AEROSPACE QUALIFIED PREPREGS

Transcription

1 PRODUCT INFORMATION : AEROSPACE QUALIFIED PREPREGS DELIVERING THE FUTURE OF COMPOSITE SOLUTIONS AEROSPACE QUALIFIED PREPREGS gurit@gurit.com

2 ADVANCED COMPOSITE MATERIALS FOR THE AEROSPACE INDUSTRY Gurit has developed a broad range of strong, light and fire-retardant aerospace materials which are ideally suited for interior or structural components such as passenger and cargo floor panels, cabin linings, ceiling panels, air ducts, plenums, overhead compartments, lavatories, galleys, bars, wardrobes, partitions, seats, flap track and belly fairings, winglets and fins, landing gear doors, trailing edges and brackets. Gurit offers four resin chemistries: CHEMISTRY DESCRIPTION PAGE PHENOLIC Phenolic based chemistry is well established within the aerospace and rail industries where ultimate fire retardancy, low smoke emission and low smoke toxicity (FST) properties are required. Phenolic prepregs are therefore commonly used in interior aircraft components such as side walls and flooring. 2 RESIN CHEMISTRIES EPOXY CYANATE ESTER Gurit has a range of fire-retardant epoxy systems suitable for applications where increased mechanical properties are required. They generally exhibit good flame spread properties and can be used in more structural components compared to phenolics such as flooring panels. Where the optimum blend of FST and mechanical properties is required, Gurit epoxy prepregs also can be co-cured with phenolic prepregs. This is an established approach to the manufacture of aerospace flooring sandwich panels. Cyanate ester prepregs provide excellent FST properties and can be used in thermally demanding applications due to their high glass transition temperatures (>200 o C). Laminates constructed with cyanate ester prepregs demonstrate very low gas permeability and are volatile-free, resulting in low void and porous free components. This together with their excellent FST and high Tg properties make them ideal for airconditioning ducting construction in aerospace applications. 4 6 BENZOXAZINE Gurit s Benzoxazine prepregs represent the next generation of fire-retardant chemistry where similar FST properties to phenolics are required. An advantage of Benzoxazine chemistry is that it is phenol and formaldehyde free meeting the latest environmental standards. Additionally, during cure, Benzoxazine prepregs are volatile-free resulting in low void and porus-free components, therefore eliminating costly reworking processes associated with the manufacture of phenolic-based prepreg components. 7 FLOORING DUCTING INTERIORS COMPONENTS TYPICAL APPLICATIONS PAGE Front cover image courtesy of Pilatus Aircraft Ltd. AEROSPACE APPLICATIONS A. SECONDARY STRUCTURES, LAMINATES AND SANDWICHES Belly Fairing, Flap Track Fairing, APU Air Intake and Fairing, D-Nose (leading Edge) Vertical Tail Plane B. INTERIOR 1. ENVIRONMENTAL CONTROL SYSTEM / AIRDUCTS 9 2. PASSENGER INTERIOR Lining, Dado, Ceiling, Lavatories, Galleys 3. PASSENGER FLOOR CARGO LINING 5. CARGO FLOOR 6. INTERIOR GALLEYS 7. HELICOPTER INTERIOR

