Railway and Automotive Parts Made of Composites REQUIREMENTS MATERIALS PROCESSES AND PROPERTIES

Transcription

1 Railway and Automotive Parts Made of Composites REQUIREMENTS MATERIALS PROCESSES AND PROPERTIES

2 Agenda 1. SAERTEX Brief Introduction 2. Automotive Parts: Requirements in HPRTM and NCF Solutions 3. SAERTEX LEO: Composite Parts in Infusion with Good Structural and FST Properties

3 SAERTEX - business segments Stade Reinforcement materials in glass, carbon, aramid Composite part services for aerospace and high end applications Fire protection materials for composite systems Pipe rehabilitation in civil engineering

4 SAERTEX facts & figures Foundation [year]: 1982 Subsidiaries [n]: 13 Customer service [countries]: 50 Sales 2015 [MIO. ]: 320 Customized solutions [n]: Parts manufactured [n] Employees [n]: 1200

5 A worldwide network with production and service And technical service in more than 50 countries worldwide Australia, Austria, Belgium, Bosnia, Brazil, China, Croatia, Czech Republic, Denmark, Estonia, England, Finland, France, Germany, Greece, Hungary, India, Israel, Italy, Korea, Lithuania, Latvia, Macedonia, Montenegro, Netherlands, Norway, Northern Ireland, Poland, Portugal, Romania, Russia, Scotland, Serbia, Slovakia, Slovenia, South Africa, Spain, Sweden, Switzerland, Taiwan, Turkey, Ukraine, USA, VAE, Wales

6 Our applications: experience in many different industries Wind energy Aerospace Transportation Automotive Civil engineering Coatings Industrial applications Marine Sport Offshore Many more

7 Requirements coming from the part Structural performance Fibre orientation Fibre type Fabric quality Surface quality Fabric type (woven/ncf/...) Fabric construction (+/-45, 0/90, UD) Fabric quality (gaps)

8 Requirements coming from the HPRTM Process Stability Stitching parameter Binder type (reactive/thermoplastic) Permeability Fabric type (woven/ncf/...) Fabric construction (+/-45, 0/90, UD) Fibre type Stitching parameter

9 Requirements coming from the Preforming Process Drapability and handling Fabric construction Fibre orientation (fibre orientation after preforming can be different from before) Stitching parameter Fibre type

10 Requirements coming from the Cutting Process Low cutting waste Optimal fabric width Fibre fuzz (at edges) Fabric construction (especially UDs are critical) Powder binder application (level of impregnation)

11 Requirements coming from the Fabric Production Efficient production Heavy tows also for low areal weight Suitable width (to use machine capacity)

12 SAERTEX Solution: Cooperate with customer for engineering, procurement & production Engineering Cutting & Kitting Part production Turnkey solutions Use our know-how: Consulting Prototyping Testing: GL certified laboratory Ready-made materials: Individual cutting Efficient nesting Commissioning in line with your production process Manufacturing according to your drawings: NCF & Prepreg processing: Infusion, RTM Autoclave 3x15m Everything from a single source: SAERTEX Engineering & Manufacturing of parts One contact, one part number, one solution

13 Getting the Structural Performace Advantages of NCF: The fibres, weights and orientation of the layers are freely definable Stretched fibres for optimal load-bearing capacity Cost savings through fewer layers

14 Getting the Right Surface Quality (1/2) Shrinking during Cross-Linking (Curing = Hardening) Relatively High Thermal Expansion Coefficient Critical Areas Matrix Process Fibres/ Fabric Cure Temperature Thermal Shrinkage Fibre Content (Possibly Lower on Surface) Resin Injection During Gel Phase Reduce Chemical Shrinkage No Chemical Shrinkage Relatively Low Thermal Expansion Coefficient Closed Fabric Surface Required Overlaps Critical Glass Veil

15 Better Surface Quality Getting the Right Surface Quality (2/2) UD Carbon look roof BMW M3 CSL - A lot of sanding... ±45 Painted Roof Lamborghini Aventador Roadster (Directly out of the Mould) 0/90

