Toho Tenax Product family Dry Reinforcements DR 07. 2014, R. Wockatz (MP) Toho Tenax Product family...

April, 07. 2014, R. Wockatz (MP)

Toho Tenax

Product family

Dry Reinforcements ‘DR’

1

Rodrigo Cesar Berardine – Sales and Marketing Manager

Toho Tenax America

April, 07. 2014, R. Wockatz (MP) 2

Content

1. Background and Motivation

2. Non-Crimp Fabrics – Tenax DRNF

3. Woven Fabrics – Tenax DRWF

4. Tenax Toughener Development

5. Outlook


Increasing requirements for future Aerospace and Automotive developments in terms of performance, weight, cost and environmental requirements drive new material needs.

To meet growing demand for composites the current available materials themselves are now borderline to fulfil the given requirements.

Prepreg materials which are the baseline reference and normal first choice material esp. in Aerospace are problematical in terms of highly complex parts (tolerances etc.) and large production volumes.

Textile technologies in combination with resin infusion processes are offering significant potential in manufacturing processes for high production rates, integral structures and flexibility but to date with some disadvantage in mechanical properties.

1. Background and Motivation


Advantages

Strength and stiffness in multiple directions (possibility to optimize weight distribution and minimize material costs)

Adapted areal weights (low <-> heavy) achievable for minimizing waste for complex lay-ups (cross plies)

Areal weights using high tow counts (12K & 24K) in established prepreg thicknesses now possible

Reduced processing costs

Very low level of misalignment

Disadvantages

Mech. Properties nearly matching Prepreg baseline levels

2. Non-Crimp Fabrics – Tenax DRNF


Therefore Toho Tenax initiated on-going development activities within the last years

to solve these issues and provide in partner cooperation new solutions to the market

Tenax® Dry Reinforcements.

Major tasks for improvements have been :

Lower and flexible adaptable areal weights (based on high tow count CF, 12K+)

Improved preforming and toughness properties

Adapted/flexible drapeability incorporating sufficient permeability

Mechanical properties equivalent to today’s Prepreg baseline

Low material bulk factor for preforming (e.g. for complex RTM tools)

High fibre volume content (target 58% +/-4%) even with toughened and powder

bindered material in infusion technology

2. NCF – Development Tasks


2. Tenax NCF improvement program

6

NCF beginning of

year 2000 NCF ca. year 2005

Latest NCF – Tenax Dry

Reinforcements (DRNF)

Prepreg-Reference


0

100

200

300

400

500

600

700

800

Compression plain OHC

Str

en

gth

[M

Pa

]

Bidiagonal-NCF (+/- 45°), 268gsm (134gsm per layer), stacking [(90°/0°)8]S Tenax®-E IMS65 E23 24K 830tex, Test in acc. to EN 6036

NCF SoA

Prepreg

New NCF

7

Very close

or better to Prepreg level

2. Tenax NCF improvement program

Latest

Tenax NCF


all developments are based on latest NCF technology available in the market

cutting edge technology especially for Tenax®-E HTS45 E23 12K, 24K and Tenax®-E IMS65 E23 24K carbon fibres

up to 5 layers in only one production run possible to lay down

areal weights from ca. 70gsm per layer upwards possible (depends on CF type)

fixed material width of maximum 1.27m (50”)

cutting technology available -> 5 cutter, e.g. for cutting 5 x 254mm (10”) stripes

roll length flexible (customized, typically 40m - 70m, depends on weight)

2. NCF technology – General details


e.g. Non-woven

for Toughening

Creel material (warp & weft)

Tenax®-E IMS65 E23 24K

Tenax®-E HTS45 E23 12K

Tenax®-E STS40 F13 24K, 48K

Stitching yarn

2. NCF technology – Possible building blocks


2. NCF technology – technical details

Typically NCF stacking's are:

• Bidiagonal (BD)

e.g. +30°/-30°; +45°/-45°; +60°/-60°;…

• Biaxial (BA)

e.g. 0/90°; 90°/0°

• Triaxial (TA)

e.g. +30°/90°/-30°; +45°/0°/-45°; +60°/-60°/+60°; …

• Quadaxial (QA): e.g. +30°/90°/-30°/0°; +45°/0°/-45°/90° ;…

• Multiaxial: e.g. 0°/+45°/0°/-45°/90°

Possibility to add toughening system (veil) on each CF layer incl. as the first

layer (Bottom) and the last layer (Top).

Both outer layer can be Powder Binder coated for additional preforming

abilities.


