Improving the Cosmetic Quality and Finished Durability of Glass Fiber Reinforced Composites. ArmorGuard ARMORCOTE
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1 Improving the Cosmetic Quality and Finished Durability of Glass Fiber Reinforced Composites ArmorGuard ARMORCOTE
2 Cosmetic Quality Products with the best cosmetics are perceived to be higher quality are more likely to be purchased command a higher selling price Consumers expectations continue to evolve This issue effects all composite manufacturers Open Molding Closed Molding RTM, Infusion can have greater surface distortion than open molding Across Markets Marine Transportation General
3 Defining Cosmetic Quality Cosmetic surface flaws go by many different names: Printthough, glass print, woven roving checks Distortion, waviness, wrinkles Heat lines, heat distortion Orange peel, dimples, Pock marks Core print, balsa print All of these terms describe a visible flaw in the smoothness of the surface of a finished fiberglass part. These flaws are usually only cosmetic in nature and rarely disrupt the underlying structure integrity.
4 Sources of Cosmetic Flaws Tooling Every flaw in the tooling is transferred to the part. Shrinkage Resins and gel coats shrink when they cure Thermal Contraction Thermal Distortion
5 Shrinkage of Neat Unsaturated Polyester Resin Linear Shrink Mold Linear Shrink Mold with Uncured UPR Linear Shrink Mold with Cured UPR UPR has significant shrinkage.
6 Cure Shrinkage While the gel coat stays in contact with the mold the shrinkage is driven to the back side. Fibers do not shrink Gel Coat shrinks Resin shrinks around fibers Reinforced layers and unreinforced layers shrinkage different amounts Differential shrinkage can result in warpage If cure continues when the gel coat is off the mold shrinkage occurs on both front and back sides. Prerelease Post cure
7 Thermal Shrinkage All items expand and contract with changes in temperature. Rates of expansion or contraction are different for different materials. Temperature changes cause stresses. The temperature at which the resin solidifies has no thermal stress, or the stressfree temperature. High exotherm causes high stressfree temperatures. High stressfree temperatures cause high thermal stresses and contraction (shrinkage) when it cools to ambient temperature. Worst thermal case is outdoor winter storage. Low exotherm minimizes thermal stress, contraction (shrinkage).
8 Thermal Distortion: Polymers used in resins and gel coats have a glass transition temperature (Tg) Near and above the Tg polymers lose some of their stiffness and may warp/distort due to stress relaxation. Happens even when fully cured The higher the Tg of the polymer the higher the temperature must be for the stress relaxation to occur.
9 Improving Cosmetics Minimize Shrinkage Long, slow cure Low exotherm to minimize thermal stresses. Complete cure to avoid postcure Long hold times on molds Thinner is better Multiple cure steps to reach laminate thickness Rework Airfiling, block sanding, fairing, postfinishing, repairs, QC work, buffing, patching, resprays, P.I. All these have defined labor dollars in the manufacturing process.
10 The Cost of Cosmetic Quality Example: Ski Boat Manufacturer Boats per Day Work week, days 5.00 Number of 25 ft. boats per day % Number of 1819 ft boats per day % Finish and Repair Repair Labor Cost / Hr $ Per Boat Per Day Per Week Per Year Hours Repair for Air / Distortion per Boat 6.00 $150 $1,800 $9,000 $450,000 Warranty Repair Average Warranty Repair Cost due to Distortion per month $ 5, $417 $1,000 $1,250 $60,000 Total Cost of Print and Distortion $567 $2,800 $10,250 $510,000
11 ArmorGuard Vinyl Ester Barrier Gel Coat Improves Cosmetics Tough, Crack Resistant Reduces Osmotic Blistering Excellent Temperature Resistance Increased Production Rate = More Parts / Day
12 ArmorGuard Applied Directly behind gel coat Conventional Gel Coat Spray Equipment MEKP Catalyst Typical gel coat thickness (1620 mils wet)
13 ArmorGuard Cosmetic Improvements Isolates the gel coat surface from glass fibers ArmorGuard Barrier Coat Reduces/Eliminates Smallterm distortions Glass print Heat distortion Orange peel, dimples Will not affect large issues such as warpage
14 Quantifying Cosmetics Byk Gardner Wavescan Plus Measures light reflectance to quantify surface quality Results Long Term Waviness Short Term Waviness Overall Surface Rating DOI (Distinctness of Image)
15 Surface Cosmetics of Laminates With and Without ArmorGuard Gel Coat Only Gel Coat with ArmorGuard Gel Coat with VE Skin Gel Coat Thickness Typical (~15 mils) Thick (~30 mils) The surface rating has the scale of 0 to The higher the rating, the better the surface profile. Surface rating is based on the BYKGardner WaveScan ACTTM orange peel standards.