16 Getting the Permeability Right Source: University of Leoben, Harald Grössing Source: University of Leoben, Harald Grössing

17 Getting the Drapability (1/2)

18 Getting the Drapability (2/2) Fabric optimisation for drapability Automated fabric placement on membrane Automated preforming

19 Getting the Right Mechanical/Cost Performance of Carbon NCF Aim: Design / Cost Benefit using low areal weight NCF SAERtow NCF Low Areal Weight with 12K 24K Fibre Standard Areal Weight with 50K Fibre 12K Carbon fibre: 70 gsm per layer 50K Carbon fibre 150gsm per layer 12K Carbon fibre: 200gsm per layer 50K Carbon fibre 400 gsm per layer Conventional NCF Standard Areal Weight with 12K - 24K Fibre High Areal Weight with 50K Fibre Results: Increased design flexibility Lower ply drop thickness Improved properties Lower cost material

20 Summary Producing parts in HPRTM is a combination of: All have their own requirements on the fabric: Structural performace Matrix Surface Quality FST requirements Drapability Permeability Costs Fabric solutions are available Process Fibres/ Fabric The best solution can only be developed in close collaboration with the complete team of stakeholders

21 Our applications: experience in many different industries Wind energy Aerospace Transportation Automotive Civil engineering Coatings Industrial applications Marine Sport Offshore Many more

22 REINFORCING YOUR IDEAS SAERTEX LEO

23 SAERTEX LEO : CHARACTERISTICS 1. FRP system for highest fire protection standards Marine / Rail / Construction 2. Excellent mechanical properties Lightweight: 40 % saving with maximum resistance Much better rigidity as well as tensile and bending properties compared to hand laminates (HLU) 3. Represents no health hazards No toxic substances released in the event of fire 4. FIRST-CLASS COST-EFFECTIVENESS Maximum cost-effectiveness through the lowest possible material usage 5. Quality Standardized practices ensure highly, reproducible component quality 6. Complete System Modular assembly system 23 REINFORCING YOUR IDEAS

24 SAERTEX LEO : HIGH PERFORMANCE materials LEO Protection Layer (Topcoat/ Gelcoat) Top fire protection properties Low smoke generation Low toxicity (halogen free) Can be applied by brush or spray RT curing Core material (optional) SAERfoam (3D glass bridges) LEOcore Balsa / PVC / PET / LEO Fabrics (glass / carbon / aramid / hybrid) Incl. fire protection properties No loss of mechanical properties High permeability Free of halogens LEO Infusions Resin Suitable for infusion processes Excellent mechanical properties Adjustable gel time RT curing Resistant to chemicals 24

25 SAeRTEX LEO : PRINCIPLE (20 min at 50 kw) app 780 C on sample surface - Foam grid down - Unexposed Gelcoat Layer (tickness app. 1000µm) Structural Laminate, almost undisturbed

26 SAeRTEX LEO : Comparison of materials 3-point-bending" Parameter Reference (Hand Laminate) LEO UD -stiff- LEO -Variations (Infusion) LEO UD -light- Aluminium E-Modulus 0 [GPa] 8,3 42,5 42,5 70 Material Thickness [mm] 11,84 11,9 6,72 11,5 Weight [g] ,65 Bending [mm] 96,78 18,43 103,38 12,5 Result Reference approx. 7 % heavier approx. 40% lighter approx. 50 % heavier 5 x stiffer Similar stiffness 7 x stiffer SAERTEX LEO HLU 12 mm 12 mm 1 m 1 m 26

27 SAeRTEX LEO : Comparison of materials Bending Beam" Parameter Reference (Hand Laminate) LEO UD -stiff- LEO -Variations (Infusion) LEO UD -light- LEO Multiax -stiff- Lay-up 5 x mat (450 g/m²) 5 x UD (970 g/m²) 4 x UD (970 g/m²) 4 x Quadrax (1200 g/m²) Fibre Volume Fraction 19 % 50 % Resin Density [kg/dm³] 1,5 1,04 E-Modulus 0 [Gpa] 8,3 42,5 42,5 16,5 Material Thickness [mm] 3,64 3,73 2,24 3,69 Weight [g] Bending [mm] , ,5 Result Reference approx. 8 % heavier approx. 35 % lighter approx. 8 % heavier 5,5x stiffer approx. 1,2 x stiffer 2 x stiffer

