806 ± 45 5 GRBX 5806 ± 45 turned 6 GRBX 5806 ± 45 7 GRBX 5806 ± 45 turned 8 GRBX 5806 ± 45 9 GRBX 5806 ± 45 turned 10 GRBX 5806 ± GRBX 5806 ± 45 turned 12 GRBX 5806 ± GRBX 5806 ± 45 turned 14 GGBX 2808 ± GGBX 2808 ± 45 turned Good standard structure / Higher waste volume 1.15

16 Vacuum bag Lay-up of the vacuum bag The excess of resin passes into the non-woven fabric through perforated release film. Air circulation and ventilation of the laminates can be guaranteed even if the materials have a high resin content. Before mounting stiffening ribs onto the laminate, it is recommended to utilize a peel ply on the laminate surface. Vacuum foil Air-ducting layer AIRWEAVE Sealing tape Release film Fleece for receiving the resin surplus Perforated release film Peel ply Laminate Master form Lay-up of the vacuum bag for the intermediate compression For best surface qualities, a intermediate compression time of 12 hours for the first layer is recommended. Sealing tape Vacuum foil Air-ducting layer Embossed film (Pyramid pattern top facing to Prepreg) Laminate Master form 1.16

17 PREPREG System BX Autoclave curing To guarantee the quality of the laminates, it is very important to lead the airflow in the autoclave as evenly as possible through the model which contains the lay-up. The model has to be positioned in the autoclave in a way that ensures good air circulation and sufficient heat transfer. If the upper side of the laminate cures before the lower side, inclusions of volatile components and deformation will be unavoidable due to internal stresses. The ideal case for curing a laminate would be an uniform heating from both sides. Then the laminate cures evenly throughout the cross section. In molding processes with models of different wall thicknesses, an uniform heating of the laminate is only possible when the gradual warming of all model and laminate zones is realized. This can only be achieved by the correct curing cycle and an appropriate positioning of the tool in the autoclave. Lay-up on autoclave carts Apart from the curing cycle, which enables a slow and constant heating even through different cross sections of the master form, the airflow in the autoclave is also important for component quality. The airflow should be as undisturbed as possible when being passed through the upper and lower sides. The model should be positioned as shown in the figure below. 1.17

18 Technical data of KGBX 0909 Prepreg characteristic values Property Standard Unit Typical value Resin type - - Epoxy resin Fiber reinforcement type - - Carbon-HT - 1K Fiber areal weight EN g / m² 93 Warp tex 67 Yarn count Weft DIN EN ISO 1889 tex 67 Warp ends / cm 7 Thread count Weft DIN EN ends / cm 7 Weave style DIN ISO Plain Resin flow DIN EN 2560 % > 20 PREPREG areal weight DIN EN 2557 g / m² 175 Resin content DIN EN 2559 % by weight 47 Fiber density - g / cm³ 1.78 Cured ply thickness (fiber volume content of 50 %) - mm 0.11 Laminate characteristic values Property Standard Unit Typical value Flexural strength DIN EN ISO MPa > 800 Tensile strength DIN EN ISO MPa - Interlaminar shear strength DIN EN ISO MPa 40 Flexural modulus DIN EN ISO GPa - Tensile modulus DIN EN ISO GPa - Laminate density DIN g / cm³ 1.6 Fiber-dependent parameters are converted to 50 % by volume according to EN

19 PREPREG System BX Technical data of KGBX 2508 Prepreg characteristic values Property Standard Unit Typical value Resin type - - Epoxy resin Fiber reinforcement type - - Carbon HT - 3K Fiber areal weight EN g / m² 245 Warp tex 200 Yarn count Weft DIN EN ISO 1889 tex 200 Warp Thread count 6 Thread count Weft DIN EN Thread count 6 Weave style DIN ISO Twill 2/2 Resin flow DIN EN 2560 % > 20 PREPREG areal weight DIN EN 2557 g / m² 440 Resin content DIN EN 2559 % by weight 44 Fiber density - g / cm³ 1.78 Cured ply thickness (fiber volume content of 50 %) - mm 0.28 Laminate characteristic values Property Standard Unit Typical value Flexural strength DIN EN ISO MPa 850 Tensile strength DIN EN ISO MPa - Interlaminar shear strength DIN EN ISO MPa 40 Flexural modulus DIN EN ISO GPa 50 Tensile modulus DIN EN ISO GPa - Laminate density DIN g / cm³ 1.6 Fiber-dependent parameters are converted to 50 % by volume according to EN

