Infrared Heating for Composite Materials · INFRARED vs Convection App. 50% energy savings App. 80%...

Infrared Heating for Composite Materials

Martin Klinecky, Heraeus Noblelight

1 Heraeus Noblelight. All rights reserved, see last page

Introduction

2

Martin Klinecky - Heraeus Noblelight Germany

Electrical engineer, graduate 1999 / Germany

Area Sales Manager – Infrared Process Technology

Responsible for eastern Europe, Scandinavia, Brazil

With Heraeus Noblelight since 2001

until 2014 R&D of Infrared Emitters

INFRARED FOR COMPOSITE MATERIALS

Martin Klinecky | HNG-IP | Oct 2015 Heraeus Noblelight. All rights reserved, see last page

Agenda

3

Motivation: heating processes at composites

production

Heat transfer via Infrared Radiation

IR Heating Composites - Results and Discussion

Application Examples

INFRARED FOR COMPOSITE MATERIALS


Heating processes during composites production

Processing of thermoplastic FRP

Before or during compounding

Infiltration

Pressing

(Re-) shaping of organo sheets:

thermoforming process

Composite repair: bring in energy

locally

Processing of thermoset FRP

Start polymerization

Decrease temperature difference

fiber – resin

Save time in autoclave

Composite repair: bring in energy

locally

MOTIVATION

Fiber pretreatment

Applying and drying of fiber sizing

Surface activating

4 Heraeus Noblelight. All rights reserved, see last page Martin Klinecky | HNG-IP | Oct 2015

The heating process

Conventional oven

Energy transfer via medium – detour of energy

Low efficiency due to low heat conductivity and low thermal heat transfer coefficient

Air is good for complex structures but very slow

Conventional

oven … heats air

…heats

workpiece

Infrared

…heats

workpiece

directly Processing time

MOTIVATION


The heating process

Infrared

Energy transfer directly to workpiece

High efficiency for most polymer matrices (high absorptions)

Fast, controllable and adjustable system: heat on demand

Conventional

oven … heats air

…heats

workpiece

Infrared

…heats

workpiece

directly Processing time

MOTIVATION


INFRARED vs Convection

App. 50% energy savings

App. 80% space saving

Process time reduction

Clean / dust-free working

Precise process control

Contact-free, no contamination

No enclosure needed

Industry experienced equipment

7

MOTIVATION

INFRARED further features


V = 10m/s

V = 1m/s

T [°C]

Source: RWE 1991

0

20

40

60

80

kW/m2

200 400 600

Convection Heat up to 40 kW/m2

Infrared Heat up to 1 MW/m2

Heat transfer via INFRARED Radiation

Basic principles and measurement techniques


Infrared Energy Transfer

Thermal radiation is energy…

…emitted by hot matter

…transported by radiation

Energy transfer without a medium

Spectral distribution depends on

source temperature (Planck´s law)

Industrial heating processes work

best in spectral range between 1-5

µm due to high power densities

Heraeus emitters cover full relevant

range for IR applications

BASIC PRINCIPLES


Infrared Energy Transfer – Different Emitter Types

10

BASIC PRINCIPLES


Sh

ort

Wa

ve

C

arb

on

M

ed

ium

Wa

ve

Infrared Energy Transfer – Risks and Safety Precautions

11

Hot surfaces contact

Cover, fence

Eye stress

Cover, glasses

Skin stress

Distance, cover

Material overheating

power regulation

temperature monitoring

European Regulations:

DIN EN12198

DIN EN 14255

BASIC PRINCIPLES


Sh

ort

Wa

ve

C

arb

on

M

ed

ium

Wa

ve

Heating FRP With Infrared

Aproach and Results


Testing of IR Heating for Composites - Approach

Samples were irradiated from one

side (top)

Temperature was monitored on

irradiated side and non-irradiated

side (bottom)

MEASUREMENT TECHNIQUE

FRP

Ttop

Tbottom

thickness


Testing of IR Heating for Composites - Approach

Samples were irradiated from one

side (top)

Temperature was monitored on

irradiated side and non-irradiated

side (bottom)

When Temperature on irradiated

surface is reached (heating time),

sample was removed from emitter

field

Temperature difference between top

and bottom ( T-Gradient)

Time-Temperature-curves were

created

MEASUREMENT TECHNIQUE

FRP

Ttop

Tbottom

thickness

Ttop

Tbottom

Start

Remove sample

T-gradient

Heating time


Influence of Spectrum and Power: Heating Time

The higher power, the shorter

heating time for CFRP material

No difference between medium-

wave carbon emitter and short-

wave emitter in heating time on

top surface is observed.

