JEC COMPOSITES MAGAZINE - Issue #39 - March/April 2008 - 113

KNOW-HOW Process Liquid composite moulding with honeycomb A new one-step process that integrates honeycomb into liquid moulding technologies such as resin infusion (RI) or resin transfer moulding (RTM) is now available to produce advanced composite parts. The Honeycomb Liquid Moulding (EC-HLM) process finally brings together the best of both worlds: sealed cells that stay empty, excellent surface quality and bond strength. OLIVER BOTTLER, MANAGER R&D HORST WILLKOMM, DIRECTOR EURO-COMPOSITES S.A. T he use of honeycomb is widely accepted and offers a lot of benefits. Until recently, in structural aircraft applications, honeycomb could only be used in combination with prepreg or tape fibre placement (TFP) technologies and had to be cured in autoclaves or presses. All liquid composite moulding (LCM) processing trials, especially with resin infusion, had disappointing results for one or more of the following reasons: - Cell sealing was not perfect. Some resin would still enter the cell, making the final composite product heavier than wanted. - Bonding quality to the honeycomb was unsatisfactory. With some approaches, the sealing of the cell worked fine, with the trade-off that the connection between honeycomb and sealant became the weakest link in the chain, making the final product useless in structural applications. - Surface quality was poor. In certain applications, most trials shared a problem with the prepreg technology: an unsatisfactory high porosity of the part surface led to a migration of humidity into the cells over time. - Processing costs were too high. Most attempts to solve the problem ended up in complicated, multi-step, multi-process technologies, which resulted in prohibitively high costs. For the first time, the patented honeycomb liquid moulding process developed by Euro-Composites® (EC-HLM) allows the use of honeycomb in RI processes – with the additional benefit of a low porosity of the part surface – and successfully prevents the migration of humidity into the cells. The new process is more than just a clever combination of materials; it is a totally new manufacturing approach and has adapted all aspects of the process: sealing, lay-up, curing and deforming. After sealing the honeycomb it will then be laid-up together with dry fabric and the necessary auxiliary materials like peel-ply, draining medium, resin inlets and vacuum bagging. After infusion of the structural resin at temperatures between 23-120°C (depending on resin type) the resin wetted fabric will be cured under vacuum pressure normally for 2 hours between 120- 180°C. After cooling the formed or flat sandwich part can be demolded from the tool and from the infusion materials. The process is shown in figure 1 to 3 Lay-up and Infusion Process. Fig.1: Layup of part Fig.2: Resin infusion and curing of part Fig.3: Finished part after curing No39 March - April 2008 / JEC Composites Magazine

JEC COMPOSITES MAGAZINE - Issue #39 - March/April 2008

Table of Contents for the Digital Edition of JEC COMPOSITES MAGAZINE - Issue #39 - March/April 2008

