Innovative Advanced Composite Materials for Various Industries

Transcription

1 Innovative Advanced Composite Materials for Various Industries 2017

2 About UMATEX Group UMATEX Group is a management company and part of a new promising Composite Materials Division of ROSATOM State Corporation. Its s comprising an R&D centre and enterprises manufacturing highstrength and high-modulus carbon fibers (CF) and CF fabrics, was set up to form a market of composite materials in Russia. UMATEX Group includes the following entities that provides 95% carbon fiber production in Russia: Management Company NPK Khimprominzhiniring, JSC, Moscow ALABUGA-FIBRE, LLC - a state-of-the-art plant manufacturing carbon fiber in the special economic zone, Alabuga, Republic of Tatarstan. The capacity of the line producing carbon fibers of different grades amounts to more than 1,400 tones per year. The plant was officially opened in May of 2015; Argon, LLC, Balakovo, Saratov Region - a plant producing carbon fibers for defense enterprises, nuclear, aviation, rocket and space and civil industries; ZUKM, LLC, Chelyabinsk - a plant producing carbon-based composites, carbon fiber reinforced plastics, heat insulating carbon materials; R&D center, NPK Khimprominzhiniring, JSC, Moscow - the center is involved in developing and integrating technologies for production PAN precursor and carbon fiber.

3 Types of products UMATEX Group PAN-precursor Fabrics Carbon Fibers Prepregs Polymer Resins

4 Definition of Composite Materials Composite materials nonhomogenous solid materials consisting of two components: reinforcing component and matrix providing joint work of reinforcing components. Reinforcing component (fiber, particles, etc.) defines mechanical characteristics of a material: strength, stiffness and deformability. Matrix (resin) provides monolithic character of a material, stress transition in reinforcing component elements and resistance to various exposures. Matrix Reinforcing component Features of composite materials: Two and more components Clear interphase boundary New unique properties different from properties of its components Non-homogenous in a microscale, but homogenous in a macroscale Composition, form and distribution of components are designed in advance

5 Classification of Composite Materials By mechanical structure By matrix nature Dispersion-reinforced or dispersionstrengthened (with a filler in the form of finely dispersed particles) Polymer (PCM) Carbon-carbon (CCCM) Fibrous (reinforced with fibers or filamentary crystals) Layered (reinforced with films, plates, fabrics; the filler and the matrix are located in layers) Metal (MCM) Ceramic (CCM)

6 Comparison of different materials properties Density (kg/m 3 ) Tensile strength (MPa) Tensile modulus (GPa) CFRP Carbon Fiber Reinforced Plastics

7 Definition and main properties of Carbon Fibers Carbon fiber (CF) a material which consists of filaments with a diameter of 4 8 microns formed mainly by carbon atoms (92 99%). Types of carbon fiber: Small yarns: 1, 3, 6, 12 and 24K (from 1,000 to 24,000 filaments) Big tows: 48(50) and 320K (from 48,000 to 320,000 filaments) Properties of carbon fiber: From 1,000 to 320,000 filaments Filament s diameter from 4 to 8 microns Carbon content in the fiber from 92 to 99% Low density ( 1 Τ4 of steel) High strength (Specific strength 10 times stronger than steel) High modulus (Specific modulus 10 times stronger than steel) High resistance to fatigue Good electric conductivity High corrosion and chemical resistance X-ray transparency High heat resistance ( С in the air)

8 Tensile strength, GPa Classification of Carbon Fibers (by mechanical properties) CF classification Type Modulus Strength I Low modulus LM (up to 200 GPa) up to 3.5 GPa 8 7 II III IV V Standard modulus SM ( GPa) Intermediate modulus IM ( GPa) High modulus HM ( GPa) Ultra high modulus UHM (more than 450 GPa) GPa (high-strength) GPa (high-strength) GPa GPa I II III IV V Tensile modulus, GPa

9 Process chain for production final products based on carbon fiber polymer materials Weaving Tows impregnation Textile structures: carbon fabrics, tapes, braids UD-tapes/Fabrics impregnation Vacuum bagging, autoclave molding Final products Hand lay-up, Vacuum infusion, RTM, RIFT, VARTM, RFI Carbon fiber Prepregs Cutting Spray lay-up SMC, BMC Chopped fiber Filament winding, Pultrusion

10 (Ktons/year) Integration of Carbon Fiber into various fields Industrial application Aviation Sport & leisure

11 Main consumers of Carbon Fibers in the World Europe China North America Japan Others Windenergy Construction and infrastructure Chopped fiber Sport Vessels Oil and gas Asia Aircraft construction and defense Car construction Other industries

12 Carbon fiber UMATEX Group 2016

13 UMATEX Group s strategy for carbon fibers Toray carbon fibers Target properties of carbon fiber UMATEX Group: 12/24K Tensile strength: GPa Tensile modulus: GPa 50K Tensile strength: GPa Tensile modulus: GPa 3/6K Tensile strength: GPa Tensile modulus: GPa These properties hit the most massive applications: automotive, wind energy, construction, sport&leisure goods and aviation CF 12/24K is as a raw material to make HM CF: Tensile strength: GPa Tensile modulus: up to 500 GPa

14 LLC Alabuga-Fibre is the biggest CF plant in Russia and in CIS countries

15 Alabuga-Fibre carbon fiber technology Oxidation multi-stage heat treatment of PANprecursor at C in the air atmosphere Carbonization increasing the carbon content in the fiber when it is heat-treated at C in an inert atmosphere due to removal of heteroatoms in the form of volatile products Surface treatment is used to improve wettability and adhesion of polymer resins to the carbon fiber surface (the sizing also serves to improve carbon fiber processability on subsequent technological processes) Winding Unwinding Carbonization Surface treatment (electrochemical + sizing) Oxidation

16 High strength and high modulus Carbon fibers UMATEX Group Carbon Fiber Properties UMT is a high strength and high modulus polyacrylonitrile (PAN) based carbon fibеr. It has been developed for Customer to use it in industrial composite applications including aviation, automobile, wind, marine and others UMT Carbon Fiber Properties Carbon fiber type Number of filaments, K Yield, tex Tensile strength, Gpa Tensile modulus, Gpa Elongation at break, % Density, g/cm3 UMT UMT SM UMT UMT IM UMT45/ UMT HM UMT UMT All types of CF can be produced with EP or VE sizing

17 Structural External Reinforcement System + resin system

18 Structural External Reinforcement System (company) Object Status amount of material m2 kg 1. Pipe complete Production building complete Crane beams complete Roof beams complete Building complete - - TVEL 6. Production building complete 750* Production building complete Production building complete Production building complete More than 10 buildings reinforced

19 Thank you for attention