A maximum power density of

50-60 kW/m2 is sufficient

RESULTS AND DISCUSSION

Carbon (MW)

Short-wave

applied power [kW/m2]

rela

tive h

eating tim

e[-

]

IR-heating of C/PPS, 4.3mm


Influence of Spectrum and Power: Temperature Gradient

Temperature gradient increases

with higher power density

short-wave emitters show a

distinct smaller temperature

gradient than medium-wave

carbon emitters !

Deeper penetration depth of short-

wave radiation.

good for samples with high

thickness

decrease of thermal stresses in

material gentle heat process


applied power [kW/m2]

Tem

pera

ture

gra

die

nt

[°/m

m]

IR-heating of C/PPS, 4.3 mm

Carbon (MW)

Short-wave


Heraeus Noblelight. All rights reserved, see last page

• Absorption (Lambert-Beer)

• Inelastic scattering

• IR excitation in volume

• short ways for thermal conductivity

“Good absorption” or “volume heating (deep penetration)”?


• IR excitation on surface:

• long ways for thermal conductivity

medium-wave emitter short-wave emitter

17 Martin Klinecky | HNG-IP | Oct 2015

Influence of material: organo sheets

Different fiber/matrix combinations different heating times

Seite 18

Different fibers

Different matrices

CF/PPS

GF/PPS

GF/PA6

Martin Klinecky | HNG-IP | Oct 2015 18 Heraeus Noblelight. All rights reserved, see last page

Influence of Material: weaves

GF/PET and CF/PET weave

Heating of Carbon fiber weave is

faster

No Temperature gradient for glass

fiber weave

homogeneous heating with IR

gradient free


Preheating of weaves before consolidation works excellent with IR-heating

IR Spectrum should be considered

CF/PET

GF/PET


A good and efficient process depends on numerous factors

Power and spectra of IR system

Properties of substrate

Optical properties

Thermophysical properties (heat capacity, heat conductivity, …)

Geometry (thickness, surface to volume ratio,…)

Environmental conditions

Humidity

Temperature

Air flows

Reflecting walls, …

An Infrared system with fast reaction times is essential for good process control.

Reaction time of Heraeus emitter: 1-2 s

Closed-loop control possible



Application examples

Heraeus Infrared Process Technology

21 Martin Klinecky | HNG-IP | Oct 2015 Heraeus Noblelight. All rights reserved, see last page

Emitters

.

Modules & Controls & Conveyors/Lifts

Electrical Infrared Solutions

22 Martin Klinecky | Infrared Process Technology |

Solutions

Application: Heating Yarns

23

Concept study Example yarns


Application: Drying of fiber sizing

24

Carbon IR

Modules

Wavelength

converter on back

side

Pyrometer for

temperature

monitoring

Heraeus @ ITV Denkendorf


Application: Braiding pultrusion process - concept


Application: Braiding pultrusion process - Real construction

26

Heraeus @ ITV Denkendorf


Application: Braiding pultrusion process – IR Module Impressions


Application: IR welding of pressure tanks

28

Polypropylene cylinder body

glass-filled

IR features:

efficient melting in 40s

Power focused on target

surfaces

2s reaction time, power during

heating cycles only

contact free – no frequent tool

cleaning

Short wave emitters (19kW)


Video: http://www.heraeus-

noblelight.com/en/industriesandapplications/

infraredweldingofplastics.aspx

Application: IR softening of multi-ply, pre-preg for forming

29

Aircraft tooling - Softening

before specified profile

moulding

IR features:

Smaller dimensions

compared to hot air oven

Not risk of contamination

compared to oil-heated tools

Accurate material

temperature of 70°C

Integration into robot system


Application: IR interim processing of laid-up composites

30

De-bulking of composite

layers - rear spar assembly

for Airbus 350 XWB

IR features:

Prevents subsequent

wrinkling safe & fast

Integrated into semi robotic

work stations

Tailor made and optimized

IR-System

Total IR power 465kW

3 heating sections with 7

control zones each


31

BUSINESS GROUP SPECIALTY LIGHT SOURCES – HERAEUS NOBLELIGHT

Application: IR interim processing of laid-up composites

Application: IR on Composite Sheets for Foam-Sandwich Structures

32

Thermo-pressing of

composite top and bottom

layers with foam core in

between

IR Flexibility in Timing,

Power, Geometry

Can follow different material

specifications

Easy to adapt to changing

semi-product sizes and

geometries

Easy to transfer to series

production


Thank you for your attention!


Internet: www.heraeus-noblelight.com

Email: [email protected]

http://www.heraeus-noblelight.com/



Last presentation slide containing legal notices

This presentation including all its parts (e.g. photographs, diagrams, drawings etc.)

is protected by copyright. Any exploitation outside the close limits of the Copyright

Act is inadmissible and punishable, unless pre-approved by Heraeus. This applies

in particular to photocopies, publications, translations as well as storage and

processing in electronic systems.

All data in this presentation were thoroughly ascertained by Heraeus. However,

Heraeus does not assume any liability for their correctness or completeness.

The data are based on conditions of use and environmental influences assumed by

Heraeus. They cannot be adopted indiscriminately, but require prior verification for

the respective use of the customer.

Exclusively Heraeus’ General Terms of Delivery shall apply to all deliveries of

Heraeus for commercial transactions with business enterprises.


34 Martin Klinecky | HNG-IP | Oct 2015 Last page

Applications

Glass

Metal Plastic

Paper/Printing Food

Automotive Industry


All rights reserved | Heraeus Noblelight GmbH | 05/2013

36

INFRARED APPLICATION EXAMPLES - AUTOMOTIVE

Individual IR - 3D shaped contour emitters

Any changes reserved, see last page of this presentation/ Änderungen vorbehalten, siehe letzte Seite dieser Präsentation

Plastic Material:

Thermoforming

Deburring

ABS, EPDM, PC, PE,

PP, PS

Welding

ABS, EPDM, PA, PC,

PE, POM, PP, PS, PUR,

PVC

Welding of plastic dashboards for automotives

2D and 3D emitters target heat

37 Any changes reserved, see last page of this presentation/ Änderungen vorbehalten, siehe letzte Seite dieser Präsentation 2D and 3D emitters target heat


ANWENDUNGEN FÜR KUNSTSTOFFE

APPLICATIONS IN PLASTICS PROCESSING


Trocknung Kleber an Glasfaser

verstärkten Kunststoffstreben

Curing glue on glassfiber

reinforced plastic strutt section

Pre-aging of car hoods



39

Leather smoothening in car seats



40

Adhesing of rear spoiler and rear boot badges



41

Hot riveting of plastic pins for automotive interior parts



42

Martin Klinecky | Infrared Process Technology | Seite 43

HERAEUS NOBLELIGHT

Application Examples - Electric IR

Powder coating on steel cylinders

Cylinder length app. 1,8 m

Output app. 50 pcs / h

Convection Infrared Savings

Oven length App. 30m App. 6m 80%

Gelling & curing 30 – 60min 5 – 10min 80%


Seite 44

HERAEUS NOBLELIGHT

Martin Klinecky | Infrared Process Technology |

Powder coating on aluminium rims

Oven length app. 1 m

Gelling and curing 3 min

Temperature 180 – 230°C

Weight 17 – 20 kg / rim



HERAEUS NOBLELIGHT

Powder coating on gas filled springs

Sealing remain “cool”

