2026 Gleich Klaus

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Thermoplastic Composites

and Processes

Klaus F. Gleich

Senior Research Associate,Johns Manville Technical Center

www.acmashow.org

February 21-23, 2012 Mandalay Bay Convention Center, Las Vegas, NV


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2

Overview

Introduction into Thermoplastic Fiber Composites

Semi-Finished Materials

Manufacturing Processes

Economics

Applications


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Introduction


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Specfic Tensile Properties of Polymer Matrix Composites

0

0.5

1

1.5

2

2.5

3

3.5

4

4.5

0 1 2 3 4 5 6

Specific Strength (x106 in.)

SpecificModulus(x108i

n.)

Metals

Continuous Uni-

directional Carbon

Composites

LFT Glass

Composites

Continuous Uni-directional

Glass Composites

LFT CarbonComposites

Plastics

Glass & Carbon

LFT & Continuous

Other Fibers

Varying Fiber Orientations

Why Use Composite Materials ?


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One Reason For Using Composites

Charlestown Bridge Boston


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Benefits

Unique properties

Vibration dampening

Light weight

Potential for low cost

Shelf life

Recyclable

DurabilityFatigue

Corrosion

Toughness

Limitations

CostMaterials

Manufacturing

Tooling

Design know-how

Manufacturing know-how

Use temperature


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Many Polymer Options

Polyethylenes

Polypropylenes

Nylons

Polycarbonates

Acrylics

Polyesters

PolyimidesPolysulfones

Polyketones

Polyurethanes

the list continues

Many Property Options

ultimate strain > 100%no micro cracking

no delamination

dampening

no water uptake

low dielectric propertiesmelt formable

weldable

elastomeric - plastic - elastic behavior

the list continues

Thermoplastic composites can be tailored to meet the

required properties.

Fiber Options

Glass FiberCarbon Fiber

Natural Fiber

Polymer Fiber

Stainless Steel Fiber


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Basic Properties of Fibers and other

Engineering Materials

Material Type Tensile Strenght Tensile Modulus Typical Density Specific Modulus

(MPa) (GPa) (g/cm3) (GPa)

Carbon HS 3500 160 - 270 1.8 90 - 150

Carbon IM 5300 270 - 325 1.8 150 - 180

Carbon HM 3500 325 - 440 1.8 180 - 240

Carbon UHM 2000 440+ 2 200+

Aramid LM 3600 60 1.45 40

Aramid HM 3100 120 1.45 80

Aramid UHM 3400 180 1.47 120

Glass - E glass 2400 69 2.5 27

Glass - S2 glass 3450 86 2.5 34

Glass - quartz 3700 69 2.2 31

Aluminum Alloy (7020) 400 69 2.7 26

Titanium 950 110 4.5 24

Mild Steel (55 Grade) 450 205 7.8 26

Stainless Steel (A5-80) 800 196 7.8 25

HS Steel (17/4 H900) 1241 197 7.8 25

Source: www.netcomposites.com


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Importance of Fiber Length

Models predict that over

90% strength of

continuous fibercomposite is achieved

when fiber aspect ratio

approaches 2000

This correlates to glassfiber lengths of ~1.3

and carbon fiber Lengths

of ~0.6


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Composite Performance

versus Fiber Length for PP/Glass

0.0

0.2

0.4

0.6

0.8

1.0

1.2

0.1 1 10 100Length (mm)

RelativeProperty

Level

Modulus

Strength

Impact

Processibility

Short Fiber ContinuousFillers Long Fiber

Source: OCF


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Impact and Fiber Length

Source: Ticona


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Key Factors

Fiber length

Fiber dispersion

Fiber impregnation

processing conditions and

technique


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The Long Fiber Advantage

Stress is transferred to the

fibers - the structural

members of the composite

Long fibers create askeletal structure within

the molded article that

resist distortion and

provide unmatched

strength, toughness, and

overall performance

Source: Ticona


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High-Performance Thermoplastic

Composites

Properties are fiber dominated

Oriented long or continuous fiber reinforcement

High volume fiber fraction (up to 65% by volume)Key benefits:

Reducing thermal limitations (e.g. creep) caused by the TP

matrix system

Reducing costs and weight and retaining toughness,

formability, weldability, short cycle times, recycling are

benefits of the thermoplastic matrix


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Continuous Fiber Advantage

In continuous oriented fibers the load is ultimately

fully transferred to the fiber

As a result tensile creep is limited in fiber direction


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History Of Low Cost


Year1972 1980 1990 2000

GMT/AzdelLFT /LNP

Inj. Mold

LFT/Ticona

CompressionMolding

LFT concentrates

Twintex /

Vetrotex

Azdel SuperliteD-LFT

Compr. Mold.

