Compósitos em SMC- Sheet Molding Compound : Estrutura, propriedades e Aplicações Palestrante: Everton Sterzo

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Painel Aeroespacial -2017 Compósitos em SMC- Sheet Molding

1 Painel Aeroespacial Compósitos em SMC- Sheet Molding Compound : Estrutura, propriedades e Aplicações Palestrante: Everton Sterzo

2 A.Schulman Inc. in the World A. Schulman operate facilities in the Americas, Europe and Asia-Pacific regions. Its plants, offices and technical centers are strategically located to serve customer needs in markets throughout the world. 2

3 Rio Claro Plant Plant Size: ,29 m² Built area: 8.821,13 m² Location: Meridian, 55 Distrito Industrial Rio Claro SP, Brasil Inaugurated Date: 1997 Associates: 65

4 Rio Claro Plant / Internal Area

5 Materials Engineered Tetrahedron Products / End Market Process Properties Chemical Structure

6 Chemical Structure - SMC & BMC SMC & BMC Formulation Thermosetting resin - Unsaturated Polyester, Vinyl Ester, Epoxy, Phenolic Catalyst Inhibitor Mold Releases Crosslink Agents Reological additives Fillers Reinforcement ( Glass Fiber, Carbon Fiber,etc)

7 Chemical Structure - SMC & BMC Polymer Matrix Thermosseting Resin Basic Component that will be cure process Unsaturated Polyester Vinyl Ester

8 Chemical Structure - SMC & BMC Polymer Matrix Thermosseting Resin Basic Component that will be cure process Epoxy Phenolic

9 Chemical Structure - SMC & BMC Catalyst Increase reaction speed, Decrease activity energy, same Free Energy

10 Chemical Structure - SMC & BMC Others Additives Inhibitor Mold Release Fillers = ( o + A)e BP

Chemical Structure - SMC & BMC Reinforcement (Glass and Carbon Fiber) For SMC, BMC and Pultrusion, the reinforcement can be used in Chopped Strand, continuous or mat shape.

11 Chemical Structure - SMC & BMC Reinforcement (Glass and Carbon Fiber) For SMC, BMC and Pultrusion, the reinforcement can be used in Chopped Strand, continuous or mat shape. Composição do Vidro -E Ingredientes % Sílica (SiO 2 ) Óxido de Cálcio (CaO) Alumina (Al 2 O 3 ) Óxido de Boro (B 2 O 3 ) 5 10 Mágnésia (MgO) 0 5 Óxidos Alcalinos (Na 2 O e K 2 O) 0 2 Dióxido de Titânio (TiO 2 ) Óxido Férrico (Fe 2 O 3 ) Fluoreto (F 2 ) Interface

12 Process BMC SMC Pultrusion Compression Mold Injection Mold

fillers reinforced thermoset molding compound Used on hot-tool press

14 WHAT IS BMC? Bulk Molding Compound (or Composite) Polyester resin, glass-fiber and fillers reinforced thermoset molding compound Used on hot-tool press molding Specifically formulated for each end-use application Contains 5 % to 30 % chopped strand Can be injection, compression or transfer

16 WHAT IS SMC? Sheet Molding Compound (or Composite) Chemically-thickened, glass-fiber/carbonreinforced thermoset molding compound Used on hot-tool press molding Specifically formulated for each end-use application Contains ½ to 2 inch chopped glass roving Can be compression

17 Press

reinforced polymer structural shapes with constant cross-sections.

19 WHAT IS PULTRUSION? Pultrusion is a manufacturing process for producing continuous lengths of reinforced polymer structural shapes with constant cross-sections. Raw materials are a liquid resin mixture (containing resin, fillers and specialized additives) and flexible textile reinforcing fibers.

20 Properties Physical-chemical Thermal Mechanical Electrical Optical

Ạ thermoplastic polymer is a polymer that becomes pliable or moldable above a specific temperature, and returns to a solid state upon cooling.

21 What is a Thermoset? A thermosetting polymer is a prepolymer in a soft solid or viscous state that changes irreversibly into an infusible, insoluble polymer network by curing. Ạ thermoplastic polymer is a polymer that becomes pliable or moldable above a specific temperature, and returns to a solid state upon cooling. Most thermoplastics have a high molecular weight, whose chains associate through intermolecular forces; this property allows thermoplastics to be remolded because the intermolecular interactions spontaneously reform upon cooling. In this way, thermoplastics differ from thermosetting polymers, which form irreversible chemical bonds during the curing process.