3 PHENOLIC PREPREG SYSTEMS PRODUCT MAIN FEATURES FIRE PERFORMANCE / QUALIFICATIONS PH600 (Ks)* / PF800 (Zu)* Modified phenolic resol systems Worldwide most used phenolic systems Long shelf life and shop life Optimised peel strength Equivalent systems Self adhesive to core materials FAR (FST and HR/HRR) ATS ABS 5047 AIMS AIMS AIMS AIMS AIMS AIMS DAN 407 DAN /2 DAN /2 DAN /2 ECMS PF801 Modified phenolic novolac resin Formaldehyd and phenol free Co-curing with EP121 Only dry tack available (T0) Most used system in Airbus floors Self adhesive to core materials ATS ABS 5034 DAN 407 AIMS * DAN AIMS * DAN ABS 5047 AIMS DAN AIMS * DAN * qualification ongoing PF808 Phenol resol system Excellent adhesion to honeycomb Long shelf and shop life FAR (FST and HR/HRR) ATS ABS 5047 AIMS AIMS AIMS AIMS AIMS (S2 glass) AIMS (S2 glass) PF811 Tack 0 or 2 Suitable for hot in/out press processes (crushed core) Fast curing Excellent surface finish Light colored appearance after cure Low smell level during curing New development for A380 (crushed-core) ABS 5047 (glass) AIMS AIMS ABS 5034 (carbon) AIMS AIMS NTA PF812 Tack 2 Fast curing excellent surface finish Light colored appearance after cure Low smell level during curing New development for A380 ABS 5047 (glass) AIMS AIMS ABS 5034 (carbon) AIMS PH831 Suitable for hot in/out press processes (crushed core) Excellent surface finish Fast curing Very versatile system FAR (FST and HR/HRR) ATS ABS 5047 AIMS AIMS AIMS AIMS AIMS DAN 407 DAN DAN DAN DAN DAN PH840 Established product for railway interiors Halogen free modified phenolic system Light colored appearance after cure Improved vacuum process surface finish BS 6853 a1(s4,sr2,st2) UNE M1 DIN 5510 (S4,SR2,ST2) NF F (M1,F1) FAR (FST and HR/HRR) PH860 Crush core prepreg Fast curing Amber colour for decorative finish Non-halogenated formulation 75-T Notes: - Reinforcements according to customer specifications - Widths of prepregs: 1000, 1270 or up to 1550 mm (61 ) for fabrics depending on prepreg and 1200 mm (47.3 ) for tapes - Upper limit of Tservice approximately equal to Tg - 30 C. * Ks = manufacture at Gurit Kassel RECOMMENDED PROCESS Crushed Core Crushed Core STORAGE -18 O C (months) O C (days) LOWEST MINS O C MINS O C HIGHEST TSERVICE ( O C) o C) o C) o C) o C) o C) ) o C 160 o C) TYPICAL APPLICATIONS Aircraft interior parts Sidewalls Hatracks Ceilings Doors Galleys Co-curing with epoxy system EP121 Current floor panel generation at Airbus Aircraft Bulk and Cargo Container Compartment Lining (BCC/CCC) Class partition Crushed-Core interior parts and panels Aircraft interior parts Sidewalls Hatracks Ceilings Doors Galleys Aircraft interior parts Sidewalls Hatracks Ceilings Doors Galleys Monolithic or sandwich structures Railway exterior and interior structural components Crushed-Core interior parts and panels 2 3

4 EPOXY PREPREG SYSTEMS PRODUCT MAIN FEATURES FIRE PERFORMANCE / QUALIFICATIONS RECOMMENDED PROCESS EP112 (Zu)* / EH250 (Ks)* Highly toughened epoxy resin systems Controlled resin flow Outstanding adhesion to core materials High volume, reference aerospace epoxy system FAR LTV (BV 11) LN WL WL /1 WL WL WL WL /1 WL WL WL /1 WL /1 WL WL EIP-W EP-ECS 7042 EP121 Highly toughened epoxy resin system Improved hot/wet stability Controlled resin flow Suitable for co-curing with phenolic novolac systems such as PF801 Excellent adhesion to core materials Shop life of 15 days at RT ABS 5003 DAN AIMS ABS 5672 AIMS ABS 5009 DAN DAN IGC EIP W AWMS AWMS EP127 Resin system for structural applications Toughened modified epoxy resin system Improved hot/wet properties at 135 C Improved self-adhesion to core materials Free standing post cure, Tg up to 230 C Self-adhesive to core materials FAR Flame test - (Self extinguishing) EP137 Low smoke density epoxy system Highly toughened epoxy resin system Improved hot/wet stability Controlled resin flow Excellent adhesion to core materials Shop life of 15 days at RT ATS ABS 5671/72 AIMS /27 AIMS /2 NTA EP141 High performance toughened epoxy Low smoke density epoxy system Good hot-wet properties at 135 C Self-adhesive to core materials ATS ABS 5672 AIMS EH275 Increased service temperature as EP112/EH250 Controlled resin flow High volume, reference aerospace epoxy system LTV (BV 11) LN WL /1 WL /1 WL WL WL /1 WL WL EIP-W EH420 / EH420 C Short curing time Extended shop life 30 days at RT Available in hotmelt and solvent (C) Suitable for co-curing with phenolic systems such as PH850C EH421 also available as tack 2 variant ATS ABS 5009 DAN DAN Notes: - Reinforcements according to customer specifications - Widths of prepregs: 1000, 1270 or up to 1550 mm (61 ) for fabrics depending on prepreg and 1200 mm (47.3 ) for tapes - See also GURIT Cyanate Ester Prepreg Systems PN900 and PN901 for high temperature requirements - Following systems may be produced currently but are either replaced by newer or improved systems, by equivalent systems or are no more produced. EP114 See EH275 for Aerospace applications - Upper limit of Tservice approximately equal to Tg - 30 C. - + qualification ongoing * Ks = manufacture at Gurit Kassel STORAGE LOWEST HIGHEST -18 O C (months) O C (days) MINS O C MINS O C TSERVICE ( O C) 200 o C 135 o C 135 o C TYPICAL APPLICATIONS Airbus secondary Aircraft structures such as flap track fairing belly fairing leading edge VTP (vertical tail plane) Inserts for sandwich panels Co-cured with PF801 for floor panels Secondary Aircraft structures such as BCC floor (bulk cargo compartment) Inserts for sandwich panels A380 Primary structures for A/C and helicopters Engine cowlings Thrust reverse A380 high performance passenger floor panels Cargo and bulk floor panels with S2-glass reinforcement Monolithic and sandwich structures for aerospace applications Fairings for helicopters Monolithic and sandwich structures for interior parts of Aircraft such as Aircraft floor panels Aircraft seats 4 5