D-LFT

Inj. Mold.

D-LFT

chopped fiber

Compr. Mold.

(CPI)

VW Golf A4 front end carrierFirst front end in GMT

VW Passat front end carrier

First front end in D-LFT


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House Of Production

Successful Part Production

MaterialSelection

Selectionofthe

ManufacturingPro

cess

Design

Internal/Extern

al

Knowledge

Economics

Part Requirements / Specification / VOC


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House Of Production - Often Seen


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Semi-Finished Materials


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Commercial Semi-Finished Materials

GMT (Glass Mat ReinforcedThermoplastics) Needled mat

Extrusion process

Slurry process (e.g. AzdelSuperLite)

Pultruded Products LFT (Long Fiber Reinforced

Thermoplastics)

CFT (Continuous FiberReinforced Thermoplastics)

Wire coated products

Commingled fibers

Powder coated materials

Film stacking

Self-reinforced materials


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GMT

Needling of the Mat

Source: Symalit (Quadrant Plastics Composites)


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GMT

The Consolidation Process

Source: Symalit (Quadrant Plastics Composites)


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Slurry Based ProcessThe AZDEL

SuperLite as an Example

Source: AZDEL

S i i C i


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Short Fiber, Long Fiber and Continuous

Fiber Composites

Typical short fiber

thermoplastic

material,

granules with fiberlength of approx. 2

to 4 mm,

resulting fiber length

in a part of approx.

0.4 mm

Long fiber

thermoplastic material,

pellets of and 1

fiber length, resultingfiber length in a part of

approx. 4-6 mm in

injection molding and

approx. 20 mm in

compression molding

Continuous

reinforced

thermoplastic

material, tape usedfor woven sheets

(thermoforming),

filament winding

or pultrusion


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70%i s Pr ocess Technol ogy

30%i s Pr oduct Composi t i on

Cooling

Haul-off/

Puller Pelletizer

Cleaning

Finishing

Packaging

Block

Glass

The Pultrusion Process

Courtesy of GEN


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Typical Pultruded Prepregs

Fiber: E-glass, S-glass, Carbon, Aramid, polymer fibers, metal

fibers

Matrix:

PE, PP, PA (6, 6/66, 12, ), PET, PBT, PC, PEI, PPS,SMA, blends,

Fiber content: 20% - 60% standard, some up to 84%

Product forms: Tape, pellets (0.5, 1), woven tapes more complex textile structures in development


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Typical Use of GMT and LFT Today

Processes

GMT compression molding

LFT-pellet approach

Direct LFT approach LFT mainly used in compression molding and

injection molding

Applications

Semi-structural and non-structural applications


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GlassTP

Commingling

Roving

Extruder

Source: Vetrotex

TwintexPrepreg

Temperature+ Pressure

Source: Vetrotex

E Glass

adapted sizing

Plastic filament

Additives :- coupling agent

- UV stabilizer

- natural or black

Source for all pictures: Vetrotex (OCV)

Twintex - Commingled Fiber Products

T i t C i l d Fib P d t


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Twintex - Commingled Fiber Products

Today OCV and Fiber Glass

Industries (license from OCV)

Fiber/matrix combinations:

E-glass/PP, E-glass/PET

Fiber content:

53 % and 70 % by weight

Product forms:

Roving, fabric (1:1, 4:1),

consolidated fabric, pellets


0

0.5

1

1.5

2

2.5

3

3.5

4

4.5

0 1 2 3 4 5 6

Metals


Carbon Composites

LFT Glass

Composites

Continuous Uni-directional Glass

Composites

LFT Carbon

Composites

Plastics

Glass & Carbon

LFT & Continuous

Other Fibers


Twintex

Limitations:

Matrix material must be usable for a fiber spinning processlimitations in MFI/viscosity, additive type and additive content

Twintex

P d I t d P


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Powder Impregnated Prepregs

The Hexcel TowFlex-Technology

Source: Hexcel

Fiber Creel

Racks

Fluidized Bed

Powder Coating

Chamber

IR Oven PullerTake-up

System

Charged ResinPowder

To Weaving

To Tapes

To Pellets


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Hexcel TowFlex

Typical fibers:

Carbon, E-glass, S-

glass

Typical resins: PP, PA6, PPS, PEI,

PEEK

Typical product forms:

Flexible Towpreg

Woven fabric

Braided Sleeving

Unidirectional Tape


0

0.5

1

1.5

2

2.5

3

3.5

4

4.5

0 1 2 3 4 5 6

Specific Strength (x106

in.)

SpecificModulus(x108i

n.)

Metals

Continuous Uni-

directional Carbon

Composites

LFT Glass

Composites


Glass Composites

LFT Carbon

Composites

Plastics

Glass & Carbon

LFT & Continuous

Other Fibers


Carbon Towflex

Glass Towflex

`

TowFlexGlass Carbon


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Film Stacking

Layers of fibers and thermoplastic film materials areplaced above each other and consolidated in a doublebelt press with a heating and cooling zone (similar tothe GMT process)

Glass, carbon, aramid fibers and combinations aretypically used

Most of thermoplastic resins available

Impregnation/wet out sometimes tricky Typically used as a semi-finshed material for

thermoforming


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Curv

Self-reinforced polypropylene Consists of hot compacted polypropylene fiber or tape

Surface of tape or fiber melts during compaction to form the matrixthat binds the directional elements together

Oriented morphology provides over six-fold increase in tensile

strength and nearly 5-fold increase in tensile modulus overisotropic polypropylene, with ~2% weight penalty

Nearly doubles tensile strength of 40% random mat short glasspolypropylene, with comparable modulus and 22% weightsavings

Elimination of glass reinforcement has several advantages: Increased recyclability

Reduced weight

Lower temperatures and pressures for thermoforming

High strain to failure, with good impact strength

Data from A New Self-Reinforced Polypropylene Composite Jones, Renita S. and Derek E. Riley


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Manufacturing Processes


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Manufacturing Processes for TP-Composites

Low volume manufacturing processes

Discontinuous processes

Thermoforming

Thermoplastic S-RIM, RTM and VARTM

Thermoplastic filament winding

Vacuum bag molding


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Manufacturing Processes for TP-Composites

High volume manufacturing processes Discontinuous processes Injection molding with

LFT-pellets and concentrates (high performance resin/fiber combinations)

Inline compounding (high performance resin/fiber combinations)

Back molding / local reinforcement

Compression molding LFT-pellets and concentrates (high performance resin/fiber combinations) Inline compounding (high performance resin/fiber combinations)

Back molding / local reinforcement

Stamp forming Preheated preforms

Matched metal tools

Potential to manufacture very thin sections (0.5 to 1 mm) Drapable material required

Continuous processes Pultrusion

LFT-extrusion


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Current Composite Materials and Processes

Process Type of Application

Injection Molding

Compression

Molding

Thermoforming

Hand Lay Up /

Vacuum Bag /

Autoclave

Low-Structural

Components

Semi-Structural

Components

Structural Components


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Low Volume Manufacturing Processes


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Thermoforming

Heat in Oven Thermoforming

Operation

Finished

Product


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Thermoforming

Weight performance: Good weight/performance ratio for fabric reinforced sheets due tocontinuous fibers

Reduced weight/performance ratio for extruded sheets depending onthe resulting fiber length

Design flexibility: Limited, especially for complex geometries

Simulation tools available

Processing: Stabilization against oxidation necessary

Fiber misalignments with continuous fibers possible depending on

geometry, material, tooling and process conditions Recycling:

High rate of production scrap (fixation)

