Development Of Improved Composites And Adhesives For .
Development of ImprovedComposites andAdhesives for AircraftStructures andInteriorsDennis CardozaOlaf LammerschopDavid LeachHelen LiSixth International Aircraft Fire and CabinSafety Research ConferenceOctober 25-28, 2010
Agenda¾ Henkel Background¾ Development of Improved Products¾New Approach to development of FST products¾Specific Examples:¾Structural Paste adhesive for Aircraft Interiors¾Composites for structural aplications¾SummarySixth International Aircraft Fire and Cabin Safety Research Conference
Henkel Areas of CompetenceLaundry &Home y with Brands & TechnologiesSixth International Aircraft Fire and Cabin Safety Research Conference
Structural Adhesive ProductsHysol Aerospace ProductsPaste, Films, Primers, Wet Peel PlySynCore Syntactic FilmsLightweight stiffening replacementSynSpand Expanding Syntactic FilmsLightweight core fill & pottingJet engine abradable seal applicationsSynSkin Composite Surfacing FilmsSuperior surface for painting & lightning strikefoil/screen protectionFrekote Composite Release PolymersWorld’s standard semi-permanent mold release systemSixth International Aircraft Fire and Cabin Safety Research Conference
Aerospace Group of Henkel¾ Henkel leverages R&D and PD laboratories over the world to servethe Aerospace market¾ Henkel Aerospace covers the product range from pretreatment to thefinal bonding processAmersfoort,NetherlandsRocky Hill, CT, USAMadison Heights,MI, USADusseldorf,Headquarters,GermanyBay Point, CA, USASixth International Aircraft Fire and Cabin Safety Research Conference
Development of Improved Products:Industry NeedsSixth International Aircraft Fire and Cabin Safety Research Conference
Industry Needs¾ Improved Flame, Smoke and Toxicity¾ Performance criteria: mechanical, damage, temperature, ageing .¾ Meet current and future environmental standardsWorkplace exposure resins/flame retardantsIn service exposureEnd of life¾ Cost:Acquisition: material and fabricationTotal life cost¾ Ease of use:Storage, processability, working life, cure etcSixth International Aircraft Fire and Cabin Safety Research Conference
Our Strategy for Sustainability:Five Focal AreasSixth International Aircraft Fire and Cabin Safety Research Conference
Industrial Applications/Markets ofFlame Resistant MaterialsAerospace IndustryInterior (adhesives, core materials, acoustic materials, laminates)Composite structuresRailway and road transportation marketInteriors (adhesives, foams, laminates)Composite structuresNaval StructuresInteriors (adhesives, foams, laminates)Composite structuresElectronics, PCB, battery marketsLow ignition materials, dielectricsOffshore Oil & Gas Production PlatformBuilding & Construction IndustrySixth International Aircraft Fire and Cabin Safety Research Conference
Technical Analysis – Flame ResistancePhenolicsBenzoxazinesStandard pecialty EpoxiesVulcanized RubbersResinsResinsCyanate EstersBismaleimide Resins (BMI)PhenolicsDICYCurativesAcidsAnhydridesAmines High Crosslink DensityMelaminesAmines Low Crosslink DensitySixth International Aircraft Fire and Cabin Safety Research ConferenceCurativesCresol Novolacs
Technical Analysis – Flame Resistance“Thethermal stability of epoxy resins, as well as their flammability,depends on the structure of the monomer,the structure of the curing agent and the crosslink density““Thermal decomposition, combustion and flame-retardancy of epoxy resins – a review of the recent literature“S V Levchik, E D Weil Polym Int. 53 1901-1929 (2004)General TrendsHigher Crosslink Density Lower Crosslink DensityÆ 1-Part Heat Cure & High Tg 2-Part RT Cure & Low/Med TgHigher Charring Tendency Lower Charring TendencyÆ Phenolic Systems, Highly filled Systems betterSixth International Aircraft Fire and Cabin Safety Research Conference
Paths to Improved Flammability ResistanceNew ResinChemistryNew FlameRetardantsFormulationDesignUse these approaches individuallyor in combinationSixth International Aircraft Fire and Cabin Safety Research Conference
Structural Paste Adhesive:Aircraft Interior ApplicationsSixth International Aircraft Fire and Cabin Safety Research Conference
