热塑性复合材料

RecentDevelopmentsinHigh-PerformanceThermoplasticComposites,AllanMurray,EcoplexusInc.KlausGleich,SouthernResearchInstituteACCE2003,Overview,IntroductionMaterialsProcessTechnologyApplications,WhyUseCompositeMaterials?,ThermoplasticComposites,BenefitsUniquepropertiesVibrationdampeningLightweightPotentialforlowcostShelflifeRecyclableDurabilityFatigueCorrosionToughness,LimitationsCostMaterialsManufacturingToolingDesignknow-howManufacturingknow-howUsetemperature,ThermoplasticComposites,ManyPolymerOptionsPolyethylenesPolypropylenesNylonsPolycarbonatesAcrylicsPolyestersPolyimidesPolysulfonesPolyketonesPolyurethanesthelistcontinues,ManyPropertyOptionsultimatestrain100%nomicrocrackingnodelaminationdampeningnowateruptakelowdielectricpropertiesmeltformableweldableelastomeric-plastic-elasticbehaviorthelistcontinues,CostChallenge,High-PerformanceThermoplasticComposites,PropertiesarefiberdominatedOrientedlongorcontinuousfiberreinforcementHighvolumefiberfraction(upto65%byvolume)Keybenefits:Reducingthermallimitations(e.g.creep)causedbytheTPmatrixsystemReducingcostsandweightandretainingtoughness,formability,weldability,shortcycletimes,recyclabilitybenefitsofthethermoplasticmatrix,ThermoplasticMaterials,CommercialMaterials,GMT(GlassMatReinforcedThermoplastics)PultrudedProductsLFT(LongFiberReinforcedThermoplastics)CFT(ContinuousFiberReinforcedThermopastics)WirecoatedproductsCommingledfibersPowdercoatedmaterialsFilmstickingSlurryprocesses,Long-FiberThermoplasticComposites,NewHot-meltProcessProducesFullyWet-outCompositeProductsWideRangeofPolymersandFibersContinuousTapeandRodProductsDiscontinuousProductswithAnyFiberLengthGlassProducts$1.00/lbCarbonProducts$8.00/lb,PilotProductionforThermoplasticComposites,ShortFiber,LongFiberandContinuousFiberComposites,Typicalshortfiberthermoplasticmaterial,granuleswithfiberlengthofapprox.2to4mm,resultingfiberlengthinapartofapprox.0.4mm,Longfiberthermoplasticmaterial,pelletsof”and1“fiberlength,resultingfiberlengthinapartofapprox.4-6mmininjectionmoldingandapprox.20mmincompressionmolding,Continuousreinforcedthermoplasticmaterial,tapeusedforwovensheets(thermoforming),filamentwindingorpultrusion,TypicalPultrudedPrepregs,Fiber:E-glass,S-glass,Carbon,Aramid,polymerfibersMatrix:PE,PP,PA(6,6/66,12,),PET,PBT,PC,PEI,PPS,SMA,blends,Fibercontent:20%-60%standard,someupto84%Productforms:Tape,pellets(0.5”,1”),woventapesmorecomplextextilestructuresindevelopment,Twintex-TheComminglingConcept,TwintexPrepreg,ConsolidatedComposite,Temperature+Pressure,Source:Vetrotex,TwintexTheComminglingConcept,EGlassadaptedsizing,PlasticfilamentAdditives:-couplingagent-UVstabilizer-naturalorblack,Source:Vetrotex,TwintexTheManufacturingProcess,Glass,TP,Commingling,Roving,Extruder,Bushing,Source:Vetrotex,Twintex-CommingledFiberProducts,Fiber/matrixcombinations:E-glass/PP,E-glass/PETFibercontent:60%and75%byweightProductforms:Roving,fabric,pellets,Limitations:MatrixmaterialmustbeusableforafiberspinningprocesslimitationsinMFI/viscosity,additivetypeandadditivecontent,Twintex,VetrotexTwintex,Source:Saint-GobainVetrotex,“TwintexPPandPETMechanicalProperties(nonstandard)”,PhysicalPropertyData,PowderImpregnatedPrepregsTheHexcelTowFlex-Technology,Source:Hexcel,