No direct recycling

Use in other processes like plastication or regranulation


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VARTM / RTM / S-RIM

Process VARTM RTM S-RIM

Typical Injection

Pressure

1 bar 5 bar 50 bar

Tooling Single sided tool Double sided tool Double sided steel

tool

Injection Unit Mixing vessel Pressure vessel,

most cases no

mixing heat

Separate tanks for

each component,

mixing head

Typical

Achievable Fiber

Volume Content

40% 40 % 55%

Reactive Thermoplastic


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Reactive Thermoplastic

VARTM/RTM/S-RIM

Similar the thermoset process

Reaction of at least two components creates a

thermoplastic resin that can be melted, pre-

shaped, welded,

Low viscosity is required

Possible materials: Nylon, TPU, C-PBT

(Cyclics)

Process Technology Of The Anionic


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Process Technology Of The Anionic

Polymerization Of Caprolactam

Explanations

1. Storage vessel for caprolactam

2. Reactor for caprolactam with

activator

3. Reactor for caprolactam with

catalyst

4. Mixing head

5. Mold, heated

6. Flexible tube

7. Mixing head, valve

Flowchart

Source: Brueggemann Chemical U.S., Inc.


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TP S-RIM, RTM, VARTM

Weight/performance: Excellent

Design flexibility: Limited to preforming capability, flow length and flow

behavior of the resin

Processing: Reaction can be sensitive to moisture and fiber sizing

Recycling:

Production scrap due to preforming step depending onpreforming method

No direct recycling; can be used in other processes

Materials Used For Liquid Molding


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Materials Used For Liquid Molding

Processes

Materials used for liquid molding processes

Cyclics

Reactive Nylon

Fulcrum

Requirement for these materials

Viscosity less than 3000 mPa.s (cP) (better lessthan 1000 mPa.s (cP))

Viscosity influences achievable fiber content


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Cyclics

Cyclic form of PBT, PET, PC and others

Only PBT commercial available

Based on a ring shaped cyclical form

One or two part systems Solid at room temperaturelow viscosity resin at

elevated temperature (approx. 150 cP)

Polymerize into the Polymer using a catalyst

Isothermal process

Typical process temperature: 180200 oC

C t P l id 6 P l id 6


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Cast Polyamide 6 vs. Polyamide 6

There are differences between Cast Polyamide 6 and Polyamide 6 chips.

Production:

Use of simple inexpensive molds possible High part weights with various thickness

Efficient for low quantities

Material:

Improved mechanical properties Better wear resistance Better crystalline structure, higher crystallinity


Basic Principles Of Nylon Casting


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Basic Principles Of Nylon Casting

Raw Materials

-Caprolactam: AP-Quality (Anionic Polymerization) water content

< 200ppm

Catalyst: Sodium-Caprolactam used in concentration of

app. 1.2- 3.0%

Activator: Caprolactam blocked isocyanate or similar used

in concentration of app. 1.0-2.5%

Cast Polyamide 6 vs. Injection Molded


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Cast Polyamide 6 vs. Injection Molded

Polyamide 6

Examples of mechanical properties

TENSILE STRENGTH

0

1020

30

40

50

60

70

Nylon 6 Cast Nylon 6

N/mm

MODULUS OF ELASTICITY

0

1000

2000

3000

4000

Nylon 6 Cast Nylon 6

N/mm


F l


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Fulcrum

ISOPLAST matrix (Dow proprietary engineeringthermoplastic polyurethane)

Thermoplastic viscosity issues addressed by ability toreverse polymerization in the melt stage, reducingviscosity to ensure good impregnation

Repolymerizes upon cooling, retaining traditional

thermoplastic composite advantages High impact resistance

Recycling

High elongation to failure (~2.5%, versus ~1-1.5% forthermosets)

Zero-emissions processing

Fulcrum is the combination of ISOPLAST andpultrusion, with specific hardware design

Provides 10-fold line speed improvement overtypical thermoset pultrusion lines

Allows thermoforming, welding, and overmolding of

finished pieces

Thermoformed Fulcrum Components

Figures from Fulcrum Thermoplastic Technology; Making High-Performance Composite via Thermoplastic Pultrusion Dow Plastics, January 2000

Problems Connected With Reactive


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Problems Connected With Reactive