22 What is a Thermoset? Thermoplastic Thermosetting Heat

23 What is a Thermoset? Thermoplastic Thermosetting Cooling

24 Tensile Strenght (Mpa) Mechanical Properties BMC/SMC Tensile Properties Special Materials -CF SMC SMC BMC Fiber content(%)

25 Materials properties Comparision Propriedades x Materiais Part Consolidation Comparable Mass Corrosion Resistance Stamped Steel SMC/BMC Thermoplastic CF SMC Aluminum Baseline Excellent Excellent Excellent Very Good % 70% <60% >80% Baseline Superior Superior Superior Poor Tooling Cost 100% 40% 60% 40% 115% CLTE 100% % % % % HDT N/A Baseline Poor Baseline N/A *This table uses steel as a standard by which all other processes are compared. **Costs may vary. 25

26 Thermoset Composite Materials

27 CF SMC TDS *This table uses steel as a standard by which all other processes are compared. **Costs may vary. 27

28 CF SMC TDS *This table uses steel as a standard by which all other processes are compared. **Costs may vary. 28

29 A.Schulman Laboratory

30 What is the SMC advantages? High Heat Resistance- HDT and Tg Dimension Stability Lower CLTE Flame Retardant Low Smoke Emission Excellent Chemical Resistance Excellent Creep Resistance Little to No Creep Tailored Glass Transition Temperatures Formulations which are Easily Customizable to your Application

31 Why SMC? Part Consolidation High yield Easy handling Excellent properties Formulations which are Easily Customizable to your Application Low Cost 31

32 Products/ End Market Motorcycle Agricultural Industrial Appliances Electrical Truck Automotive Aerospace 32

33 Products/ End Market BMC Applications BMC (Headlamps)

34 Products/ End Market BMC Applications Valve Cover

35 Products/ End Market BMC Applications BMC - Sewing Machine

36 Products/ End Market BMC Applications Electrical Parts

37 Products/ End Market SMC - Sheet Molding Compounds

38 Products/ End Market SMC - Sheet Molding Compounds Electrical

39 Products/ End Market SMC - Sheet Molding Compounds Grill Grill

40 Products/ End Market SMC - Sheet Molding Compounds Ford Troller Structural SMC

41 Products/ End Market SMC - Sheet Molding Compounds Ford Troller Class A SMC

42 Products/ End Market SMC - Sheet Molding Compounds Rear Floor - Renault

43 Products/ End Market SMC - Sheet Molding Compounds Empilhadeira - Nacco

Products/ End Market Lytex Parts used on Commercial Jets Quantum Composites material is used extensively in tertiary and secondary structure applicationswhere net shape compression molding can

44 Products/ End Market Lytex Parts used on Commercial Jets Quantum Composites material is used extensively in tertiary and secondary structure applicationswhere net shape compression molding can provide cost and weight reduction benefits over aluminum and other metals including cost reduction over prepreg materials. LYTEX 9063 Flap track cones Trailing edge fairing Aircraft companies have increased their reliance on compression molded Lytex components as overall composite usage has increased in the next generation aircraft with higher carbon and glass fiber composite content. Inboard track fairing Inboard fan duct fairing UnderGwing Thermal panel Lytex is usually chosen because of its much lower part cost versus a prepreg part. A key benefit that Lytex offers is the ability to easily mold in ribs, bosses and changes in thickness. Hundreds of part numbers are compression molded using Lytex materials in complex geometries for commercial aircraft 22

45 Products/ End Market Seat Components 23

46 Products/ End Market Aerospace Oxygen Canister Container for Long Haul (Boeing and Airbus) and other Regional Aircra0

47 Certificates ISO/ TS 16949:2009 ISO 9001:2008

48 Certificates : ISO :2004

49 Thank you!!!! Everton Sterzo Quality & Development Manager Engineered Composites A. Schulman, Inc. T: 55 (19) // C: 55 (19)

Painel Automotivo, 2015

Painel Automotivo, 2015 Rio Claro Plant Palestrante: Everton Sterzo Rio Claro Plant Plant Size: 43.665,29 m² Built area: 8.821,13 m² Location: Meridian, 55 Distrito Industrial Rio Claro SP, Brasil 13505-610