JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - 25

Higher production capacity thanks to Automated manufacturing

Tab.1:Technical data - Rohacell® Hero PMI closed cell rigid foam core range

Physical properties Test Method*

Unit

Rohacell®
51 Hero

Rohacell®
71 Hero

Rohacell®
110 Hero

Rohacell®
200 Hero

Density

ISO 845
ASTM D 1622

kg/m3
lbs/ft3

52
3.25

75
4.68

110
6.87

205
12.80

Compressive
strength

ISO 844
ASTM D 1621

MPa
psi

0.6
87

1.1
160

2.5
363

7.1
1,030

Compressive
modulus

ISO 844
ASTM D 1621

MPa
psi

32
4,960

48
6,960

83
12,000

180
26,100

Tensile strength

ISO 527-2
ASTM D 638

MPa
psi

2.6
377

4.1
595

6.3
914

12.3
1,780

Tensile modulus

ISO 527-2
ASTM D 638

MPa
psi

82
11,900

123
17,800

189
27,400

389
56,400

Elongation
at break

ISO 527-2
ASTM D 638

%

8

9.5

9.9

10.8

Shear strength

DIN 53294
ASTM C 273

MPa
psi

0.7
102

1.3
189

2.3
334

5.2
754

Shear modulus

DIN 53294
ASTM C 273

MPa
psi

22
3,190

28
4,060

50
7,250

109
15,800

Maximum shear
strain

DIN 53294
ASTM C 273

%

7.0

7.2

7.2

7.2

1/K*10E-5

3.76

3.77

3.72

4.26

Coefficient of
thermal expansion

Independent testing
and AIMS approval
Following completion of extensive testing
and trials, Rohacell® HERO is now an
Airbus AIMS 04-11-011-qualified aircraft
flight-approved core material, in addition to
being technically proven in the narrow-body
Airbus A320 family of airliners in a vertical
stabilizer leading edge panel project.
Specifying the Rohacell® HERO foam core
material does not compromise the structural
integrity of an exterior aircraft part, as validated by the independent tests carried out
by the Fraunhofer IWM Institute in Halle,
Germany, to verify its mechanical properties
and suitability as part of sandwich composite
designs for Class A and B aircraft structural
parts.
The Fraunhofer IWM Institute's rigorous
testing programme included a series of
comparative NDT after impact tests between
an equivalent aircraft-grade structural honeycomb core and Rohacell® HERO, which
provided exactly the same level of damage
resistance and visual inspection detectability
in both materials.
Rohacell® HERO is unique, being the only
rigid, closed-cell structural foam core ma-

terial currently available that can handle up
to 180°C cure temperatures under extreme
pressure, which are the moulding conditions
required for many aircraft-approved epoxy
resin grades. Its technical data are listed in
Table 1.
From a design engineering standpoint,
independent testing has proven that the
same mechanical properties can be obtained
with Rohacell® HERO, while realizing all the
other manufacturing savings, higher output
rates and improved in-service MRO benefits.
Study conclusions
The automatization feasibility studies both
proved that the Rohacell® HERO rigid
closed-cell foam core material handles far
better than an equivalent aircraft-qualified
honeycomb core.
The two studies also demonstrated that
much higher output rates are possible by
combining automatization with Evonik's
foam core material and that an output rate
of 40-50 parts per day with the right capital
investment in an automated robot line is realistically possible for rapidly producing glass,
carbon or aramid fibre-reinforced sandwich
composite parts.

Automated sandwich technology in
combination with a machined Rohacell®
HERO foam core was proven to be a viable,
high-output way to manufacture liquid
epoxy resin or epoxy prepreg structural composite parts for both interior and exterior
aircraft applications. According to technical
data published by Evonik, higher-density
grades, such as Rohacell® HERO 110, can be
autoclaved at up to 180°C and 7 bar pressure.
The overall conclusion is that the significant
weight and cost savings, combined with the
potential doubling of production capacity
by combining automatization with the use
of a structural foam core, provide three
compelling reasons for an aircraft OEM to
move from a honeycomb core to a Rohacell®
HERO foam core. The business case and
productivity gains become even more financially compelling with more geometrically
complex aircraft components.
Future application opportunities
The latest studies show that automatization
can provide aircraft manufacturers with the
productivity gains that the industry needs.
Evonik expects robot automation technology and digitization to be used more and more
by the aircraft industry as the sector invests in
Industry 4.0 for composite part manufacturing. The feasibility studies have shown that
automation is a perfect technology fit with
the Rohacell® HERO foam core material,
particularly for producing complex-shaped
parts.
With this high-performance foam material,
aircraft OEMs can still gain all the lightweight, integral structural design benefits of
a sandwich composite laminate and attain
output rates that simply would not be
possible using existing honeycomb cores
without significant investments in tooling
and adaptions to automated production line
robot arms. Rohacell® HERO, currently the
only technically-proven Airbus flight-qualified foam core sandwich material to replace
a honeycomb core, offers a real competitive
advantage that Evonik believes aircraft part
producers will increasingly look to benefit
from in the coming years.