Thermoplastic Molding

Reaction can be stopped or made incomplete

by

MoistureChemicals in fiber sizing

Most of the thermoplastic compatible sizings are not

developed for such type of processes

Availability of compatible sizings in form of fabric isvery limited

Oxygen


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TP Filament Winding

Typically done with pre-impregnated fibers

Weight/performance: Excellent

Design flexibility: Limited to symmetric parts that can be wound on a mandrel

Processing: Higher oxidative stabilization required

Recycling: Low rate of production scrap

No direct recycling

Scrap can be used in other processes


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Vacuum Bag

Weight/performance Excellent due to continuous fiber reinforcement

Design flexibility Limited to drapability and to the possibility of manually lay up

Processing Higher void content due to low pressure consolidation

Using autoclave to reduce void content

Often fiber dealignments

Recycling High rate of production scrap possible depending on the size of the

material sheets and the part geometry No direct recycling

Scrap can be reused in other processes


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High Volume Manufacturing Processes

Extrusion /Compression


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Extrusion /Compression

Molding

Shot exiting extruder / plasticator

Shot placed on tool

Molded part

Tool in press

M f t i P U i LFT P ll t


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Manufacturing Processes Using LFT-Pellets

Injection Molding

Injection and injection compression molding

Low pressure molding

Compression Molding

Plasticator

Continuous extrusion Flying knife and belt plunger

Source: C.A. Lawton


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Problematic General Purpose Screw

Source: Krauss-Maffei

Compression Molding


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Compression Molding

of Thermoplastic Composites

GMT LFT ILCmanufacturing of mats pultrusion of the

semi-finished product

(manufacturing of PP-film)

extrusion of matrix and

consolidation using adouble belt press

(cutting of the GMT-sheets)

heating in GMT-oven plastication in-line compounding

material handling material handling material handling

compression molding compression molding compression molding

Semi-finished

Material

Pa

rtproduction

R lti Fib L th i P t


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Resulting Fiber Length in a Part

I li C di


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Inline-Compounding

Processes using chopped fibers only CPI Binani

JCI (slurry process (Fibrolen, plastication process)

Processes using rovings (most of them capable for choppedfibers)

Compression Molding Berstorff

Coperion

Dieffenbacher

Lawton LMG

PlastiComp

Injection Molding Husky

Krauss Maffei

PlastiComp

P T h l i F LFT


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Process Technologies For LFT

Compression (GMT) little fiber damage

small fiber orientation

high impact strength

Compression (LFT-D, LFT-G/P)

reduced cost for intermediate

product

thin wall thickness possible

variability of fiber content

Injection Molding

reliable and stable process

technology

good surface quality

variability of fiber content

no finishing work necessary

GMT

LFT-D

LFT-G/P

LFT-D

IMC

LFT-G/P

Compression Injection Molding

Fiberlengthi

nt

he

part

Source: Krauss Maffei

ILC Injection Molding


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ILC Injection Molding

Pictures: KraussMaffei

Proprietary
http://localhost/var/www/apps/conversion/tmp/scratch_3/VIDEO2.MPGhttp://localhost/var/www/apps/conversion/tmp/scratch_3/Gesamtanimation.mpg


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Proprietary

Compounding System

***All materials are gravimetrically fed for precise content***

Overhead View

Th Di ff b h S t


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The Dieffenbacher-System

Picture: Rieter

Th Di ff b h S t


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The Dieffenbacher System

Source: Dieffenbacher

The Coperion S stem


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The Coperion System

1 Polymer pellets 5 Twin-screw compounder ZSK 8 Separating unit

2 Gravimetric feeder 6 Devolatilizing 9 Robot

3 Rovings 7 Cutting unit 10 Press

4 Motor and gearbox

Source: Coperion

The Berstorff System


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y

Source: Berstorff

The Lawton System


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The Lawton System

Conveyers

Flat Sheet Die

Roving System

Four-Component Gravimetric

Feeder

Twin Screw Pre-

Plasticator

Control Panel

Reciprocating Screw

Plasticator

Single

Component

Gravimetric

Controlled

Vibrational

Feeder

Vibratory Track Vacuum

Feeder from

Octabin

Source: Lawton

PlastiCompPushtrusion


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p

Injection Molding

Source: PlastiComp

PlastiComp

Pushtrusion


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Compression Molding

Source: PlastiComp

Material For D-LFT Processes


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Material For D-LFT Processes

