Railway and Automotive Parts Made of Composites

REQUIREMENTS MATERIALS PROCESSES AND PROPERTIES

Agenda

1. SAERTEX – Brief Introduction

2. Automotive Parts: Requirements in HPRTM and NCF Solutions

3. SAERTEX LEO: Composite Parts in Infusion with Good Structural and FST Properties

SAERTEX - business segments

Reinforcement materials in glass, carbon, aramid

Stade Composite part services for aerospace and high end applications

Fire protection materials for composite systems

Pipe rehabilitation in civil engineering

SAERTEX facts & figures

Foundation [year]: 1982

Subsidiaries [n]: 13

Customer service [countries]: 50

Sales 2015 [MIO. €]: 320

Customized solutions [n]: 2.500

Parts manufactured [n] 45.000

Employees [n]: 1200

A worldwide network with production and service

And technical service in more than 50 countries worldwide Australia, Austria, Belgium, Bosnia, Brazil, China, Croatia, Czech Republic, Denmark, Estonia, England, Finland, France, Germany, Greece, Hungary, India, Israel, Italy, Korea, Lithuania, Latvia, Macedonia, Montenegro, Netherlands, Norway, Northern Ireland, Poland, Portugal, Romania, Russia, Scotland, Serbia, Slovakia, Slovenia, South Africa, Spain, Sweden, Switzerland, Taiwan, Turkey, Ukraine, USA, VAE, Wales

Our applications: experience in many different industries

Wind energy Aerospace Transportation Automotive

Marine Sport Offshore Many more

• Civil engineering • Coatings • Industrial applications

Requirements coming from the part

Structural performance

Surface quality

• Fabric type

(woven/NCF/...)

• Fabric construction

(+/-45, 0/90, UD)

• Fabric quality (gaps)

• Fibre orientation

• Fibre type

• Fabric quality

Requirements coming from the HPRTM Process

Permeability

• Fabric type (woven/NCF/...)

• Fabric construction (+/-45, 0/90, UD)

• Fibre type

• Stitching parameter

Stability

• Stitching parameter

• Binder type (reactive/thermoplastic)

Requirements coming from the Preforming Process

Drapability and handling

• Fabric construction

• Fibre orientation (fibre orientation

after preforming can be different from

before)

• Stitching parameter

• Fibre type

Requirements coming from the Cutting Process

Fibre fuzz (at edges)

• Fabric construction (especially UDs

are critical)

• Powder binder application (level of

impregnation)

Low cutting waste • Optimal fabric width

Requirements coming from the Fabric Production

Efficient production

• Heavy tows also for low areal weight

• Suitable width (to use machine

capacity)

SAERTEX Solution: Cooperate with customer for engineering, procurement & production

Engineering Use our know-how: • Consulting • Prototyping • Testing: GL certified

laboratory

Cutting & Kitting Ready-made materials: • Individual cutting • Efficient nesting • Commissioning in line with

your production process

Turnkey solutions Everything from a single source: • SAERTEX Engineering &

Manufacturing of parts • One contact, one part

number, one solution

Part production Manufacturing according to your drawings: • NCF & Prepreg processing:

Infusion, RTM • Autoclave 3x15m

Getting the Structural Performace

Advantages of NCF: The fibres, weights and orientation of the

layers are freely definable Stretched fibres for optimal load-bearing

capacity Cost savings through fewer layers

Getting the Right Surface Quality (1/2)

Matrix

Fibres/

Fabric Process

Shrinking during Cross-Linking (Curing = Hardening)

Relatively High Thermal Expansion Coefficient

No Chemical Shrinkage

Relatively Low Thermal Expansion Coefficient

Closed Fabric Surface Required

Overlaps Critical

Glass Veil

Cure Temperature Thermal Shrinkage

Fibre Content (Possibly Lower on Surface)

Resin Injection During Gel Phase

Reduce Chemical Shrinkage

Critical Areas

Getting the Right Surface Quality (2/2)

Bett

er

Su

rface Q

uali

ty

Carbon look roof BMW M3 CSL -

A lot of sanding....

