Textile Technologies. Carbon Textiles Solutions. Global Partners

Transcription

1 Carbon Textiles Solutions

2 SAMPE Brazil Application and Processing of Complex Fabrics for Lightweight structures Joanne Blakeley Development Engineer, Sigmatex UK Tel: +44 (0)

3 Application and Processing of Complex Fabrics for Lightweight structures Contents: 1. Market Opportunities for Lightweight Materials 2. Improving the attractiveness of carbon fibre for high volume manufacturing sectors (Automotive) 3. Enabling Technologies providing opportunities in lightweight fabrics 4. Processing Capabilities Technologies overview, inc. a comparison of Material Profiles 5. Powder Coating

4 Application and Processing of Complex Fabrics for Lightweight structures Contents: 1. Market Opportunities for Lightweight Materials 2. Improving the attractiveness of carbon fibre for high volume manufacturing sectors (Automotive) 3. Enabling Technologies providing opportunities in lightweight fabrics 4. Processing Capabilities Technologies overview, inc. a comparison of Material Profiles. 5. Powder Coating

5 1. Market opportunities Current opportunities in existing markets Auto Sports Marine Automotive Aerospace Sporting Goods Industrial Applications

6 1. Market opportunities Global demand - Size of market and anticipated growth, some indications: Forecasts are that global demand for carbon fibre will grow from 46,000 (2011) to 140,000 tonnes by [VALUE]% Sports goods [VALUE]% Aerospace [VALUE]% Wind energy & automotive [VALUE]% Industrial With improved material performance, output and characteristics, Materials will be increasingly attractive to more widespread applications SOURCE The Carbon Fibre Industry Worldwide

7 Application and Processing of Complex Fabrics for Lightweight structures Contents: 1. Market Opportunities for Lightweight Materials 2. Improving the attractiveness of carbon fibre for high volume manufacturing sectors (Automotive) 3. Enabling Technologies providing opportunities in lightweight fabrics 4. Processing Capabilities Technologies overview, inc. a comparison of Material Profiles 5. Powder Coating

8 2. Improving marketability "What is the most significant challenge to overcome for composites to be more widely deployed in high-volume vehicles?" 61% from 14 Nations said Cost!! [VALUE] % COST Hybrid Materials What can materials manufacturers do to improve the attractiveness of Carbon Fibre in high volume applications? Output rates + Multifunctional materials = Cost Hybrid materials Near net shape materials Weight output (Kg (lb) / hr) Length output (LMs (Yrds) / hr) Near net shape

9 Application and Processing of Complex Fabrics for Lightweight structures Contents: 1. Market Opportunities for Lightweight Materials 2. Improving the attractiveness of carbon fibre for high volume manufacturing sectors (Automotive) 3. Enabling Technologies providing opportunities in lightweight fabrics 4. Processing Capabilities Technologies overview, inc. a comparison of Material Profiles 5. Powder Coating

10 3. Enabling Technologies Enabling Technologies and solutions providing opportunities in high volume lightweight fabrics and high volume heavy weight fabrics: 2D Woven ST Woven 3D Architectures Mult-iaxial NCF Uni-Directional Materials

11 Application and Processing of Complex Fabrics for Lightweight structures Contents: 1. Market Opportunities for Lightweight Materials 2. Improving the attractiveness of carbon fibre for high volume manufacturing sectors (Automotive) 3. Enabling Technologies providing opportunities in lightweight fabrics 4. Processing Capabilities Technologies overview, inc. a comparison of Material Profiles 5. Powder Coating

12 4. Overview: 2D weaving 2D Weaving Well understood technology Largest amount of capacity in the supply chain Broader range of possibilities than has to date been exploited All fibre types capable High Modulus IM SM etc.. Multi-axial capability

13 4. Overview: 2D weaving 2D Weaving provides: Wide variety of fibre architecture Plain, Standard 2x2 Twill, Satin Scafolded Low crimp Fabrics Multilayer woven Uni and Bi Directional hybrids Plain Weave Woven geometry Fibre linear density Cover factor Weight 2x2 Twill Output rates (Kg/hr) 5 Harness Satin Scafolded LC Limitations on output rates for low weight materials has led to ST materials.

14 4. Overview: Spread Tow weaving Tape materials - High volume linear metres & Low weight materials How are Sigmatex using High Speed rapier machines to develop Tape materials for high volume applications? Back to weaving functions: Warp New creel and control method Weft Insertion Flat tow high speed rapier technology weft accumulation linear insertion. Beat up Replaced by fell/fabric movement & fibre placement Take up Special features ensure movement of fabric causes minimum disruption to fibre and fabric tension. Key to success is also tape manufacture.

15 4. Overview: Spread Tow weaving Pick control During weft insertion it is essential to ensure pick is not distorted. Path from package to inserted pick must be linear. When unwound directly off spool, twist is imparted. This has been improved with the Linear unwind methods Twist and narrowing of fibre No twist and flatter tow The ST process uses pre-spread fibre that has been wound onto cassettes without twist providing a more linear and regular fibre.