FiberCreelRacks,FluidizedBedPowderCoatingChamber,IROven,Puller,Take-upSystem,ChargedResinPowder,ToWeaving,ToTapes,ToPellets,HexcelTowFlex,Typicalfibers:Carbon,E-glass,S-glassTypicalresins:PP,PA6,PPS,PEI,PEEKTypicalproductforms:FlexibleTowpregWovenfabricBraidedSleevingUnidirectionalTape,TowFlex,GlassCarbon,HexcelTowflex,PhysicalPropertyData,Source:HexcelComposites(March2003)www.H,ProcessTechnology,CurrentCompositeMaterialsandProcesses,CompositePerformanceversusFiberLength,ShortFiber,Continuous,Fillers,LongFiber,Source:OCF,TheLongFiberAdvantage,Stressistransferredtothefibers-thestructuralmembersofthecompositeLongfiberscreatea“skeletalstructure”withinthemoldedarticlethatresistdistortionandprovideunmatchedstrength,toughness,andoverallperformance,Source:Ticona,ContinuousFiberAdvantage,IncontinuousorientedfiberstheloadisultimatelyfullytransferredtothefiberAsaresulttensilecreepislimitedinfiberdirection,ManufacturingProcessesforHigh-PerformanceTP-Composites,LowvolumemanufacturingprocessesDiscontinuousprocessesThermoformingThermoplasticS-RIM,RTMandVARTMThermoplasticfilamentwindingVacuumbagmoldingNetshapepreforming(modifiedP4),ManufacturingProcessesforHigh-PerformanceTP-Composites,HighvolumemanufacturingprocessesDiscontinuousprocessesInjectionmoldingwithLFT-pelletsandconcentrates(highperformanceresin/fibercombinations)Inlinecompounding(highperformanceresin/fibercombinations)Backmolding/localreinforcementCompressionmoldingLFT-pelletsandconcentrates(highperformanceresin/fibercombinations)Inlinecompounding(highperformanceresin/fibercombinations)Backmolding/localreinforcementStampformingPreheatedpreformsMatchedmetaltoolsPotentialtomanufactureverythinsections(0.5to1mm)DrapablematerialrequiredContinuousprocessesPultrusionLFT-extrusion,MaterialsUsedForLiquidMoldingProcesses,MaterialsusedforliquidmoldingprocessesCyclicsReactivenylonFulcrumRequirementforthesematerialsViscositylessthan3000mPa.s(cP)(betterlessthan1000mPa.s(cP),Cyclics,CyclicformofPBT,PET,PCandothersOnlyPBTcommercialavailableBasedonaringshapedcyclicalformOneortwopartsystemsSolidatroomtemperaturelowviscosityresinatelevatedtemperature(approx.150cP)PolymerizeintothePolymerusingacatalystIsothermalprocessTypicalprocesstemperature:180200oC,ReactiveNylon,Formoreinformationseepresentationon“ReactiveThermoplasticVARTM/RTM/S-RIM”,Fulcrum,ISOPLASTmatrix(Dowproprietaryengineeringthermoplasticpolyurethane)Thermoplasticviscosityissuesaddressedbyabilitytoreversepolymerizationinthemeltstage,reducingviscositytoensuregoodimpregnationRepolymerizesuponcooling,retainingtraditionalthermoplasticcompositeadvantagesHighimpactresistanceRecyclabilityHighelongationtofailure(2.5%,versus1-1.5%forthermosets)Zero-emissionsprocessingFulcrumisthecombinationofISOPLASTandpultrusion,withspecifichardwaredesignProvides10-foldlinespeedimprovementovertypicalthermosetpultrusionlinesAllowsthermoforming,welding,andovermoldingoffinishedpieces,ThermoformedFulcrumComponents,Figuresfrom“FulcrumThermoplasticTechnology;MakingHigh-PerformanceCompositeviaThermoplasticPultrusion”DowPlastics,January2000,DowFulcrum,45v.%and55v.%datafromM76.6wt.%and66wt.