20 Technical data of KGBX 6006 Prepreg characteristic values Property Standard Unit Typical value Resin type - - Epoxy resin Fiber reinforcement type - - Carbon HT - 12K Fiber areal weight EN g / m² 600 Warp tex 800 Yarn count Weft DIN EN ISO 1889 tex 800 Warp Thread count 3.7 Thread count Weft DIN EN Thread count 3.7 Weave style DIN ISO Twill 2 / 2 Resin flow DIN EN 2560 % > 20 PREPREG areal weight DIN EN 2557 g / m² 1000 Resin content DIN EN 2559 % by weight 40 Fiber density - g / cm³ - Cured ply thickness (fiber volume content of 50 %) - mm 0.67 Laminate characteristic values Property Standard Unit Typical value Flexural strength DIN EN ISO MPa > 700 Tensile strength DIN EN ISO MPa 570 Interlaminar shear strength DIN EN ISO MPa 56 Flexural modulus DIN EN ISO GPa 56 Tensile modulus DIN EN ISO GPa 54 Laminate density DIN g / cm³ 1.6 Fiber-dependent parameters are converted to 50 % by volume according to EN

21 PREPREG System BX Mechanical properties after exposure to high temperature, for example KGBX 2508* Characterisitc values at different temperatures Property Unit Room temperature 120 C 180 C Interlaminar shear strength MPa Flexural strength MPa Flexural modulus GPa Characterisitc values after long-term exposure at 180 C (test performed at room temperature) Property Unit 100 h 200 h 400 h 2500 h 5000 h Interlaminar shear strength MPa Flexural strength MPa Flexural modulus GPa Characterisitc values after x runs of the temperature cycle ** (test performed at room temperature) Property Unit Number of runs 50 Number of runs 100 Interlaminar shear strength MPa Flexural strength MPa Flexural modulus GPa Number of runs 200 * The test laminates are cured and post-cured by curing cycle BX60 ** Temperature cycle Heating rate 2.6 C / min. to 180 C Dwell 180 C for 2 hours Cooling rate 2.6 C / min. to 25 C 1.21

22 Technical data of GGBX 1109 Prepreg characteristic values Property Standard Unit Typical value Resin type - - Epoxy resin Fiber reinforcement type - - Glass filament fabric Fiber areal weight EN g / m² 105 Warp tex EC 5-11 x 2 Yarn count Weft DIN EN ISO 1889 tex EC 5-11 x 2 Warp Thread count 24 Thread count Weft DIN EN Thread count 23 Weave style DIN ISO Twill 1/3 Resin flow DIN EN 2332 % > 20 PREPREG areal weight DIN EN 2329 g / m² 200 Resin content DIN EN 2331 % by weight 47 Fiber density - g / cm³ 2.54 Cured ply thickness (fiber volume content of 50 %) - mm 0.08 Laminate characteristic values Property Standard Unit Typical value Flexural strength DIN EN ISO MPa > 340 Tensile strength DIN EN ISO MPa - Interlaminar shear strength DIN EN ISO MPa 40 Flexural modulus DIN EN ISO GPa 18 Tensile modulus DIN EN ISO GPa - Laminate density DIN g / cm³ 2.0 Fiber-dependent parameters are converted to 50 % by volume according to EN

23 PREPREG System BX Technical data of GGBX 2808 Prepreg characteristic values Property Standard Unit Typical value Resin type - - Epoxy resin Fiber reinforcement type - - Glass filament fabric Fiber areal weight EN g / m² 280 Warp tex EC 9-68 x 3to Yarn count Weft DIN EN ISO 1889 tex EC 9-204tex Warp Thread count 7 Thread count Weft DIN EN Thread count 6.5 Weave style DIN ISO Twill 2/2 Resin flow DIN EN 2332 % > 20 PREPREG areal weight DIN EN 2329 g / m² 505 Resin content DIN EN 2331 % by weight 44 Fiber density - g / cm³ 2.54 Cured ply thickness (fiber volume content of 50 %) - mm 0.22 Laminate characteristic values Property Standard Unit Typical value Flexural strength DIN EN ISO MPa 600 Tensile strength DIN EN ISO MPa - Interlaminar shear strength DIN EN ISO MPa 50 Flexural modulus DIN EN ISO GPa 18 Tensile modulus DIN EN ISO GPa - Laminate density DIN g / cm³ 2.0 Fiber-dependent parameters are converted to 50 % by volume according to EN

