Huntsman Advanced Materials - SPE AutomotiveAdvanced Materials 12 BMW M3 roof parts with Araldite ®...

Advanced Materials 1

Huntsman Advanced Materials


Compression Moulding – High Pressure RTM

Two complementary technologies for cost effective carbon

composites mass production in Automotive

Duncan Howland, Klaus Ritter


Table of Content

> Composites in Automotive: Applications, Liquid Composite Processes

> Resin-Transfer-Moulding Epoxy Solutions

> Standard low Pressure RTM

> High-Pressure RTM

> Comparison on latest Epoxy RTM Resin Technologies

> Compression-Moulding Epoxy Solutions

> Expandable Epoxy Systems (EES)

> Wet Compression Moulding for Structural Parts

> Mold-Technologies

> Influence of Accelerator Content

> Conclusion: Comparison HP RTM vs. Compression Moulding> Cycle-times and Material-Properties

> Outlook


Composites Applications in Automotive

Roof

Bonnet

Interior panelsEES technology

Drive shafts

Trunk panelEES technology

Chassis

Leaf springs

Wheels


Liquid Composites Processes in Automotive

Complexity vs. production speed


Resin Transfer Moulding Solutions

- Standard Low Pressure RTM

- High Pressure RTM


Resin Transfer Moulding Process

Main features and benefits

� Design freedom !!!

� Short cycle time

� Industrial process for medium-to-high volume car part production

� High quality – reproducibility

� Integrated function (eg. reduced number of parts, metallic insert integration…)


Standard Pressure vs. High Pressure RTM

Low pressure: static mixer

Low Pressure Mixing Head with courtesy of Cannon


Standard Pressure vs. High Pressure RTM

High pressure: mixing chamber

* HP-RTM requires the use of internal release agent, which can either be pre-dosed in the resin or mixed as a third component directly in the mixing chamber. FPL mixing head: with courtesy of Cannon


Standard Pressure vs. High Pressure RTM Epoxy Solutions

Production cycle comparison

(1) Out of the mould postcure often required

(2) Includes mould closure and vacuum

(3) Tg DMA obtained with 1% internal release agent

STANDARD RTM (1)

HP RTM SOLUTIONS

Araldite® LY 3585 / XB 3458

NEWAraldite® LY 3585 /

Aradur® 3475

= System 1

Preform set (2) 1 - 5 min 0.5 min

Mould Temperature 30 – 120°C 100°C 115°C

Injection 2 - 15 minup to 0.5 min

(small to medium part)up to 1 min

(small to large part)

Cure 10 - 60 min > 5 min > 2 min

Demoulding 1 - 5 min 0.5 min

Part production time(minimum)

14 - 85 min 6.5 min 4 min

DMA Tg onset (3) 100 – 190°C 93 – 103 °C 105 – 115°C

Advanced Materials

Cure Latency During Mold filling

System1 + 2 phr IRA

Unit

Mix ratio 100 : 21

Mix viscosity at 110ºC / 115ºC mPas < 50

Injection time at 110ºC / 115ºC s ca 60

0

500

1000

1500

2000

0 10 20 30 40 50 60 70

vis

co

sit

y i

n m

Pa

.s

time in seconds

XB 3585 / XB 3458 @ 100°C

XB 3585 / Aradur 3475 @ 110°C

XB 3585 / Aradur 3475 @ 115°C


BMW M3 roof parts with Araldite® XB 3523 / XB 3458

Araldite® Solutions / Case Histories

Benefits• Low weight, high stiffness and high dimensional stability• Fashion / aesthetics due to carbon look• Class A finish• Low shrinkage

Lamborghini Aventador LP700-4’s chassis with Araldite®XB 3518 / Aradur® 22962

BMW i3 - Life - Cell Araldite® LY 3585 / XB 3458

Benefits• Low viscosity during injection• Sufficient pot life• Low shrinkage (surface quality)• High mechanical properties (good balance Tg / Toughness)• Good hot / wet properties

Benefits• Fast curing • Versatile for RTM and Compression Molding• Low water pick up• high mechanical performance


Binder for Preform Manufacture

Typical preforming conditions: cold pressing after infra-red heating

Product Designation

Type Gel time Softening point

Tg Typical applications Recommended preforming cycle

Conditions 130°C DSC mid point

Unit sec °C °C

Resin

Araldite® LT 3366

Epoxynon reactive

na ca. 150 75 - 85 High pressure RTM 20 ±10 sec at 180 ±20°C+ cold stamping


Compression Molding Technology

- Expandable Epoxy Systems (EES) & Natural Fibre

- Wet Compression Moulding of Structural Parts


Expandable Epoxy Systems / Compression Moulding Process


� Possibility of extremely short cycle times (45-60 s at 150-160°C)

� Low density laminates (~ 0.7 g/cm3 with natural fibres)

� Moderate investment cost

� Easy and exact moulding of complicated shapes

� Closed cells (no water penetration)

� Monolithic laminates as well as sandwich structures

� Adjustable porosity for vacuum assisted covering

with decorative films

Cooling JigApplication of resin system

Wet-reinforcement

placement

Mould-closure and cure

De-moulding

Mould and press occupation time

Expansion of EES resin and fibre impregnation


Conti Duo™ Patented Processand Material Properties of EES


� Fully automated process with a low investment cost

� Cost competitive for large series production

� Minimum material waste associated with high quality consistency

� Resin consumption minimised as there is no over-spray (clean process vs. spray)

