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Korea Institute of Carbon Convergence Technology 1 / 28
CFRP Engine Acoustic Cover : Low Cost
Manufacturing Process by Microwave Curing
and Carbon Valley Activity in Korea
CFK-Valley Stade Convention
Henry Shin
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CONTENTS
1. Overview : Carbon Fiber Composites & Carbon Valley in Korea
2. Objective
3. Experiments
4. Test & Results
- Specimens & Products , Mechanical Properties
6. Conclusion
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Overview
※ Source: Lucintel, ACMA Composites 2012
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Nameplate capacities, small tow[metric tonnes] Brand 2012 2013 2014 2015 2016
Toray Group, Japan Torayca 17,600 20,800 25,800 26,800 26,800
Toray, Ehime Plant, Japan 7,000 8,000 8,000 9,000 9,000
Toray Carbon Fiber Europe [CFE], France 5,200 5,200 5,200 5,200 5,200
Toray Carbon Fiber America [CFA], USA 5,400 5,400 7,900 7,900 7,900
Toray Advanced Materails Korea [TAK], Republic of Korea - 2,200 4,700 4,700 4,700
Toho Tenax Group, Japan Tenax 13,900 13,900 13,900 13,900 13,900
Toho Tenax Japan, Japan 6,400 6,400 6,400 6,400 6,400
Toho Tenax Europe, Germany 5,100 5,100 5,100 5,100 5,100
Toho Tenax America, USA 2,400 2,400 2,400 2,400 2,400
Mitsubishi Rayon, Japan 7,400 7,400 10,800 10,800 10,800
Japan Pyrofil 5,400 5,400 8,800 8,800 8,800
Grafil, USA Grafil 2,000 2,000 2,000 2,000 2,000
Chinese Manufacturers 7,650 15,650 18,650 18,650 18,650
Hengshen Fiber Material 1,000 3,000 6,000 6,000 6,000
Zhongfu-Shenying [CNBM] 3,000 4,000 4,000 4,000 4,000
Jilin Tangu Carbon Fiber C., Ltd. [Jilin Qifeng Chemical Fiber] - 3,500 3,500 3,500 3,500
Weihai Tuozhan Fiber [150T[3K] et 2000T[12k]] 2,150 2,150 2,150 2,150 2,150
Sinosteel Jiangcheng Carbon Fiber 500 2,000 2,000 2,000 2,000
Dalian Xingke Carbon Fiber 1,000 1,000 1,000 1,000 1,000
Formosa Plastics Group, Taiwan Tairyfill 8,750 8,750 8,750 8,750 8,750
Hexcel, USA HexTow 7,000 8,400 9,800 11,200 11,200
USA 6,350 7,750 7,750 10,550 10,550
Spain 650 650 650 650 650
Cytec, USA Thornel 3,000 2,000 2,000 4,000 4,000
Dow-AKSA, Turkey Aksaca 3,500 3,500 3,500 3,500 3,500
Kemrock, India 2,000 2,500 4,000 4,000 4,000
Hyosung, Republic of Korea Tansome 500 2,500 2,500 6,500 6,500
Taekwang Industrial, Republic of Korea Acepora 500 2,000 2,000 2,000 2,000
Composite Holding Company - - 1,500 1,500 1,500
OJSC NPK Khimpromengineering [ArgonБZUKM], Russia ? ? ? ? ?
