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Additives for Thermoset Composites

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Additives for Thermoset Composites C M Y K Contacts worldwide Additives for Thermoset Composites Asia BASF East Asia Regional Headquarters Ltd. Formulation Additives by BASF 45/F, Jardine House No. 1 Connaught Place Central Hong Kong [email protected] Europe BASF SE Formulation Additives 67056 Ludwigshafen Germany [email protected] North America BASF Corporation 11501 Steele Creek Road Charlotte, NC 28273 USA [email protected] South America BASF S.A. Rochaverá - Crystal Tower Av. das Naçoes Unidas, 14.171 Morumbi - São Paulo-SP Brazil [email protected] BASF SE ED2 0319e Formulation Additives Dispersions & Pigments Division 67056 Ludwigshafen Germany www.basf.com/formulation-additives The data contained in this publication are based on our current knowledge and experience. In view of the many factors that may affect processing and application of our product, these data do not relieve processors from carrying out their own investigations and tests; neither do these data imply any guarantee of certain properties, nor the suitability of the product for a specific purpose. Any descriptions, drawings, photographs, data, proportions, weights, etc. given herein may change without prior information and do not constitute the agreed contractual quality of the product. The agreed contractual quality of the product results exclusively from the statements made in the product specification. It is the responsibility of the recipient of our product to ensure that any proprietary rights and existing laws and legislation are observed. When handling these products, advice and information given in the safety data sheet must be complied with. Further, protective and workplace hygiene measures adequate for handling chemicals must be observed. ® = registered trademark of the BASF Group Europe, March 2019 C M Y K We create chemistry C M Y K Additives for Thermoset Composites Additives for Thermoset Composites 16 Formulation Additives by BASF Formulation Additives by BASF 1 Leveling is defined as the ability of a coating to flow out after application in order to reduce any surface irregularities such as brush PREAMBLE and roller marks, orange peel, peaks or craters. Good to know Orange peel is a surface BASF is the world’s leading chemical company and a premier provider of innovative solutions bumpiness or waviness that is for the paints and coatings industry. BASF offers virtually every ingredient needed to often caused by poor leveling make high-quality coatings and has the know-how to solve formulation challenges and and resembles skin of an support the development of new coating concepts. Our portfolio encompasses orange. dispersions, pigments, resins and a broad range of additives such as light stabilizers and formulation additives. When it comes to formulation additives, BASF offers a strong portfolio of industry- Figure 12: leading products that help to enable sustainable and performance-driven solutions. Good and bad leveling (“orange peel”) Our offer is comprised of the broadest technology base of dispersing agents, wetting agents, surface modifiers, defoamers, rheology modifiers and film forming agents. We prioritize our understanding, listening and collaboration skills to serve our BASF serves the composites industry with three major classes of wetting agents and surface modifiers which includes products based customers' needs. With global manufacturing capabilities, a strong research and on polysiloxanes, polyacrylates and fluorinated polyacrylates. The properties of wetting agents and surface modifiers by chemistry are development platform, full-service regional technical laboratories, pre-screening illustrated in Figure 13. capabilities and a team of experienced and knowledgeable experts, BASF can help make your coatings better and your business more successful. This brochure has been developed to give composites and gelcoat producers, molding companies and assemblers first-hand guidance on the use of formulation additives from BASF and on making the most out of their performance characteristics. Looking for innovative solutions where little helpers make all the difference for your high-quality composites? BASF – We create chemistry 5: Excellent effect 0: No effect Figure 13: Properties of wetting agents and surface modifiers by chemistry C M Y K Additives for Thermoset Composites Additives for Thermoset Composites 2 Formulation Additives by BASF Formulation Additives by BASF 3 Composites: An Introduction Composites materials are clearly established in nearly all Additives are used in low quantities by weight but help improve Table of Contents significant economic sectors. Innovative developments for new the cost performance ratio of the final composite