innovative pultrusion thermoset solutions for wind, · pdf fileinnovative pultrusion thermoset...

Advanced Materials

Innovative Pultrusion Thermoset Solutions for Wind, Automotive and AerospaceCompetence Day Pultrusion, 28th of June 2017, Munich

Advanced Materials2

Agenda

1. Huntsman Advanced Materials

2. Pultrusion Capabilities & Partners

3. Thermoset Solutions

• Amine system with low Tg

• Amine system with medium Tg

• Anhydride system with adjustable Tg

• Hybrid system with FST requirements

4. Examples of Applications

5. Support by Simulation

Advanced Materials3

Agenda










Advanced Materials

Huntsman Corporation

We are a global manu-facturer and marketer of differentiated chemical products that improve the quality of life for people around the world.

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Advanced Materials

Advanced Materials

Our Business DivisionsHuntsman Corporation

Systems for Composites

Adhesives

Resins

Curing Agents

Dyes

Chemicals

Apparel

Home & Institutional

Technical Textiles

PerformanceProducts

AdvancedMaterials

TextileEffects

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Amines

Surfactants

MaleicAnhydride

Upstream Intermediates

MDI

Polyols

PO/MTBE

TPU

PU Systems

Polyurethanes

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Serving more than 2,000 customers in over 30 countries in three regions

Huntsman Advanced Materials

Advanced Materials

Serving more than 2,000 customers in over 30 countries in three regions


Americas

Europe, Middle East, Africa (EMEA)

Asia Pacific, (APAC), India

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Advanced Materials

Over 30 years of experienceStrong market position (A350, A380, Dreamliner)

Rigorous safety and performance specifications are key factors

Aerospace Sports Wind

50 years of experience

Lightweight, strength, flexibility,

design freedom and fatigue

resistance are key factors

affecting athletic performance

Over 30 years of experienceCost competitive systems for mass produced composite blades are essential

Demanding supply chain requirements for large volume on time in full delivery need to be met

A leader in Advanced Composite Technology


Advanced Materials

Araldite ® XB 3518 / Aradur ® 22962

Araldite ®

LY 3585 / XB 3458

Lamborghini Aventador BMW I program

Our partners

Mass ProductionSupercarsFormula 1

Multiple Products

McLaren

A leader in Automotive CompositesHuntsman Advanced Materials

Advanced Materials10

Agenda











Pultrusion Capabilities & Partners

Huntsman Technical Center, Auburn Hills, USA

Huntsman Asia-Pacific Technical Center, Shanghai, China

KraussMaffei Technical Center, Munich, Germany

Fraunhofer IGCV, Augsburg, Germany


Agenda










Advanced Materials

Amine System with low Tg(LY3585/ Aradur 3489)

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Thermoset Solutions

ILSS acc. to ASTM D2344/13; flexural acc. to ISO14125/98

Possible Wetting technology

Open bath & Injection box

Process parameters

Die temperature [°C] 200/220/220/180

Line speed [m/min] 0.6 (OB&IB)

Pulling force [t] < 2

Properties (incl. 6phr of ITM)

Fiber Glass 3B – SE3030 Carbon – Mitsubishi 50k

Profile dimension [mm] 115 x 3 60 x 5

Fiber Volume Fraction [%] approx. 63 - 65% approx. 60 -62%

Surface quality shiny surface shiny surface

Ultimate Tg (DSC Midpoint) [°C] 95 – 100 95 – 100

ILSS* [MPA] 54 – 58 64 – 68

Flexural modulus in 0° [Gpa] 46 – 49 130 – 134

Flexural strength in 0° [MPa] 1390 – 1410 1280 – 1310

Flexural modulus in 90° [Gpa] 12 – 14 N.A.

Flexural strength in 90° [MPa] 98 – 104 N.A.