Alabuga-Colokno, Republic of Tatarstan - - 1,500 1,500 1,500
Rostec, Russia - 300 300 300 300
Total [small tow] 71,800 87,700 103,500 111,900 111,900
Output [coefficient 0.7] 50,260 61,390 72,450 78,330 78,330
(Source : JEC magazine No.88)
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Nameplate capacities, large tow[metric tonnes] Brand 2012 2013 2014 2015 2016
Toray Group - 17,300 21,300 26,300 26,300
Ex-Zolteck, Hungary Panex - 9,000 9,000 10,000 10,000
Ex-Zoltek, USA Б Mexico Panex - 6,000 8,000 10,000 10,000
Ex-Zolteck, china Panex - 2,000 4,000 6,000 6,000
Japan Torauca - 300 300 300 300
SGL Group Sigrafil - 9,000 9,000 9,000 9,000
Muir of Ord, UK - 4,000 4,000 4,000 4,000
Evanston, USA - 2,000 2,000 2,000 2,000
Moses Lake, USA - 3,000 3,000 3,000 3,000
Bluestar Sigrafil - 3,700 3,700 3,700 3,700
China - 3,200 3,200 3,200 3,200
UK - 500 500 500 500
Kemrock, India Tairyfill - - 1,500 1,500 1,500
Mitsubishi Rayon, Japan HexTow - 2,700 2,700 2,700 2,700
Total [large tow] - 32,700 38,200 43,200 43,200
Output [coefficient 0.9] - 29,430 34,380 38,880 38,880
(Source : JEC magazine No.88)
PAN-based carbon fiber [both small and large tow] 2012 2013 2014 2015 2016
Total nameplate capacities 71,800 120,400 141,700 155,100 155,100
Total output 50,260 90,820 106,830 117,210 117,210
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Project Objectives
Development of Fundamental Technology of Carbon
Materials with world-class competitive Cost
Development of Core technology and
Commercialization
Integration of Carbon Industries and R&BD support
Infrastructure
Project Overview
Hosted of Ministry of Knowledge Economy(MKE)
Period : ‘11 ~ ’15yr (5yr)
Total Budget : 177M USD
(Government 130, Local 11, Private 25)
Project Budget
Sum Central Local Private
R&D 152 78 0 74
Test-Bed 25 19 6 0
Sum 177 97 6 74
[USD] (M USD)
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Large Tow Carbon Fiber
Low Cost Carbon Fiber
Intermediate Product and Application
Carbon Fiber(Coal Tar Pitch )
Carbon Fiber
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Convergence Technology Center
Testing Center Light Weight Metal
Carbon Fiber Manufacturing
PAN Fiber Manufacturing
SMC Manufacturing
Light Weight Metal (Mg/Al Parts Development)
Abrasion Resistance Material Technology Development
Manufacturing Support Center
Joint Venture 1, 2
R&D Application Center
Global Carbon Plaza (Global Joint R&D)
Carbon Valley in Jeonju city
Carbon Technical Education Center
Business Incubator
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2003
2006
2013
2003. 3. Establishment of JMC
2004. 3. Awarded First-Class of Promotion of local Industries Competition (MOTIE)
Awarded President of Best practices for Regional Innovation
2006. 11. Held the First International Carbon Festival
2011. 6. Built up Carbon Precursor & Fiber production system (200 mT/yr)
2013. 5. Changed to Korea Institute of Carbon Convergence Technology
2009. 12. Awarded MKE of Best practices for Regional Innovation
2005. 10.
2010. 10. Opened Int’l Carbon R&D center and Signed MOU (USA, Germany, Japan)
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○ Aerospace Structural Testing & System Integrations
○ Assembly & Design : Auto fiber placement & Microwave curing technology
○ Advanced Material (Composites) Machining Centre
○ Nuclear Manufacturing Centre
The AMRC Composite Centre hosts world-class design, manufacturing and machining
facilities for all types of composite materials. (UK Sheffield)
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Overview
AS IS
High Cost of Carbon Fiber
Low Productivity
: Hand lay- up, Autoclave
Recycle : Thermoset
Cost down
Productivity
Cycle time
Recycle
CF cost down
Melt Spinning
OoA Process (RTM, Compression)
& Fast Curing Process
Thermoplastic
Increasing
Productivity
COST
DOWN
Fast, Stable, Uniform Manufacturing
Advanced Process : Microwave curing process
Trend of Carbon Fiber Composites
Preforming
Automation
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Objective
To develop a new low cost manufacturing process
- AFP(Auto Fiber Placement) process
- Microwave curing process
Compared with conventional manufacturing process
- Cycle time, energy consumption, mechanical properties.
