JEC COMPOSITES MAGAZINE - Issue #50 - July/August 2009 - 52
KNOW-HOW Ductile prepregs Formable aligned-fibre composite materials The challenge facing structural composites is to industrialise manufacturing. The need for new, more compliant materials that can be processed rapidly and cheaply is now recognised as an essential step in realising this transformation. Perform discontinuous fibre prepregs are being developed to meet this need. Theoretical studies on the rheological behaviour of highly concentrated suspensions of aligned fibres [5] subsequently revealed that the axial elongational viscosity η11, which determines the axial deformation stress, is a complex function of the matrix viscosity η, the fibre volume fraction f and the fibre aspect ratio (l/d): η11 = (η.f)/2.(κ-1)(l/d)2 where κ is a function of the fibre volume fraction. With fibre diameters in the range of 0.005 to 0.025 mm and a normal spread of fibre lengths generated by stretch-breaking of 25-150 mm, individual fibre aspect ratios can be as high as 30,000, with a mean value in the region of 15,000. Since η11 is proportional to (l/d)2, it is hardly surprising that these materials proved difficult to form. ROGER FORD, MANAGING DIRECTOR BOB GRIFFITHS, BUSINESS DEVELOPMENT DIRECTOR INTEGRATED MATERIALS TECHNOLOGY LTD (IMT) o be useful, materials need to be shaped. This can be by addition or removal of material, but more frequently it involves deformation, which is less wasteful. By definition, this requires material flow, which for existing aligned-fibre composites involves the following five flow processes: • Resin percolation • Transverse flow • Inter-ply shear or slip • Inter-ply rotation • Intra-ply shear T However, vital flow along the fibre axes is prevented in materials that contain continuous reinforcement. As a result, successful forming of more complex shapes can be a slow and difficult process. To overcome this elongational flow problem, it is clearly necessary to use materials with aligned discontinuous fibres. However, achieving the required balance between the mechanical and deformation properties of such aligned discontinuous fibre systems, based on chopped [1, 2] or stretch-broken fibres [3, 4], has proved to be more difficult than expected. The problem with chopped fibres was that fibre lengths were limited to ~3 mm by the method of alignment , which depended on convergent flow in a viscous fluid. The products were easy to form, but the mechanical properties, in particular impact properties, were inadequate. In the case of stretch-broken tows with a fibre length spread from 25-150 mm, the mechanical properties were acceptable, but the materials were found to have very high peak yield stresses during forming that resisted the initiation of axial flow and led to serious problems in controlling the forming process. The Perform process To reduce the axial deformation stress to a level that will ease forming, the aspect ratios of the micro-structural elements involved in deformation must be substantially reduced. This clearly will not be achieved if deformation continues to depend on shearing between individual fibres. The Perform process [6, 7] was developed to overcome this difficulty. It uses laser micro-perforation to convert standard UD prepregs to discontinuous form by drilling a pattern of small holes in a single UD ply. The process calls for precision, speed and a small hole size. Laser drilling was chosen because of its capability to meet these needs. Also, as a non-contact process, it offered prolonged operation with consistent hole size. The hole densities used, which are determined by the required fibre length, are typically between 105 and 106 holes/m2. The associated void levels introduced by the drilling are in the 0.05-0.15% range, which is not enough to cause laminate problems. In practice, they increase the ease of gas evacuation during lamination before being filled by matrix flow. 52 jec composites magazine / No50 July-August 2009
JEC COMPOSITES MAGAZINE - Issue #50 - July/August 2009
Table of Contents for the Digital Edition of JEC COMPOSITES MAGAZINE - Issue #50 - July/August 2009
Cover
Index
Contents
- NEWS WORLDWIDE -
Companies - Innovation: the guiding principe at Hunstman
Companies - More V: operating on a practically boundless market
Companies - IDI Composites buys former Menzolit facilities
Companies - Colan Australia, threads worth their weight in gold!
