Toho Tenax Americas Carbon Fiber Presentation Carlos Leao Leutewiler Sales and Marketing Manager South America October, 2017

Transcription

1 Toho Tenax Americas Carbon Fiber Presentation Carlos Leao Leutewiler Sales and Marketing Manager South America October, 2017 Mobile:

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6 2. Company Overview Outline of Toho Tenax Global Network Toho Tenax Europe GmbH Teijin Limited Toho Tenax Co,. LTD DSC Sales Office CF Production CF R&D Composites Shanghai Office Toho Tenax America, Inc. Singapore Office Europe Head Office: Rep. Office: CF Prod. Composites Wuppertal, Germany France Italy Finland Oberbruch, Germany Oberbruch, Germany Asia Head Office: Office: CF Prod. Composites Tokyo, Japan Shanghai, China Singapore Mishima, Shizuoka Ibigawa, Gifu North America Head Office: Sales Office: CF Prod. Composites Rockwood, TN Huntersville, NC Portland. OR Sao Paulo- Brazil Rockwood, TN Erlanger, KY

7 Introduction of Toho Tenax Carbon Fiber Specialties Toho Tenax Co., LTD

8 Carbon Fiber Production Process CF Production Process Precursor Oxidation Carbonization Surface treatment, Sizing Acrylic fiber for CF (Precursor) Oxidized PAN fiber Pyromex Carbon Fiber TENAX

9 Carbon Fiber Production Process Chopped Fiber production process Sizing Drying Chopping Filament Chopped Fiber Nickel Coated CF production process Nickel Coating Washing Sizing Drying Filament Nickel Coated CF Milled Fiber production process Milling Filament Milled Fiber

10 PART GEOMETRY COMPLEXITY Toho Tenax Product Families Short fiber Tenax Short Fiber Long-Fiber Tenax HTS45 P12 Tenax IMS65 P12 Unlimited Fiber Length Limited Fiber Length Stretch-Broken Fiber Co-mingled Tenax TPWF ThermoPlastic Woven Fabric Woven Fabric Tenax TPCL ThermoPlastic Consolidated Laminate Tenax TPUD ThermoPlastic UniDirectional Uni-directional MECHANICAL PROPERTIES

11 Carbon Fiber Products Forms Filament Woven Cloth Prepreg Composite Chopped for Compounding

12 Carbon Fiber Characteristics Light weight Carbon Fiber is ¼ the Density of Steel Specific gravity of carbon fiber 1.8 Specific gravity of Steel 7.8, Aluminum 2.7, Glass 2.5 High tensile strength and modulus Specific strength > steel Specific modulus > steel Other properties Electrically conductive Excellent fatigue resistance Excellent thermal dimensional stability Excellent corrosion & chemical resistance X-ray transparent

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14 Heat Resistance (Tg) [ o C] Toho Tenax Matrix Resin Product Mix #304 #301 #101 #195 Ultra high Heat Resistance Ultra Heat Resistance High Heat Resistance #112 #132 Self-adhesive for Secondary Structure #144 Low Temp. Curing #138 Rapid cure type #135 Interior Structure Self-adhesive Impact Resistance (CAI) [MPa] #501 for Aerospace #133 Ultra Impact Resistance for Primary Structure #133-4 & # Epoxy Resin BMI Benzoxazine

15 Diversified Structural Composites 1.6% 4.6% 1.3% 6.7% 19.8% 5.9% 16.5% 21.6% 22.2% CONSTRUCTION FENESTRATION ENERGY ELECTRICAL LEISURE OEM MEDICAL AEROSPACE TRANSPORTATION

16 DSC Curved Pultrusion Technology DSC-CPT (Curved Pultrusion Technology): Offers the capability to produce curved pultruded profiles, and the internal capability of design and development the necessary tooling and process methods. Benefits: Mold parts into an additional dimension, overcoming the limitation of Pultrusion to straight profiles. Manufacture pultruded parts with a controlled, constant radius. Unique process technology in the custom pultrusion industry, which offers cost advantages over other processes Excellent part to part consistency High volume capability Low labor costs- highly automated

17 DSC Curved Pultrusion Technology Helical Coil O&G Application

18 Various type of chopped fiber in the market

19 These percentages are not based on volumes but on SKU s Thermoplastic Resins Where Chopped Carbon Fiber is Used

20 ThermoPlastic UniDirectional (TPUD)

21 Tenax TPUD PEEK-HTS45 - Part Making

22 Tenax TPUD PEEK-HTS45 Laminate Mechanical Properties Equivalent Properties to Thermoset UD-Prepreg (Dry/RT) High fracture toughness Improved Hot/Wet Properties vs. Thermoset (i.e Compr. Strength) Low Moisture Absorption (~ 0.2%) & Reversible Mechanical Properties (test direction) Glass transition temperature onset Conditioning / Test temperature 23 C, 50% r.h./ 23 C, 50% r.h Typical value 143 C 289 F Tensile (0 ) DIN EN 2561 Type A modulus 23 C, 50% r.h./ 142 GPa 20.6 Msi strength 23 C, 50% r.h 2450 MPa ksi Tensile (90 ) DIN EN 2597 Type B strength 23 C, 50% r.h./ 23 C, 50% r.h 88 MPa 12.8 ksi Flexure (0 ) DIN 2562 Type A Compression (0 ) EN 2850 Type A3 modulus 23 C, 50% r.h./ 130 GPa 18.9 Msi strength 23 C, 50% r.h 1760 MPa ksi modulus 23 C, 50% r.h./ 130 GPa 18.9 Msi strength 23 C, 50% r.h 1545 MPa ksi