5 CYANATE ESTER RESIN PREPREG SYSTEMS PRODUCT MAIN FEATURES FIRE PERFORMANCE / QUALIFICATIONS PN900 Modified cyanate ester resin system Excellent balance between mechanical and FST properties Volatile content < 1% numerous FST requirements High quality surface finish Self adhesive to honeycomb Post curing possible to Tg 235 C ATS ABS 5047 AIMS * AIMS ABS 5736 AIMS MDD DMS 2296, 2297, 2441 Boeing BMS DAN 407 DAN DAN NTA NTA PN901 Modified cyanate ester resin system High temperature system Post curing possible to Tg of 300 C Low moisture absorption Good hot/wet properties Suitable for primary aircraft structures PN901 may substitute BMI resin system ATS FAR (FST PN903 Modified cyanate ester resin system Extremely high self-extinguishing behaviour at combustion Very low FST values, very short afterflame times at RHP Test High quality surface finish Self-adhesive to honeycombs and other core materials Post curing to 235 C (Tg 240 C) ATS FAR (RHP) Notes: - Reinforcements according to customer specifications - Widths of prepregs: 1000, 1270 or up to 1550 mm (61 ) for fabrics depending on prepreg and 1200mm (47.3 ) for tapes - See also GURIT Epoxy Prepreg System EP142 for resin systems with high temperature requirements - Upper limit of Tservice approximately equal to Tg - 30 C. - * qualification ongoing BENZOXAZINE RESIN PREPREG SYSTEMS PRODUCT MAIN FEATURE FIRE PERFORMANCE / QUALIFICATIONS PB1000 Ecological solution (no volatile release while curing, REACH compliant) Fast curing system (economical advantage on processing time) Meets FST / OSU requirements Excellent mechanical properties Optimised surface quality and HR/HRR RECOMMENDED PROCESS RECOMMENDED PROCESS STORAGE LOWEST HIGHEST -18 O C (months) O C (days) MINS O C MINS O C STORAGE LOWEST HIGHEST -18 O C (months) O C (days) MINS O C MINS O C TSERVICE ( O C) 200 o C 270 o C 200 o C TSERVICE ( O C) TYPICAL APPLICATIONS Aircraft air conditioning system (ACS) Radomes Aircraft Structures for high temperature applications e.g. engine cowling flaps, etc. Aircraft air conditioning system (ACS) Radomes TYPICAL APPLICATIONS Monolithic and sandwich structures Sidewalls Galleys Seating 6 7