16 ArmorGuard Tough, Crack Resistant Comparison of Mechanical Properties for a Typical Gel Coat and a VE Barrier Coat Typical Gel Coat ArmorGuard Barrier Coat Tensile Strength (psi) 7,000 11,400 Tensile Modulus (psi) 600, ,000 Elongation (%) Flexural Strength (psi) 13,000 17,700 Flexural Modulus (psi) 550, ,000 HDT ( C) * The test was not done at the same time. Some variations may occur due to the sample preparation.
17 ArmorGuard Tough, Crack Resistant Flexural Toughness at First Crack Flexure to First Crack Test Schematic Load Gel Coat (in tension) Toughness, (in.lb,/in³) Load Load 0 Tested on gel coated laminates using typical laminating resin and 30% glass. Gel Coat (40mil) Gel Coat (20 mil) Gel Coat (20 mil) / ArmorGuard (20 mil)
18 ArmorGuard Vinyl Ester Chemistry Improves Water Resistance Standard Isophthalic Resin VE s have fewer Ester Groups BisphenolA base VE Low Water Absorption Ester linkage shielded by methyl group Structure Resistant to Hydrolysis
19 ArmorGuard Blister Resistance STANDARD GEL COAT THICK SECTION THIN SECTION NO BARRIER VE SKIN with FIBER VE BARRIER BARRIER + SKIN 100 C Blister Rating (Thick) Blister Rating (Thin)
20 ArmorGuard Heat Resistance Vinyl Ester Chemistry Excellent Heat Resistance Resistant to Thermal Distortion Limited surface change during part life Applicable to Mold Fabrication Excellent initial cosmetics Resistant to surface changes during mold life Tough, crack resistant Also recommended for Closed Molding applications Mold Build
21 ArmorGuard Increased Production Rate ArmorGuard barrier coat can replace the skin laminate. Faster application ArmorGuard Sprays on Skin laminate Hand lay or spray application followed by rolling Less Material ArmorGuard Only 20 mils needs for great protection Skin laminate 6090 mils Reduced Cure Wait Times ArmorGuard can be applied wetonwet with gel coat ArmorGuard cures as fast as a gel coat Skin Laminate must wait for barcol development prior to bulk lamination
22 ArmorGuard Increased Production Rate Gelcoat Cure Stage Barrier Coat Application Barrier Coat Cure Skin Coat Application and Gel Skin Coat Cure ( 20 Barcol ) Skin Coat Peak Interval (no Barcol) Bulk Lamination Typical (High Volume) Boat Manufacturing Cycle Time Comparison Over a One Hour Time Savings per Unit Using a Barrier Coat With ArmorGard Barrier Coat Curent Production with Skin Coat TimeZero After Gel Application Ti m e, Min u te s
23 ARMORCOTE 951 Series Advanced technology polyesters based gel coats Superior weathering resistance Minimize surface weathering and chalking Designed for use in markets were exterior durability is critical Marine Transportation Construction Good blister resistance as a stand alone gel coat. Outstanding blister resistance when used in combination with ArmorGuard Good flexibility for cracking resistance
24 ARMORCOTE 951 Series Weathering South Florida Exposure ARMORCOTE 951 POLYCOR 944 Gloss (60 deg.) White Post Buffed Months
25 ARMORCOTE 951 Series Weathering South Florida Exposure ARMORCOTE 951 POLYCOR 944 Total Color Change (Delta E) White Post Buffed Months
26 Summary Meet Customer Expectations for Cosmetics and Durability Maintain Tooling Minimize Shrinkage Low exotherm to minimize thermal stresses. Complete cure inmold to avoid postcure ArmorGuard Vinyl Ester Barrier Gel Coat Improves Cosmetics Tough, Crack Resistant Reduces Osmotic Blistering Excellent Temperature Resistance Increased Production Rate = More Parts / Day ARMORCOTE 951 Series Advanced technology polyesters based gel coats Superior weathering resistance Good blister resistance as a stand alone gel coat. Outstanding blister resistance when used in combination with ArmorGuard Good flexibility for cracking resistance
27 Additional Information Sources Applications Guide (Cook Book) English book, CD or on Spanish book or CD 11 Courses Scheduled for 2011
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