%datafrom“FULCRUM:ThermoplasticCompositeTechnology,MakingHigh-performanceCompositeviaThermoplasticPultrusion”DowPlastics,January2000,PhysicalPropertyData,ReactiveThermoplasticVARTM/RTM/S-RIM,SimilarthethermosetprocessReactionofatleasttwocomponentscreatesathermoplasticresinthatcanbemelted,pre-shaped,welded,LowviscosityisrequiredPossiblematerials:Nylon,TPU,C-PBT(Cyclics),ProblemsConnectedWithThermoplasticRTM,ReactioncanbestoppedormadeincompletebyMoistureChemicalsinfibersizingMostofthethermoplasticcompatiblesizingsarenotdevelopedforsuchtypeofprocessesAvailabilityofcompatiblesizingsinformoffabricisverylimitedOxygenOnlylimitedsupportofmaterialmanufacturersMaterialcosts(incaseofc-PBT),Thermoforming,Thermoforming,Weightperformance:Goodweight/performanceratioforfabricreinforcedsheetsduetocontinuousfibersReducedweight/performanceratioforextrudedsheetsdependingontheresultingfiberlengthDesignflexibility:Limited,especiallyforcomplexgeometriesSimulationtoolsavailableProcessability:StabilizationagainstoxidationnecessaryFiberdisalignmentswithcontinuousfiberspossibledependingongeometry,material,toolingandprocessconditionsRecyclability:Highrateofproductionscrap(fixation)NodirectrecyclabilityUseinotherprocesseslikeplasticationofregranulation,TPS-RIM,RTM,VARTM,Weight/performance:ExcellentDesignflexibility:Limitedtopreformingcapability,flowlengthandflowbehavioroftheresinProcessability:ReactioncanbesensitivetomoistureandfibersizingRecyclability:ProductionscrapduetopreformingstepdependingonpreformingmethodNodirectrecyclability;canbeusedinotherprocesses,TPFilamentWinding,Weight/performance:ExcellentDesignflexibility:LimitedtosymmetricpartsthatcanbewoundonamandrelProcessability:HigheroxidativestabilizationrequiredRecyclability:LowrateofproductionscrapNodirectrecyclabilityScrapcanbeusedinotherprocesses,VaccumBag/HandLay-Up,Weight/performanceExcellentduetocontinuousfiberreinforcementDesignflexibilityLimitedtodrapabilityandtotheposibilityofmanuallylayupProcessabilityHighervoidcontentduetolowpressureconsolidationUsingautoclavetoreducevoidcontentOftenfiberdisalignmentsRecyclabilityHighrateofproductionscrappossibledependingonthesizeofthematerialsheetsandthepartgeometryNodirectrecyclabilityScrapcanbereusedinotherprocesses,LFT-InjectionMolding,Weight/PerformanceLowerendofthermoplasticcompositesduetoreducedfiberlengthinthefinalpartImprovementspossiblebyusinglocalreinforcements(usingpultrudedsections,sheetsortapesofcontinuouscompositeslocalizedstrengtheningandstiffening,reductionofwarpage)DesignFlexibilityHighFlowchannelsandpositionsofgateshavetobecarefullydesignedProcessabilityHighlystableRecyclabilityLowproductionscraprateCanbereusedinthesameprocess,CompressionMolding,Weight/PerformanceMediumRetainingfiberlengthgivesexcellentpropertiesforarandomorientedmaterial,butislowerthanusingafabricLocalreinforcementorfabricreinforcedGMTimproveit(usingpultrudedsections,sheetsortapesofcontinuouscompositeslocalizedstrengtheningandstiffening,reductionofwarpage)DesignflexibilityHighSpecialsimulationtoolsavailableProcessabilityVerystableprocessRecyclabilitySomeproductionscrapduetotrimoperationsScrapcanbeaddedandreusedinthesameprocess(GMTonlysheetscanbereusedinthesameprocess,butnotrecommended),Curv,Self-reinforcedpolypropyleneConsistsof“hotcompacted”polypropylenefiberortapeSurfaceoftapeorfibermeltsduringcompactiontoformthe“matrix”thatbindsthedirectionalelementstogetherOrientedmorphologyprovidesoversix-foldincreaseintensilestrengthandnearly5-foldincreaseintensilemodulusoverisotropicpolypropylene,with2%weightpenaltyNearlydoublestensilestrengthof40%randommatshortglasspolypropylene,withcomparablemodulusand22%weightsavingsEliminationofglassreinforcementhasseveraladvantages:IncreasedrecyclabilityReducedweightLowertemperaturesandpressuresforthermoformingReducedirritationintheworkplaceHighstraintofailure,withgoodimpactstrength,Datafrom“ANewSelf-ReinforcedPolypropyleneComposite”Jones,RenitaS.andDerekE.Riley,Curv,fromBPdocument“ANewSelf-ReinforcedPolypropyleneComposite”Jones,RenitaS.andDerekE.Riley,2002,PhysicalPropertyData,Pultrusion,Weight/performanceGoodtoexcellentduetocontinuousreinforcementDesignflexibilityLowdesignflexibilityLimitedtoconstantcrosssections,butcanbeshaped(pull/press)ProcessabilityOnlylimitedexperienceavailableDependsonstabilizationofthematerialaswellasusedmaterialformRecyclabilityLowrateofproductionscrapexpectedNodirectrecyclabilityCanbeusedinotherprocesses,LFT-Extrusion,Weight/performanceMediumweightperformanceDependsonretainingfiberlengthDesignflexibilityLowdesignflexibilityLimitedtoconstantcrosssectionsCanbepostshapedorpullformedProcessabilityNotalotofexperienceAstableprocessisexpectedusingtherightdiedesignRecyclabilityLowrateofproductionscrapCanbereusedinthesameprocess,Economics,Applications,ApplicationsForHigh-PerformanceThermoplasticComposites,Aerospaceanddefense:Radomes,wingandfuselagesextions,anti-ballisticsInfrastructureandConstructionWindowprofiles,rebar,beams,structures,compositeboltsConsumer/recreationalOrthotics,safetyshoes,sportinggoods,helmets,personalinjuryprotextion,speakercones,enclosures,bedsuspensionslatsAutoandtruckBumperbeams,skidplates,loadfloor,seatstructuresTransportationRailcarstructure,bodystructureandclosuresEnergyproductionandstorageOilandgasstructuratube,windturbines,BMWM3BumperBeam,Source:JacobKunststofftechnikGmbH&Co.KGwww.jacob-kunststofftechnik.de,-BeamandcrushcolumnsmanufacturedusingHexcelTowFlexPA6Partsweldedbyhighfrequencyvibrationalwelding2versions:StandardM3basedonglassfiberreinforcement(approx.40cars/day)M3CSL(limitedto1600total)usingCarbonfiberreinforcement,Helmets,MilitaryhelmetforNorwegianArmyMadebyCatoComposites50,000/yearTEPEXantiballistic302Aramid/PA6continuousreinforcement,Source:Bond-LaminatesGmbHwww.bond-,Source:Bond-LaminatesGmbHwww.bond-,WhitewaterhelmetMadebyPrijonTEPEXdynalite701Glas,Carbon,Aramid/PA6.6Continuousreinforcement,AircraftApplications,FixedwingleadingedgeforAirbusFokkerSpecialProducts/AirbusTEPEXsemipreg107Nonfullyconsolidated,flexiblelayersofcontinuousfiberreinforcedthermoplasticsGlass/PPS,WingaccesspanelforAirbusFokkerSpecialProducts/AirbusTEPEXsemipreg207Nonfullyconsolidated,flexiblelayersofcontinuousfiberreinforcedthermoplasticsCarbon/PPS,MineSweeperArmouring,MadefromTEPEXantiballistic302Aramid/PA6ContinuousreinforcedMadebyKvaerner,Source:Bond-LaminatesGmbHwww.bond-,SafetyShoes,CompositeToecapHistory:CompositeToecapsweremanufacturedinthepastusingGMTwith50%fiberglasscontentChangingtheregulations,thiswasnotsufficienttomeetthe200Jre