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Jeroen de Vries - KVE Composites Group
- 1. KVE COMPOSITES GROUP Advanced Composites for Demanding Markets Mikrocentrum Themadag ‘Hoogwaardige Composieten’ Compression Moulding of High Performance Compounds Presented by Ir. Jeroen de Vries 13 December 2011 KVE COMPOSITES GROUP b.v. CONFIDENTIAL IN BUSINESS December 2011
- 2. KVE COMPOSITES GROUP Advanced Composites for Demanding Markets • Brief introduction of KVE Composites Group • Introduction into Composites and Lightweight construction • Compression Moulding of Thermoset Compounds • Compression Moulding of Thermoplastic Compounds KVE COMPOSITES GROUP b.v. CONFIDENTIAL IN BUSINESS December 2011
- 3. KVE COMPOSITES GROUP Advanced Composites for Demanding Markets WHAT DOES KVE COMPOSITES DO • Design, development and Manufacturing of Advanced Composite and Lightweight structures • Knowledge intensive projects: engineering ánd manufacturing • SME: 30 employees • Complex, mostly structural components KVE COMPOSITES GROUP b.v. CONFIDENTIAL IN BUSINESS December 2011
- 4. KVE COMPOSITES GROUP Advanced Composites for Demanding Markets WHERE IS KVE COMPOSITES LOCATED • The Hague, The Netherlands • Maastricht Aachen Airport, The Netherlands • Treviso, Italy KVE COMPOSITES GROUP b.v. CONFIDENTIAL IN BUSINESS December 2011
- 5. KVE COMPOSITES GROUP Advanced Composites for Demanding Markets WHICH MARKETS DOES KVE COMPOSITES SERVE • Aerospace • Medical Technology • Defense Industries • High Performance Machine Construction KVE COMPOSITES GROUP b.v. CONFIDENTIAL IN BUSINESS December 2011
- 6. KVE COMPOSITES GROUP Advanced Composites for Demanding Markets WHAT ARE THE CAPABILITIES OF KVE COMPOSITES • Product Design and Engineering • Process Design and Engineering • Testing and Qualification of Product and Process • Manufacturing of Composite Structures • Repair of Composite Structures KVE COMPOSITES GROUP b.v. CONFIDENTIAL IN BUSINESS December 2011
- 7. KVE COMPOSITES GROUP Advanced Composites for Demanding Markets LIGHTWEIGHT STRUCTURES: GENERAL STRATEGIES AT PRODUCT DESIGN LEVEL • Replace heavy materials by lightweight materials • Optimise product design for weight • Reduce loads of the structure • Combine, seperate or eliminate functions in the product design • Reduce requirements (risk management) KVE COMPOSITES GROUP b.v. CONFIDENTIAL IN BUSINESS December 2011
- 8. KVE COMPOSITES GROUP Advanced Composites for Demanding Markets COMPOSITE STRUCTURES • Combination of fibers and resin • Final material properties can be designed • Resin types: • Thermoset: polyester, epoxy, • Thermoplastic: PP, PE, nylon, PET, PPS, PEKK, PEEK KVE COMPOSITES GROUP b.v. CONFIDENTIAL IN BUSINESS December 2011
- 9. KVE COMPOSITES GROUP Advanced Composites for Demanding Markets ADVANTAGES OF COMPOSITE MATERIALS • High specific stiffness and specific strength • Thermal • Low thermal expansion • Thermal Insulation • Freedom of shape • Dynamic behavior: eigenfrequency, fatigue, internal damping • X-ray transparancy • Corrosion resistance KVE COMPOSITES GROUP b.v. CONFIDENTIAL IN BUSINESS December 2011
