Carbon Fiber Sheet Moulding Compound: High Performance @ Industrial Grade
Carbon Fiber Sheet MouldingCompound: High Performance@ Industrial GradeGUILLERMO ASTORQUILUUK GROENEWOUDTOBIAS POTYRABusiness Development ManagerASTAR S.A.Sangroniz, 30E48150 SondikaBizkaia (Spain)Tel: 34 944 531 c Projects ManagerAOC Nederland B.V.Ceintuurbaan 5Zwolle8022AWThe NetherlandsMobile: 31683648839Office: ins.comGlobal Automotive DirectorZoltek Corporation3101 McKelvey RoadBridgeton, MO 63044, USACell Phone: 49 (172) 692 7347tobias.potyra@zoltek.comwww.zoltek.com
Outline1. Company Introduction ASTARAOCZoltek2. Materials ResinFiber3. Compounding Fiber bedMaturation4. Results Mechanical PropertiesVOCsE-coat ready5. Summary
Companies
AstarThe European company Astar is specialized informulating and manufacturing SMC, BMC andCSMC thermoset compounds for moulders andOEMs. Astar has been developing custom-madeformulations for more than 55 years in order todeliver high quality solutions for each specificapplication and end market.
ASTAR’s production plants2 automated SMC linesMax. Capacity: 27.000 TN/yearSMC PRODUCTION1 NEW dedicated Carbon Fibre SMC lineMax. Capacity: 5.000 TN/yearCSMC PRODUCTIONBMC PRODUCTIONR&D CENTRE2 automated BMC linesMax. Capacity: 8.000 TN/year1 SMC / CSMC pilot machine1 BMC / CBMC pilot machine2 compression presses1 injection machine
CSMC Opportunities Relatively new technologyGrowing interest from OEMsReplacement of other materials to save weightLow price compared to other carbon fibrecomposites
Cost Reduction AutomationContinuous ProductionInnovative CSMC based on split 50K carbon fiberPrice of 50K fibrePerformance of 3K fibre
AOCGlobal player in high-performance thermosetsChinaR&D CenterNanjing Production Founded in 2018 out ofAOC and AliancysEuropeR&D CentersZwolle (NL), Filago (I)(former DSM CompositeResins) 17 sites globally, 4 R&Dcenters, HQ inCollierville, TN (USA) Employees: 1200USAR&D CentersCollierville (TN), Valparaiso (IN)
AOCKey markets Unsaturated Polyesters andVinyl esters High performance hybrid resins Focus on Styrene Free andCarbon Fiber developments
Zoltek Corporate Profile Company Name: Zoltek Companies, Inc.Founded: 1975Headquarters: St. Louis, MO, United States100% subsidiary of Toray GroupRepresentative: Nobuya Ando (CEO, COO &President) Group Companies: 3 Consolidated Subsidiaries Employees: 2,300Zoltek PX35 50k Carbon Fiber 50K Filament Manufactured from PAN Precursor DNV-GL Approved Processing Support Available Spool to Spool ConsistencyPropertySIUSTensile Strength4,137 MPa600 ksiTensile Modulus242 GPa35 msiElongationDensityFiber Diameter1.64%1.81 g/cc0.065 lb/in37.2µm0.283 mils
Zoltek’s Carbon Fiber PlantsOne ZoltekPX35 50kcarbon fiberquality from twoseparate, fullyintegratedlocations:Hungary andMexicoZoltekPAN PrecursorZoltek PX35Carbon FiberIntermediateProductsCONSOLIDATEDSUPPLY CHAIN
Materials
Daron 8151 for SMC Low viscosity enabling high fibercontent Smell friendly compound Robust ambient temperatureprocessing at all steps Tuneable thickening and flow High strength and stiffness Ultralow emissions and smell enableinterior parts
Daron Urethane ThickeningThickening plateau tunable via amount of isocyanate added31.5 phr Lupranat M20R30.5 phr Lupranat M20RViscosity (mPa.s)29.5 phr Lupranat M20R28.0 phr Lupranat M20R Ambient temperaturematuration and storage Consistent thickening Stable plateauTime (hrs)14
MOLDING VISCOSITYExcellent material flow and faster curing Daron 8151 gives lower flowFaster cureviscosity than MgO thickenedVinylester compounds Yet, fibers are transported wellLower viscoDaron 8151 Urethane thickenedVE MgO thickenedTemperature Cure of Daron 8151 is fasterthan MgO thickened Vinylester
MOLDING VISCOSITY CAN BE TUNEDFLOW VISCOSITYFlow viscosity can be tuned foryour specific part complexityvia the isocyanate amount usedDecreasing amount ofadded IsocyanateTime
Carbon Tow TechnologyThe most suitable Carbon Fiber tow must contain Right Sizing Chemistry Right Sizing Content Right WindingSizings are available for the following resin PolyamideVinyl esterHigh TemperatureThermoplasticsPolyesterPolyurethane
Several Tow ke)Wide & FlatSplit to 3k 015K-13SpreadNot spreadaple22-25 mm 20mm with several strandsTwistsTwistedNo TwistNo TwistApplicationHigh AW fabricsLow AW fabrics (150-300 gsm)SMCStandard tow shape, rope styleSpreadable tow shape, wide and flatSplit tow with 3k substrands
Sheet Molding Compound - SMCZOLTEKTM Split Fiber PX35 K for Sheet Molding CompoundZoltek PX3550kZoltek PX35 50kKASSENPre-split to 3ksubstrands50k choppedfibersChopping3k choppedfibersChopping &separating
ProcessProcess
SMC ProcessStandard SMC conditionsStandard ProcessingAdapted to carbon fiberConditions Processing at ambientfor carbon fibertemperature Resin and fiberMaturation at roomimpregnation is optimizedtemperature (controlledfor high fiber contentconditions) Fiber feeding is optimized Storage and transportationTypically no fillers areaddedat ambient conditionsStandard SMC line at room temperature
Picker/Dispersion RollThere are two main types of Dispersion RollsNo Dispersion/ Picker RollBest: A wire type dispersionroll. Result is good andstable dispersion.OK: A needle type dispersionroll. But, may result inunstable dispersionWorse: No Dispersion rollunder the chopper.
