pccr csrve spe final power point 2014
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100 East Cott age Avenue | Carpentersville, IL 60110 | www.pccrusa.com
A novel approach to reduce fatigue cycling damage, impact resistance, and crack propagation in composite structures
High Performance Toughened Vinyl Ester Resins
100 East Cott age Avenue | Carpentersville, IL 60110 | www.pccrusa.com
Critical Damage/Recovery Properties of Vinyl Ester Resin with Rubber Modifier
Need to:
• Retain strength in the presence of flaws/damages
• Be able to store and recover large strains in response to temperature
2
100 East Cott age Avenue | Carpentersville, IL 60110 | www.pccrusa.com 3
Typical Graphical Representation of Glass Transition Range using DMA
100 East Cott age Avenue | Carpentersville, IL 60110 | www.pccrusa.com 4
• Standard vinyl ester
• Core shell rubber modified vinyl ester
• Low viscosity epoxy resin used in the wind industry.
Resins Chosen for Study
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• Flexural properties (ASTM D790)
• Tensile properties (ASTM D638)
• Plane-strain fracture toughness (ASTM D5045) single-edge-notch bending (SENB) K1c and G1c
Clear Cast Mechanical Properties
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• Short beam shear (ASTM D2344)
• Drop ball impact
• Fatigue testing
Fiber Reinforced Mechanical Properties
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Flexural Test ASTM D790 on CSRVE at Maximum Deflection
100 East Cott age Avenue | Carpentersville, IL 60110 | www.pccrusa.com 8
Heating above Resin Tg (130 C)- Coupon Original Shape Recovered after 3 minutes
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Damage Recovery to Show Flexural Strength Retention
0
2000
4000
6000
8000
10000
12000
14000
16000
18000
20000
0.00 0.10 0.20 0.30
Stress (psi)
Extension (in)
123[4]
100 East Cott age Avenue | Carpentersville, IL 60110 | www.pccrusa.com 10
Flexural Strength Retention Data
Flexural Peak Stress
Original Anneal 1 Anneal 2 Anneal 3
20,000
16,000
12,000
8,000
4,000
0
(psi)
Flexural Modulus
Original Anneal 1 Anneal 2 Anneal 3
500,000
450,000
400,000
350,000
300,000
250,000
200,000
(psi)
100 East Cott age Avenue | Carpentersville, IL 60110 | www.pccrusa.com 11
Flexural Test – ISO 178-2010(similar to ASTM D790)
• CSRVE – (135 MPa)Flexural no breaks - no permanent deformation
• Epoxy – (125 MPa)Flexural no breaks, light permanent deformation
• Vinyl standard – (145 MPa)Bending - breaking
• Polyester standard – (115 MPa)
Bending - breaking/shattered
100 East Cott age Avenue | Carpentersville, IL 60110 | www.pccrusa.com 12
Typical Tensile Properties of the Various Base Resins
0
1000
2000
3000
4000
5000
6000
7000
8000
9000
10000
11000
12000
13000
0.00 0.02 0.04 0.06 0.08 0.10 0.12 0.14
Stress (psi)
Strain (in/in)
Epoxy 2
CSRVE 2
DCPD
Standard VE
Epoxy 1
CSRVE 1
100 East Cott age Avenue | Carpentersville, IL 60110 | www.pccrusa.com 14
Damage Recovery after Tensile Testing(ASTM D638)
Control Coupon — has not been tested
Coupon was stressed before failure
Coupon annealed above the glass transition andrecovered
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Typical Tensile Properties of the Various Base ResinsPlane-Strain Fracture Toughness(ASTM D5045) (SENB) – G1c
• K1C is standing for critical stress intensity factor
• G1C is standing for critical energy release rate
100 East Cott age Avenue | Carpentersville, IL 60110 | www.pccrusa.com
Plane-Strain Fracture Toughness(ASTM D5045) (SENB) – K1c and G1c
specimen: 60 mm x 12.8 mm x 3.2 mmpre-crack: 6 mm depth by blade-tappinghead speed: 1mm/min.
100 East Cott age Avenue | Carpentersville, IL 60110 | www.pccrusa.com
Elongation Comparison With Fracture Toughness, K1C
100 East Cott age Avenue | Carpentersville, IL 60110 | www.pccrusa.com
Energy per unit area of crack surface or critical strain energy release rate, G1C, at fracture initiation.
