3D Parts from Thick PEEK/Carbon Fiber Laminates

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1 3D Parts from Thick PEEK/Carbon Fiber Laminates SAMPE BRAZIL October 2015 Joe Spangler Technical Services Manager Toho Tenax America, Inc. Phone: +1(859) Mobile: +1(513) Toho Tenax America

2 Introduction Slide 1 of 20

3 Content General Toho Tenax CFRTP Product Families Why use Thick Laminates 2D to 3D Laminate Examples Material Characteristics, Selection, Properties 2D and 3D Laminate Specifics 2D and 3D Part Making General Applications and Uses 3D Part Making Development with TPWF and TPUD Conclusions Slide 2 of 20

4 Toho Tenax CFRTP* Product Families Short fiber Tenax HTS45 P12 Tenax IMS65 P12 Unlimited Fiber Length PART GEOMETRY COMPLEXITY Tenax Short Fiber Limited Fiber Length Long-Fiber Stretch-Broken Fiber Co-mingled Tenax TPWF ThermoPlastic Woven Fabric Woven Fabric Tenax TPCL ThermoPlastic Consolidated Laminate Tenax TPUD ThermoPlastic UniDirectional Uni-directional *CFRTP: Carbon Fiber Reinforced ThermoPlastics MECHANICAL PROPERTIES Slide 3 of 20

5 Why Thick Laminates? Thermoset resins are mostly not suitable due to resin exothermic reaction. A block or billet of composite material is created that can be machined into a finished part. Complex parts without any molds Thin plies allow for precise details in finished parts. Low to Zero Void Content. Provides lightweight, structural parts Slide 4 of 20

6 2D to 3D Laminate Examples Traditional 2D thin laminate New 3D thick laminate Slide 5 of 20

7 Material Characteristics Great Mechanical Properties Exceptional Wear Resistance Excellent Toughness High Impact Strength Excellent Vibration Dampening High Service Temperature Easily Recyclable Slide 6 of 20

8 Material Selection Why this material combination? PEEK resin crystalizes rapidly providing a wide processing window. PEEK resin has very good mechanical and thermal properties. Fine grain structure in the laminate allows it to be machined into very detailed three dimensional parts. Low to Zero Void Content Slide 7 of 20

9 Laminate Material Properties COMPOSITE PROPERTIES 1 UNITS 0 LAYUP 0 / 90 LAYUP 0 /+45 /-45/ 90 LAYUP Tensile Strength MPa (ksi) 2000 (290) 951 (138) 648 (94) Tensile Modulus GPa (Msi) 117 (17) 60 (8.7) 42 (6.1) Flexural Strength MPa (ksi) 1758 (255) 1220 (177) 953 (140) Flexural Modulus GPa (Msi) 117 (17) 64 (9.4) 46 (6.8) Compressive Strength MPa (ksi) 1296 (188) 724 (105) 510 (74) 1 tested per ASTM methods Slide 8 of 20

10 Comparative Material Properties COMPOSITE UNITS COMPOSITE PROPERTIES 1 VALUE ALUMINUM 6061 TITANIUM Grade 1 PEEK RESIN Tensile Modulus GPa (Msi) 42 (6.1) 69 (10) 105 (15.2) 3.5 (0.51) Tensile Strength MPa (ksi) 648 (94) 310 (45) Compression Modulus Compression Strength (25-45) 97 (14) GPa (Msi) 60 (8.6) 69 (10) 110 (16.0) 4.1 (0.6) MPa (ksi) 510 (74) 207 (30) NA 118 (17) Flexural Modulus GPa (Msi) 46 (6.8) 69 (10) NA 4.1 (0.59) Flexural Strength MPa (ksi) 953 (140) 607 (88) NA 170 (24.7) Density g/cm HDT at 264 psi C ( F) 260 (500) NA NA 160 (320) Tg C ( F) 143 (289) NA NA 143 (289) 1 tested per ASTM methods Slide 9 of 20

11 2D/3D Laminate Specifics Tenax TPCL PEEK-HTA40 Billet: Toho Tenax HTA40 3K 5HS PEEK Prepreg. Thickness from.31mm ( ply) to 101mm ( plies) Slide 10 of 20

12 2D Part Making Tenax TPCL PEEK-HTA40 -Laminate* Automated Process Complex Part Shape Very Short Cycle Time Joining Technologies *TPCL: ThermoPlastics Consolidated Laminate Slide 11 of 20

13 3D Part Making Tenax TPCL PEEK-HTA40 -Billet Thick TPCL Machined Billet Finished Part(s) Slide 12 of 20

14 General Applications Oil & Gas Medical Aerospace Slide 13 of 20

15 O&G Sealing Ring 3D Laminate Uses Medical Device External Fixation Slide 14 of 20

16 Oil & Gas O & G use as backing rings to support elastomeric seals in high temperature and high pressure applications. Long fibers in the finished machined part provide excellent mechanical & temperature resistivity that are not found in injection molded parts. Material excels in applications because of its quasiisotropic fiber orientation. The majority of the reinforcing fibers are cantilevered across the gap which will reduce creep vs. a wound composite where the fibers are parallel to the gap that is being sealed. Slide 15 of 20

17 Medical External Fixation and Surgical Components. The metallic components in external fixation are heavier than carbon fiber composites which makes them less desirable. Carbon fiber components are x-ray translucent with makes it easier for the doctor to analyze the images on the x-ray. High thermal stability of PEEK / carbon allows it to be sterilized multiple times. Slide 16 of 20

18 Additional 3D Laminate Uses Aerospace Bracket(s) Slide 17 of 20

19 Current Development & Future 3D Part Making TPWF*: 1). Tenax HTA40 PEEK Fabric (a). Compression/cavity molded Cut TPWF PEEK pre-preg -.5 cm squares. Special Compression-Molded Processing with Stainless Steel Inserts *TPWF: ThermoPlastics Woven Fabric Slide 18 of 20

20 Current Development & Future 3D Part Making TPUD: 1). Tenax HTS45 PEEK UD Tape (P12 sized) (a). Compression/cavity molded Cut TPUD PEEK UD Tape 1 X 3 cm strip. Special Compression-Molded Processing with Stainless Steel Inserts *TPUD: ThermoPlastics Uni Directional Slide 19 of 20

21 Conclusions High performance mechanical properties can be achieved using a combination of woven carbon fiber and PEEK resin. Material combination has proven to create a new category of material that is capable of changing the selection of materials that designers currently have available. Excellent machinability and ability to be molded into thick laminates; creating a new category of material. Combination of unique fiber placement and excellent machinability make it a great choice for high temperature and high pressure backing rings in the Oil & Gas market. High strength, temperature stability, and machinability have proven to be a great asset in the Medical external fixation market. Material will improve components in the Medical, Oil & Gas, Machine Design, and the Aerospace industry. Slide 20 of 20

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