Split 50K Fiber vs 12K Fiber12k carbon fiber50k carbon fiber split to 3k12k carbon fiber50k carbon fiber split to 3k
ResultsProcessResults24
Sheet Moulding Compound – SMCStandard PX35 50k tow Large tow with 50k filaments Suitable for SMC Available with several sizings forPolyester resin, Epoxy resin,Vinylester resinZoltek PX35 50kPX35 KS tow Based on Zoltek PX35 50k tow Falls apart into 3k strands afterchopping Can be processed in standardSMC sheet machinesZoltek PX35 KS (split tow 3k)
MECHANICAL RESULTS LAB-LINE AOCTensile strength (Mpa)Splitting up increases tensile strength considerably400300200PX35 KS 50-1312K1000204060% split fiber80100
12K vs 50K Splitted MechanicalPerformanceIndustrial Scale ResultsVE CSMC 50% WfFIBRETENSILEMODULUSTENSILESTRENGTH12K2700015050K TH12K2500025050K splitted27000330
Mechanical PerformanceIndustrial Scale ResultsDaron 8151 CSMC 57% WfFIBRETENSILEMODULUSTENSILESTRENGTH50K splitted36000325MATERIAL50K splittedFLEXURAL FLEXURALMODULUS STRENGTH30500460
VOC EMISSIONS FROM MOLDED PARTSVery low smell and emission, no styreneTotal VOC450400Daron 8151VOC (μg/g)350300250200150Interiorthreshold100500Low VOC VE SMCDaron 8151EpoxySource Daron 8151 : IMAT-UVEMolded for 1 min/mm @ 145 C, No Post-TreatmentMethod: VDA 278 ThermodesorptionSource Low VOC VE SMC: presentation Ashland at SPE ACCE 2016Source Epoxy: Presentation Hexion at JEC conference 2017Total VOC(VDA 278)23Smell(VDA 270)3
DARON 8151 E-COAT COMPATIBLEE-coat bathOven (30 min at 210 C)No delaminations
ProcessSummarySummary
Summary Carbon Fiber SMC on full industrial scale Commercially available High Mechanical Performance E-coat ready No VOCs
Zoltek Corporation 3101 McKelvey Road Bridgeton, MO 63044, USA . 1 NEW dedicated Carbon Fibre SMC line Max. Capacity: 5.000 TN/year BMC PRODUCTION 2 automated BMC lines Max. Capacity: 8.000 TN/year . Sheet Molding Compound - SMC ZOLTEKTM Split Fiber PX35 K for Sheet Molding Compound Zoltek PX35 50k
Components of injection moulding are - mould base, core and cavity, feed system, cooling system and ejection system. (Fig 1) Fig. 1 Component of Injection Moulding 1.2 Split Injection Moulding Split injection moulding is a process that is used where there is an amount of undercut. The undercut may be external & internal.
Injection Moulding Operator Table of Content S. No. Modules and Units 1. Overview on Rubber Industry and Generic Skills Unit 1.1 - Introduction to Rubber Industry and Injection Moulding 2. Preparing Injection Moulding Machine (RSC/ N0701) Unit 2.1 - Preparing Injection Moulding Machine Unit 2.2 - Raw Material Appropriateness 3. Perform .
Lamp manufacture; laser cutting and drape forming. f) moulding – blow moulding, injection moulding, vacuum forming, extrusion, rotational moulding (including use of specialist tools). NEA: Demonstrate the use of the laser cutter and the processing of acrylic through it. All candidates ne
The individual properties of SIGRABOND are determined by various factors, namely the type of fiber, fiber content, fiber arrange-ment, matrix materials layer build-up, densification, thermal treatment and any upgrading. Carbon fiber-reinforced carbon (CC) can thus be adapted to each individual profile of requirements or desired component design.
Fiber damage, changes in the fiber wall structure, reduced single softwood kraft fiber strength and fiber deformations (curl, kinks and dislocations) all affected the fiber network properties. Mechanical treatment at the end of kraft cooking conditions resulted in fiber damage such that single fiber strength was reduced.
C A B L E B L O w i N ghand held Fiber Blower The Condux hand held fiber blower is ideal for shorter run fiber optic cable or micro fiber optic cable installations. The unit's hinged design makes it easy to install and remove duct and fiber. The Condux hand held fiber blower installs fiber from 0.20 inches (5.8 mm) to 1.13 inches (28.7 mm)
properties of fiber composites [1]. A number of tests involving specimens with a single fiber have been developed, such as single fiber pull-out tests, single fiber fragmentation tests and fiber push-out tests [2-4]. Yet it still remains a challenge to characterize the mechanical properties of the fiber/matrix interface for several reasons.
AUTOMOTIVE EMC TEST SYSTEMS FOR AUTOMOTIVE ELECTRONICS AUTOMOTIVE EMC TEST SYSTEMS FOR AUTOMOTIVE ELECTRONICS Step 1 Step 2 Step 3: Set the parameters Step 4: Active test. Load dump pulses have high pulse energy, which can be highly destructive to electrical or electronic equipment. The LD 200N series simulates these pulses with high energy in a range of up to 1.2 seconds. The LD 200N .