Flat 115 x 3 mm

Flat 60 x 5 mm

Advanced Materials

Amine System with medium Tg(LY3585/ Aradur 3475)

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Thermoset Solutions


Injection box

Process parameters

Die temperature [°C] 130/180/180

Line speed [m/min] 0.7 (status quo)

Pulling force [t] < 0.8


Fiber Glass 3B - 399 Carbon – DowAksa 24k


Fiber Volume Fraction [%] approx. 65% approx. 65%


Ultimate Tg (DSC Midpoint) [°C] 120 – 130 120 – 130

ILSS* [MPA] 63 – 67 N.A.


Flexural strength in 0° [MPa] 1200 - 1400 N.A.


Flexural strength in 90° [MPa] 29 – 34 N.A.


Flat 120 x 3 mm

Flat 120 x 3 mm

Advanced Materials

Anhydride System with adjustable Tg(LY3585/ CY 179/ Aradur 917-1/ DY 080)

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Thermoset Solutions


Open bath & Injection box

Process parameters

Die temperature [°C] 155/195/195/195

Line speed [m/min] up to 1.5 m/min (depending on fiber and part geometry)



Fiber Glass 3B – SE3030 Carbon – Mitsubishi 50k Carbon - Dow Aksa 24k

Profile dimension [mm] 60 x 5 60 x 5 60 x 3

Fiber Volume Fraction [%] approx. 65 – 67% approx. 61 – 63% approx. 63 – 64%

Surface quality shiny surface shiny surface shiny surface

Ultimate Tg (DSC Midpoint) [°C] 120 – 125 120 – 125 120 – 125

ILSS* [MPA] 62 – 64 71 – 74 74 – 76

Flexural modulus in 0° [Gpa] 50 – 52 133 – 136 130 – 138

Flexural strength in 0° [MPa] 1400 – 1430 1410 – 1440 1450 – 1600

Flexural modulus in 90° [Gpa] N.A. N.A. N.A.

Flexural strength in 90° [MPa] N.A. N.A. N.A.


Advanced Materials

• Profile: rod with diameter of 8mm• Resin system: anhydride system with high Tg (175°-180°C DSC midpoint)• Fibers:

• core: carbon fibers T700sc 12k• outer shell: glass fiber ECR 468A-1200tex

Anhydride System with adjustable Tg(LY3585/ CY 179/ Aradur 917-1/ DY 080)

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Thermoset Solutions

IMG_0432.MOV

Anhydride(LY3595/CY179-1/AD917-1/DY080/IC25)

Pultrusion speed [m/min] 0,8 1,5

Die temperature [°C] 155/195/195 170/220/220 180/220/220

Tg after die(DMA onset) [°C]

160 159 163

Tg after post-cure1h@180°C(DMA onset) [°C]

174 170 171

Advanced Materials

Hybrid system with FST requirements

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Thermoset Solutions


Injection box

Process parameters

Die temperature [°C] 150/196/160/active cooling

Line speed [m/min] 0.2 (glass); 0.15 (carbon)



Fiber Glass 3B - 399 Carbon – Dow Aksa 24k


Fiber Volume Fraction [%] approx. 65% approx. 62%


Ultimate Tg (DSC Midpoint) [°C] 250 250

ILSS* [MPA] 80 – 90 being tested

Flexural modulus in 0° [Gpa] N.A. being tested

Flexural strength in 0° [MPa] N.A. being tested

Flexural modulus in 90° [Gpa] 14 – 15 being tested

Flexural strength in 90° [MPa] 90 – 100 being tested

Flat 120 x 3 mm – after die

Flat 120 x 3 mm – after post-cure(2h @180°C)


Flat 60 x 2 mm – after die


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Advanced Materials

General information:• Fiber: Carbon fiber 50k• Resin:

• Anhydride system(LY3585/ Aradur 917-1/ DY 080)

• Amine with low Tg(LY3585/ Aradur 3489)

• Profile: • 60 x 4 mm2

• 60 x 5 mm2

• FVC: 63-64%• Die length: approx. 900mm

Peel plies tested:• Econostitch G from AirTech• Release Ply G from Airtech• Stich Ply A from AirTech