Painted Roof

Lamborghini Aventador Roadster

(Directly out of the Mould)

UD

±45°

0/90°

Getting the Permeability Right

Source: University of Leoben, Harald Grössing

Source: University of Leoben, Harald Grössing

Getting the Drapability (1/2)

Getting the Drapability (2/2)

• Fabric optimisation for drapability

• Automated fabric placement on membrane

• Automated preforming

Getting the Right Mechanical/Cost Performance of Carbon NCF

SAERtow™ NCF Low Areal Weight with 12K – 24K Fibre

Standard Areal Weight with 50K Fibre

Conventional NCF Standard Areal Weight with 12K - 24K Fibre

High Areal Weight with 50K Fibre

12K Carbon fibre:

200gsm per layer

12K Carbon fibre:

70 gsm per layer

50K Carbon fibre

400 gsm per layer

50K Carbon fibre

150gsm per layer

Aim:

Design / Cost Benefit

using low areal weight NCF

Results:

Increased design flexibility

Lower ply drop thickness

Improved properties

Lower cost material

Summary

• Producing parts in HPRTM is a combination of:

• All have their own requirements on the fabric:

• Structural performace

• Surface Quality

• FST requirements

• Drapability

• Permeability

• Costs

• Fabric solutions are available

• The best solution can only be developed in close collaboration with the complete team of

stakeholders

Matrix

Fibres/

Fabric Process

Our applications: experience in many different industries

Wind energy Aerospace Transportation Automotive

Marine Sport Offshore Many more

• Civil engineering • Coatings • Industrial applications

REINFORCING YOUR IDEAS

SAERTEX LEO®

SAERTEX LEO®: CHARACTERISTICS

1. FRP system for highest fire protection standards • Marine / Rail / Construction

2. Excellent mechanical properties • Lightweight: 40 % saving with maximum resistance • Much better rigidity as well as tensile and bending properties compared to hand laminates (HLU)

3. Represents no health hazards • No toxic substances released in the event of fire

4. FIRST-CLASS COST-EFFECTIVENESS • Maximum cost-effectiveness through the lowest possible material usage

5. Quality • Standardized practices ensure highly, reproducible component quality

6. Complete System • Modular assembly system

REINFORCING YOUR IDEAS

23

SAERTEX LEO®: HIGH PERFORMANCE materials

24

LEO Fabrics (glass / carbon / aramid / hybrid) • Incl. fire protection properties • No loss of mechanical properties • High permeability • Free of halogens

LEO Infusions Resin • Suitable for infusion processes • Excellent mechanical properties • Adjustable gel time • RT curing • Resistant to chemicals

LEO Protection Layer (Topcoat/ Gelcoat) • Top fire protection properties • Low smoke generation • Low toxicity (halogen free) • Can be applied by brush or spray • RT curing

Core material (optional) • SAERfoam (3D glass

bridges) • LEOcore • Balsa / PVC / PET / …

25 10.06.2016

SAeRTEX LEO®: PRINCIPLE

(20 min at 50 kW) app 780 °C on sample surface - Foam grid down -

Unexposed Gelcoat Layer (tickness app. 1000µm)

Structural Laminate, almost undisturbed

26

10.06.2016

SAeRTEX LEO®: Comparison of materials

„3-point-bending"

Parameter Reference

(Hand Laminate)

LEO -Variations (Infusion)

Aluminium LEO UD -stiff-

LEO UD -light-

E-Modulus 0° [GPa] 8,3 42,5 42,5 70

Material Thickness [mm] 11,84 11,9 6,72 11,5

Weight [g] 3.036 3.259 1.833 4,65

Bending [mm] 96,78 18,43 103,38 12,5

Result Reference approx. 7 % heavier approx. 40% lighter approx. 50 % heavier

5 x stiffer Similar stiffness 7 x stiffer

SAERTEX LEO®

12 mm

1 m

HLU

12 mm

1 m

SAeRTEX LEO®: Comparison of materials

27

10.06.2016

„Bending Beam"

Parameter Reference LEO -Variations (Infusion)

(Hand Laminate) LEO UD -stiff-

LEO UD -light-

LEO Multiax -stiff-

Lay-up 5 x mat

(450 g/m²) 5 x UD

(970 g/m²) 4 x UD

(970 g/m²) 4 x Quadrax (1200 g/m²)

Fibre Volume Fraction 19 % 50 %

Resin Density [kg/dm³] 1,5 1,04

E-Modulus 0° [Gpa] 8,3 42,5 42,5 16,5

Material Thickness [mm] 3,64 3,73 2,24 3,69

Weight [g] 156 170 102 168

Bending [mm] 208 37,8 174 100,5

Result Reference approx. 8 % heavier approx. 35 % lighter approx. 8 % heavier

5,5x stiffer approx. 1,2 x stiffer 2 x stiffer

SAeRTEX LEO®: FIRE PROTECTION performance

28

10.06.2016

MARINE RAIL CONSTRUCTION OTHERS

IMO RES. A 653 (16) FTP CODE MSC 61 (67)

