Dry Reinforcements DR

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1 Toho Tenax Product family Dry Reinforcements DR Rodrigo Cesar Berardine Sales and Marketing Manager Toho Tenax America April, , R. Wockatz (MP) 1

2 Content 1. Background and Motivation 2. Non-Crimp Fabrics Tenax DRNF 3. Woven Fabrics Tenax DRWF 4. Tenax Toughener Development 5. Outlook April, , R. Wockatz (MP) 2

3 1. Background and Motivation Increasing requirements for future Aerospace and Automotive developments in terms of performance, weight, cost and environmental requirements drive new material needs. To meet growing demand for composites the current available materials themselves are now borderline to fulfil the given requirements. Prepreg materials which are the baseline reference and normal first choice material esp. in Aerospace are problematical in terms of highly complex parts (tolerances etc.) and large production volumes. Textile technologies in combination with resin infusion processes are offering significant potential in manufacturing processes for high production rates, integral structures and flexibility but to date with some disadvantage in mechanical properties. April, , R. Wockatz (MP) 3

4 2. Non-Crimp Fabrics Tenax DRNF Advantages Strength and stiffness in multiple directions (possibility to optimize weight distribution and minimize material costs) Adapted areal weights (low <-> heavy) achievable for minimizing waste for complex lay-ups (cross plies) Areal weights using high tow counts (12K & 24K) in established prepreg thicknesses now possible Reduced processing costs Very low level of misalignment Disadvantages Mech. Properties nearly matching Prepreg baseline levels April, , R. Wockatz (MP) 4

5 2. NCF Development Tasks Therefore Toho Tenax initiated on-going development activities within the last years to solve these issues and provide in partner cooperation new solutions to the market Tenax Dry Reinforcements. Major tasks for improvements have been : Lower and flexible adaptable areal weights (based on high tow count CF, 12K+) Improved preforming and toughness properties Adapted/flexible drapeability incorporating sufficient permeability Mechanical properties equivalent to today s Prepreg baseline Low material bulk factor for preforming (e.g. for complex RTM tools) High fibre volume content (target 58% +/-4%) even with toughened and powder bindered material in infusion technology April, , R. Wockatz (MP) 5

6 2. Tenax NCF improvement program Prepreg-Reference NCF beginning of year 2000 NCF ca. year 2005 Latest NCF Tenax Dry Reinforcements (DRNF) April, , R. Wockatz (MP) 6

7 Strength [MPa] 2. Tenax NCF improvement program 800 Bidiagonal-NCF (+/- 45 ), 268gsm (134gsm per layer), stacking [(90 /0 ) 8 ] S Tenax -E IMS65 E23 24K 830tex, Test in acc. to EN Very close NCF SoA Prepreg Latest New NCF Tenax NCF or better to Prepreg level 0 Compression plain OHC April, , R. Wockatz (MP) 7

2. NCF technology General details all developments are based on latest NCF technology available in the market cutting edge technology especially for Tenax -E HTS45 E23 12K, 24K and Tenax -E IMS65 E23

8 2. NCF technology General details all developments are based on latest NCF technology available in the market cutting edge technology especially for Tenax -E HTS45 E23 12K, 24K and Tenax -E IMS65 E23 24K carbon fibres up to 5 layers in only one production run possible to lay down areal weights from ca. 70gsm per layer upwards possible (depends on CF type) fixed material width of maximum 1.27m (50 ) cutting technology available -> 5 cutter, e.g. for cutting 5 x 254mm (10 ) stripes roll length flexible (customized, typically 40m - 70m, depends on weight) April, , R. Wockatz (MP) 8

9 2. NCF technology Possible building blocks Stitching yarn e.g. Non-woven for Toughening Creel material (warp & weft) Tenax -E IMS65 E23 24K Tenax -E HTS45 E23 12K Tenax -E STS40 F13 24K, 48K April, , R. Wockatz (MP) 9

2. NCF technology technical details Typically NCF stacking's are: Bidiagonal (BD) e.g. +30 /-30 ; +45 /-45 ; +60 /-60 ; Biaxial (BA) e.g. 0/90 ; 90 /0 Triaxial (TA) e.g. +30 /90 /-30 ; +45 /0 /-45 ; +60 /-60 /+60 ; Quadaxial (QA): e.

10 2. NCF technology technical details Typically NCF stacking's are: Bidiagonal (BD) e.g. +30 /-30 ; +45 /-45 ; +60 /-60 ; Biaxial (BA) e.g. 0/90 ; 90 /0 Triaxial (TA) e.g. +30 /90 /-30 ; +45 /0 /-45 ; +60 /-60 /+60 ; Quadaxial (QA): e.g. +30 /90 /-30 /0 ; +45 /0 /-45 /90 ; Multiaxial: e.g. 0 /+45 /0 /-45 /90 Possibility to add toughening system (veil) on each CF layer incl. as the first layer (Bottom) and the last layer (Top). Both outer layer can be Powder Binder coated for additional preforming abilities. April, , R. Wockatz (MP) 10