6 AEROSPACE QUALIFIED PREPREGS A. Secondary Structures, laminates and sandwiches Typical applications: Belly Fairing, Flap Track Fairing, APU Air Intake and Fairing, D-Nose (leading Edge) Vertical Tail Plane CHEMISTRY RESIN SPECIFICATION SPECIFICATION FAMILY FIBRE PRODUCT NAME WL /1 A EHG / EP ± x3 Crowfoot (4HS) WL A EHG / EP ± x3 Crowfoot (4HS) WL /1 A EHG / EP ± HS WL A EHG / EP ± HS EH250 (Ks)* / EP112 (Zu)* WL /1 A EHG / EP ± x3 Crowfoot (4HS) WL A EHG / EP ± x3 Crowfoot (4HS) Code A: 120 C Epoxy Resin WL /1 A EHG ± x2 Twill WL A EHG ± x2 Twill WL /1 A EHG ± x2 Twill Epoxy WL A AIMS / EHG ± x2 Twill WL /1 B LN (DAN 93) EHG / EP ± x3 Crowfoot (4HS) WL B EHG / EP ± x3 Crowfoot (4HS) WL /1 B EHG / EP ± HS WL B EHG / EP ± HS EH275 (Ks)* / EP114 (Zu)* WL B EHG ± x3 Crowfoot (4HS) WL B EHG ± x3 Crowfoot (4HS) Code B: 180 C Epoxy Resin WL B EHG ± x2 Twill WL B EHG ± x2 Twill WL B EHG ± x2 Twill WL B EHG ± x2 Twill * Ks = manufactured at Gurit Kassel B. Interior 1. Environmental Control Systems / Airducts RC % FAW g/m² DAN / AIMS * (ABS ) PN ± x3 Crowfoot (4HS) Low volatile, fullfils AP2091 DAN / AIMS * (ABS ) ABS 5047 (DAN 407) / AIMS (DAN 406) PN ± HS Low volatile, fullfils AP2091 AIMS (ABS ) PN900-G ± x3 Crowfoot (4HS) Low volatile, fullfils AP2091, A380 Cyanate Ester Resin PN900 AIMS (ABS ) ABS 5736 / AIMS / Carbon Hybrid PN900-C ± X2 Twill 50/50 /CF Low volatile, fullfils AP2091, A380 PN900-C ± x2 Twill (50/50) Alenia (Sukhoi) NTA43654 NTA43654 PN ± x3 Crowfoot Alenia (Sukhoi) BMS (MDD DMS 2296, 2297, 2441) BOEING BMS PN ± HS Low volatile, Boeing 747 and 787 EH421C-A ±3 285 Twill 2/2 B737/777 (Pending) Epoxy EH421C BMS8-264 BOEING BMS8-264 EH421C-A ±3 124 Plain B737/777 (Pending) Aramide Phenolic PF812 BMS8-381 BOEING BMS8-381 PF812-A ±3 285 Twill 2/2 B787/747 (Pending) PF812-A ±3 220 Plain B787/747 (Pending) 8 9