24 Technical data of GRBX 5806 Prepreg characteristic values Property Standard Unit Typical value Resin type - - Epoxy resin Fiber reinforcement type - - Glass roving fabric Fiber areal weight EN g / m² 580 Yarn count Warp tex EC DIN EN ISO 1889 Weft tex EC Thread count Warp Thread count 2.5 DIN EN Weft Thread count 2.2 Weave style DIN ISO Plain Resin flow DIN EN 2332 % > 20 PREPREG areal weight DIN EN 2329 g / m² 930 Resin content DIN EN 2331 % by weight 38 Fiber density - g / cm³ 2.54 Cured ply thickness (fiber volume content of 50 %) - mm 0.46 Laminate characteristic values Property Standard Unit Typical value Flexural strength DIN EN ISO MPa 360 Tensile strength DIN EN ISO MPa - Interlaminar shear strength DIN EN ISO MPa 40 Flexural modulus DIN EN ISO GPa 18 Tensile modulus DIN EN ISO GPa - Laminate density DIN g / cm³ 2.0 Fiber-dependent parameters are converted to 50 % by volume according to EN

25 PREPREG System BX Mechanical properties after exposure to high temperature, for example GGBX 1109* Characterisitc values at different temperatures Property Unit Room temperature 120 C 180 C Interlaminar shear strength MPa Flexural strength MPa Flexural modulus GPa Characterisitc values after long-term exposure at 180 C (test performed at room temperature) Eigenschaft Einheit 100 h 200 h 400 h 1250 h 2500 h 5000 h Interlaminar shear strength MPa Flexural strength MPa Flexural modulus GPa Characterisitc values after x runs of the temperature cycle ** (test performed at room temperature) Property Unit Number of runs 50 Number of runs 100 Interlaminar shear strength MPa Flexural strength MPa Flexural modulus GPa Number of runs 200 * The test laminates are cured and post-cured by curing cycle BX60 ** Temperature cycle Heating rate 2.6 C / min. to 180 C Dwell 180 C for 2 hours Cooling rate 2.6 C / min. to 25 C 1.25

26 Gel time and viscosity Gel time and viscosity of PREPREG system BX TIME [min.] COMPLEX VISCOSITY [Pa s] K/min 2 K/min TEMPERATURE [ C] 0, TEMPERATURE [ C] 1,0E ,0E COMPLEX VISCOSITY [Pa s] 1,0E+05 1,0E+04 1,0E+03 1,0E+02 1,0E+01 Temperature Viscosity TEMPERATURE [ C] 1,0E ,0E TIME [min] Glass transition temperature depending on curing temperature Curing Tg Glass transition temperature 6 h / 60 C 65 C 40 C + 3 h / 80 C114 C 88 C + 2 h / 100 C136 C110 C + 3 h / 125 C162 C131 C + 2 h / 150 C175 C150 C + 4 h / 180 C193 C174 C Tw* Resoftening temperature *Temperature limit under mechanical stress (temperature at which the storage modulus decreases significantly) 1.26

27 PREPREG System BX Nomenclature Different PREPREG types are described by combinations of letters and digits, from which the structure and application range of the material can be read. PREPREGS UD PREPREGS PREPREGS are described by 4 letters and 4 following digits. e.g. PREPREG K G B X st letter fiber type A aramid fibers B basalt E polyester fibers G E-glass fibers H blended fibers K carbon fibers (HT) M carbon fibers (HM) Q silicate fibers 2nd letter surface structures B bidirectional 0/90 G fabric M multi-directional R roving fabric U unidirectional C crossply ±45 3rd letter resin type B epoxy resin C triazine resin H polyimide resin P phenolic resin T epoxy resin (TGDA) S silicone resins 4th letter Curing temperature A 60 C B 80 C C 100 C D 120 C E 140 C F 160 C G 180 C H 200 C I 222 C X variable temperature 1st + 2nd digit x 10 Carrier grammage in g / m² for example 25 x 10 = 250 g / m² 3rd + 4th digit x 10 Resin coating in % by weight of the carrier for example 08 x 10 = 80 % by weight All values should be considered as guideline values. Subject to change. We assume no obligations or liability concerning this information. Version: 10/2016 KREMPEL GmbH ǀ info@krempel-group.com ǀ Tel: ǀ

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29 PREPREG System BX Note 1.29

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31 PREPREG System BX Note 1.31

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