28 SAeRTEX LEO : FIRE PROTECTION performance MARINE RAIL CONSTRUCTION OTHERS IMO RES. A 653 (16) FTP CODE MSC 61 (67) Annex 1 Part 2 Annex 1 Part 5 DIN EN :2016 HL 3 for R1 HL 3 for R7 HL 3 for R17 EN ISO :2007 B - s2,d0 STANAG 4602 AFAP 4/5 - F2 AFAP 2 - S2 AFAP 3 - T1 IMO FTP Code; Part 10 (HSC 2000 (ISO 9705) 9 min 46 DIN 5510 S4/SR2/ST2 DIN B1 DIN B1 NFF UNE :1990 M1 / F1 NFF M1 / F1 ASTM E 84 class A / class 1 BS 6853 BS class 0 BS class 1 BS 6853, Annex B cat1b exterior cat 2 interior ASTM E 84 class A / class NFPA 13:2007 ASTM E 662 ASTM E 162 ASTM E 1354 BSS 7239 UNE :1990 M1 / F1 28

29 SAeRTEX LEO : LEOCORE Sandwich lay-ups Cooperation with Gaugler & Lutz ohg Classification according to EN ( ) Core thicknesses 2 40 mm Lay up 2 mm HL3 40 mm HL3 Protection Layer LEO R µm LEO R µm Fabric Q-E-821 g/m²; type LEO - 1 layer Q-E-821 g/m²; type LEO - 5 layer Core thickness 2 mm 40 mm Fabric Q-E-821 g/m²; type LEO - 1 layer Q-E-821 g/m²; type LEO - 5 layer Infusion Resin LEO R-65xx series LEO R-65xx series Fiber volume fraction 50 % 50 % Panel thickness 4,2 mm 48,42 mm Panel weight 5,56 kg/m² 24,6 kg/m² Results HL3 for R1 HL3 for R7 HL3 for R17 HL3 for R1 HL3 for R7 HL3 for R17 29

30 SAERTEX LEO : example rail interior Cooperation with our Polish customer Buster Sp.j. Objective: to investigate how components can be manufactured using the SAERTEX LEO system excellent mechanical properties: 40% weight savings with impressive strength and an oftentimes improved stiffness, together with tensile strength and bending characteristics that are comparable with hand lay-up laminates (HLU) and steel Weight reduction by 50%, Bending strength increased by 40 % PROTECTIVE ELEMENT ROOF COVERING EXTERIOR PANELLING More informationen: 30

31 SAERTEX LEO : Example RAIL exterior Application: Segment: Designation of part: Manufacturer: End customer: Rail Tram Front Nose Lätzsch Stadler Reinforcement: +/- 45 E-Glass NCF Protection Layer: LEO R 6501 Matrix: LEO R 6500 Technical Parameters of FRP part Dimensions: x 1100 mm² Mfg. Process: Infusion FST Norm: DIN 5510 Fiber Mass Content: 72 %

32 SAERTEX LEO : example RAIL plumbing unit Application: Segment: Designation of Part: Manufacturer: End customer: Rail Interior Universal Plumbing Unit RCS GmbH, GER London Midland and First TPE Reinforcement: +/- 45 Glass NCF (1200 gsm) gsm CSM Protection Layer: Protection Layer LEO R 6500 Injection Resin: LEO R 6500 Technical Parameters of FRP part: Mfg. Process: Vacuum Infusion FST Norm: BS 6853 cat 2 32

33 THANK YOU FOR YOUR ATTENTION. HOW CAN WE REINFORCE YOUR IDEAS? SAERTEX GmbH & Co KG (Bangkok Office) Dr. Helge Haberkern +66 (0) Skype: helge.haberkern