Flame Resistant Structural Paste Adhesive¾ Flameretardant paste adhesive designed for interior applications¾ White, two-part paste¾ High dispensability¾ High Mechanical properties¾ Meets FST requirementsSixth International Aircraft Fire and Cabin Safety Research Conference
Flame Resistant Structural Paste AdhesiveLP31007.0ComponentsPart APart BColorWhiteStraw1.431.35Moderate ViscosityLiquidThixotropicPasteSpecific volume/volumeMix Ratio 2.12/123 C (75 F)9137 C (99 F)30023 C (75 F)0.852.2gpminches / 10 mincm / 10 min1. Dispensability determined using 200 ml side-by-side cartridgesSixth International Aircraft Fire and Cabin Safety Research Conference
Typical Flammability ResultsExtinguishing Time(seconds)Burn length(cm / in) 12.5 – 3.8cm(1 – 1.5inch)¾ Corner exposed to flame for 60 Seconds¾ Extinguish time is time to extinguishafter ignition source is removed¾ Burn Length is the distance the surfaceskin was eroded from the edge ofspecimenSixth International Aircraft Fire and Cabin Safety Research Conference
Flame Resistant Structural Paste AdhesiveMechanical PerformanceCured PropertiesLap Shear StrengthUnitsTestTemperatureLP31007.023 C (75 F)23.671 C (160 F)19.1MPaWorking Life after 1 hour at 23 C (75 F)MPa23 C (75 F)23.6Working Life after 1 hour at 37 C (99 F)(300 gpm)MPa23 C (75 F)21.8Modified Bell PeelN/cm23 C (75 F)34.7N23 C (75 F)133secNA 1'Ditch and Pot' Mechanical Strength'Ditch and Pot' Burn (extinguish time)Sixth International Aircraft Fire and Cabin Safety Research Conference
Flame Resistant Structural Paste AdhesiveConclusions¾ Usingnew Technology Approach Henkel has develop a newStructural Paste Adhesive which:¾ Exceeds flammability requirements¾ Has improved mechanical performance¾ Meets dispensability requirements¾ Long working life¾ Self colored whiteSixth International Aircraft Fire and Cabin Safety Research Conference
Structural Composites:Benzoxazine Matrix ResinsSixth International Aircraft Fire and Cabin Safety Research Conference
Structural CompositesIndustry Needs¾ Structural Composites used for many years:¾ Commercial Aircraft – secondary structures¾ Military Aircraft – primary structures¾ Main Resin Systems:¾ Epoxy¾ Bismaleimide¾ Increasing use of composites in commercial aircraft¾ Structure:Fuselage, Wings¾ Engines and nacelles¾ High temperature areas:APUsEngine pylonsWheel wellsLeading edges (de-icing)Sixth International Aircraft Fire and Cabin Safety Research Conference
Henkel Benzoxazine Resin Ambient shipping and storageCompared to epoxy resins Material costs comparable to Epoxy¾Lower cure shrinkage and heat release Process equivalent to Epoxy¾Higher hot/wet performance Excellent FST performance¾Inherent FST characteristicsCompared to phenolicsEpoxyG1CHenkelBZ Resin¾No microcracks¾No water generatedCompared to BMIBMIPhenolic50100150¾Lower cure temp and shorter cure time¾Lower cost¾Higher toughness200Hot/Wet Tg, oCSixth International Aircraft Fire and Cabin Safety Research Conference
Epsilon Benzoxazine Prepreg Resins¾¾¾¾High retention of hot/wet propertiesDamage tolerance equivalent to toughened epoxy prepregsMeets flammability and burn-through requirementsExtended room temperature storage350300Strength (MPa)250200150100CAI, 30J impact50OHC, Room Temperature, As moldedOHC, 82 C, after 14-days water @ 71 C0069Storage Time at Room Temperature (Months)Sixth International Aircraft Fire and Cabin Safety Research Conference
Epsilon Benzoxazine Prepreg Composite:Flame, Smoke and ToxicityPropertyUnitsLimitEpsilonCompositeAfter burn lengthinch60.91After flame timeAfter flame time of dripssecs152secs3Smoke DensitySpecific Optical 002SO2/H2Sppm10002HFppm10000HClppm15011Vertical Burn: 60secsNo DripsNon-FlamingFlamingModeModeToxicity4-ply Carbon Fiber Composite Unidirectional Tape: 1mm thickSixth International Aircraft Fire and Cabin Safety Research Conference
Structural Composite: Smoke Test ResultsCarbon Fiber Unidirectional tapeFiber areal weight: 190g/m2Resin content 35%Sixth International Aircraft Fire and Cabin Safety Research Conference