part. applications, or as substitutes for metallic alloys, are key elements in demanding markets like aerospace, automotive, As composite materials can be tailored to meet specific needs, energy, sports and military. several properties like strength, stiffness, weight, aesthetics, Composites: An Introduction 3 resistance to corrosion and chemical stability can be Manufacturing Processes for Thermoset Composites 4 Traditional composites typically consist of combinations of considerably improved through proper choice of additives. different components: BASF Formulation Additives for Composites 8 Finding accurate raw materials is one of the most important Matrix is generally a thermosetting resin as unsaturated steps for developing the ideal composite part. Commonly used ・ Air Release Agents 10 polyesters or epoxies that binds the reinforcement together, raw materials for composite formulations are shown in keeps it firmly in place and protects it from environmental Figure 1. ・ Dispersing Agents 12 influences. ・ ・ Wetting Agents and Surface Modifiers 14 Reinforcements are usually in the form of fibers or particles ・ ATH Air release agents ・ Calcium carbonates ・ Dispersing agents that enhance the mechanical and physical properties of the ・ TiO2 ・ Wetting agents & parts. ・ Kaolin surface modifiers ・ Colored pigments ・ Mold release agents Fillers and pigments are used to enhance coloristic and other ・ Shrinkage control agents physical properties. Fillers are typically the least expensive components of major ingredients. They improve functional properties such as water and temperature resistance and can Fillers/ Additives help control shrinkage. Pigments Formulation Additives are applied to optimize composite properties like shrinkage, rheology, flow and wetting behavior and adhesion. Reinforce- Resins ment ・ Unsaturated polyesters ・ Glass fibers ・ Epoxy resins ・ Carbon fibers ・ Vinyl esters ・ Aramid fibers ・ Polyurethanes ・ Natural fibers Figure 1: Example formulation components for thermoset composites. C M Y K Additives for Thermoset Composites Additives for Thermoset Composites 4 Formulation Additives by BASF Formulation Additives by BASF 5 Manufacturing Processes for Thermoset Composites Manufacturing The matrix nature, reinforcement type and the designated end application of the designed composite part are crucial selection elements for the fabrication process. The basic manufacturing methods used to fabricate composites include: lay-up, spray-up, filament Processes for winding, pultrusion and resin transfer molding. The major fabrication routes for thermoset composites are shown in Figure 2. Thermoset Composites Short-Fiber ・ Injection Molding BMC / TMC ・ Compression Molding Fabrication routes ・ Liquid Molding (RTM) ・ Spray-up SMC for thermoset composites Continuous- Fiber ・ Lay-up ・ Filament Winding ・ Liquid Molding (RTM) ・ Pultrusion Figure 2: Fabrication routes for thermoset composites SMC/BMC/TMC (Sheet/Bulk/Thick Molding Compounds): SMC, BMC and TMC are premixes made up of thermoset resins, mineral fillers and additives. The compounds are further formed into complex shapes through high volume injection or compression molding processes at high temperatures of around 150°C. The resulting composite parts compete with steel parts in their mechanical properties, ensure pronounced chemical and, corrosion resistance and allow very high design freedom. SMC BMC TMC Fiber content: 10-60% Fiber content: 10-30% Fiber content: 10-20% Fiber length: 25-50 mm Fiber length: 6-12 mm Fiber length: 12-50 mm Characteristics: Characteristics: Characteristics: Superior mechanical Better flow and Combined properties properties due to the temperature resistance of BMC (good flow) longer fibers than SMC due to the and SMC (best shorter fibers and mechanical properties) higher filler content Figure 3: Composition and characteristics of SMC/BMC/TMC compounds C M Y K Additives for Thermoset Composites Additives for Thermoset Composites 6 Formulation Additives by BASF Formulation Additives by BASF 7 Manufacturing Processes for Thermoset Composites Hand Lay-up RTM (Resin Hand lay-up consists of manual positioning of fiber reinforced mats or prepreg plies onto a prepared mold. Thermosetting Transfer Molding) resins are then applied by brushing, spraying or resin infusion. RTM is a vacuum-assisted closed mold process. Fiber Entrapped air can be removed with the aid of rolling, and the reinforcements are positioned in a matched male and female laminate can be left to dry at room temperature. Curing can be mold, which is then closed and clamped. The matrix is injected accelerated in ovens or by vacuum. Hand lay-up is a simple under pressure until the mold is filled. The parts cured in the and relatively low cost processing method for large mold are normally heated
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