23 Tenax TPUD PEEK-HTS45 - Part Making

24 TPUD Industrial Applications: 1). Riser/Piping Demonstration Part using ¼ slit TPUD 2). Umbilical Spring using 2.0 wide slit TPUD

25 ThermoPlastic Woven Fabric (TPWF)

26 (TPWF) : 1). Material characterization currently in Development (a). Provide Toho Tenax a Customer base for the material. Pre-cut HTA40 PEEK Prepreg -.5 cm squares Special Compression-Molded Processing with Inserts

27 ThermoPlastic Consolidated Laminate (TPCL)

28 Tenax TPCL PEEK-HTA40 - Mechanical Properties Similar Mechanical Properties to Thermoset Properties (test direction) Conditioning / Test temperature Typical value Melting point Peak DSC 343 C 649 F Glass transition temperature Tensile (1) (warp, 0 ) ISO Compression (1) (warp, 0 ) EN 2850 Type B Flexural (warp, 0 ) EN 2562 Type A onset 23 C, 50% r.h./ 23 C, 50% r.h 143 C 289 F modulus 23 C, 50% r.h./ 60 GPa 8.7 Msi strength 23 C, 50% r.h 963 MPa ksi modulus 23 C, 50% r.h./ 59 GPa 8.6 Msi strength 23 C, 50% r.h 725 MPa ksi modulus 23 C, 50% r.h./ 64 GPa 9.3 Msi strength 23 C, 50% r.h 1166 MPa ksi (1) normalized to nominal thickness (0.31mm) (.0012 )

29 Tenax TPCL PEEK-HTA40 Part Making (Clips) Automated Process Complex Part Shape Very Short Cycle Time Joining Technologies Video _toho-tenax-v8-2-low.mp4

30 Thermo Plastic Consolidated Laminate Tenax TPCL PEEK-HTA40 ON BOARD OF AIRBUS A350XWB Source: Airbus Page 30

31 ThermoPlastic ConsolidatedLaminate Tenax TPCL PEEK-HTA40 ON BOARD OF AIRBUS A350XWB Source: Airbus Page 31

32 Airframe Composite Fuselage - Airbus A350 Page 32

33 Aerospace: the Original Force Behind Carbon Fiber

34 This information is property of Embraer and cannot be used or reproduced without written permission. Legacy 500/450 Radome Fiberglass/Epoxy Empennages Carbon/Epoxy Hand Layup ATL Ribs Thermoplastics HS Tip Carbon/Epoxy VARTM Wing Fus. Fairing Fiberglass/epoxy Hand Layup Control Surfaces Flap, Aileron, Rudder, Elevator, Spoilers Carbon/Epoxy Hand Layup ,125 nm Pylon Fairing Carbon/epoxy RTM Aft Pressure Bulkhead Carbon/Epoxy RFI

35 This information is property of Embraer and cannot be used or reproduced without written permission. E175 E2 Control Surfaces Flap, Aileron, Rudder, Elevator, Spoilers Carbon/Epoxy Hand Layup AFP Hot forming Floor panel Carbon or Fiberglass Sandwich panels Outboard Flap Carbon/Epoxy ATL Hot forming Thermoplastic Thermophorming Radome Fiberglass/Epoxy Empennage Horizontal Tail Carbon/Epoxy ATL AFP Hot forming Landing Gear Doors NLG door, MLG doors Carbon/Epoxy Hand Layup Wing Fus. Fairing Fiberglass/epoxy Hand Layup ,800 nm

36 Composites % - airframe weight Fairings & Radome + Control Surfaces 15% Fairings & Radome 25% + Rear Fuselage + Empennage & Pressure Bulkhead + Control Surfaces 20% 50% + Wing box & Fuselage + Empennage & Pressure Bulkhead Larger Aircraft Embraer

37 Fleet Engine A320neo / 737 MAX propulsion system: - LEAP-X Engine -Composite Fan Blades -Composite Fan Case -Composite OGV s - Nacelle System -Composite Inlet Cowl -Composite Reverser -Composite Fan Cowl Doors CFMI LEAP-X LEAP-X Nacelle System 15 percent improvement in fuel consumption Confidential

38 Engineering, Testing & Technology Early 1990 s State of the Art: Boeing Research & Technology GT Copyrigh

39 Engineering, Testing & Technology Boeing Research & Technology GT 2010 s State of the Art: Steel 10% Other 5% Titanium 15% Composites 50% Video Boeing VIDEO-Boeing mp4 Aluminum 20% Copyright 2014 Boeing. All rightsreserved.

40 Thank you for your attention!