Industrial Application and Manufacturing Process of Carbon Composites

Transcription

1 Industrial Application and Manufacturing Process of Composites DACC carbon co., Ltd -15 June Th International CFK-VALLEY STADE CONVENTION June 2016, STADEUM Stade (Germany) 15 June

2 15 June Contents I. Company Overview II. Industrial Applications III. C/C Aircraft brake discs IV.C/SiC Automotive brake discs V. Composites Properties VI.Braking Characteristics

3 15 June Company Overview Spin-off Spin-off 2014 Daewoo Heavy Ind. Sales/employee : 10Mil. USD/53. Patents : 95(Foreign patents 48) Quality Approval Korea Aerospace Ind. (KAI) - ISO 9001 Quality Management System - KDS Defense Quality Management System DACC Co., Ltd - AS9100Rev.C Aerospace Quality Management System DACC carbon Co., Ltd DACC Composite DACC CSP

4 15 June Company Overview Defense &Aerospace Div. Aircraft Div. Ceramic Div. nozzle extension for rocket launcher Flame-resistance Plate for battleship Fighter brake discs (T50, KF16, F16,TA50) Automotive Brake discs SiC Fiber Dyno. Test for aircraft High speed elevator brakes

5 15 June Company Overview Seoul Land of 13,200SM Jeonju Busan composites valley Complex

6 15 June Industrial Application Development of carbon composites(cmc composites); Spin-off from space technologies to terrestrial applications First application to civil aircraft brake discs for Concorde in 1970s Application to Formula 1 racing cars in 1980s First public unveiling of sports cars in 2000s

7 15 June Industrial Application Key advantage in brake discs of CMC composites; lightweight, thermal stability, wear resistance and Stable friction coefficient C/C aircraft brake disc C/SiC automotive brake disc

8 15 June Assembly C/C aircraft brake discs; Rotors, Stators, Pressure plate, End plate Toque tube End plate Rotor disc Pressure plate Stator disc Piston housing

9 15 June Assembly C/SiC brake disc ring assembled with metallic bell using bush and bolts

10 15 June Manufacturing Process Manufacturing process for C/C aircraft brake disc Continuous carbon fiber Preform TG-CVI fiber content of 25~40 vol.% by needling process Pyrolysis of propane gas at above 900 in normal pressure Heat treatment Graphitized at above 1,800 in inert gas atmosphere C/C composites Density of 1.7 g/cm 3 and over

11 15 June Manufacturing Process TG-CVI process and I-CVI process in terms of matrix densification methods Thermal gradient-cvi process Isothermal-CVI process T1 > T2 > T3 > T4 Fast process time Single process without clogging of pores T1 > T2 Excellent reproducibility Several densification process Slow processing

12 15 June Microstructure Build up of pyrotic carbon-matrix : coexistence of SL and RL structures Smooth laminar Rough laminar

13 15 June Manufacturing Process Two types of manufacturing process for C/SiC automotive brake disc Continuous carbon fiber Preform Chopped carbon fiber Mixing Resin TG-CVI Heat treatment Hot press molding Heat treatment SMI C/SiC composites

14 15 June Manufacturing Process Processing time and cost : Type1 >Type2 Starting materials Build up of matrix Type1 Mixturer Chopped fiber + Phenolics (powder) Hot press molding Cross-section Type2 Hydrocarbon gas (CH 4, C 3 H 8 ) Needling carbon preform TG-CVI

15 Matrix Matrix Void Matrix Matrix 15 June Manufacturing Process Build up and formation of matrix for manufacturing C/SiC composites Step Type 1 Type 2 CFRP (Preform) Fiber bundle Thermosetting Phenolics resin Fiber bundle fiber content of 47~50 vol.% by Hot pressing molding process Fiber bundle Void Void Fiber bundle fiber content of 25~30 vol.% by needling process C/Cs (Build up of carbon matrix) Fiber bundle Void Fiber bundle ized at above 950 in inert gas atmosphere Obtain density of g/cm 3 with many pores C/SiCs (Formation of SiC matrix) Fiber bundle SiC Fiber bundle Impregnated into C/Cs at above 1,410 in inert gas atmosphere Obtain density of over 2.0 g/cm 3 with low porosity

16 15 June Microstructure Matrix components of C/SiC composites for automotive brake disc Cross-section Type 1 Type 2 Cross-section Cross-section fiber bundle (C f ), black color Silicon Carbide Matrix (SiC M ), gray color Silicon residual (Si), white color

17 15 June Microstructure Matrix components close by carbon fiber bundle to C/SiC composites fiber protected against attack from molten Si Type 1 Type 2

18 15 June Properties Major properties of the CMC composites developed by our company Materials Unit C/Cs C/SiCs (Type 2) C/SiCs (Type 1) Manufacturing process - CVI CVI+SMI SMI Reinforcement ( Fiber content) - Preform (25 40 vol.%) Preform (25-30 vol.%) Chopped fiber (47-50 vol.%) Density g/cm Flexural strength (4-1/4 point) MPa CTE (α, RT-1000 C) 10-6 /K Thermal conductivity (1000 C) W/m K

19 15 June Braking Characteristics RTO(Brake reject take off) test with kinetic energy of 47.2 Mil. ft-lbs Stop distance : 5,836 ft (Test pass : 7,600 ft) Wear rate of thickness of brake disc : 2.6 % Specification of dynamometer Max. Velocity Inertia Main drum Dia. Brake torque Kinetic energy 300 mph 50,000 Lb IE 120 in 200,000 lb-ft 194 Mil. ft-lbs

20 Stop distance (m) 15 June Temperature ( ) Braking Characteristics AMS Fade Test Number of braking Speed (km/h) Decel. Braking Interval (sec.) G 25 Result -Temperature of brake disc is relatively consistent from the 18 th braking test - Stop distance decrease as the number of braking times increase (No fade) Number of braking Stop distance Temp. of brake disc Temp. of brake pad

21 15 June Thank you for your attention DACC Co., Ltd 30 Unamro, Deokjin, Jeonju, Jeonbuk, Korea Phone: / Fax: / choiyeonho2001@dacc21.com /Web: