Compression Molding

Composites 201

John P. Busel, F.ACI, HoF.ACMA VP, Composites Growth Initiative American Composites Manufacturers Association

2 Objectives of Session

• To build on the information presented in Composites 101 to provide: • a greater understanding of FRP composite materials and properties, and • options to manufacture composites • General guidelines in design of FRP composites products • Help answer the question – why composites.

3 September 21-24, 2020 / www.theCAMX.org Outline

1. Fiber Reinforcements 2. Polymers (matrix) 3. Manufacturing / Product and Process Characteristics 4. Designing with Composites 5. Recycling Composites

4 September 21-24, 2020 / www.theCAMX.org Composites 101 – An Overview

From the ACMA CCT Program, Composites defined as: • “A combination of reinforcement fiber in a polymer resin matrix, whereas the reinforcement has an aspect ratio that enables the transfer of loads between fibers, and the fibers are chemically bonded to the resin matrix”. – A combination of fiber in a polymer matrix – A resin matrix reinforced with a fiber • The reinforcement has an aspect ratio that enables the transfer of loads between fibers – The fibers are long and narrow, and where they overlap the polymer matrix transfers loads to the adjacent fibers • The fibers are chemically bonded to the resin matrix – There is adhesion between the fibers and matrix and the fibers do not move within their encapsulation when loaded

5 September 21-24, 2020 / www.theCAMX.org 1. Fiber Reinforcements

6 Constituent Components: Fibers Typical Composite Reinforcing Fibers: Glass • E-Glass (Alumina-calcium-borosilicate): – General purpose fiber with good strength and high electrical resistivity – Forms • Single end “direct draw” roving for fabric weaving, stitch-bonding, braiding, pultrusion, filament winding – From very fine yarn for electrical circuit boards to heavy roving for industrial composites • Multi-end “assembled” roving for chopped mat – Nomenclature and composition outlined in ASTM D578 – Typically named after sizing type – Select Products: • Hybon® 2026 (PPG/NEG), StarRov® (JM), 469L (CPIC), TD44C (Vetrotex) • ECR-Glass (Calcium aluminosilicate): – Boron oxide-free version of E-glass which increases acid corrosion resistance – Produced in same forms as E-glass – Select Products: • Advantex® (Owens Corning), E6CR™ 396 (Jushi)

7 September 21-24, 2020 / www.theCAMX.org Constituent Components: Fibers Typical Composite Reinforcing Fibers: Glass • A-Glass (Soda lime silicate): – Lower strength/durability fiber compared to E-glass, only in veil/mat format – Select Products: • Surmat® 200 veil (Superior Composites Co.) • H-Glass (Calcium aluminosilicate): – Higher strength and modulus version of ECR-glass fiber – Select Products: • Xstrand® H (Owens Corning) • R-Glass (Calcium aluminosilicate and Basalt): – Higher strength and modulus than H-glass fiber – Select Products: • INNOFIBER® Hybon® XM (PPG/NEG) • C-Glass (Calcium borosilicate): – Used for highly corrosive acidic environments, usually only in nonwoven veil format – Select Products: • C64 C-Veil (Owens Corning)

8 September 21-24, 2020 / www.theCAMX.org Constituent Components: Fibers Typical Composite Reinforcing Fibers: Glass • AR-Glass (Alkali zirconium): – Highly alkali resistant fiber used for cement and concrete reinforcement – Select Products: • Cem-FIL® (Owens Corning) • S-Glass (Magnesium aluminosilicate): – Higher strength and modulus fiber than R-glass, also very good high temperature and corrosion resistance – Select Products: • S-1 Glass™, S-2 Glass®, & S-3 Glass™ (AGY) • Quartz (99.99% Pure silica): – Highly expensive fiber with very low coefficient of thermal expansion (CTE) and superior electromagnetic properties (for radio frequency transparency – radomes) – Select Products: • Astroquartz® (JPS) , Quartzel® (Saint-Gobain)

9 September 21-24, 2020 / www.theCAMX.org Constituent Components: Fibers

10 September 21-24, 2020 / www.theCAMX.org Constituent Components: Fibers

Typical Composite Reinforcing Fibers: PAN Based Carbon – The most widely available and utilized type is produced from a specially formulated polyacrylonitrile (PAN) precursor fiber • The PAN carbon fiber is generally classed in 3 different groups according to modulus – Standard Modulus (SM) / High Strength (HS) • Most widely used in industrial applications • Most cost effective – Intermediate Modulus (IM) • Best blend of strength/modulus, • Typically used in aerospace/defense applications – High Modulus (HM) • Highest stiffness, lowest CTE, highest conductivity, & lower strength than SM & IM versions, highest cost, • Typically used in space craft/satellites/sporting equipment

11 September 21-24, 2020 / www.theCAMX.org Constituent Components: Fibers

Tensile Modulus* Tensile Strength* Classification Msi GPa ksi MPa Standard Modulus/High Strength 33-37 230-255 500-725 3,450-5,000 Intermediate Modulus 40-45 275-310 600-925 4,130-6,370 High Modulus 45-87 310-600 275-700 1,890-4,900

*Note: Carbon fiber modulus, strength, and elongation to beak are ideal values produced via impregnated strand testing and may not translate directly to the corresponding fabric/composite properties due to fiber misalignment, resin compatibility, and damage during processing

12 September 21-24, 2020 / www.theCAMX.org Constituent Components: Fibers Typical Composite Reinforcing Fibers: PAN Based Carbon Standard Modulus (SM) / High Strength (HS): • Small (1K) to Large (60K) tow sizes available, aerospace to industrial grade • Select Products: – Toray: T300, T700S & Zoltek (Subsidiary): Panex® 35; Toho-Tenax: HTA40; UTS50, Mitsubishi Chemical/Grafil: 34-700, TRH50; SGL: C T24, C T50; Hexcel: AS4, AS7; Solvay (Cytec): T-300 – Others: AKSA, Bluestar, Formosa, Hyosung, Dalian Xingke, GanSu HaoShi Intermediate Modulus (IM): • Smaller range of tow sizes (6K-24K), recent work on large tow industrial versions (ORNL) • Select Products: – Toray: T800H, T1000G; Toho-Tenax: IMS40, IMS65; Mitsubishi Chemical/Grafil: MR40, MR 60H; Hexcel: IM7, IM10; Solvay (Cytec): T-650; Formosa: T-42 High Modulus (HM): • Small range of tow sizes (3K-12K) • Select Products: – Toray: M40J, M60J; Toho-Tenax: UMS40, HMA35; Mitsubishi Chemical/Grafil: HR 40, HS 40; Formosa: TC55

13 September 21-24, 2020 / www.theCAMX.org Constituent Components: Fibers Typical Composite Reinforcing Fibers: Pitch Based Carbon • Precursor material is by-product of fossil fuel processing: – Coal & Petrol Tar (i.e. Pitch) • Isotropic: Typically low modulus, used for thermal management applications • Mesophase Pitch: (made by polymerizing isotropic pitch to a higher molecular weight) – Highly aligned carbon chains along fiber axis provide extremely high modulus, thermal conductivity and are called “Ultra High Modulus” (UHM) carbon or graphite fiber – 1K-16K tow sizes typically available – There has been work on lower cost precursor (ref. CompositesWorld) – Applications: aerospace, civil engineering (concrete strengthening), sports – golf shafts • Select Products: – Mitsubishi Chemical: DIALEAD® K63712, K13C2U – Nippon Graphite Fiber: GRANOC YSH-50A-10S, YS-80A-60S Tensile Modulus* Tensile Strength* Classification Msi GPa ksi MPa Ultra High Modulus 75-136 520-935 375-550 2,600-3,800

14 September 21-24, 2020 / www.theCAMX.org Constituent Components: Fibers

Typical Composite Reinforcing Fibers: Polymer Based • Para-Aramid: – Low density and high strength with high impact and fatigue resistance – Fiber exhibits a “soft” failure mode in that it doesn’t shatter upon impact or flexing – Has UV and moisture absorption issues – For composites, use the “high modulus” versions: K49, K149, & T2200, low modulus for ballistics (K29) – Select Products: • Kevlar® (Dupont) & Twaron® (Teijin)

15 September 21-24, 2020 / www.theCAMX.org Constituent Components: Fibers Typical Composite Reinforcing Fibers: Comparison FIBER PROPERTIES (IMPREGNATED STRAND) Tensile Tensile Fiber Elongation Density Cost Strength Modulus Type ksi Msi % lb/in3 E-Glass 290 to 360 10 to 10.5 3 to 5 0.092 to 0.094 $ E-CR Glass 320 to 375 11.75 3 to 5 0.095 $ H-Glass 350 to 420 13.00 3 to 5 0.094 $$

Glass R-Glass 440 to 493 13.00 5.35 0.092 $$$ S-Glass 495 to 555 13.25 5.50 0.089 $$$$ Basalt (R-Gl.) 392 to 464 12.34 to 13.79 3 to 5 0.096 $$$$ SM Carbon 500-725 34 to 37 1.5 to 2.0 0.065 $$$$$ IM Carbon 600 to 925 40 to 45 1.5 to 2.2 0.065 $$$$$$

Carbon HM Carbon 275 to 700 45 to 87 ~1.0 0.063 to 0.069 $$$$$$$ UHM Carbon 380 to 550 114 to 135 >1.0 0.070 to 0.078 $$$$$$$$

Aramid (K49) 525 16.30 2.4 0.052 $$$$$

Aramid Aramid (K149) 501 26.00 1.9 0.053 $$$$$$

16 September 21-24, 2020 / www.theCAMX.org Constituent Components: Fibers Typical Composite Reinforcing Fibers: Polymer Based • Polypropylene: Innegra™ (Innegra Technologies) – Extremely (< 1.0 g/cc) low density polyolefin fiber with very good dynamic response characteristics – Fairly low mechanical properties, but a cost-effective alternative to para-aramid / UHMWPE / PBO/LCP fibers with better matrix resin bonding properties – Works well as a hybrid with more brittle fiber (i.e. carbon) for increased ductility and impact resistance • Ultra High Molecular Weight Polyethylene - UHMWPE: Spectra® (Honeywell) & Dyneema® (DSM) – Very low-density polyolefin fiber made of extremely long polymer chains of polyethylene – High resistance to chemicals, water & ultraviolet light, 40% stronger than aramid fiber – Capable of withstanding high-load and strain-rates – Need special fiber surface modifications to properly bond to composite matrix resins, can have creep issues • Polybenzoxazole - PBO: Zylon® (Toyobo) – Comparable to slightly higher tensile properties compared to UHMPE fibers, but with higher heat resistance – The fiber is almost twice as strong as aramid fibers, about 10 times stronger than steel – Also needs surface treatments for proper use with composite resins • Liquid Crystal Polymer - LCP: Vectran™ (Kuraray) – Excellent creep and abrasion resistance, minimal moisture absorption, chemical resistance, Low CTE, high dielectric strength, & high impact strength – Same bonding issues as with UHMWPE and PBO fibers. – Outstanding strength at extreme temperatures, resistance to virtually all chemicals, weathering, radiation and burning – Pound for pound, Vectran™ is 5x stronger than steel, 10x stronger than aluminum

17 September 21-24, 2020 / www.theCAMX.org Constituent Components: Fibers Typical Composite Reinforcing Fibers: Other/Special • Ceramic: – For high temperature applications up to 2372°F (1300°C) – Used in ceramic matrix and metal matrix composites – SiC (Silicon Carbide): • High strength properties up to 2192°F (1200°C), wettability for metals, low electrical conductivity, high heat resistance, and corrosion resistance/chemical stability • Select Products: SCS-6 (Specialty Materials, Inc.), Tyranno Fiber® (UBE Industries) Typical SiC / Alumina Fiber Application – Oxide/Alumina: • High chemical stability, high melting point, high modulus, and good strength at high temperature • Select Products: Nextel™312, Nextel™440 (3M) • Boron: – Elemental boron is deposited on a fine tungsten wire substrate and produced in diameters of 4mil up to 11mil. – Known for high compression properties, but low conformability • Select Products: Boron fiber (Specialty Materials, Inc.) SEM Photo of Boron Fiber

18 September 21-24, 2020 / www.theCAMX.org Constituent Components: Fibers Typical Composite Reinforcing Fibers: Other/Special Natural: using these fibers revolve around environmental sustainability • Typical Example Types: ✓ bast fibers such as jute, flax, hemp, ramie, and kenaf; ✓ leaf fibers such as banana, sisal, agave, and pineapple; ✓ seed fibers such as coir, cotton, and kapok; ✓ core fibers such as kenaf, hemp, and jute; ✓ grass and reed fibers such as wheat, corn, rice, and bamboo • Advantages: – Low density, are biodegradable, are derived from renewable resources, have a small carbon footprint, provide good thermal and acoustical insulation, good vibration damping, moderate mechanical properties and high specific properties • Challenges: – Still have matrix-fiber interface issues – hydrophilic nature makes them incompatible with existing hydrophobic resin systems used in the industry – Very low load transfer efficiency – There are few in the composites industry with enough experience to work with them confidently – Mostly derived from plants grown in developing countries such as Bangladesh, India, Sri Lanka, also China • Select Products: Most natural fiber reinforcements are used in nonwoven form – Increasing use in automotive interior panels – Flax: Biotex (Composites Evolution) – Cellulose: BioMid® (GS Consulting)

19 September 21-24, 2020 / www.theCAMX.org Constituent Components: Fibers Typical Composite Reinforcing Fibers: Other/Special Graphene: • A single, 2D layer of carbon atoms, tightly packed in a hexagonal lattice structure • Graphite is made up of millions of layers of Graphene – 1 mm of graphite is ~3 million of layers of Graphene thick – Graphite is mixed with clay to make pencil “lead” • Properties – It is the thinnest, strongest material yet discovered and the most efficient conductor of both heat and electricity currently available – Size: Single-Wall Carbon Nanotubes (SWCNT) = ~1-2 nm, DNA = 2.5 nm • Perspective: COVID-19 Virus Diameter is 350-400 x The Thickness of Graphene! – Strength: 300 times the tensile strength of steel – Performance: 20 times the thermal conductivity of copper, 5-6 times of diamond – Electrical: Can be a Semiconductor, a Superconductor or a perfect Insulator depending on how it is used – Appearance: Nearly transparent, at one layer, Graphene absorbs ~1.7% of light • How is Graphene made? – Mechanical Exfoliation – Chemical Vapor deposition (CVD) • Where has Graphene been used – Clothing, golf balls, ink, tires, concrete, asphalt, fire retardant paint, coatings – Automotive – engine compartment, sound-attenuating foam for 2019 F-150 and F-250 Pickup, Lincoln Navigator and Mustang

20 September 21-24, 2020 / www.theCAMX.org 2. Polymers (Matrix)

21 Constituent Components: Matrix Typical Composite Thermoset Matrices – Unsaturated Polyester (UPR) • Accounts for approximately 75% of matrix resins used for composites molding • Comprises isophthalic, orthophthalic, DCPD, and terephthalic based systems • Polymer comes mixed with a reactive diluent (typically styrene) – Vinyl Ester • Formulated by reacting an epoxy (Bisphenol-A or Novolac) backbone with methacrylic acid, forming a polymer that has characteristics of both UPR and epoxy • Superior corrosion resistance, low water permeability, and good fatigue resistance – Epoxy • Most widely used matrix resin in high performance applications • Superior mechanical properties, resistance to corrosive environments, superior electrical properties, and elevated temperature performance – Urethane/Urea • Highly reactive 2-part matrix resin producing high flexibility and toughness • Moisture sensitive cure and components can be a health hazard (isocyanates) – Phenolic • Low structural properties, but very good fire resistance • Condensation reaction (produces water) which can lead to porosity in the laminate when manufactured

22 September 21-24, 2020 / www.theCAMX.org Constituent Components: Matrix Typical Composite Thermoset Matrices • High Temperature – BMI & Polyimide: • High temperature resistance (service temp up to 260°C), chemical and radiation stability – Cyanate Ester: • High Tg (300°C), low outgassing, and low dielectric constant and loss – Benzoxazine: • Excellent stiffness and high-temperature performance, low resin shrinkage for improved dimensional stability

23 September 21-24, 2020 / www.theCAMX.org Constituent Components: Matrix

Typical Composite Thermoset Matrices • Hybrids – Urethane Ester: • Excellent toughness, adhesion, water resistance, and speed of cure • Select Products: – Xycon® 047-8023 (Polynt) – Urethane Acrylate: • Similar in properties to the urethane ester, and has a Tg around 280°C • Select Products: – Crestapol® 1250LV (Scott Bader) – Core Shell Rubber-Modified Vinyl Ester: • Nano-particle enhance technology that significantly improves the impact and energy absorbing properties of a polymer matrix • Select Products: – 781-6010 (Polynt)

24 September 21-24, 2020 / www.theCAMX.org Constituent Components: Matrix Typical Composite Thermoplastic Matrices • Commodity – Polypropylene (PP): Low cost polymer, low melting point, excellent moisture resistance – Polyester (PET) : Low cost polymer, high chemical resistance, low moisture regain – Polyamide 6 (Nylon 6): Good price/performance ratio, good chemical resistance, high strength – Polyamide 12 (Nylon 12): Lower moisture regain and lower melting point than Nylon 6, good resistance to shock and chemicals • Engineered/High Temperature – Polyetherimide - PEI: High thermal stability, low flame and smoke, similar to PEEK but lower temperature resistance and impact strength – Polyphenylene sulfide - PPS: Chemical resistance, flame retardancy, dimensional stability, low moisture absorption – Polyetheretherketone - PEEK: Thermal stability, abrasion resistance, superior chemical resistance, flame retardancy, high stiffness and low density – Polyaryletherketone - PAEK: Highly fire-resistant, has good chemical resistance, and can be used for high temperature applications

25 September 21-24, 2020 / www.theCAMX.org 3. Manufacturing / Process and Product Characteristics

26 The World of Manufacturing

• Teamwork is important – Design Engineer – Stress Engineer – Manufacturing Engineer – Materials Engineer – Tool Designer/Tool Engineer – Technicians – Inspection/Quality

27 September 21-24, 2020 / www.theCAMX.org Process Selection Considerations

• Surface complexity expense of the tool • Performance complexity of laminate fiber architecture • Surface appearance secondary operations needed • Size of the part hand vs machine • Production rate hand vs machine • Total production volume hand vs machine • Economic target (limit) hand vs machine – Part cost • materials, tooling, equipment, labor)

28 September 21-24, 2020 / www.theCAMX.org Categories of Manufacturing Processes

• Open Molding – One side is a tool surface, opposite side there is no tool surface • Closed Molding – There is a tool surface on both sides • Types of Manufacturing Processes – Common or Basic – Advanced

29 September 21-24, 2020 / www.theCAMX.org Typical Open Molding Processes

• Casting (Cast Polymer Molding) • Centrifugal Casting • Filament Winding – Wet winding – Prepreg winding • Hand Lay-up – Wet Lay-up vacuum bagging – Prepreg Lay-up vacuum bagging (autoclave molding) • Spray-up

30 September 21-24, 2020 / www.theCAMX.org Typical Closed Molding Processes

• Compression Molding – Wet Compression Molding (WCM) (also known as liquid molding or cold molding) – Sheet Molding Compound (SMC) – Bulk Molding Compound (BMC) – Dynamic Fluid Compression Molding • Continuous Lamination • Cured In-Place Pipe (CIPP) • Extrusion