To proposal the new technology of CFRP Process
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CF Prepreg Hand lay-up
Conventional
Process
Advanced
Process
Microwave
Autoclave
AFP CF Tape
The manufacturing process
• UD, 600mm
• Epoxy resin 32%
• UD, 6.5mm(1/4") • Epoxy resin 32%
• Automated Dynamics • Heating : hot gas
• LBBC Autoclave • 1m x 2m • up to 400℃, 200bar
• Vötsch(Germany) • 1.8m x 2.m • up to 450℃
1st STEP Raw Materials
2nd STEP Preforming
3rd STEP Curing
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Matrix
MANUFACTURING PROCESS
Remark Curing
Preforming
Autoclave
(AC)
Microwave
(MW)
Oven
(OV)
Sample
Hand lay-up
(HND) HND-AC HND-MW HND-OV
AFP AFP-AC AFP-MW AFP-OV
SPECIMEN ID DESCRITION Remark
HND-AC Hand lay-up + Autoclave curing process
HND-MW Hand lay-up + Microwave curing process
HND-OV Hand lay-up + Oven curing process
AFP-AC AFP + Autoclave curing process
AFP-MW AFP + Microwave curing process
AFP-OV AFP + Oven curing process
3 types curing process + 2 types of preforming
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Advantages
High deposition rates
High accuracy
High complexity components achievable
Reduced need for vacuum de-bulking
Disadvantages
Typically expensive equipment
Expensive material due to secondary slitting
Limited in process inspection technologies available
Auto Fiber Placement(AFP)
Carbon Fiber slit tows (MTM44-1, UMECO)
Hand lay-up
AFP Process
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Microwave Curing
Vacuum bag for microwave cure Microwave System
Microwave Heating (2.45 GHz, magnetron)
Non contacting heating
High speed heating and cooling
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NDI Test
C scan Conditions
: scan machine is a Vertical 1 Channel,
2 Axis Jet Rig Scanner, the machine
works by ultrasonic transmission.
NDI Results
- All specimens have no defects
in the hand lay-up, automatic placement
and all curing process. Tested by Composites Testing Laboratory(Ireland)
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Compressive Test
Test Method : ASTM D6484
(Open hole compressive test)
Test Speed : 2mm/min
Hole diameter : 6.35mm
Test Results
• HND-AC is the highest value
• AFP is lower value than that of HND
• AFP-MC is 80% value(HND-AC : 100%)
200
300
400
HND-AC HND-MC HND-OV ATP-AC ATP-MC ATP-OV
before after
OHC failure
MPa
HND-AC HND-MC HND-OV AFP-AC AFP-MC AFP-OV
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ILSS
Test Method : ASTM D2344
Test Speed : 1.0mm/min
Radius of the loading nose : 3mm
Radius of the supports : 3mm
Test results
12mm
20mm
6mm
3mm
0
25
50
75
100
HND-AC HND-MC HND-ON ATP-AC ATP-MC ATP-ON
• HND-AC & AFP AC are highest value
• AFP is similar to that of HND
• AFP-MC is 80% value(HND-AC : 100%)
MPa
HND-AC HND-MC HND-OV AFP-AC AFP-MC AFP-OV
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Modal analysis
Material : Carbon Fabric prepreg(2x2 twill weave)
Natural frequency
Mode #1
(Torsion mode)
Mode #2
(Bending mode)
Mode #3
(Panel main mode)
66 Hz 130 Hz 273 Hz(target : 266Hz↑) *ref : original : 87Hz
#1
#3 #2
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Product : Acoustic Cover
Hand lay-up + Microwave AFP + Microwave
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Test Conditions : C-scan, 10 MHz Probes with water jet coupling.
scanning rate 200mms-1, raster pitch 0.2mm
Tested by NCCEF in Manchester University
NDI
※ NCCEF(National Composites Certification and Evaluation Facility)
HND-AC HND-OV HND-MW
AFP-AC AFP-OV AFP-MW
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ACURSTIC COVER
: PA6 , G/F 7% & M/F 30%
CFRP ACURSTIC COVER
: Epoxy/CF Fabric Prepreg Lay-up
& MW curing
Prototype of Acoustic Cover : Microwave process
Weight Reduction : 40%
Good mechanical and acoustic properties in the automobile
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Acoustic Cover : Testing
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developed new low cost manufacturing process of CFRP
- speed up CFRP process
@ automation & MW process : 7.5hr, hand lay-up & autoclave : 14.5hr
- reduced CFRP production costs & increase energy efficient : 60~70%
- increase product quality by homogeneity
Compared the properties of MW process and Autoclave process
- mechanical strength of MW is 80% that of autoclave but higher than that of
oven process.
- MW process is possible to alternative process of autoclave for aerospace
and automobile industries.
Conclusion
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Acknowledgements
Dr. J. Lee & R. Scaife
International R&D Fund of Jeonju City in Korea
Project Funding
Cooperate with AMRC with Boeing (UK)
Cooperate with Sheffield University (UK)
Cooperate with SSANGYONG MOTOR(KOREA)
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