JEC COMPOSITES MAGAZINE - Issue #119 - March 2018 - 54

MATERIALS: PUSHING BOUNDARIES resin
Tab.1: Epoxy SMC compounding parameters

Setting

Fibre length

25 mm

Parameter

Setting

Resin temperature

25°C

135/145°C

Resin film
thickness

1.5 mm

Lower film thickness resulted
in better fibre wet-out

Core/cavity
temperature
Vacuum

On

3500 g/m2

Lower basis weights resulted
in better fibre wet-out

Until resin gel point
(~40 s)

Load profile

75 bar

Constant

Line speed

1.5 m/min

The maximum speed is
1.5 m/min for operator safety

Speed profile
(slow)

1 mm/s

Only from SMC
charge height

Fibre volume

45%

Line heating

Off

Line heat at 40°C resulted
in improved fibre wet-out

Mould
coverage

50%

Centre placed

Compaction
"pressure"

75 mm

Roller offset value; roughly
equivalent to 0.25 bar

Cure time

3 min

~60 s/mm

Basis weight

a sandwich-panel style SMC charge such
that both materials were simultaneously
cured when moulded together. Here,
the carbon fibre was identical in both
the SMC and prepreg materials and the
respective resin contents similar. The
prepreg did use a different Hexion epoxy
system, but one selected for its similar
chemistry, thereby preventing differential
curing and the resultant micro-cracking
and delamination at the SMC/prepreg interface. The prepreg was added in several
weight fractions as unidirectional material
aligned with the SMC machine direction.
A fibre spreading device was installed in
the SMC line to better open the fibre bundles prior to compaction. The approach
used to spread the fibre is proprietary to
Dieffenbacher and is designed specifically
for high-tow carbon fibre. Using this
method, the carbon fibre is not fully filamentized, making the reduced fibre bundle sizes easier to disperse and impregnate
during compaction.
The epoxy SMC was matured according
to the recommended guidelines at room
temperature for at least one week prior
to moulding. Square panels of 2-3 mm
thickness were compression moulded in
a chromed tool previously seasoned with
the LOCTITE™ FREKOTETM 770NC
mould release agent available from
Henkel Adhesives North America. Panels
were moulded such that the SMC charges
maintained the "machine direction", the
partial alignment of fibre parallel to the
compounding belt direction.
The SMC moulding parameters were
generally held constant with incremental

54

Notes

Tab.2: Epoxy SMC moulding parameters

Parameter

adjustments trial-to-trial to improve the
quality of the panels. Among the major
settings captured in Table 2, one of the
critical parameters was found to be the
mould filling speed (controlled by the
press closing speed), whereby a slower
speed during the final few millimetres
prevented certain moulding defects.
Figure 2 shows several sample panels
as-moulded from the baseline formulation, the spread tow, a co-cured sandwich
panel, and the test coupon pattern. These
panels generally exhibited a clean, blister-free surface, but were not fabricated for
the purpose of achieving class-A quality.
The moulded panels were sectioned into
testing specimens following European

Fig. 2:
Sample SMC panels:
a) baseline,
b) spread tow,
c) co-cured sandwich,
d) sample pattern

jec composites magazine / N°119 March 2018

Notes

standards: tensile samples according to
ISO 527-4 and flexural samples according
to ISO 14125. For reference, the disks and
tensile gauges (post-test) were subjected
to ignition loss testing according to ISO
7822 to map out the panel fibre volume
content and variability. Some dynamic
mechanical analysis samples were also
taken from each sample panel for separate
study.
Excellent mechanical properties
for structural design
The tensile results for two selected carbon
fibre formulations and one glass fibre formulation are presented in Table 3. These
raw results are averages for all the tested
coupons in both the machine direction



Table of Contents for the Digital Edition of JEC COMPOSITES MAGAZINE - Issue #119 - March 2018