31 September 21-24, 2020 / www.theCAMX.org Typical Closed Molding Processes

• Injection Molding – Bulk Molding Compound (BMC) – Hybrid injection-molding/thermoforming • Pultrusion • Reinforced Reaction Injection Molding (RRIM) – RIM Overmolding • Resin Transfer Molding (RTM) – Light RTM • Vacuum Assisted RTM (VA-RTM) – Resin Infusion – Vacuum Infusion Processing (VIP) – High Pressure – RTM (HP-RTM)

32 September 21-24, 2020 / www.theCAMX.org Hand Lay-Up

Just about anything, large or small

33 September 21-24, 2020 / www.theCAMX.org Wet Lay-up Vacuum Bagging

Vacuum Vacuum

Just about anything, large or small

34 34 September 21-24, 2020 / www.theCAMX.org Spray-Up Process

Boats, tubs, showers, sinks, panels

35 September 21-24, 2020 / www.theCAMX.org PROCESS Characteristics Hand Lay-up / Spray-up

• MAX SIZE: Unlimited • PART GEOMETRY: Simple - Complex • PRODUCTION VOLUME: Low - Med • CYCLE TIME: Slow • SURFACE FINISH: Good - Excellent • TOOLING COST: Low • EQUIPMENT COST: Low

36 September 21-24, 2020 / www.theCAMX.org PRODUCT Characteristics Hand Lay-up / Spray-up • Small to large parts achievable • Cost effective solution • Prototype to production parts • Any shape, size, surface texture possible • Laminates, sandwich panel construction • Complicated lay-up of lamina possible • Inexpensive to expensive materials could be used • Can be automated with spray-up • Highly operator dependent – potential for wide variations in quality

37 September 21-24, 2020 / www.theCAMX.org Filament Winding

Resin

Utility poles, columns, pipe, missile casing, tanks, stack liners

38 September 21-24, 2020 / www.theCAMX.org PROCESS Characteristics Filament Winding

• MAX SIZE: <65’ Diameter • PART GEOMETRY: Simple • PRODUCTION VOLUME: Low - Med • CYCLE TIME: Low - Med • SURFACE FINISH: Inside - Good/Excellent, Outside – Fair** • TOOLING COST: Med - High • EQUIPMENT COST: Med - High

**depends on material (wet vs prepreg)

39 September 21-24, 2020 / www.theCAMX.org PRODUCT Characteristics Filament Winding • Body of revolution • Controlled strength • Directional strength • Computer controlled fiber placement • Low labor • Products can be made in the factory or out in the field • Emission controls required (except pre-preg)

40 September 21-24, 2020 / www.theCAMX.org Centrifugal Casting

• Centrifugal Casting is used for making cylindrical, hollow shapes such as tanks, pipes and poles. • Chopped strand mat is placed into a hollow, cylindrical mold, or continuous roving is chopped and directed onto the inside walls of the mold.

• Resin is applied to the inside of Source: CompositesLab.org the rotating mold

41 September 21-24, 2020 / www.theCAMX.org PROCESS Characteristics Centrifugal Casting

• MAX SIZE: <15’ Diameter • PART GEOMETRY: Simple • PRODUCTION VOLUME: Med • CYCLE TIME: Low - Med • SURFACE FINISH: Good • TOOLING COST: Med • EQUIPMENT COST: Med

42 September 21-24, 2020 / www.theCAMX.org PRODUCT Characteristics Centrifugal Casting

• Body of revolution • Outside surface is finished (tool side) • Limited part size (mold and machine)

43 September 21-24, 2020 / www.theCAMX.org Compression Molding

SMC

44 September 21-24, 2020 / www.theCAMX.org PROCESS Characteristics Compression Molding

• MAX SIZE: Limited by Press Machine • PART GEOMETRY: Simple - Complex • PRODUCTION VOLUME: High • CYCLE TIME: Fast • SURFACE FINISH: Good - Excellent • TOOLING COST: High • EQUIPMENT COST: High

45 September 21-24, 2020 / www.theCAMX.org PRODUCT Characteristics Compression Molding • High Volume Output • Inside & Outside has finished “tool” surface • Low per part cost in high volume manufacturing • Low finishing cost • Close part tolerances are achievable • Molded-in texture and color possible • Low scrap materials – supports sustainability

46 September 21-24, 2020 / www.theCAMX.org Compression Molding

• Alternative Molding Materials: – Sheet Molding Compound (SMC) – Bulk Molding Compound (BMC) – Wet layup and preform system – Reinforced thermoplastic sheet goods

47 September 21-24, 2020 / www.theCAMX.org SMC

• PROCESS Characteristics – High volume productions – High equipment and mold costs

– Low labor costs Source: IDI Composites International – Engineered material systems SMC - mixture of polymer resin, inert – Process reproducible fillers, fiber reinforcement, catalysts, pigments and stabilizers, release agents, • Advantages and thickeners and possesses strong – Directly formed to net shape dielectric properties – Integral ribs and bosses – Variable wall thickness possible