- 10. KVE COMPOSITES GROUP Advanced Composites for Demanding Markets COMPOSITE STRUCTURES • Fiber types: • Glass, Carbon, Aramid • Fiber Length • Continuous: weaves and NCF • Short: 10 – 50 mm in compounds KVE COMPOSITES GROUP b.v. CONFIDENTIAL IN BUSINESS December 2011
- 11. KVE COMPOSITES GROUP Advanced Composites for Demanding Markets COMPRESSION MOULDED COMPOUNDS • Fiber length • Range from 10 mm to 50 mm • Resin types: • Thermoset: current state-of-art • Thermoplastic: demonstrator and prototypes KVE COMPOSITES GROUP b.v. CONFIDENTIAL IN BUSINESS December 2011
- 12. KVE COMPOSITES GROUP Advanced Composites for Demanding Markets COMPRESSION MOULDING OF COMPOUNDS: ADVANTAGES ACHIEVED • Higher specific strength and stiffness compared to metals • Automated Production • Co-Moulding of metal inserts • Integration with UD or tri-axial reinforcements • Freedom of design (3D shapes) KVE COMPOSITES GROUP b.v. CONFIDENTIAL IN BUSINESS December 2011
- 13. KVE COMPOSITES GROUP Advanced Composites for Demanding Markets THERMOSET COMPOUNDS RESIN TYPES • Epoxy (Tg up to 210°C) • Vinyl ester (Tg up to 160°C) • BMI (Tg up to 380°C) • Phenolics (meets FST and Heat Release) KVE COMPOSITES GROUP b.v. CONFIDENTIAL IN BUSINESS December 2011
- 14. KVE COMPOSITES GROUP Advanced Composites for Demanding Markets THERMOSET COMPOUNDS FIBER TYPES • High strength carbon (HPCC_HS) • High stiffness carbon (HPCC_UHM) • Complex geometry carbon (HPCC_IM) • High operational temperature carbon (HPCC_HT) • High strength glass fibre (HPGC) KVE COMPOSITES GROUP b.v. CONFIDENTIAL IN BUSINESS December 2011
- 15. KVE COMPOSITES GROUP Advanced Composites for Demanding Markets SOME CHARACTERISTICS: • Density: 1.5-1.8 kg/m3 • Stiffness: 43 -130 GPa • Strength: 200 - 350 MPa • Low thermal expansion: (0.2 – 12 ppm) • Operating temperatures: (120 °C - 210 °C) • Raw Material costs: 25 – 600 €/kg • Cycle time: 2-30 min KVE COMPOSITES GROUP b.v. CONFIDENTIAL IN BUSINESS December 2011
- 16. KVE COMPOSITES GROUP Advanced Composites for Demanding Markets COMPRESSION MOULDING PROCESS • Start with Chopped Fiber, impregnated with resin • Creation of Preform, placed into mould cavity • Compression step, elevated temperatures for resin cure • Demoulding after short cycle time KVE COMPOSITES GROUP b.v. CONFIDENTIAL IN BUSINESS December 2011
- 17. KVE COMPOSITES GROUP Advanced Composites for Demanding Markets CHARACTERISTICS OF COMPOUNDS Strength vs Stiffness 230 HPCC_HS Specific Tensile Strength [σ0.2/ρ] 210 HPCC_HT 190 HPCC_UHP 170 Ti 6Al-4V AL7075 HPCC_IM 150 130 HPGC RAMAX HPCC_UHM 110 90 70 10 30 50 70 90 Specific Tensile Modulus [E/ρ] KVE COMPOSITES GROUP b.v. CONFIDENTIAL IN BUSINESS December 2011
- 18. KVE COMPOSITES GROUP Advanced Composites for Demanding Markets COMPRESSION MOULDED COMPOUNDS VS. CONTINUOUS FIBER COMPOSITES • Small dimensions (high level of detail) • High tolerance (±0.05 mm out-of-mould) • Isotropic material • High quantity (from 100 to 100.000 /year) • Low cycle time • Highly repetitive process/behavior KVE COMPOSITES GROUP b.v. CONFIDENTIAL IN BUSINESS December 2011