Cover
Edito
Opinion: Aeronautics
Contents
NEWS
In brief
Agenda
BUSINESS
KPIs - Up-to-date key performance indicators for the fibre-reinforced plastics market
Opportunities - Advanced plastics and composites break through the automotive sector
EV - China: driving the whole car supply chain, electric vehicles are in full swing
MANUFACTURING
Surface - New machine system takes surface finishing to a new level
3D printing - Additive manufacturing of highperformance composite structures
Automotive - Body in black versus body in white
Automotive - Sheet moulding compression of prepreg sheets for a composite subframe
Simulation - High-quality sound-absorbing automotive carpets
Curing - GRP composite manufacturing optimization: opportunities with UV curing
FEATURE Materials: pushing boundaries - Do materials have their limits?
Fastener - High-resistance fastener for structural composite parts
Recycling - Applications of recycled carbon fibre in high volume manufacturing
Resin - High-performance epoxy/carbon fibre SM
Honeycomb - High-performance polypropylene honeycomb boards at minimal cost
CFRTP - Beautiful, lightweight, and tunable
SOLUTIONS
Aeronautics - A demountable composite wing box for private planes
Civil engineering - Repair and replacement of concrete pipes with carbon composites
Sports - Sustainable composite manufacturing kicks into high gear
Medical - lmproving lives with carbon composites
TECHNOLOGY
NDT - NDT in-line inspection using the NIDIT procedure
Assembly - Ensuring the durability of adhesive-bonded assemblies
Index
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JEC COMPOSITES MAGAZINE - Issue #119 - March 2018 - 84
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JEC COMPOSITES MAGAZINE - Issue #119 - March 2018 - Opinion: Aeronautics
JEC COMPOSITES MAGAZINE - Issue #119 - March 2018 - 5
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JEC COMPOSITES MAGAZINE - Issue #119 - March 2018 - Contents
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JEC COMPOSITES MAGAZINE - Issue #119 - March 2018 - In brief
JEC COMPOSITES MAGAZINE - Issue #119 - March 2018 - 9
JEC COMPOSITES MAGAZINE - Issue #119 - March 2018 - 10
JEC COMPOSITES MAGAZINE - Issue #119 - March 2018 - 11
JEC COMPOSITES MAGAZINE - Issue #119 - March 2018 - Agenda
JEC COMPOSITES MAGAZINE - Issue #119 - March 2018 - 13
JEC COMPOSITES MAGAZINE - Issue #119 - March 2018 - 14
JEC COMPOSITES MAGAZINE - Issue #119 - March 2018 - 15
JEC COMPOSITES MAGAZINE - Issue #119 - March 2018 - 16
JEC COMPOSITES MAGAZINE - Issue #119 - March 2018 - KPIs - Up-to-date key performance indicators for the fibre-reinforced plastics market
JEC COMPOSITES MAGAZINE - Issue #119 - March 2018 - 18
JEC COMPOSITES MAGAZINE - Issue #119 - March 2018 - 19
JEC COMPOSITES MAGAZINE - Issue #119 - March 2018 - Opportunities - Advanced plastics and composites break through the automotive sector
JEC COMPOSITES MAGAZINE - Issue #119 - March 2018 - 21
JEC COMPOSITES MAGAZINE - Issue #119 - March 2018 - 22
JEC COMPOSITES MAGAZINE - Issue #119 - March 2018 - EV - China: driving the whole car supply chain, electric vehicles are in full swing
JEC COMPOSITES MAGAZINE - Issue #119 - March 2018 - 24
JEC COMPOSITES MAGAZINE - Issue #119 - March 2018 - 25
JEC COMPOSITES MAGAZINE - Issue #119 - March 2018 - Ad4
JEC COMPOSITES MAGAZINE - Issue #119 - March 2018 - Ad5
JEC COMPOSITES MAGAZINE - Issue #119 - March 2018 - Surface - New machine system takes surface finishing to a new level
JEC COMPOSITES MAGAZINE - Issue #119 - March 2018 - 27
JEC COMPOSITES MAGAZINE - Issue #119 - March 2018 - 28
JEC COMPOSITES MAGAZINE - Issue #119 - March 2018 - 3D printing - Additive manufacturing of highperformance composite structures