48 September 21-24, 2020 / www.theCAMX.org BMC

BMC - Is a thermoset resin blend of various inert fillers, fiber reinforcement, • PROCESS Characteristics catalysts, stabilizers, and pigments that form a viscous, 'puttylike' injection – High equipment and mold cost molding compound. It is often highly filled – Low labor and reinforced with short fibers. – High material efficiency – Highly reproducible • Advantages – Can mold highly complex shapes – Can be used in both compression and injection molding – Low cost alternative

49 September 21-24, 2020 / www.theCAMX.org Pultrusion

Heated Die Cured Profile Resin

Bridge decks, rebar, structural profiles, sheet piling, dowel bars, utility poles & cross arms, grating, cable trays, marine pier decks

50 September 21-24, 2020 / www.theCAMX.org PROCESS Characteristics Pultrusion

• MAX SIZE: Length: Unlimited, Width: Tool Dependent • PART GEOMETRY: Simple - Complex • PRODUCTION VOLUME: Med - High • CYCLE TIME: Med • SURFACE FINISH: Good • TOOLING COST: Med - High • EQUIPMENT COST: Med - High

51 September 21-24, 2020 / www.theCAMX.org PRODUCT Characteristics Pultrusion • Constant cross section shapes • Continuous lengths • Highly oriented strengths (longitudinal direction) • Complex profiles possible • Hybrid reinforcements can be used • **shapes can be curved

52 September 21-24, 2020 / www.theCAMX.org Resin Transfer Molding

Resin Injection Unit

Vent Vent

53 September 21-24, 2020 / www.theCAMX.org Resin Transfer Molding

• LRTM: “Light Resin Transfer Molding” – Low pressure thermoset resin injection w/ reinforcement loading between matched low cost tooling • RTM: “Resin Transfer Molding” – Higher pressure thermoset resin injection w/ reinforcement loading between matched tooling

54 September 21-24, 2020 / www.theCAMX.org PROCESS Characteristics Resin Transfer Molding

• MAX SIZE: 6’ x 6’ • PART GEOMETRY: Complex • PRODUCTION VOLUME: Med • CYCLE TIME: Med • SURFACE FINISH: Good - Excellent • TOOLING COST: Med • EQUIPMENT COST: Med

55 September 21-24, 2020 / www.theCAMX.org PRODUCT Characteristics Resin Transfer Molding • Two controlled tool surfaces • Molded in finishes • Molded in stiffeners and connection points • Large part capable, depends on tool size

56 September 21-24, 2020 / www.theCAMX.org Vacuum Infusion Processing VIP ➢ VARTM ➢ Resin Infusion ➢ SCRIMP™ Resin Vacuum Vacuum

Boats, marine piling, bridge decks, architectural products,

57 September 21-24, 2020 / www.theCAMX.org PROCESS Characteristics VIP (VARTM)

• MAX SIZE: Unlimited • PART GEOMETRY: Simple - Complex • PRODUCTION VOLUME: Low - Med • CYCLE TIME: Slow-Fast (size dependent) • SURFACE FINISH: Good • TOOLING COST: Low • EQUIPMENT COST: Low

58 September 21-24, 2020 / www.theCAMX.org PRODUCT Characteristics VIP (VARTM) • No voids • High fiber volume (65%) • High strength applications • Large part size – Flat – Curve or rounded – Long (limited by shipping) • Fabrication possible in the field, although controlled factory conditions are preferred

59 September 21-24, 2020 / www.theCAMX.org Advanced Manufacturing Processes

• Autoclave Molding – Prepreg • Co-Curing • Automated Tape Placement (ATP) • Automated Fiber Placement (AFP) • Out of Autoclave Processing – Vacuum Bag Molding – Reusable Bag Molding (RSBM) • Additive Manufacturing (AM)

60 September 21-24, 2020 / www.theCAMX.org Autoclave Molding Pre-Preg Vacuum Bagging

Vacuum Vacuum

61 61 September 21-24, 2020 / www.theCAMX.org Automated Fiber Placement

Source: Electroimpact.com

62 September 21-24, 2020 / www.theCAMX.org Automated Tape Placement

Source: Sciencedirect.com

Source: CompositesWorld.com

63 September 21-24, 2020 / www.theCAMX.org Additive Manufacturing

• Types of Additive Manufacturing Processes – 3-D Printing • Reactive Additive Manufacturing (RAM) new – Digital Light Processing (DLP) – Fused Deposition Modeling (FDM) – Fused Filament Fabrication (FFF) – Selective Laser Sintering (SLS) – Stereolithography (SLA) • BAAM – Big Area Additive Manufacturing

64 September 21-24, 2020 / www.theCAMX.org PROCESS Characteristics Advanced Manufacturing Processes

• MAX SIZE: Small - Large • PART GEOMETRY: Simple - Complex • PRODUCTION VOLUME: Low - Med • CYCLE TIME: Slow-Med (size dependent) • SURFACE FINISH: Good • TOOLING COST: High • EQUIPMENT COST: High

65 September 21-24, 2020 / www.theCAMX.org PRODUCT Characteristics Advanced Manufacturing Processes • Prototype to full production • Long time to qualify materials • Can expect no voids in laminate – process dependent • High fiber volume (+65%) • High Strength Applications • Large part size – Flat – Curved or rounded – Long (limited by shipping) – Complex contour

66 September 21-24, 2020 / www.theCAMX.org 4. Designing with Composites

67 Thinking Composites

• Composites are simply another material system. • They are not the only solution for all product applications. • Each individual material has a unique set of attributes that determine whether that material is suitable. • A composite design should not imitate both form and function of an existing design in another material if composites are to offer value.