7 2. Passenger Interior Typical applications: Lining, Dado, Ceiling, Lavatories, Galleys AIMS (ABS ) PHG / PF ± HS DAN / DAN AIMS (ABS ) PHG / PF ± HS DAN / DAN PH600 (Ks) / PF800 (Zu) (AIMS ) PF800-G ±3 265 Open Weave AIMS (ABS ) PHG / PF ± x3 Crowfoot (4HS) DAN / DAN AIMS (ABS ) PHG / PF ± x3 Crowfoot (4HS) DAN / DAN AIMS (ABS ) PHG / PF ± x2 Twill DAN / DAN AIMS (ABS ) PHG / PF ± x2 Twill DAN / DAN AIMS (ABS ) PHF ± x2 Twill DAN / DAN AIMS (ABS ) PHG ± HS DAN / DAN ABS 5047 / AIMS PH831 AIMS (ABS ) PHG (T0) 40 ± HS Crushed Core AIMS (ABS ) PH ± x3 Crowfoot (4HS) DAN / DAN AIMS (ABS ) PHG ± x3 Crowfoot (4HS) Crushed core AIMS (ABS ) PF ± x3 Crowfoot (4HS) DAN / DAN PF808 Phenolic AIMS (ABS ) PF ± HS DAN / DAN AIMS (ABS ) PF ± x3 Crowfoot (4HS) DAN / DAN AIMS (ABS ) PF ± x2 Twill DAN / DAN AIMS (ABS ) PF811-G ± x2 Crowfoot For A380 PF812-G ± x2 Crowfoot For A380 PF ±3 200 Plain Weave FMS 2401 FMS 2401 PF811 PF ± x3 Crowfoot PF ± HS NTA NTA PF ± HS Alenia (Sukhoi) PF ± x3 Crowfoot Alenia (Sukhoi) AIMS (ABS ) ABS 5047 / AIMS S2-Glass PF812 AIMS (ABS 5034-D) PF811-G ± HS For A380 PF812-G ± HS For A380 PF812-C ±3 193 Plain Weave A380 PF811 AIMS (ABS 5034-E) ABS 5034 / AIMS Carbon AIMS (ABS ) ABS 5671 / AIMS / Carbon Hybrid PF811-C ±3 135 Open Weave A380 PF811-C ±3 193 Plain Weave A380 PF811-F ± g/m², 12k UD 48g/m² E-glass, Plain weave Face Sheet Concept * Ks = manufactured at Gurit Kassel 3. Passenger Floor EH250 (Ks)/ EP112 (Zu) DAN402 E (WL A) DAN 402 E and DAN 402 F Insert: EHG ± HS EH420 C DAN402 F (ABS 5009-C40) Insert: EHG420C ± HS Diameter: mm (± 0.1 mm) Thickness: mm (± 0.05 mm) A380 EP137 AIMS (ABS ) ABS 5672 / AIMS EP ±3 48 Plain Weave A380 DAN / AIMS * ABS 5003 / AIMS EP121-C ±3 193 Plain Weave Co-Curing with PF801 EP121 Carbon IGC IGC EP121-C ± HS Cockpit Section EP121-C ±3 170 Plain Weave Cockpit Section AIMS (ABS ) ABS 5672 / AIMS EP137-G ±3 115 Plain Weave A380 Epoxy S2-Glass EP137 EP137-GR108/ ±3 235 Alenia (ATR) NTA43654 NTA43654 Unidirectional EP137-CR509/ ±3 176 Alenia (ATR) AIMS A (ABS ) EP137-CR527/ ±3 80 Unidirectional A380 AIMS B (ABS ) Carbon EP137-CR527/ ±3 100 Unidirectional A380 EP137 ABS 5671 / AIMS AIMS C (ABS ) EP137-CR527/ ±3 120 Unidirectional A380 Phenolic PF801 AIMS (ABS ) EP137-CR527/100-G ±3 100 DAN / AIMS * (ABS ) DAN (AIMS *) (DAN ) DAN / AIMS * (ABS 5034-A02) DAN / AIMS * (ABS 5034-B01) ABS 5047 / AIMS ABS 5034 / AIMS Carbon Unidirectional, 25 g/ m² scrim A380 PF ± x3 Crowfoot (4HS) Co-Curing with EP121 PF ±3 48 Plain Weave Co-Curing with EP121 PF801-C ±3 193 Plain Weave Co-Curing with EP121 PF801-C ±3 160 Plain Weave Co-Curing with EP121 Ks = manufactured at Gurit Kassel 10 11

8 4. Cargo Lining PF808-G ± HS A380 AIMS A (ABS A) AIMS B (ABS B) ABS 5047 / AIMS PF808-G ± HS A380 S2-Glass AIMS A (ABS A) 000 PF808-G ± HS A380 j j j j j j j Phenolic PF808 AIMS B (ABS B) PF808-G ± HS A Cargo Floor A380, colored grey A380, colored grey A380, colored grey EP141-G ± HS AIMS A EP141 ABS 5672 / AIMS AIMS B S2-Glass EP141-G ± HS 000 Epoxy EP121 AIMS B EP121-G ± HS 6. Interior Galleys PHG ± HS BA/E Galley MS1230 PHG White 43 ±3 200 Plain BA/E A350 Galley PHG ± HS PH840 A350-ERS-015_B Phenolic PHG x 3 Crowfoot Zodiac-Sell Galleys 8HS PHG ±3 296 PH600 WO PF808 S-Glass PF808-G Helicopter Interior Epoxy EP121 AWMS EP ± HS Agusta AW

9 Aero Prepregs Bro