JEC COMPOSITES MAGAZINE - Issue #119 - March 2018 - 30
JEC COMPOSITES MAGAZINE - Issue #119 - March 2018 - 31
JEC COMPOSITES MAGAZINE - Issue #119 - March 2018 - 32
JEC COMPOSITES MAGAZINE - Issue #119 - March 2018 - 33
JEC COMPOSITES MAGAZINE - Issue #119 - March 2018 - 34
JEC COMPOSITES MAGAZINE - Issue #119 - March 2018 - Automotive - Body in black versus body in white
JEC COMPOSITES MAGAZINE - Issue #119 - March 2018 - 36
JEC COMPOSITES MAGAZINE - Issue #119 - March 2018 - 37
JEC COMPOSITES MAGAZINE - Issue #119 - March 2018 - 38
JEC COMPOSITES MAGAZINE - Issue #119 - March 2018 - Automotive - Sheet moulding compression of prepreg sheets for a composite subframe
JEC COMPOSITES MAGAZINE - Issue #119 - March 2018 - 40
JEC COMPOSITES MAGAZINE - Issue #119 - March 2018 - 41
JEC COMPOSITES MAGAZINE - Issue #119 - March 2018 - Simulation - High-quality sound-absorbing automotive carpets
JEC COMPOSITES MAGAZINE - Issue #119 - March 2018 - 43
JEC COMPOSITES MAGAZINE - Issue #119 - March 2018 - Curing - GRP composite manufacturing optimization: opportunities with UV curing
JEC COMPOSITES MAGAZINE - Issue #119 - March 2018 - 45
JEC COMPOSITES MAGAZINE - Issue #119 - March 2018 - 46
JEC COMPOSITES MAGAZINE - Issue #119 - March 2018 - 47
JEC COMPOSITES MAGAZINE - Issue #119 - March 2018 - Fastener - High-resistance fastener for structural composite parts
JEC COMPOSITES MAGAZINE - Issue #119 - March 2018 - 49
JEC COMPOSITES MAGAZINE - Issue #119 - March 2018 - 50
JEC COMPOSITES MAGAZINE - Issue #119 - March 2018 - Recycling - Applications of recycled carbon fibre in high volume manufacturing
JEC COMPOSITES MAGAZINE - Issue #119 - March 2018 - 52
JEC COMPOSITES MAGAZINE - Issue #119 - March 2018 - Resin - High-performance epoxy/carbon fibre SM
JEC COMPOSITES MAGAZINE - Issue #119 - March 2018 - 54
JEC COMPOSITES MAGAZINE - Issue #119 - March 2018 - 55
JEC COMPOSITES MAGAZINE - Issue #119 - March 2018 - 56
JEC COMPOSITES MAGAZINE - Issue #119 - March 2018 - Honeycomb - High-performance polypropylene honeycomb boards at minimal cost
JEC COMPOSITES MAGAZINE - Issue #119 - March 2018 - 58
JEC COMPOSITES MAGAZINE - Issue #119 - March 2018 - CFRTP - Beautiful, lightweight, and tunable
JEC COMPOSITES MAGAZINE - Issue #119 - March 2018 - 60
JEC COMPOSITES MAGAZINE - Issue #119 - March 2018 - 61
JEC COMPOSITES MAGAZINE - Issue #119 - March 2018 - 62
JEC COMPOSITES MAGAZINE - Issue #119 - March 2018 - Aeronautics - A demountable composite wing box for private planes
JEC COMPOSITES MAGAZINE - Issue #119 - March 2018 - 64
JEC COMPOSITES MAGAZINE - Issue #119 - March 2018 - 65
JEC COMPOSITES MAGAZINE - Issue #119 - March 2018 - Civil engineering - Repair and replacement of concrete pipes with carbon composites
JEC COMPOSITES MAGAZINE - Issue #119 - March 2018 - 67
JEC COMPOSITES MAGAZINE - Issue #119 - March 2018 - 68
JEC COMPOSITES MAGAZINE - Issue #119 - March 2018 - Sports - Sustainable composite manufacturing kicks into high gear
JEC COMPOSITES MAGAZINE - Issue #119 - March 2018 - 70
JEC COMPOSITES MAGAZINE - Issue #119 - March 2018 - Medical - lmproving lives with carbon composites
JEC COMPOSITES MAGAZINE - Issue #119 - March 2018 - 72
JEC COMPOSITES MAGAZINE - Issue #119 - March 2018 - 73
JEC COMPOSITES MAGAZINE - Issue #119 - March 2018 - NDT - NDT in-line inspection using the NIDIT procedure
JEC COMPOSITES MAGAZINE - Issue #119 - March 2018 - 75
JEC COMPOSITES MAGAZINE - Issue #119 - March 2018 - 76
JEC COMPOSITES MAGAZINE - Issue #119 - March 2018 - Assembly - Ensuring the durability of adhesive-bonded assemblies
JEC COMPOSITES MAGAZINE - Issue #119 - March 2018 - 78
JEC COMPOSITES MAGAZINE - Issue #119 - March 2018 - 79
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