2. Tenax NCF Product benefits Smooth and even material surface quality with lowest grade of material undulation Lower and flexible adaptable areal weights

properties matching today s Prepreg baseline due to very straight and parallel fibre alignment Low level of material bulk factor for preforming High fibre volume

11 2. Tenax NCF Product benefits Smooth and even material surface quality with lowest grade of material undulation Lower and flexible adaptable areal weights possible Improved preforming and toughness behaviour allowing excellent mechanical properties Adapted drapeability even for complex shaped parts Mechanical properties matching today s Prepreg baseline due to very straight and parallel fibre alignment Low level of material bulk factor for preforming High fibre volume content (~58%) even with toughened and powder bindered material in infusion technology (e.g. via pure vacuum process, like VAP) demonstrated April, , R. Wockatz (MP) 11

12 3. Woven fabrics Tenax DRWF Specialised Woven Fabrics are still needed for future (aerospace) applications. In a close cooperation with partner companies several materials are now ready to market: UD woven fabric with high carbon fibre alignment and optimised permeability in a broad range of fabric areal weights as well as fields of applications. Curved fabric materials which can be adapted to complex shape of parts Modified standard woven fabrics with target of high material toughness improvement as well as improved preforming abilities Lightning strike protection (LSP) material based on material combinations and areal weights April, , R. Wockatz (MP) 12

13 Strength [MPa] 3. Woven Fabrics UD fabric This newly developed material is dedicated for high performance application, where high carbon fibre alignment and optimised permeability are key features. A broad range of fabric areal weights as well as fields of applications may be targeted a combination with non-woven s and powder binders are possible too Tenax -E DRWF-UD + RTM C 3rd gen. Epoxy Prepreg Carbon Fibre: Tenax -E HTS40 12K 800tex Areal Weight: 134gsm per layer mm New UD Woven fabric Tension Strength (EN 2561 B) Compression Strength (EN 2850 A1) OHC (EN 6036) April, , R. Wockatz (MP) 13

A specialised material was developed within a close partner cooperation which can be adapted to

14 3. Woven Fabrics Curved fabric For complex and curved designed parts, e.g. fuselage frames, the drapeability of fabrics is limited. A specialised material was developed within a close partner cooperation which can be adapted to individual shapes and guarantee best performance and fibre alignment. UD-fabric with high drapeability UD-fabric adapted for curved parts April, , R. Wockatz (MP) 14

15 Curved UD-fabric 3. Woven Fabrics Curved fabric Product benefits Excellent performance due to straight fibre alignment CF areal weights between gsm (depends on CF type) possible Radius of min. 50mm upwards possible Fabric width min. 10mm max. 350mm Roll length customized (typically m) Toughness improvement (e.g. via nonwoven) possible Preforming improvement (e.g. via powder binder) possible April, , R. Wockatz (MP) 15

16 3. Woven Fabrics Lightning Strike Protection April, , R. Wockatz (MP) 16

17 3. Woven Fabrics Lightning Strike Protection April, , R. Wockatz (MP) 17

18 3. Woven Fabrics Lightning Strike Protection Many fabric combinations (style/weights) are possible. Powdered LSP Woven fabric Lightning strike tests passed successful! April, , R. Wockatz (MP) 18

Testing reference is a newly developed high performance UD woven fabric which allows laminate stacking for each test

19 4. Tenax Toughener developments Based on before showed test results, materials were combined and tested to verify mechanical performance. Testing reference is a newly developed high performance UD woven fabric which allows laminate stacking for each test methods. Laminate Fabric style Carbon fibre Resin Binder Toughener 1mm 1 UD Tenax - E Momentive w/o woven IMS65 E23 24K Momentive EP05311 fabric 830tex EPS ~7 g/m² 194 g/m² with New UD Woven fabric April, , R. Wockatz (MP) 19

20 CAI - Residual Strength [MPa] CAI 3x30J, AITM , UD-Fabric, 194gsm, Tenax -E IMS65 E23 24K 830tex, Resin EPS600, Stacking [+45/0/-45/90] 3S CAI - Damaged Area [mm²] With Tenax Toughening System w/o Toughener Residual Strength Damaged Area Laminate 1 Laminate 2 0 April, , R. Wockatz (MP) 20

21 4. Toughener Development Moisture uptake [EN3615] of Tenax toughening system No additional water/moisture uptake No left moisture after dry back procedure April, , R. Wockatz (MP) 21

22 5. Outlook Toho Tenax is keen to support customer requirements for new textile specialised materials. Combinations of building blocks are always possible to meet particular customer needs. Material combinations for components may include Non-crimp fabrics, (UD)-Woven fabrics as well as Powdered Non-woven LSP (Toughening) to fulfil given Woven fabric requirements like high Toughness performance as well as preforming abilities. April, , R. Wockatz (MP) 22

23 Thank you for your attention! Powdered LSP Woven fabric April, , R. Wockatz (MP) 23

Faserverbundwerkstoffe Composite Technology

Faserverbundwerkstoffe Composite Technology New products 6/2009 New products, updated 17.06.2009. Prices may vary. Further offers, availability and ordering see eshop at www.r-g.de. Aramid-/Carbon-mesh fabric 40 g/m² Plain weave, width 100 cm Woven