Toho Tenax America...Toho Tenax America October 19th, 2015 Advanced Composites Fundamentals Seminar...

Toho Tenax America October 19th, 2015

Advanced Composites Fundamentals

Seminar

“From Carbon Fiber to Carbon Fiber

Reinforced Thermoplastic”

Rodrigo Cesar Berardine

Sales and Marketing Manager

South America

São Paulo - Brazil

Part 1 Carbon Fiber Material Fundamentals

• Carbon Fiber production and properties overview

• Carbon Fiber Market in Brazil

Part 2 Thermoplastic Composites Fundamentals

• Thermoplastics versus Thermosets

• Importance of sizings for Thermoplastics

• Thermoplastic UniDirectional Tapes (TPUD)

• Thermoplastic Woven Fabrics (TPWF)

• Thermoplastic Consolidated Laminates (TPCL)

• Commingled Yarn Technology

Content

PART 1 – CARBON FIBER MATERIAL FUNDAMENTALS

Solvent Acrylonitrile

(Monomer)

Polymerization

Filtration

SPINNING

Washing Surface Treatment Drying Stretching Packing

Precursor (PAN) Production Process

Stretching Oxidation Carbonization Surface Treatment Winding

LT HT

LT

Carbon Fiber Production Process

Complex chemical plant: nitrogen, energy, toxic exhaust fumes

Substantial plant size 200m length, 18m height

Three shift, 24 hours production process on 360 day/year

2kgs of PAN for 1kg of carbon fiber

Tenax carbon fiber production line

Reinforcement Products

IMS65

HTS40

S-Glass

E-Glass

Aramid

Steel

Standard

Modulus

IMS40

HMA35

IMS60

UMS40 UMS45

UMS55

Tenax® Carbon Fibers

Glass Fiber

Aramid Fiber

Steel

Tensile Modulus (GPa)

HTR40

UTS50

High

Modulus

Ultra High

Modulus

Intermediate

Modulus

Ten

sile

Str

en

gth

(M

Pa

)

690

1380

2070

2760

3450

0

4140

4830

5520

6210

69 138 207 276 345 414 483 552

Blue – Aerospace Grade

Red – Industrial Grade

Continuous Filaments

Chopped Fiber

Milled Fiber

Carbon Fiber Supply Forms

SHORT FIBERS

PERFORMANCE OF METAL COATED

CARBON FIBER

CARBON FIBER MARKET IN BRAZIL

Carbon Fiber Market in Brazil

Last 4-years Outlook

• GE48.5m Wind Blade Production brought strong demand from 2012 until 2014

• Market Decrease in 2015 – GE blade out of production effect

Carbon Fiber Market in Brazil

Next 5-years Forecast

2011

2012

2013

2014

2015

2016

2017

2018

2019

2020

Tons Millions of US$

PART 1 CONCLUSIONS

• Variety of carbon fiber grades and supply forms enable versatile

composite design;

• New generation of Carbon Fibers bring multi-functional characteristics –

not just mechanical performance but also lightning strike performance;

• Carbon Fiber market in Brazil under development / expansion –

strong emphasis in Oil&Gas, Wind Energy and Aerospace

PART 2 – THERMOPLASTICS

Thermoplastics versus Thermosets

*more difficult

THERMOPLASTIC RESINS

PERFORMANCE PYRAMID

Source: http://wiki.zero-emissions.at/index.php?title=Information_about_the_chemical_industry

IMPORTANCE OF CARBON FIBER SIZINGS FOR

THERMOPLASTICS

Thermoplastic Unidiretional tapes comparison

SEM Pictures

Tenax® TPUD: Part making

TPUD

Hand Lay-up + Local welding

(HLY)

Automated Tape Laying

(ATL)

Automated Fibre Placement

(AFP)

Vacuum bagging

Oven

Autoclave

Static Press

5-30 min

(consolidation time) Without debulking

(time saving vs. TS)

Similar to Thermoset Prepreg

Lay-up Consolidation

using heat & pressure

Filament Winding

(FW)

(semi)-Continuous

Press Forming (CPF)

Tenax® TPUD

1mm

TPUD PEEK-HTS40 laminate

out of 8 plies (+/- 45°)

136 µm

Tenax®-E TPUD PEEK-HTS40

TPUD PEEK-HTS40

Press consolidated laminate

• Press and vacuum consolidation possible

• Low sensitivity of cristallinity to cooling rate 35 +/- 3 %

• Low void content in TPUD and Laminate < 2 %

TPUD Mechanical Properties

Thermoplastic Woven Fabric

TPCL: Part Making

TPCL Part Making

TPCL Technical Characteristics

Glass Fabric surface ply for Corrosion Protection

Bronze Mesh for LSP

TPCL: Mechanical Properties

Thermoplastic Consolidated Laminates

Technology Readiness Level

COMMINGLED YARN TECHNOLOGY

COMMINGLED YARN TECHNOLOGY

Source: Concordia Fibers

COMMINGLED YARN APPLICATIONS

Carbon / Nylon 6

Racket Frame


COMMINGLED YARN APPLICATIONS

Carbon / PEEK

YF-22 Structural Parts


COMMINGLED YARN – SEM PICTURES

CARBON / NYLON BRAID CARBON / PPS BRAID


COMMINGLED YARN – SEM PICTURES

CARBON / PEEK FABRIC


PART 2 CONCLUSIONS

• Thermoplastic composites market growth driven by short cycle processing,

recycling and logistics advantages.

• New sizing technologies for Carbon Fibers allow excellent fiber/resin

bonding

• Excellent impact and fracture toughness properties

• Processing temperatures and high viscosity are challenges

Rodrigo Cesar Berardine

Sales and Marketing Manager

[email protected]

+55 11 5070-3862

+55 11 98706-1766

mailto:[email protected]



Toho Tenax America...Toho Tenax America October 19th, 2015 Advanced Composites Fundamentals Seminar...

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