Cover
NEWS WORLDWIDE - Companies
- Epsilon Composite
- Agenda of events
- Equipment : Laser placement
- Ply placement by live video image
BUSINESS - Market survey
- Formosa Plastics Corp.
- Topkey at a crossroads
- Trends : robotics
- Niche market : Patient positioning
FEATURE : ENVIRONMENT
- Management
- Biopolymers
- Natural fibre
PROCESS - Software
- Infusion
- Simulation
SPECIAL JEC COMPOSITES 2008 - JEC End-users Forums
- JEC innovation award programme
- Innovations
USER'S PLATFORM - Composites in the world
- Better acoustics for a concert hall
- Leather and fibres - No more excuses
- Applications
- Aircraft interior : more than just a seat
KNOW HOW - Composite tooloing
- Process
- Liquid composite moulding
JEC COMPOSITES MAGAZINE - Issue #39 - March/April 2008 - Cover
JEC COMPOSITES MAGAZINE - Issue #39 - March/April 2008 - 2
JEC COMPOSITES MAGAZINE - Issue #39 - March/April 2008 - 3
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JEC COMPOSITES MAGAZINE - Issue #39 - March/April 2008 - NEWS WORLDWIDE - Companies
JEC COMPOSITES MAGAZINE - Issue #39 - March/April 2008 - 9
JEC COMPOSITES MAGAZINE - Issue #39 - March/April 2008 - 10
JEC COMPOSITES MAGAZINE - Issue #39 - March/April 2008 - 11
JEC COMPOSITES MAGAZINE - Issue #39 - March/April 2008 - - Epsilon Composite
JEC COMPOSITES MAGAZINE - Issue #39 - March/April 2008 - 13
JEC COMPOSITES MAGAZINE - Issue #39 - March/April 2008 - - Agenda of events
JEC COMPOSITES MAGAZINE - Issue #39 - March/April 2008 - 15
JEC COMPOSITES MAGAZINE - Issue #39 - March/April 2008 - - Equipment : Laser placement
JEC COMPOSITES MAGAZINE - Issue #39 - March/April 2008 - 17
JEC COMPOSITES MAGAZINE - Issue #39 - March/April 2008 - - Ply placement by live video image
JEC COMPOSITES MAGAZINE - Issue #39 - March/April 2008 - 19
JEC COMPOSITES MAGAZINE - Issue #39 - March/April 2008 - 20
JEC COMPOSITES MAGAZINE - Issue #39 - March/April 2008 - 21
JEC COMPOSITES MAGAZINE - Issue #39 - March/April 2008 - BUSINESS - Market survey
JEC COMPOSITES MAGAZINE - Issue #39 - March/April 2008 - 23
JEC COMPOSITES MAGAZINE - Issue #39 - March/April 2008 - 24
JEC COMPOSITES MAGAZINE - Issue #39 - March/April 2008 - 25
JEC COMPOSITES MAGAZINE - Issue #39 - March/April 2008 - - Formosa Plastics Corp.
JEC COMPOSITES MAGAZINE - Issue #39 - March/April 2008 - 27
JEC COMPOSITES MAGAZINE - Issue #39 - March/April 2008 - 28
JEC COMPOSITES MAGAZINE - Issue #39 - March/April 2008 - 29
JEC COMPOSITES MAGAZINE - Issue #39 - March/April 2008 - - Topkey at a crossroads
JEC COMPOSITES MAGAZINE - Issue #39 - March/April 2008 - 31
JEC COMPOSITES MAGAZINE - Issue #39 - March/April 2008 - - Trends : robotics
JEC COMPOSITES MAGAZINE - Issue #39 - March/April 2008 - 33
JEC COMPOSITES MAGAZINE - Issue #39 - March/April 2008 - - Niche market : Patient positioning
JEC COMPOSITES MAGAZINE - Issue #39 - March/April 2008 - 35
JEC COMPOSITES MAGAZINE - Issue #39 - March/April 2008 - - Management
JEC COMPOSITES MAGAZINE - Issue #39 - March/April 2008 - 37
JEC COMPOSITES MAGAZINE - Issue #39 - March/April 2008 - - Biopolymers
JEC COMPOSITES MAGAZINE - Issue #39 - March/April 2008 - 39
JEC COMPOSITES MAGAZINE - Issue #39 - March/April 2008 - 40
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JEC COMPOSITES MAGAZINE - Issue #39 - March/April 2008 - 45
JEC COMPOSITES MAGAZINE - Issue #39 - March/April 2008 - - Natural fibre
JEC COMPOSITES MAGAZINE - Issue #39 - March/April 2008 - 47
JEC COMPOSITES MAGAZINE - Issue #39 - March/April 2008 - 48
JEC COMPOSITES MAGAZINE - Issue #39 - March/April 2008 - 49
JEC COMPOSITES MAGAZINE - Issue #39 - March/April 2008 - PROCESS - Software
JEC COMPOSITES MAGAZINE - Issue #39 - March/April 2008 - 51
JEC COMPOSITES MAGAZINE - Issue #39 - March/April 2008 - 52
JEC COMPOSITES MAGAZINE - Issue #39 - March/April 2008 - 53
JEC COMPOSITES MAGAZINE - Issue #39 - March/April 2008 - - Infusion
JEC COMPOSITES MAGAZINE - Issue #39 - March/April 2008 - 55
JEC COMPOSITES MAGAZINE - Issue #39 - March/April 2008 - 56
JEC COMPOSITES MAGAZINE - Issue #39 - March/April 2008 - - Simulation
JEC COMPOSITES MAGAZINE - Issue #39 - March/April 2008 - 58
JEC COMPOSITES MAGAZINE - Issue #39 - March/April 2008 - 59
JEC COMPOSITES MAGAZINE - Issue #39 - March/April 2008 - SPECIAL JEC COMPOSITES 2008 - JEC End-users Forums
JEC COMPOSITES MAGAZINE - Issue #39 - March/April 2008 - 61
JEC COMPOSITES MAGAZINE - Issue #39 - March/April 2008 - 62
JEC COMPOSITES MAGAZINE - Issue #39 - March/April 2008 - - JEC innovation award programme
JEC COMPOSITES MAGAZINE - Issue #39 - March/April 2008 - 64
JEC COMPOSITES MAGAZINE - Issue #39 - March/April 2008 - 65
JEC COMPOSITES MAGAZINE - Issue #39 - March/April 2008 - 66
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JEC COMPOSITES MAGAZINE - Issue #39 - March/April 2008 - - Innovations
JEC COMPOSITES MAGAZINE - Issue #39 - March/April 2008 - 76
JEC COMPOSITES MAGAZINE - Issue #39 - March/April 2008 - 77
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JEC COMPOSITES MAGAZINE - Issue #39 - March/April 2008 - 99
JEC COMPOSITES MAGAZINE - Issue #39 - March/April 2008 - - Better acoustics for a concert hall
JEC COMPOSITES MAGAZINE - Issue #39 - March/April 2008 - - Leather and fibres - No more excuses
JEC COMPOSITES MAGAZINE - Issue #39 - March/April 2008 - - Applications
JEC COMPOSITES MAGAZINE - Issue #39 - March/April 2008 - 103
JEC COMPOSITES MAGAZINE - Issue #39 - March/April 2008 - - Aircraft interior : more than just a seat
JEC COMPOSITES MAGAZINE - Issue #39 - March/April 2008 - 105
JEC COMPOSITES MAGAZINE - Issue #39 - March/April 2008 - 106
JEC COMPOSITES MAGAZINE - Issue #39 - March/April 2008 - 107
JEC COMPOSITES MAGAZINE - Issue #39 - March/April 2008 - KNOW HOW - Composite tooloing
JEC COMPOSITES MAGAZINE - Issue #39 - March/April 2008 - 109
JEC COMPOSITES MAGAZINE - Issue #39 - March/April 2008 - - Process
JEC COMPOSITES MAGAZINE - Issue #39 - March/April 2008 - 111
JEC COMPOSITES MAGAZINE - Issue #39 - March/April 2008 - 112
JEC COMPOSITES MAGAZINE - Issue #39 - March/April 2008 - - Liquid composite moulding
JEC COMPOSITES MAGAZINE - Issue #39 - March/April 2008 - 114
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JEC COMPOSITES MAGAZINE - Issue #39 - March/April 2008 - 116
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