16 4. Overview: Spread Tow weaving Key enabling features to optimise fabric throughput: Tow width Warp Tension Control 1. Tow width - directly related to machine throughput in yrds/hr Machine speed 1 RPM = 1 pick insertion High speed & wide tow width results in significant output. 2. Warp tension control if warp tension is not controlled then the resultant fabric can have significant defects: Slack edges during pre-impregnation Fabric distortion during post weaving process Wrinkling of fabric during wind up Fabric Bow Fabric Skew

17 4. Overview: Spread Tow weaving Crimped length of the tow be C (mm) Un-crimped length of the tow be U (mm) Crimp % (X) = (U C)/C X 100 Plain Woven (DV ) Specimen Warp Weft Number Crimped Length (mm) Un-crimped Length (mm) Crimp % Crimped Length (mm) Un-crimped Length (mm) Crim p % Average 0.48 % Average 0.6 % Tape Woven (DV ) Specimen Number Crimped Length (mm) Warp Un-crimped Length (mm) Crimp % Crimped Length (mm) Weft Un-crimped Length (mm) Average 0.14 % Average 0.18 % Cri mp %

18 4. Overview: Spread Tow weaving Surface Characteristics Standard Woven Fabric Sigma ST Fabric High crimp = Surface undulations Low crimp = No Surface undulations

19 4. Materials Profile In summary for woven fabrics: Standard weaving can offer high output in Kg/hr and LMs/hr but cover factor can be reduced if fibre is not spread. With Tape Weaving high throughput in linear metres can be achieved, however these are not suitable for heavy weight fabric applications. Wider tows offer higher throughput Reduced crimp and flatter surface can be realised with the Spread Tow fabrics.

20 4. Overview: 3D Weaving How can 3D weaving offer a solution for light weighting? 1.4 Metre width 5000 individual hooks Full size machine 12mm thickness 25mm under development Self monitoring Multiple structures capable

21 4. Overview: 3D Weaving 3D woven structures are currently used within the Aerospace industries for Joining elements, e.g. Pi clips. Also being used in the rear pressure bulkhead and for engine fan blades. Other opportunities for 3D include weaving honeycomb structures. These can be designed to have different cellular sizes all interconnected.

22 4. Overview: 3D Weaving Lightweight opportunities and advantages using 3D structures; Reduced engineering time, by building functionality into the 3D preform. Parts can be designed and woven in one piece. Different fibre types can be woven in different layers Different weave styles can be woven on different layers. Many types of 3D materials can be woven without the need to change machine setup, e.g. A solid structure can be woven after an expandable 3D section. High warp weights are available with very high density warps when combined with low 90 degree weft fill fibres output can be very high

23 4. Overview: Multi-axial NC Fabrics Multi-axial Non Crimp Fabrics 2.54M width High speed output (double width at 1270mm) Bi-axial, Tri-axial, Quad-axial capability 100gsm/layer and lighter if required

24 4. Overview: Multi-axial NC Fabrics Comparison of Surface Characteristics between Standard NCF Standard NCF Spread NCF Eggbox effect - Unevenness Improved spread

25 Output Kg/hour Textile Technologies 4. Overview: Multi-axial NC Fabrics For Multi axial warp knitted Non Crimp materials increasing the layer weight of the materials in conjunction with laying in of the fibres (Triaxial and Quadraxial formats), increases the weight throughput of manufacturing Material Output at different Layer weights GSM per Layer For woven fabrics a similar principle applies, however the machine throughput is directly related to thread density (picks per inch). High linear density yarns = higher weight and high throughput during weaving process.

26 4. Materials Profile Summary of 3D and NCF 3D can offer advantages for light weighting although mainly through design not spread fibre. High volume by weight can be achieved but not suitable for lightweight layered structures. NCF fabrics can be manufactured at high output weights and also suitable for lightweight materials. Linear output is constant with multiple layers being created simultaneously. For higher output in weight per hour, heavier weight fabrics need to be manufactured.

27 Application and Processing of Complex Fabrics for Lightweight structures Contents: 1. Market Opportunities for Lightweight Materials 2. Improving the attractiveness of carbon fibre for high volume manufacturing sectors (Automotive) 3. Enabling Technologies providing opportunities in lightweight fabrics 4. Processing Capabilities Technologies overview, inc. a comparison of Material Profiles 5. Powder Coating

28 The Powder Coating line at Sigmatex facilitates: 1. Powder Coating 2. Heat treatment 3. Lamination of a single material or one to another. 5. Powder Coating Working width: 1800mm Powder Density: Kg/L Application: 5 800gsm Installed as part of a CiC funded project,

29 5. Powder Coating Technical information: Adaptable Process used to coat a variety of Sigmatex products. Epoxy & Polyester powder resin systems currently utilised. Fine control of powder add-on. IR capability to adapt to customer requirements. Laminating temperature range up to 230 C. Pressure can be applied depending on the requirement. Available for powder coating and laminating trials.

30 Thank You for your attention Joanne Blakeley Development Engineer Web: Phone: +44 (0)