	

N°136 September - October 2020

More information:
www.Rohacell.com
www.composites.evonik.com

/ jec composites magazine

25


http://www.Rohacell.com http://www.composites.evonik.com

JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020

Table of Contents for the Digital Edition of JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020

Cover
Edito
“We can change the way we envision global shipping overall”
Contents
NEWS
In brief
Agenda
BUSINESS
Reinforcement - Natural-fibre composites: an overview
Startup - When 3D printing meets sustainability
China - Xinzhou bets on the bamboo-based composites industry
MANUFACTURING
Wind - lnnovation in wind power through multi-process-capable systems
Automation - Higher production capacity thanks to automated manufacturing
FEATURE Sustainability - The path has been plotted
Recycling ecosystem - Composites recycling: in search of the circular economy
Mobility - A new generation of recycled composite materials for sustainable mobility
Preimpregnated textile - Healable composites to improve circularity
Process - New trends in composites and plastics recycling
Raw materials - Innovative composites made from up to 92% reclaimed materials
Construction - Biocomposites and automation: a sustainable future for the building industry
Ressources - Waste-free composite wheel production
Wind energy - From bottle to blade
Durable composites - Upcycling plastic bottles into value-added composite applications
Matrix - Novel thermoset composites for more competitive and sustainable industries
SOLUTIONS
Aerospace - Slinging rockets into space
Aerospace - Composites push back the final frontier
Railway - Composite overhead line catenary system for light rail
TECHNOLOGY
Repair - Developing an eddy current-based sensor system for quality assurance of carbon fibres
Inside the lab - Advanced Composite Materials Facility University of Southampton
Resin - Development of new type of plastics: Polypropylene 2.0
Index
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JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - Cover
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - 2
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - Edito
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - “We can change the way we envision global shipping overall”
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - 5
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - Contents
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - 7
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - In brief
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - 9
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - 10
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - Agenda
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - Reinforcement - Natural-fibre composites: an overview
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - 13
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - Startup - When 3D printing meets sustainability
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - 15
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - China - Xinzhou bets on the bamboo-based composites industry
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - 17
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - Wind - lnnovation in wind power through multi-process-capable systems
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - 19
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - 20
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - 21
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - Automation - Higher production capacity thanks to automated manufacturing
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - 23
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - 24
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - 25
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - Recycling ecosystem - Composites recycling: in search of the circular economy
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - 27
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - 28
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - 29
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - 30
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - Mobility - A new generation of recycled composite materials for sustainable mobility
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - 32
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - Preimpregnated textile - Healable composites to improve circularity
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - 34
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - 35
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - Process - New trends in composites and plastics recycling
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - 37
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - Raw materials - Innovative composites made from up to 92% reclaimed materials
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - 39
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - Construction - Biocomposites and automation: a sustainable future for the building industry
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - 41
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - Ressources - Waste-free composite wheel production
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - 43
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - Wind energy - From bottle to blade
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - 45
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - Durable composites - Upcycling plastic bottles into value-added composite applications
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - 47
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - Matrix - Novel thermoset composites for more competitive and sustainable industries
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - 49
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - 50
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - Aerospace - Slinging rockets into space
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - 52
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - 53
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - Aerospace - Composites push back the final frontier
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - 55
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - Railway - Composite overhead line catenary system for light rail
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - 57
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - 58
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - Repair - Developing an eddy current-based sensor system for quality assurance of carbon fibres
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - 60
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - 61
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - Inside the lab - Advanced Composite Materials Facility University of Southampton
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - 63
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - Resin - Development of new type of plastics: Polypropylene 2.0
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - 65
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - Advertisers
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - 67
JEC COMPOSITES MAGAZINE - Issue #136 - September/October 2020 - 68
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