Painel Aeroespacial -2017 Compósitos em SMC- Sheet Molding Compound : Estrutura, propriedades e Aplicações Palestrante: Everton Sterzo
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
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 Inaugurated Date: 1997 Associates: 65
Rio Claro Plant / Internal Area
Materials Engineered Tetrahedron Products / End Market Process Properties Chemical Structure
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)
Chemical Structure - SMC & BMC Polymer Matrix Thermosseting Resin Basic Component that will be cure process Unsaturated Polyester Vinyl Ester
Chemical Structure - SMC & BMC Polymer Matrix Thermosseting Resin Basic Component that will be cure process Epoxy Phenolic
Chemical Structure - SMC & BMC Catalyst Increase reaction speed, Decrease activity energy, same Free Energy
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. Composição do Vidro -E Ingredientes % Sílica (SiO 2 ) 52 56 Óxido de Cálcio (CaO) 16 25 Alumina (Al 2 O 3 ) 12 16 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 ) 0 0.8 Óxido Férrico (Fe 2 O 3 ) 0.05 0.4 Fluoreto (F 2 ) 0 1.0 Interface
Process BMC SMC Pultrusion Compression Mold Injection Mold
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
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
Press
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.
Properties Physical-chemical Thermal Mechanical Electrical Optical
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.
What is a Thermoset? Thermoplastic Thermosetting Heat
What is a Thermoset? Thermoplastic Thermosetting Cooling
Tensile Strenght (Mpa) Mechanical Properties BMC/SMC Tensile Properties 450 400 350 300 250 200 150 100 50 0 Special Materials -CF SMC SMC BMC 10 15 20 25 30 35 40 45 50 55 60 65 Fiber content(%)
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 100 60-75% 70% <60% >80% Baseline Superior Superior Superior Poor Tooling Cost 100% 40% 60% 40% 115% CLTE 100% 100-130% 600-1000% 100-130% 170-200% 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
Thermoset Composite Materials 350 280 140 70
CF SMC TDS *This table uses steel as a standard by which all other processes are compared. **Costs may vary. 27
CF SMC TDS *This table uses steel as a standard by which all other processes are compared. **Costs may vary. 28
A.Schulman Laboratory
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
Why SMC? Part Consolidation High yield Easy handling Excellent properties Formulations which are Easily Customizable to your Application Low Cost 31
Products/ End Market Motorcycle Agricultural Industrial Appliances Electrical Truck Automotive Aerospace 32
Products/ End Market BMC Applications BMC (Headlamps)
Products/ End Market BMC Applications Valve Cover
Products/ End Market BMC Applications BMC - Sewing Machine
Products/ End Market BMC Applications Electrical Parts
Products/ End Market SMC - Sheet Molding Compounds
Products/ End Market SMC - Sheet Molding Compounds Electrical
Products/ End Market SMC - Sheet Molding Compounds Grill Grill
Products/ End Market SMC - Sheet Molding Compounds Ford Troller Structural SMC
Products/ End Market SMC - Sheet Molding Compounds Ford Troller Class A SMC
Products/ End Market SMC - Sheet Molding Compounds Rear Floor - Renault
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 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
Products/ End Market Seat Components 23
Products/ End Market Aerospace Oxygen Canister Container for Long Haul (Boeing and Airbus) and other Regional Aircra0
Certificates ISO/ TS 16949:2009 ISO 9001:2008
Certificates : ISO 140001:2004
Thank you!!!! Everton Sterzo Quality & Development Manager Engineered Composites A. Schulman, Inc. T: 55 (19) 35261229 // C: 55 (19) 9 98172600