Polymer PP (most cases)

PA

Other technical thermoplastic resins

Fiber reinforcements

Roving Chopped Fibers

68mm, 12 mm, long chopped fibers

Additives Process and heat stabilization

Coupling UV stabilization

Color

Flame Retardants

Polymer


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Polymer

PP most common

All major PP supplier

Some PP supplier have their own additive package as a

concentrate

Typical MFI 3080, sometimes higher

Homo- and Copolymers used

Nylons and others

Viscosity must allow wet out and impregnation Similar or lower viscosity used as for PP

Heat and process stabilization is much more an issue

Glass Fiber Roving


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Glass Fiber Roving

Glass Melt

Bushing

Applicator

Gathering Shoe

Fiber

Winder Dryer

Finishing

Packaging

Water Spray

Chopped Strand


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Chopped Strand

Glass Melt Bushing

Applicator

Gathering Shoe

Fiber

Winder

Dryer / Separator

Water Spray

Chopper[ ]Densification

Sizing The Interface


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SizingThe Interface

Sizing = coating of the fiber

Often applied as a water based solution during

the fiber forming process

Can be a complex mixture of chemicals

including coupling agents, film forming

polymers, lubricants, anti-foaming aids,

dispersants, fillers, stabilizers, and others

Function of a Sizing


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Function of a Sizing

Protection of fibers

during manufacture

during shipment

during processing by customers Easy to meter and feed

no fuzz

Easy to disperse

Improve wet out

Chemical coupling of fiber and resin

Sizing and Properties


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Sizing and Properties

Some functions of sizings are contradictory

easy to disperse and easy to feed

Mechanical performance of the final composite part

is controlled by the coupling agent other sizing chemicals are neutral or reduce mechanical

performance

Fiber dispersion in a final part is important for

consistency of mechanical performance

surface quality

Chemical Coupling


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Chemical Coupling

Polypropylene and fiber glass can bechemically coupled by using

Aminosilane functionality in the sizing

Maleic anhydride grafted polypropylene in theresin

The matrix polypropylene is crystallizingaround the MaH-PP that is coupled to the fiber

Interface is a combination of chemical andmechanical coupling

Influence of Additives


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Influence of Additives

Pigmentation

Carbon black changes flow and wet out characteristics

Pigments with sharp edges damage fiber

All pigmentation can influence crystallinity Impact Flame retardants

Higher processing temperatures in the LFT processes

(compared to short fiber TP) can start the reaction of the

flame retardant already during the process High influence on Dynatup impact in most cases: 5% flame

retardant can reduce impact by 20% and more.

Comparison of LFT-Processes


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Comparison of LFT-Processes

Process Average Fiber Length Warpage / FiberOrientation

Throughput

Injection Molding of

Short Fiber Compounds

0.4 mm Lowmedium High


LFT-Pellets (12.7 mm)

4 mm High High


LFT (ILC)

4 - 10 mm High High

Compression Molding of

LFT-pellets (25 mm)

20 mm Medium Medium;

concentrates: low

In-Line Compounding

Compression Molding

15 to 35 mm Medium High

Increasing Properties on LFT Parts


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Increasing Properties on LFT Parts

Sizing developments / Optimization Co-molding with unidirectional or multidirectional

inserts Compression and injection molding

LFT-extrusion with continuous reinforcement (includingbraiding)

Co-Thermoforming

Increase/design orientation of fibersby flow design

By reactive resin approach

Changing fiber/resin combination

Effects on Material and


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Equipment

Most of the engineering thermoplastic resins are moresensitive to degradation due to heat, air and moistureas polypropylene

Processing equipment and compounding additives

has to compensate for this sensitivity

If material is exposed to air, the stabilization has to beadjusted for the exposure time

All compression molding lines need higher stabilization

levels compared to injection molding lines

If material is deposited continuously on a belt, an additionalamount of stabilization is recommended

Effects on Material and


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Equipment

Moisture sensitive resins:

Resins should be dried before use

A hopper dryer is recommended for all types of D-LFTequipment when running moisture sensitive materials