68 68 September 21-24, 2020 / www.theCAMX.org Composites Features

❖ High Strength ❖ Part consolidation ❖ Corrosion resistance ❖ Design flexibility ❖ Light weight ❖ Unique shapes ❖ Electrical properties ❖ Damage tolerance ❖ Thermal properties ❖ Radar transparency ❖ Non-magnetic ❖ Tailored surface ❖ Dimensional stability ❖ Long-term durability ❖ FDA compliant

69 September 21-24, 2020 / www.theCAMX.org Part Design with Composites: Short Fiber Composites • Why are short fiber composites needed? – Low cost/high volume production • Both for thermoplastic (milled fiber injection molding) & thermoset (SMC) – Ease of fabricating complex part geometries • Continuous fibers can be difficult to conform and stretch and can become distorted and damaged – Isotropic behavior • Randomly oriented short fiber composites give isotropic behavior response, which makes them easier to analyze

70 September 21-24, 2020 / www.theCAMX.org Part Design with Composites: Short Fiber Composite Material Forms

• Milled Fiber: – 3 to 60mil long fibers – Reinforces body fillers, casting material and injection molded thermoplastics to increase strength/stiffness and dimensional stability by reducing shrinkage – Increase electrical/thermal properties (milled carbon fiber) • LFRT: – “Long Fiber Reinforced Thermoplastic” – with fibers up to 0.5in in length – Mid-range material with properties between milled fiber and chopped fiber thermoplastic composites • Longer fibers allow for higher fiber content composites, driving up mechanical performance • Chopped Fiber: – Composites typically having 2-4in long fibers – Majority of consumer good “fiberglass” (bathtubs, body panels, etc.) • Most LRTM and RTM process applications w/permeable core material

71 September 21-24, 2020 / www.theCAMX.org Part Design with Composites: Short Fiber Composites

72 September 21-24, 2020 / www.theCAMX.org Part Design with Composites: Continuous Fiber Composites Material Forms • Woven fabrics 4-Harness Satin Plain Weave Weave (Crowfoot)

Basket Weave

73 September 21-24, 2020 / www.theCAMX.org Part Design with Composites: Continuous Fiber Composites Material Forms • Woven fabrics

2x2 Twill Weave 8-Harness Satin Leno Weave Weave

74 September 21-24, 2020 / www.theCAMX.org Part Design with Composites: Continuous Fiber Composites Material Forms

• Braids – Similar to wovens, but can be used to make cylindrical and other cross sectional shape preforms – Can be slit to create broadgood fabrics

0/60/-60 Braided Broadgood Braided Beam 75 September 21-24, 2020 / www.theCAMX.org Part Design with Composites: Continuous Fiber Composites Material Forms

• NCF – Non-Crimp Fabrics – Up to 30% higher in-plane strength compared to equivalent areal weight woven reinforcements • No fiber crimp = No stress concentrations, higher fiber property translation • Lower amount of resin required for complete saturation • Greater stability, less skewing during processing

76 September 21-24, 2020 / www.theCAMX.org Part Design with Composites: Continuous Fiber Composites Material Forms

• NCF – Non-Crimp Fabrics – Typically available constructions – Up to 4 plies/layers per one-pass fabric – Bias angle vary from 300 to 900 – ±450, ±600, & 900 are most common – Standard constructions • Unidirectional (00 & 900), • Biaxial (00/900 & +450/-450), • Triaxial (00/+450/-450 & +450/900/-450), & • Quadriaxial (00/+450/900/-450)

77 September 21-24, 2020 / www.theCAMX.org Part Design with Composites: Continuous Fiber Composites Material Forms • Other Forms – 3D Wovens • Non-Crimp Woven with Z-axis fiber • 3D preforms – Prepreg • Unidirectional – Narrow tapes to wide widths Non-Crimp Fabric w/Z-Axis Fiber • Fabric – Wovens, braids, NCF Carbon Fiber Uni Prepreg Tape

3D Woven Preform 78 September 21-24, 2020 / www.theCAMX.org FRP Composites Thermoset Composites • Typical Thermoset Composites – E-Glass/UPR: • Most common for industrial composites – ECR-Glass/VE: • Used for highly corrosive applications (rebar, scrubbers, jet bubble reactors, etc.) – SM Carbon/Epoxy: • The standard for high performance composites in aerospace, sporting goods, and COPV’s – SM Carbon/VE: • Gaining use in marine and industrial composites. Needs to be evaluated per application