�Line speed (amine): 0,6 m/min�Line speed (anhydride): 0,7-0,8m/min

(status quo)

Pultrusion with peel ply

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Examples of Applications

Process Setup

Profiles

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Composite Cable Core for high voltage transmission line in power industry

� Epoxy system: High Tg anhydride system (Tg > 200°C DMA onset)

� Benefits:� Excellent processibility: High pultrusion speed � Excellent thermodynamic properties� Outstanding mechanical properties with fibers� Long-term pultrusion run performed without break-down (6,5 days; 7,5 km

with a speed of 0,8m/min)

Anhydride System with adjustable Tg

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Examples of Applications


Examples of ApplicationsAnhydride System with adjustable Tg

Composite Oil Extraction Rods

� Epoxy system: � High Tg for deep oil well (> 2 km length)

• Tg approx. 170°C

� Low Tg for shallow oil well (less 2km) • Tg approx. 140°C

� Benefits:� Excellent thermodynamic properties� Outstanding mechanical properties with fibers� Good corrosion resistance� Continuous long sucker rod, no need for connectors to guarantee the

stability and safety� Excellent processibility for big diameter (up to 29mm): Stable long-term

pultrusion run performed without break-down (5,5 days; 2,3 km with a speed of 0,3m/min)


Examples of ApplicationsHybrid system with FST requirements

Ultra-light and flame resistant carbon composite sandwich (produced by VDL (Netherland))

� Epoxy system: � FST epoxy-hybrid thermoset technology

� Benefits:� Robust processing using pultrusion thanks to low

viscosity combined with long latency � Exceptional flame resistance, smoke density/

toxicity and heat-release performance� Outstanding thermo-mechanical properties for

semi-structural parts


Agenda


2. Pultrusion Capabilities








Advanced Materials

Different processing domains

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Support by simulation

Aim: Use existing techniques with minor modifications to provide supportiveanswers to

• Exotherm behaviour• Conversion, Tg after leaving the mold• Assess the approximate transition position towards gelation

Impregnation unit:- Bath- Injection unit

Example for Pullers

Cutting unit

Aim: Designing the three phases during pultrusion: Liquid phase / Gel phase / Solid phase

Heating stages

Dry Rovings

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Current modelling approaches

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Two approaches:� Convective fields:

• Tracks motion of fluid and extendability (tools etc.) is given

• High CPU-time required• Still implementation work

required� Moving cross section:

• Simplified model similar to other modelling tasks

• Low CPU-time required• Good for fast evaluations

� Similar results in simple conditions

Approach 1: Convective fields

Approach 2: Moving cross section

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Possible Outputs

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• Provide an understanding of• Exotherm• Conversion, Tg after leaving the mold• Assess the approximate transition position towards gellation


Tem

pera

ture

(°C

) / C

onve

rsio

n (%

)

Gelation at about 65% conversion


Thank you very much for your attention!

Contact details:

Stephan Costantino (Process and Application Manager)[email protected]: +41 (0)79 248 6612

Dr.-Ing. Michael Karcher (Technical Support Engineer)[email protected]: +41 (0)79 715 4119

Advanced Materials

Legal Disclaimer

Copyright© 2015 Huntsman Corporation or an affiliate thereof. All rights reserved.

The use of the symbol® herein signifies the registration of the associated trademark in one or more, but not all, countries. While the information and recommendations included in this publication are, to the best of Huntsman’s knowledge, accurate as of the date of publication, nothing contained herein is to be construed as a representation or warranty of any kind, express or implied.

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Advanced Materials

For more information

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www.huntsman.com/advanced_materials [email protected]

EuropeHuntsman Advanced Materials (Switzerland) GmbH Klybeckstrasse 200 P.O. Box - 4002 BaselSwitzerland Tel. +41 61 299 20 41Fax +41 61 299 20 40

innovative pultrusion thermoset solutions for wind, · pdf fileinnovative pultrusion thermoset...

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