Structural Composite: 60sec Vertical Burn2004 Plies (1.0mm)5 Plies (1.25mm)7 Plies (1.75mm)Length (mm)Carbon Fiber Unidirectional tapeFiber areal weight: 190g/m2Resin content 35%150Maximum Limit10050254 Plies (1.0mm)5 Plies (1.25mm)207 Plies (1.75mm)Time (secs)0After Burn Length15Maximum Limit105Maximum Limit0After Flame TimeAfter Flame Timeof DripsSixth International Aircraft Fire and Cabin Safety Research Conference
Structural Composite Application¾A380 APU Housing & Duct:¾Carbon fiber, Glass Fiber Prepreg and Film Adhesive¾Meets Structural Performance requirement¾Meets standard FST requirements: OSU, Vertical Burn, Smoke, Toxicity¾Meets oil burner 15min, 1100 C burn-through requirementSixth International Aircraft Fire and Cabin Safety Research Conference
Summary¾ Requirementsbecoming more demanding:Flame, smoke and toxicity requirementsHealth, safety and environmental requirementsService performanceProcessabilityCost: Acquisition and total life cycle¾ Newapproach needed to materials development:Resin chemistryFlame retardantsFormulation design¾ InitialProduct DevelopmentsFlame retarded paste adhesive for structural bondingStructural composites using Benzoxazine matrix resinSixth International Aircraft Fire and Cabin Safety Research Conference
Composite structures Railway and road transportation market Interiors (adhesives, foams, laminates) Composite structures Naval Structures Interiors (adhesives, foams, laminates) Composite structures Electronics, PCB, battery markets Low ignition materials, dielectrics Offshore Oil & Gas Production Platform Building & Construction Industry
5 NATURAL FIbRE-SYNThETIC poLYMER CoMpoSITES 28 5.1 Wood Plastic Composites 29 5.2 Natural Fibre Injection Moulding Compounds 30 5.3 Non-Woven Natural Fibre Mat Composites 32 5.4 Aligned Natural Fibre-Reinforced Composites 33 6 FULLY bIo-bASEd CoMpoSITES 34 6.1 Natural Fibre-Bio-based Polymer .
The following tutorial aims at guiding you when you open the CATIA Composites Design workbench for the first time. It provides 3 step-by-step tasks for: Entering the Composites Design Workbench Defining the Composites Parameters This tutorial should take about 5 minutes t
experimental data. In addition, the mechanical properties of the hybrid composites were investigated. The hybrid composites were made via adding different fractions of recycled jute fiber at different lengths to kenaf fiber. The results indicated that; the mechanical properties of kenaf composites were improved for a certain value of weight
mechanical characteristics and the potential application of hybrid polymer composites. this paper concerned on different 1. Introduction Hybrid polymeric composites are new and more developed composites as compared to the traditional fiber reinforced polymer composites. FRP composite contains on one reinforcing phase in the single matrix but
METYX Composites is a rapidly growing division of Telateks A.S. . Please review the following pages for a full event schedule and presentation abstracts. Composites Conference June 1-3, 2009 . Crestomer Structural Adhesives and High Performance Bonding Pastes are use
the possibility of bamboo applied as a structural material, bamboo composites such as the bamboo scaffolding, laminated bamboo, and bamboo fiber reinforced composites have been fabricated and the mechanical properties of these bamboo composites have been mea-sured [15–
3rd Textile Research Conference, 29 October 2016, Dhaka, Bangladesh Braiding: From Cordage to Composites Sree Shankhachur Roy1and Prasad Potluri1 1Robotics and Textile Composites Group, Northwest Composites Centre, The University of Manchester, James Lighthill Building, Sackville Street, Manchester M1 3NJ, United Kingdom Corresponding Author Email: shankhachur.roy@manchester.ac.uk
(MS, Aerospace Engineering, 2013) This two-part series will detail the role that composites can play in Finite Element Analysis. Running on consecutive Wednesday afternoons, this series will show the use and value of composites in two separate Finite Element Modelers. The first week, we will show the analysis of composites in FEMAP.