79 September 21-24, 2020 / www.theCAMX.org FRP Composites Thermoset Composites • Typical Thermoset Composites

COMPOSITE PROPERTIES (UNIDIRECTIONAL) Vf = 55% COMPOSITE PROPERTIES (BIAXIAL 60%/40%) Vf = 55% Tensile Tensile Tensile Tensile Composite Elongation Density Elongation Density Strength Modulus Composite Strength Modulus Type 3 Type ksi Msi % lb/ft ksi Msi % lb/ft3

E-Glass/VE 185 5.87 3.15 121 E-Glass/VE 69 4.18 1.65 121 E-CR Glass/VE 197 6.67 2.95 123 E-CR Glass/VE 76 4.63 1.64 122

H-Glass/VE 218 7.35 2.97 123 H-Glass/VE 83 5.04 1.65 122 Glass R-Glass/VE 264 7.35 3.59 120 Glass R-Glass/VE 83 5.07 1.64 120

S-Glass/VE 297 7.49 3.97 117 S-Glass/VE 86 5.21 1.65 118 Basalt/VE 242 7.39 3.27 124 Basalt/VE 83 5.04 1.65 123

SM Carbon/VE 340 18.90 1.80 95 SM Carbon/VE 219 13.37 1.64 103 Carbon IM Carbon/VE 423 23.30 1.82 95 Carbon IM Carbon/VE 268 16.36 1.64 103

K49/VE 295 9.17 3.22 82 K49/VE 117 7.13 1.64 93 Aramid Aramid K149/VE 280 14.50 1.93 83 K149/VE 180 10.98 1.64 93

80 September 21-24, 2020 / www.theCAMX.org Polymer Matrix Composites (PMC): Thermoplastic Composites

• Typical Thermoplastic Composites – E-Glass/PP: • Commodity grade composite for industrial uses • Commingled continuous fiber & LFRT – E-Glass/Nylon: Carbon / PEEK Aircraft Door Fitting • Higher performance and cost over E-glass/PP

– SM Carbon/PPS (Polyphenylene sulfide): Jushi Compofil™ E-Glass/PP Commingled Fiber • High temperature & mechanical performance Woven Fabric – SM Carbon/PEEK: • Similar use to SM carbon/PPS, can be comparatively difficult to process

81 September 21-24, 2020 / www.theCAMX.org Property Comparison of FRP with Legacy Materials: Advantages

• High Specific Strength & Stiffness • Inherently Corrosion Resistant • High Durability • Flexibility: Design & Production

82 September 21-24, 2020 / www.theCAMX.org Property Comparison of FRP with Legacy Materials: Disadvantages

• Lower Direct Stiffness – Steel: 30Msi, – Aluminum: 20Msi • Flammability / Temperature • Moisture • Cost • Availability • Acceptance – Learning Curve

83 September 21-24, 2020 / www.theCAMX.org 5. Recycling Composites

84 Recycling Composites • Can Composites be recycled – Yes! – Composites are strong, durable, and non-homogenous which make them inherently difficult to recycle • Opportunities to recycle: – In-process manufacturing scrap – End-of-Life service scrap • Thermoset Composite materials can be recycled or recovered through many processes – Mechanical grinding, – Thermal (pyrolysis, fluidized bed), – Thermo-chemical (solvolysis), – Electro-mechanical (high voltage pulse fragmentation) – Or combinations of these – There are advantages and disadvantages of each • Thermoplastic Composite materials can be shredded and recycled by melting, but the supply chain is limited

85 September 21-24, 2020 / www.theCAMX.org Recycling Composites • Business Proposition – Glass fiber composites is all about volume – Carbon fiber composites is all about value – Growing supply chain of companies that recycle composites – Markets exploring composites recycling include wind energy (blades), aerospace (manufacturing scrap and plane components), automotive (car components), marine (boats) • Cement co-processing, also known as the cement kiln route, is a main technology for recycling composite scrap • Different global regions are more advanced in technology and applying recycled materials than others, but there is general global industry collaboration • What is needed: – Establishment of a recycling supply chain to collect, sort, process and deliver composites scrap support the cement kiln, grinding, pyrolysis, and other routes. – Market pull for recycled composite products – Standardization of recycling composites process, selection, and use – End-user qualification of recycled composite parts – The Composites Industry needs to think and design for sustainability!

86 September 21-24, 2020 / www.theCAMX.org Acknowledgements

• Special thanks to the following people who contributed information to this presentation:

• Trevor Gundberg, P.E., Vectorply Corporation • Andrew Pokelwaldt, CCT-I, ACMA • Steve Rogers, EmergenTek, LLC • Dan Coughlin, ACMA

87 September 21-24, 2020 / www.theCAMX.org Thank you!

John P. Busel, F.ACI, HoF.ACMA VP, Composites Growth Initiative American Composites Manufacturers Association [email protected] (914) 961-8007

88 September 21-24, 2020 / www.theCAMX.org