Quality improvement

Increase of production output



HERAEUS NOBLELIGHT

Powder coating on saw blades

Curing at app. 200°C

Automatic power regulation following

coating colour

Curing speed 50% higher

Reduction of oven length



HERAEUS NOBLELIGHT

Epoxy coating on metal seals for

corrosion protection

50% line space saved to convection

Production speed increased

Reduction of energy consumption

Quality improved


Seite 48

HERAEUS NOBLELIGHT


Gelling on aluminium profiles

2 towers 7,5m high and 0,8m wide

36 Carbon emitters 7kW each

Distance 0,2 – 0,5 m adjustable

12 zones 0 – 100%

4 pyrometers temperature control



HERAEUS NOBLELIGHT

Powder coating on compressors

Oven improvement incl. IR booster

Production speed increased from

0,6 to 1,2m / min

Total power 108kW

Homogenized and increased (70K)

surface temperature

Seite 50

HERAEUS NOBLELIGHT

Powder Coating on Metal

Application Examples – Gas Catalytic IR


Seite 51

HERAEUS NOBLELIGHT




Seite 52

HERAEUS NOBLELIGHT




Seite 53

HERAEUS NOBLELIGHT

Pre gelling ahead convection



Seite 54

HERAEUS NOBLELIGHT

Powder Coating on MDF panels / furniture industry



Any changes reserved, see last page of this presentation/ Änderungen vorbehalten, siehe letzte Seite dieser Präsentation 55


Drying coatings on fuel tanks



Relaxing of plastic pipes for the pneumatic system



Drying screen printing on car wind shields & back windows



Activating adhesives on car interior parts

59 Any changes reserved, see last page of this presentation/ Änderungen vorbehalten, siehe letzte Seite dieser Präsentation


Removal of creases from car seats



Drying of textiles for airbags

Fitting of door and boot seals



61

Cold seals are pre-

heated and then fitted to

the vehicle on line

Fast Response Medium

Wave, 24kW in two

boxes



62

Pre-heating of tyres for racing cars

Well experienced in RTP (rapid thermal processing)

for solar cell manufacturing

Seite 63

QRC Emitters Successfully in use in Vacuum Applications

QRC – QUARTZ REFLECTIVE COATING

Quelle: OTB

APPLICATIONS FOR VACUUM – QRC emitters

QRC – QUARTZ REFLECTIVE COATING

Seite 65

Lack auf Stoßstangen aus

Kunststoff trocknen

Curing of paint

on plastic bumpers


ANWENDUNGEN FÜR BESCHICHTUNGEN

APPLICATIONS IN COATINGS

Page/ Seite 66


Erwärmung Kunststoffrohr zum

Anbringen der Muffe

heating plastic pipe for

assambling of pipe colar



Page/ Seite 67


Vorwärmen Metallform zum Erzeugen einer Kunststoffhaut

preheating of mould for production of plastic skin






Trocknung Primer

Drying primer

Seite 69

Trocknung Isolation auf

elektrischen Leitungen

Drying insulation on electrical

leads


ANWENDUNGEN FÜR TROCKNUNG

APPLICATIONS IN DRYING

Page/ Seite 70




Trocknung von

Vergußmasse

curing of filling

compound

Seite 71

Trocknung Siebdruck auf Glas

Curing screen printing on

glass




Page/ Seite 72




Entfernen von

Falten an

Ledersitzen

Removing

wrinkles in leather

car seats

Page/ Seite 73




Entfernen von

Falten an

Ledersitzen

Removing

wrinkles in leather

car seats




Erwärmung Luftfilter

Heating of air filters

At the IR application centres customers

can test their materials and clarify main

process questions:

Is IR suitable for my material?

Which emitters / wavelengths are most

efficient for my process?

Which IR power levels and radiation

geometries must be considered?


Infrared application centres


Infrared application centre in Kleinostheim, Germany

Modules and individual emitters

Conveyor system

Coating equipment for wet- and

dry coatings

Multiple measurement and data

logging equipment

Evaluation and documentation


Computer Aided Engineering – Ray Tracing


usual basic setup:

1.0 m2 size,

11 emitter, all same power

optimize for conveyed substrate:

1.0 m2 size,

13 emitter, 2 different types in 3 zones

dynamic process

batch process

optimize for batch process:

1.0 m2 size,

15 emitter, 3 different types in 5

zones


Computer Aided Engineering – CFD


Infrared Heating for Composite Materials · INFRARED vs Convection App. 50% energy savings App. 80%...

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