A high volume vacuum degassing system can be

used

The Co-Molding Concept:


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Carbon fiber

ribs (depth

exaggerated)

Insert

Integration of Frame for a Bus Seat

Source: FTA-AL-26-7001.1

SEAT TOOL WITH INSERTS


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SEAT TOOL WITH INSERTS


MANUFACTURING CONCEPT


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MANUFACTURING CONCEPT

Compression molding with LFT-pellets

Compression back molding of carbon-fiber

reinforced inserts with long glass fiber reinforced

pellets

Insert will be preheated (if necessary) in an oven and

placed in the tool immediately before the compression

molding step

Geometry of plasticated material as a result of

flow simulation

PROCESSING OF INSERTS


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PP/fiber tapes back molded with LFT

Insert at tool side LFT will not melt the insert

enough to get good bonding

Insert at top of the LFT charge good bonding

Insert should be preheated directly before

processing



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Fibers of the inserted tape,

cut against fiber direction

PP rich area

LFT, random fiberorientation



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Pultrusion


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Pultrusion

Weight/performance Good to excellent due to continuous reinforcement

Design flexibility

Low design flexibility

Limited to constant cross sections, but can be shaped (pull/press)

Processing

Only limited experience available

Depends on stabilization of the material as well as used material form

Recycling

Low rate of production scrap expected

No direct recycling

Can be used in other processes

LFT-Extrusion


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t us o

Weight/performance Medium weight performance

Depends on retaining fiber length

Design flexibility Low design flexibility

Limited to constant cross sections Can be post shaped or pull formed

Processing Not a lot of experience

A stable process is expected using the right die design

Recycling Low rate of production scrap

Can be reused in the same process

Simulation - Comparison of Filling Behavior


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and Flow Simulation

Result of flow simulation Short shot shows filling behavior


Joining


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g

With the increase of mechanical properties,

joining techniques play a more important role

and are part of system design


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Economics

Cost Challenge


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Costsin

$/lb

Automotive Structures$1 - $3/lb

Innovative Materials andProcesses$5 - $20/lb

Typical Aerospace Structure$50 - $100/lb

and more

Materials:Glass Fiber / Polypropylene, SMC/BMC

Processes:Compression Molding, Injection Molding

Materials:Thermoplastic Woven Sheets, Glass,Carbon and Kevlar Fiber, Engineering

PolymersProcesses:

Co-Compression Molding, Co-Injection Molding, Thermoforming

Materials:Carbon Fiber / Epoxy, Carbon

Fiber / BMI, Carbon Fiber /PEEK

Processes:Hand Lay Up

Apply Materials andProcessing Techniques

being Developed forAutomotive Applications to

Aerospace Applications

Economics


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Process Cycle Time Tooling Costs Scrap Rate Overall Economics

Thermoforming Medium Low High Good for low volume productionwith no or limited thickness variation

TP S-RIM, RTM,

VARTM

Medium to long, up to several

minutes

VARTM: low,

single sided tool

RTM: low to

medium

S-RIM: Medium

Depends on

preforming

technique;

often high for

complex

shaped parts

Good for low volume production

TP Filament Winding Medium to long, depending onnumber of tapes and heating system

Low to medium Low Good for symmetrical parts in low tomedium volume production

Vacuum Bag/

Hand Lay-up

Long; manual preparation can be

hours for a part

Low, single sided

tool

Medium to

high

Good for prototyping. Not

recommended for production scale.

Injection Molding

-LFT

-ILC

Short cycle times; typically 5080

sec.

High; steel tools

with ejector pins

and slides

Very low Excellent for high volume

production

Compression Molding-GMT

-LFT

-ILC

Short cycle times; typically 3560sec.