Annex 1 Part 2 Annex 1 Part 5

DIN EN 45545-2:2016 HL 3 for R1 HL 3 for R7

HL 3 for R17

EN ISO 13501-1:2007 B - s2,d0

STANAG 4602 AFAP 4/5 - F2 AFAP 2 - S2 AFAP 3 - T1

IMO FTP Code; Part 10 (HSC 2000 (ISO 9705)

9 min 46´

DIN 5510 S4/SR2/ST2

DIN 4102-1 B1

DIN 4102-1 B1

NFF 16-101 UNE 23.721:1990

M1 / F1

NFF 16-101 M1 / F1

ASTM E 84 class A / class 1

BS 6853 BS 476-6 - class 0 BS 476-7 - class 1 BS 6853, Annex B

cat1b exterior cat 2 interior

ASTM E 84 class A / class 1

NFPA 13:2007 ASTM E 662 ASTM E 162

ASTM E 1354 BSS 7239

UNE 23.721:1990 M1 / F1

Lay up 2 mm – HL3 40 mm – HL3

Protection Layer LEO R-6500 - 1.000 µm LEO R-6500 - 1.000 µm

Fabric Q-E-821 g/m²; type LEO - 1 layer Q-E-821 g/m²; type LEO - 5 layer

Core thickness 2 mm 40 mm

Fabric Q-E-821 g/m²; type LEO - 1 layer Q-E-821 g/m²; type LEO - 5 layer

Infusion Resin LEO R-65xx series LEO R-65xx series

Fiber volume fraction ≈ 50 % ≈ 50 %

Panel thickness ≈ 4,2 mm 48,42 mm

Panel weight ≈ 5,56 kg/m² 24,6 kg/m²

Results

HL3 for R1

HL3 for R7

HL3 for R17

HL3 for R1

HL3 for R7

HL3 for R17

SAeRTEX LEO®: LEOCORE

29

Sandwich lay-ups

• Cooperation with Gaugler & Lutz oHG

• Classification according to EN 45.545-2 (10-2015)

• Core thicknesses 2 – 40 mm

SAERTEX LEO®: example rAIL interior

30

• Cooperation with our Polish customer Buster Sp.j.

• Objective: to investigate how components can be manufactured using the SAERTEX LEO system

• excellent mechanical properties: 40% weight savings with impressive strength and an oftentimes

improved stiffness, together with tensile strength and bending characteristics that are comparable

with hand lay-up laminates (HLU) and steel

• Weight reduction by 50%,

• Bending strength increased by 40 %

More informationen: https://www.saertex.com/de/einsatzgebiete/referenzen_uebersicht/referenz/saertex_leo_in_schienenfahrzeugen

PROTECTIVE ELEMENT ROOF COVERING EXTERIOR PANELLING

SAERTEX LEO®: Example RAIL exterior

Application: Rail Segment: Tram Designation of part: Front Nose Manufacturer: Lätzsch End customer: Stadler Reinforcement: +/- 45° E-Glass NCF Protection Layer: LEO R 6501 Matrix: LEO R 6500 Technical Parameters of FRP part Dimensions: ≈ 1.500 x 1100 mm² Mfg. Process: Infusion FST Norm: DIN 5510 Fiber Mass Content: ≈ 72 %

SAERTEX LEO®: example RAIL plumbing unit

32

10.06.2016

Application: Rail Segment: Interior Designation of Part: Universal Plumbing Unit Manufacturer: RCS GmbH, GER End customer: London Midland and First TPE Reinforcement: +/- 45° Glass NCF (1200 gsm) + 100 gsm CSM Protection Layer: Protection Layer LEO R 6500 Injection Resin: LEO R 6500 Technical Parameters of FRP part: Mfg. Process: Vacuum Infusion FST Norm: BS 6853 cat 2

THANK YOU FOR YOUR ATTENTION.

HOW CAN WE REINFORCE YOUR IDEAS?

SAERTEX GmbH & Co KG (Bangkok Office)

Dr. Helge Haberkern

h.haberkern@saertex.com

+66 (0)8 7813 8645

Skype: helge.haberkern