- 19. KVE COMPOSITES GROUP Advanced Composites for Demanding Markets EXAMPLES OF COMPRESSION MOULDED COMPONENTS • Automotive door handle • Crank for bicycle • Saddle rail and Attachment KVE COMPOSITES GROUP b.v. CONFIDENTIAL IN BUSINESS December 2011
- 20. KVE COMPOSITES GROUP Advanced Composites for Demanding Markets EXAMPLES OF COMPRESSION MOULDED COMPONENTS • Panel adjusters for astronomy antenna • Hydrolic Aircraft Component • Avionics Housing KVE COMPOSITES GROUP b.v. CONFIDENTIAL IN BUSINESS December 2011
- 21. KVE COMPOSITES GROUP Advanced Composites for Demanding Markets THERMOPLASTIC COMPRESSION MOULDING • Increased use of thermoplastic composite laminates • Main drivers for use: cost effective manufacturing and assembly • Development program for compression moulding of TP compounds • Process development • Assess mechanical properties • Comparison to thermoset and continuous fiber components KVE COMPOSITES GROUP b.v. CONFIDENTIAL IN BUSINESS December 2011
- 22. KVE COMPOSITES GROUP Advanced Composites for Demanding Markets THERMOPLASTIC COMPRESSION MOULDING • Engineering plastics • PEI, PPS, PEEK, PEKK • Melting temperatures 300 to 400C • Process more complex • Temperature cycle between RT and 400C 400 demould Tg RT KVE COMPOSITES GROUP b.v. CONFIDENTIAL IN BUSINESS December 2011
- 23. KVE COMPOSITES GROUP Advanced Composites for Demanding Markets INITIAL COMPRESSION MOULDING TESTS • Define and test mould release system: • release agent ; thin film (kapton) • Different fiber lengths, cut from TP tapes • 12 and 25 mm • Compression pressures: • 10 bar to 120 bar KVE COMPOSITES GROUP b.v. CONFIDENTIAL IN BUSINESS December 2011
- 24. KVE COMPOSITES GROUP Advanced Composites for Demanding Markets ASSESS MATERIAL PROPERTIES • Press flat plates • Raw material: CF/PEEK, 25 x 3 mm • Test specimen were cut from plate • Mechanical tests performed: • tensile, compression and ILS KVE COMPOSITES GROUP b.v. CONFIDENTIAL IN BUSINESS December 2011
- 25. KVE COMPOSITES GROUP Advanced Composites for Demanding Markets TEST RESULTS OF COMPRESSION MOULDED PLATE • Ultrasonic testing of laminates • Improvements are needed KVE COMPOSITES GROUP b.v. CONFIDENTIAL IN BUSINESS December 2011
- 26. KVE COMPOSITES GROUP Advanced Composites for Demanding Markets TEST RESULTS OF COMPRESSION MOULDED PLATE • Mechanical proporties: Tensile properties (ASTM D 3039) Modulus [GPa] Strength [MPa] Average 54 360 S dev 13.2 73.4 Tensile properties (ASTM D 3039) • Compared to thermoset: Modulus [GPa] Strength [MPa] AS4/PEEK 54 360 T700/epoxy 43 302 • Compared to Al 2024 Specific properties Stiffness Strength AS4/PEEK 26.4 187 2024-T3 26.2 124 KVE COMPOSITES GROUP b.v. CONFIDENTIAL IN BUSINESS December 2011
- 27. KVE COMPOSITES GROUP Advanced Composites for Demanding Markets MANUFACTURING OF DEMONSTRATOR • Goal: manufacture a generic ‘real world’ component • Show that the process is feasible • Generic window frame KVE COMPOSITES GROUP b.v. CONFIDENTIAL IN BUSINESS December 2011
- 28. KVE COMPOSITES GROUP Advanced Composites for Demanding Markets QUESTIONS? KVE COMPOSITES GROUP b.v. CONFIDENTIAL IN BUSINESS December 2011