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Apparent Interlaminar Shear Strength – Short-Beam Shear ISO 14130: 1997 (similar to ASTM D2334)
• Resistance test wing delamination of laminated carbon UD 300 g/m2 12K, 6-ply thickness 2mm
CSRVE deformation at 120 Mpa – no breaks
Standard VE resin deformation at 90 MPa crack breaking interlaminate
100 East Cott age Avenue | Carpentersville, IL 60110 | www.pccrusa.com 20
Apparent Interlaminar Shear Strength – Short-Beam Shear ISO 14130: 1997 (similar to ASTM D2334)
• Resistance wing delamination of laminated carbon UD 300 g/m2 12K, 6-ply thickness 2mm
DGEBA epoxy resin with 828 hardener dioxide MTHPA strain 110 MPa - no breaks
100 East Cott age Avenue | Carpentersville, IL 60110 | www.pccrusa.com
CSRVE Unique Toughness Properties
1-Lb. Steel BallDropped from 2 Feet on Un-Reinforced Castings
Standard VE CSRVE
21
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CSRVE Recovered
CSRVE Heat Treated and Recovered from DamageCSRVE Heat Treated and Recovered from Damage
22
100 East Cott age Avenue | Carpentersville, IL 60110 | www.pccrusa.com
Drop Ball Impact on 3 Ply’s of E-Glass Mat from 2 FeetDrop Ball Impact on 3 Plys of E-Glass Mat from 2 Feet
Standard VE DCPD
CSRVE 1 CSRVE 2
23
100 East Cott age Avenue | Carpentersville, IL 60110 | www.pccrusa.com
Drop Ball Impact on 3 Ply’s of E-Glass Mat from 2 FeetDrop Ball Impact on 4 Plys of 3K Carbon Weave Fabric From 3 Feet
CSRVE 2 Structural Epoxy
24
100 East Cott age Avenue | Carpentersville, IL 60110 | www.pccrusa.com
Drop Ball Impact on 3 Ply’s of E-Glass Mat from 2 FeetDrop Ball Impact on 4 Plys of 3K Carbon Weave Fabric From All Heights
25
100 East Cott age Avenue | Carpentersville, IL 60110 | www.pccrusa.com
Drop Ball Impact on 4 Ply of 3K Carbon Weave
0
1
2
3
4
5
3 4 5 6
Height (ft)
Cra
ck L
engt
h (in
)
Epoxy
CSRVE
Drop Ball Impact
26
100 East Cott age Avenue | Carpentersville, IL 60110 | www.pccrusa.com 27
Toughness and Resistance to Fatigue of the Control Resin and CSRVE
100 East Cott age Avenue | Carpentersville, IL 60110 | www.pccrusa.com 28
0
20
40
60
80
100
120
140
160
VE CSRVE 1 CSRVE 2 Epoxy 1 Epoxy 2
Te
mp
era
ture
(C
)
HD
T
HD
T
HD
T
HD
T
HD
T
Tg
Tg
Tg
Tg Tg
HDT and DSC Tg Properties
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Straight Coupon was Bent after Heating
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Heat Treated CSRVE Flat Coupon Made into a Coil
100 East Cott age Avenue | Carpentersville, IL 60110 | www.pccrusa.com 32
Recovery of Original Shape after Heat Treatment
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Application Trial – CSRVE Vacuum Infusion of Transportation Deck
100 East Cott age Avenue | Carpentersville, IL 60110 | www.pccrusa.com
Hammer Impact test on high-performance olefin yarn co-mingled with 3K carbon fiber helmet. No puncture!
100 East Cott age Avenue | Carpentersville, IL 60110 | www.pccrusa.com
Light Weight Moldable Parts using CSRVE Resin, Olefin, Carbon, Olefin/ Carbon Hybrid Fabric, and Styrofoam Beads
100 East Cott age Avenue | Carpentersville, IL 60110 | www.pccrusa.com 36
Flexural Summary
• CSRVE rebounds back to original position after testing
• Epoxy would bend but would not recover• VE fractured• CSRVE above Tg will go back to original shape –
the same sample retested retained 80% of the original strength
100 East Cott age Avenue | Carpentersville, IL 60110 | www.pccrusa.com 37
Tensile Summary
• Epoxy and standard VE were sensitive to defects and reduced elongation by half
• CSRVE samples were not sensitive to defects, very little reduction in elongation
100 East Cott age Avenue | Carpentersville, IL 60110 | www.pccrusa.com 38
G1c and Fatigue Summary
• G1c – CSRVE had 10 times the toughness of the
epoxy and VE
• Fatigue test – Control Resin pultruded spring – 125 K cycles
to failure – CSRVE pultruded spring – 1 million cycles –
did not break
100 East Cott age Avenue | Carpentersville, IL 60110 | www.pccrusa.com 39
Short Beam Shear
• CSRVE and epoxy did not shear – they bent
• VE sheared
• CSRVE had 120 MPa shear strength with no break, and epoxy resin had 110 MPa shear strength with no break.
• Overall CSRVE has very good adhesion to carbon fiber
100 East Cott age Avenue | Carpentersville, IL 60110 | www.pccrusa.com 40
Drop Ball Impact Summary
• CSRVE using CS E-glass had the least damage compared to VE laminate
• Carbon fiber laminates made with CSRVE has better crack resistances compared to the epoxy laminates
• Carbon fiber laminate made with epoxy broke in half at 6 foot drop where as the CSRVE laminate did not
100 East Cott age Avenue | Carpentersville, IL 60110 | www.pccrusa.com 41
HDT and DSC Summary
• Coupons after HDT testing show that CSRVE coupon rebounds back to original shape under static load – epoxy and VE did not have enough to rebound
• DSC scans show that all resins evaluated were fully cured
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