High; steel toolswith ejector pins

and slides

Lowmediumdepends on cut

outs. Scrap can

be reused

Excellent for high volumeproduction of large components

Pultrusion Continuous process; not enough

experience on throughput

Medium Low Limited experience available

Extrusion Continuous process; throughput

mainly limited by cooling capacityof calibration die

Medium to high Low Expected to be cost

effective for profiles

Cost Factors for High Volume Component

P d ti


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Production

Direct costs:

Material costs

Labor costs

Cycle Time

Energy and water

Quality costs

Indirect costs: Equipment costs / depreciation

Floor Space

Maintenance

Overhead Costs

Other costs:

Development costs Tooling costs

Material Costs


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All material costs are based on PP and 30% glass fiber

GMT 125 %

LFT-pellets 100 %

LFT-concentrates 85 %

Direct-LFT (raw materials) 60 %

Short fiber granules 75 %

Material Costs Including Recycling


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All material costs are based on PP and 30% glass fiber and

20% recycled scrap, costs for shredder included.

100% = LFT-pellets without recycling.

GMT 125 %

LFT-pellets 85 %

LFT-concentrates 70 %

Direct-LFT (raw materials) 48 %

Short fiber granules 62 %

Labor Costs


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Injection Molding:1 worker / shift can run multiple lines

Compression Molding:Labor costs directly correlated with the degree of

automation

No automation: average 2 to 3 workers / shift(depending on the component)

High automation: 1 worker / shift

Equipment Costs


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q p

Corrected for same throughput and a typical part size and

including post operations, if necessary

GMT 100 %

LFT-pellets 100 % LFT-concentrates 103 %

Direct-LFT 115 %

Injection molding 60 %

D-LFT injection molding 80 %

Quality Costs


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y

Related to receiving inspection test

GMT and LFT-pellets:

testing done by material supplier

only limited testing is necessaryLFT-concentrates and ILC:

different material supplier

no material supplier will take over responsibility

more test effort

material development responsibility

Quality Costs


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Related to production problems and stability

material development problems:

flow problems

long term properties mechanical properties

non-stable process

bad part design

flow problems

warpage


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Manufacturing Decisions


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Decisions on Pellet-LFT D-LFT and type ofequipment depends on multiple factors, such as

Volume and part size

Experience

Location and labor costs

Company and cost structure

Development capabilities

Has to be calculated for every case/company


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Applications

Applications


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Type of applications Metal Replacement (integration and design possibilities)

Replacement of unfilled, filled and short-fiber reinforced TPs

Corrosion resistance

Shielding (metal fiber or carbon fiber reinforced)

Typical areas Automotive

Leisure and sporting goods

Infrastructural and housing

Electrical

Office Furniture

Others

Most of the applications today are in high volume segments such as automotive

Applications For High-Performance



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Aerospace and defense: Radomes, wing and fuselage sections, anti-ballistics

Infrastructure and construction

Window profiles, rebar, beams, structures, composite bolts

Consumer / recreational Orthotics, safety shoes, sporting goods, helmets, personal injuryprotection, speaker cones, enclosures, bed suspension slats

Auto and truck

Bumper beams, skid plates, load floor, seat structures

Transportation Railcar structure, body structure and closures

Energy production and storage

Oil and gas structural tube, wind turbines


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Outlook

The Future of ThermoplasticComposites


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Composites

Will go to more structural applications usingdifferent technical thermoplastics in combination withglass, carbon and synthetic fibers.

Will replace metal applications and reduce weight.

Improved processing methods will be developed andapplied.

Future of LFT


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LFT will expand into more structural applications and in applications thatrequire higher surface quality

This will be realized by using engineering thermoplastic resins additional toPP

The major volume of LFT production will still be based on PP for the next

few years Roving and chopped fibers will each have their applications due todifferent part requirements

Combinations of LFT with in-mold decoration or painting will expand

Other fiber combinations (e.g. natural fiber) will get a bigger share on themarket

Fabric reinforcement in combination with compression molding of LFT isproviding new applications for thermoplastic composites.

The process of local reinforcement creates a lot of new opportunities bycombination of a cost effective process and high performance.

Acknowledgements


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Federal Transit Administration

SRI - Southern Research Institute

UABUniversity of Alabama at Birmingham

Allan Murray, Ecoplexus Inc.

Ed McDade, BrueggemannChemical US Inc.

All materials and equipment companiesreferred in the presentation

Contact Information


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Klaus F. Gleich

Johns Manville Technical Center

10100 W. Ute AveLittleton, CO 80127

Phone: 303-978-2286

Email: [email protected]


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