Maximum Tg Density of composites (1) Comments

Unit °C g/cm3

Araldite® LY 5310 /Aradur® 1135-1B

135 - 145 0.65 - 0.85 High Tg, extremely low emission (for interior use)

(1) With natural fibre mats density : ~ 1.4 g/cm3 ; epoxy resin ~ 35 % by weight


CSL C218 indoor panel, produced by Bushoku Automotive Europe GmbH (Europe) with Araldite® epoxy system and natural fibres

Benefits

� Very short production cycle, less than 1 min (45 s at 150°°°°C)

� Parts with high impact-strength

� Rigid, very light and dimensionally stable parts

Araldite® EES Solution for Mercedes Benz


Wet Compression Molding Processfor Structural Parts


� Very short cycle time

� No injection step

� Lower investment vs. high pressure RTM

with courtesy of Cannonwith courtesy of Cannon

Cooling JigFibre-stack placement

Mould-closure and cure

De-moulding

Mould and press occupation time

Resin application


Wet Compression Moulding ProcessTooling- Technology

Classic Compression Mold Concept with controlled

“Overflow” Channel

Compression Chamber Technology Vacuum assisted

Benefits: - Simple mould technology

- Cost of mould

- Slightly faster (no vacuum)

-> For simple parts

Benefits: - significantly higher part quality

- void free parts / highest

composite quality

- higher design freedom

- less waste


Wet Compression Moulding Processfor Structural Parts

1. Fabric stack prepared

2. Resin applied

3. Wetted stack in mouldMould closed and vacuum applied

4. Cure in press 60s


Wet Compression Moulding Processfor Structural Parts

Composite part quality: parts straight out of mould, untrimmed


Wet Compression Moulding vs. HP RTM“Parts in Minutes”

Production cycle comparison on same epoxy system

HP RTM SOLUTIONS WET COMPRESSION MOULDING SOLUTIONS

NEWEP- System 1

NEWEP-System1

Preform Normally required Optional

Preform / fabric lay-up set (1) approx. 30’’ approx. 30’’

MouldTemperature

110°C 130 - 150°C

Injection up to 1 min

(small to large part)-

Cure > 2 min 1 min

Demoulding approx. 30’’ approx. 30’’

Part production time (minimum)

appr. 4 min appr. 2’ min

(1) Includes mould closure and vacuum

Advanced Materials

Neat-resin-dataEP- System1 +

2 phr IRA

Standard Unit

Curing cycle time (1) min 2 min 115ºC 2 min 115ºC

HP-RTM – neat resin data 4 mm DRY 7 days H2O @ 23ºC

Tensile Modulus

ISO 527-2/1B

MPa 2742 2645

Tensile Strength MPa 78 76

% 9.7 13.8Tensile Elongation

Cure conversion (2)

ISO 11357-2% 100

DSC Tg onset (2) ºC 122

DMA Tg onset (3) ISO 6721-4 ºC 131 127

G1C ISO 13586 J/m2 267 285

CTE ISO11359 10-6 / K 54

(1) Based on a 12 sec injection time, (2) 10ºC / min, (3) Tensile mode, 2ºC / min, 10 Hz

Material Properties

CFRP –Data (1)

HP-RTM – CFRP 2 mm 2 min 115ºC

DMA Tg onset (2) ISO 6721-4 ºC 111

ILSS ASTM D2344 / UD MPa 60.2

(1) Based on a 12 sec injection time, (2) Torsion mode, 2ºC / min, 1 Hz

Advanced Materials

Influence of Temperature and Accelerator-Content on Curing-Speed (Conversion)

24

0 50 100 150 200 250 300 350 400 450 5000

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

0.9

1100XB3585-23LME10950-with10percacc

Time (s)

convers

ion (-)

80°°°°C100°°°°C120°°°°C140°°°°C Araldit LY 3585 – Hardener 2----- high accelerator level low accelerator level

Optimizing Formulations for Compression-Moulding


Conclusion

RTM:

� Advantage - Design Freedom !

� Pressure during injection up to 150 bar

� Proper preform mandatory to avoid fibre misalignment

RTM

Preforming Placement

Mould-closure

and

Vacuum

Demoulding

Mould and Press Occupation Time ( +/- 4 min)

Preforming Injection Cure

Compression Molding

Wet Fabric-Placement

Mould-closure

and Vacuum

Demoulding

Mould and Press Occupation Time (1’30 - 2’30’’)

Preforming

Not mandatoryCure Cooling Jig

Compression Moulding (Vacuum-Assisted):

� Preform not mandatory due to vertical

impregnation

� Higher fibre volume content possible

� Much faster process vs. RTM

� Pressure max. 30 bar

� Design freedom higher than classical compression moulding


Outlook

With process optimized epoxy systems for wet

compression molding, we expect cure-times of 30’’ ,

processing times of 1’-1’30’’ respectively, will very soon

be possible.


For more information

www.huntsman.com/advanced_materials

[email protected]

Europe

Huntsman Advanced Materials (Switzerland) GmbH

Klybeckstrasse 200

P.O. Box - 4002 Basel

Switzerland

Tel. +41 61 299 20 41

Fax +41 61 299 20 40


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Huntsman Advanced Materials - SPE AutomotiveAdvanced Materials 12 BMW M3 roof parts with Araldite ®...

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