Companies - DSM Composite Resins and Büfa: they finalize european joint venture agreements
Agenda of events
Equipment - Custom-coated carbide tools for improved adaptability and lower costs
- BUSINESS -
Market Survey - US demand for decking to reach 1.1 billion lineal metrs in 2013
Trends - Wood-plastic composites: markets, applications and performance costs
Human capital - A PhD student rewarded for his environmental concerns
- FEATURE -
Software - On the way to a high-tech process for high-performance applications
Process - The latest innovations to the LRTM molding process
Application - Large truck mid-roof to be manufactured in Brazil
Application - RTM part for Franch high-speed train
Production - An RTM production line with environmental credentials
Innovations - Plascore PP honeycomb infusion grade for Light RTM
Innovations - RTM compression press for manufacturing body panels
Innovations - Institut fuer Verbundwekstoffe GmbH
- USERS' PLATFORM -
Composites in the world - The Aston Martin One-77
Composites in the world - Cavalier pot
Composites in the world - Carbon fish sculptures
Composites in the world - Glass-fibre-reinforced body camera
Successful partners - An innovative reinforced profile for window frames
Application - MFG: boosting the growth of the wind energy market
Application - Blue Hawaiian Fiberglass Pool: leader in Florida
- KNOW-HOW -
Ductile prepregs - Formable aligned-fibre composite materials
Compound - High-modulus carbon fibres in super-structural compounds
JEC COMPOSITES MAGAZINE - Issue #50 - July/August 2009 - Cover
JEC COMPOSITES MAGAZINE - Issue #50 - July/August 2009 - 2
JEC COMPOSITES MAGAZINE - Issue #50 - July/August 2009 - 3
JEC COMPOSITES MAGAZINE - Issue #50 - July/August 2009 - 4
JEC COMPOSITES MAGAZINE - Issue #50 - July/August 2009 - Index
JEC COMPOSITES MAGAZINE - Issue #50 - July/August 2009 - Contents
JEC COMPOSITES MAGAZINE - Issue #50 - July/August 2009 - 7
JEC COMPOSITES MAGAZINE - Issue #50 - July/August 2009 - Companies - Innovation: the guiding principe at Hunstman
JEC COMPOSITES MAGAZINE - Issue #50 - July/August 2009 - Companies - More V: operating on a practically boundless market
JEC COMPOSITES MAGAZINE - Issue #50 - July/August 2009 - Companies - IDI Composites buys former Menzolit facilities
JEC COMPOSITES MAGAZINE - Issue #50 - July/August 2009 - Companies - Colan Australia, threads worth their weight in gold!
JEC COMPOSITES MAGAZINE - Issue #50 - July/August 2009 - 12
JEC COMPOSITES MAGAZINE - Issue #50 - July/August 2009 - 13
JEC COMPOSITES MAGAZINE - Issue #50 - July/August 2009 - Companies - DSM Composite Resins and Büfa: they finalize european joint venture agreements
JEC COMPOSITES MAGAZINE - Issue #50 - July/August 2009 - 15
JEC COMPOSITES MAGAZINE - Issue #50 - July/August 2009 - Agenda of events
JEC COMPOSITES MAGAZINE - Issue #50 - July/August 2009 - 17
JEC COMPOSITES MAGAZINE - Issue #50 - July/August 2009 - Equipment - Custom-coated carbide tools for improved adaptability and lower costs
JEC COMPOSITES MAGAZINE - Issue #50 - July/August 2009 - 19
JEC COMPOSITES MAGAZINE - Issue #50 - July/August 2009 - 20
JEC COMPOSITES MAGAZINE - Issue #50 - July/August 2009 - - BUSINESS -
JEC COMPOSITES MAGAZINE - Issue #50 - July/August 2009 - Market Survey - US demand for decking to reach 1.1 billion lineal metrs in 2013