2. Tenax NCF – Product benefits

Smooth and even material surface quality with

lowest grade of material undulation

Lower and flexible adaptable areal weights possible

Improved preforming and toughness behaviour

allowing excellent mechanical properties

Adapted drapeability even for complex shaped parts

Mechanical properties matching today’s Prepreg

baseline due to very straight and parallel fibre

alignment

Low level of material bulk factor for preforming

High fibre volume content (~58%) even with

toughened and powder bindered material in infusion

technology (e.g. via pure vacuum process, like VAP)

demonstrated


3. Woven fabrics – Tenax DRWF

Specialised Woven Fabrics are still needed for future (aerospace) applications.

In a close cooperation with partner companies several materials are now ready to market:

UD woven fabric with high carbon fibre alignment and optimised

permeability in a broad range of fabric areal weights as well as fields of

applications.

‘Curved’ fabric materials which can be adapted to complex shape of parts

Modified ‘standard’ woven fabrics with target of high material

toughness improvement as well as improved preforming abilities

Lightning strike protection (LSP) material based on material

combinations and areal weights


3. Woven Fabrics – UD fabric

This newly developed material is dedicated for high performance application, where high carbon fibre alignment and optimised permeability are key features.

A broad range of fabric areal weights as well as fields of applications may be targeted – a combination with non-woven’s and powder binders are possible too.

New UD

Woven fabric 0

200

400

600

800

1000

1200

1400

1600

1800

2000

2200

2400

2600

Tension Strength

(EN 2561 B)

Compression Strength

(EN 2850 A1)

OHC

(EN 6036)

Str

en

gth

[M

Pa

]

Tenax®-E DRWF-UD + RTM6

180°C 3rd gen. Epoxy Prepreg

Carbon Fibre: Tenax®-E HTS40 12K 800tex

Areal Weight: 134gsm per layer

1mm


3. Woven Fabrics – Curved fabric

UD-fabric with high drapeability UD-fabric adapted for

curved parts

For complex and curved designed parts, e.g. fuselage frames, the

drapeability of fabrics is limited.

A specialised material was developed within a close partner cooperation

which can be adapted to individual shapes and

guarantee best performance and fibre alignment.


3. Woven Fabrics – Curved fabric

Product benefits

‘Curved’ UD-fabric

Excellent performance due to straight fibre alignment

CF areal weights between 100 – 500gsm (depends on CF type) possible

Radius of min. 50mm upwards possible

Fabric width min. 10mm – max. 350mm

Roll length customized (typically 50-100m)

Toughness improvement (e.g. via non-

woven) possible

Preforming improvement (e.g. via powder

binder) possible


3. Woven Fabrics – Lightning Strike Protection



Lightning strike tests passed successful! Powdered LSP

Woven fabric Many fabric combinations

(style/weights) are possible.


New UD Woven fabric

1mm

19

4. Tenax Toughener developments

Laminate Fabric

style Carbon fibre Resin Binder Toughener

1 UD

woven

fabric

194 g/m²

Tenax® - E

IMS65 E23 24K

830tex

Momentive

EPS 600

Momentive

EP05311

~7 g/m²

w/o

2 with

Based on before showed test results, materials were combined and tested

to verify mechanical performance.

Testing reference is a newly developed high performance UD woven fabric

which allows laminate stacking for each test methods.


0

600

1200

1800

2400

3000

3600

4200

4800

0

40

80

120

160

200

240

280

320

Laminate 1 Laminate 2

CA

I - D

amag

ed

Are

a [m

m²]

CA

I - R

esi

du

al S

tre

ngt

h [

MP

a]

Residual Strength

Damaged Area

20

CAI – 3x30J, AITM 1.0010, UD-Fabric, 194gsm, Tenax®-E IMS65 E23 24K 830tex,

Resin EPS600, Stacking [+45/0/-45/90]3S

With

Tenax

Toughening

System

w/o

Toughener


4. Toughener Development –

Moisture uptake [EN3615] of Tenax toughening system

• No additional water/moisture uptake

• No left moisture after dry back procedure


5. Outlook

Powdered LSP

Woven fabric

Toho Tenax is keen to support customer requirements for new textile

specialised materials.

Combinations of building blocks are always possible to meet

particular customer needs.

Material combinations for components may include Non-crimp fabrics,

(UD)-Woven fabrics as well as Non-woven (Toughening) to fulfil given

requirements like high Toughness performance as well as preforming

abilities.


Powdered LSP

Woven fabric

Thank you for your

attention!

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