functionalization of cfrp surfaces by tp films · hexcel m18/1 and rtm6 •tg > 200 c...
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• Motivation: Project MAI Fo • Materials • Applications and results
– Corrosion protection – Non structural bonds – Structural bonds
• Outlook
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Thermoplastic films offer an endless variety of surface functions - Protection (thermal, mechanical) - Interfaces (for assembly) - Optical (illuminated, signal) - Integration of circuits and sensors and many more Films on a part surface… - concentrate the functions were needed without
influencing the component performance itself - M&P of the component itself can remain widely unchanged - Supplier capabilities can be integrated more easily into value creation chain
Motivation
By understanding and managing the application of films, numerous functions become available for the CFRP engineer
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Project MAI Fo
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Project name MAIfo: „Entwicklung von Prozessketten zur Herstellung teilfolierter Faserverbundbauteile“
Projekt coordinator Airbus Helicopters
Budget 2,35 Mio €
Duration 01.05.13 - 30.04.16
Partner BMW, BASF, LCC, AHD
MAI Fo: AHD application targets
Three film functions are targeted within MAI-Fo
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complexity
Targeted maturity (within MAI Fo)
TP film selection
Criteria • Interphase formation • Solubility with resin systems
HEXCEL M18/1 and RTM6 • Tg > 200
C • Resistance against media No solubility: PI, TPI Tg too low: SRP, PSU, COC Films not manufacturable: PPC, PBI, PAI n.a. yet: HTS
Go on with: PEI, PES, PPSU (PPE)
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[Plastics Technology]
Applications
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Org
acr
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Airb
us H
elic
opte
rs ri
ghts
rese
rved
Corrosion protection
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• Assembly of frame segments by aluminium brackets
• difference of electrochemical potenital causes contact corrosion
• State of the art: protection by paint
Intermediate steps
grinding
cleaning
Primer and paint application
Cutting, layup, compaction
a/c cycle
rework
drying
old/new approach for frame manufacturing
Film preparation
Film application
Frame assy Lower frame
bracket
rivet
film
Potential process time savings: 7.5%
part
man
ufac
ture
A
pply
pro
tect
ion
Salt spray testing
PEI film suitable as corrosion protection
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• Salt spray test: • 5% NaCl spray • 2024 aluminium alloy,
chromated …after 1000h:
• No protection: Corrosion on aluminium plate
• Protective paint: No corrosion • PES sample: showed degradation
in salt spray • PEI sample: No corrosion
PEI
No protection Paint
PES
Non structural bonding
Whole process chain through connection of MAI projects
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• 1000+ click bonds and electrical supports per h/c • adhesive joints, manual application Film integration and welding on TP surface:
Projects MAI Fo and MAI Plast (AGI)
material process part w/
film surface
joining Characterisation of assembly
testing
@ Airbus Group Innovation
40 mm
Cost saving potential for click bond application
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Marking
Cleaning substrate
Cleaning C-B
adhesive
curing
Primer
Grinding of substrate
Cutting, layup
a/c cycle
rework
Film preparation
Film application
Welding
Old/new approach for click bond attachment
Bas
e pa
rt m
anuf
actu
re
Clic
k bo
nd a
pplic
atio
n
time
- 14% - 31%
Adhesive bonding
Welding easy accesible c/b
Welding all accesible c/b
Time consumption click bond application
Interphase formation, PES and PEI
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• Both PEI and PES form interphases and bond to epoxy prepreg and infusion resin during cure cycle (180
C)
• interphase formation takes place below Tg
• Interphase thickness is between 30 µm und 50 µm • Interphase formation mechanisms and means to influence
the formation is investigated at LCC Presentation tomorrow • Translation into consequences for a serial application
is done between LCC and the industry partners
Prepreg-PEI Prepreg-PES RTM-PES
Mechanical Characterisation
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Substantial increase of GIC for PEI confirmed
[AHD/LCC]
Outlook
• Corrosion protection: Technology assessed beneficial from technical and economical point of view: Certification aspects for coming h/c programs to be evaluated
• Non-structural bonds: high cost saving potential identified and promising mechanical strength confirmed further mechanical characterization and concentration of welding technologies
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Potential of TP films for cost saving and function integration could be confirmed and will be further pushed towards a serial application at Airbus Helicopters
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