JEC COMPOSITES MAGAZINE - Issue #50 - July/August 2009 - Trends - Wood-plastic composites: markets, applications and performance costs
JEC COMPOSITES MAGAZINE - Issue #50 - July/August 2009 - 24
JEC COMPOSITES MAGAZINE - Issue #50 - July/August 2009 - 25
JEC COMPOSITES MAGAZINE - Issue #50 - July/August 2009 - Human capital - A PhD student rewarded for his environmental concerns
JEC COMPOSITES MAGAZINE - Issue #50 - July/August 2009 - Asia Show
JEC COMPOSITES MAGAZINE - Issue #50 - July/August 2009 - JCM
JEC COMPOSITES MAGAZINE - Issue #50 - July/August 2009 - - FEATURE -
JEC COMPOSITES MAGAZINE - Issue #50 - July/August 2009 - Software - On the way to a high-tech process for high-performance applications
JEC COMPOSITES MAGAZINE - Issue #50 - July/August 2009 - 29
JEC COMPOSITES MAGAZINE - Issue #50 - July/August 2009 - 30
JEC COMPOSITES MAGAZINE - Issue #50 - July/August 2009 - 31
JEC COMPOSITES MAGAZINE - Issue #50 - July/August 2009 - Process - The latest innovations to the LRTM molding process
JEC COMPOSITES MAGAZINE - Issue #50 - July/August 2009 - 33
JEC COMPOSITES MAGAZINE - Issue #50 - July/August 2009 - 34
JEC COMPOSITES MAGAZINE - Issue #50 - July/August 2009 - Application - Large truck mid-roof to be manufactured in Brazil
JEC COMPOSITES MAGAZINE - Issue #50 - July/August 2009 - Application - RTM part for Franch high-speed train
JEC COMPOSITES MAGAZINE - Issue #50 - July/August 2009 - Production - An RTM production line with environmental credentials
JEC COMPOSITES MAGAZINE - Issue #50 - July/August 2009 - 38
JEC COMPOSITES MAGAZINE - Issue #50 - July/August 2009 - 39
JEC COMPOSITES MAGAZINE - Issue #50 - July/August 2009 - Innovations - Institut fuer Verbundwekstoffe GmbH
JEC COMPOSITES MAGAZINE - Issue #50 - July/August 2009 - - USERS' PLATFORM -
JEC COMPOSITES MAGAZINE - Issue #50 - July/August 2009 - Composites in the world - Cavalier pot
JEC COMPOSITES MAGAZINE - Issue #50 - July/August 2009 - Composites in the world - Glass-fibre-reinforced body camera
JEC COMPOSITES MAGAZINE - Issue #50 - July/August 2009 - Successful partners - An innovative reinforced profile for window frames
JEC COMPOSITES MAGAZINE - Issue #50 - July/August 2009 - 45
JEC COMPOSITES MAGAZINE - Issue #50 - July/August 2009 - Application - MFG: boosting the growth of the wind energy market
JEC COMPOSITES MAGAZINE - Issue #50 - July/August 2009 - 47
JEC COMPOSITES MAGAZINE - Issue #50 - July/August 2009 - 48
JEC COMPOSITES MAGAZINE - Issue #50 - July/August 2009 - Application - Blue Hawaiian Fiberglass Pool: leader in Florida
JEC COMPOSITES MAGAZINE - Issue #50 - July/August 2009 - 50
JEC COMPOSITES MAGAZINE - Issue #50 - July/August 2009 - - KNOW-HOW -
JEC COMPOSITES MAGAZINE - Issue #50 - July/August 2009 - Ductile prepregs - Formable aligned-fibre composite materials
JEC COMPOSITES MAGAZINE - Issue #50 - July/August 2009 - 53
JEC COMPOSITES MAGAZINE - Issue #50 - July/August 2009 - 54
JEC COMPOSITES MAGAZINE - Issue #50 - July/August 2009 - Compound - High-modulus carbon fibres in super-structural compounds
JEC COMPOSITES MAGAZINE - Issue #50 - July/August 2009 - 56
JEC COMPOSITES MAGAZINE - Issue #50 - July/August 2009 - 57
JEC COMPOSITES MAGAZINE - Issue #50 - July/August 2009 - 58
JEC COMPOSITES MAGAZINE - Issue #50 - July/August 2009 - 59
JEC COMPOSITES MAGAZINE - Issue #50 - July/August 2009 - 60
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