cfrp engine acoustic cover : low cost … korea institute of carbon convergence technology 1 / 28...

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Korea Institute of Carbon Convergence Technology 1 / 28

CFRP Engine Acoustic Cover : Low Cost

Manufacturing Process by Microwave Curing

and Carbon Valley Activity in Korea

CFK-Valley Stade Convention

Henry Shin

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CONTENTS

1. Overview : Carbon Fiber Composites & Carbon Valley in Korea

2. Objective

3. Experiments

4. Test & Results

- Specimens & Products , Mechanical Properties

6. Conclusion

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Overview

※ Source: Lucintel, ACMA Composites 2012

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Nameplate capacities, small tow[metric tonnes] Brand 2012 2013 2014 2015 2016

Toray Group, Japan Torayca 17,600 20,800 25,800 26,800 26,800

Toray, Ehime Plant, Japan 7,000 8,000 8,000 9,000 9,000

Toray Carbon Fiber Europe [CFE], France 5,200 5,200 5,200 5,200 5,200

Toray Carbon Fiber America [CFA], USA 5,400 5,400 7,900 7,900 7,900

Toray Advanced Materails Korea [TAK], Republic of Korea - 2,200 4,700 4,700 4,700

Toho Tenax Group, Japan Tenax 13,900 13,900 13,900 13,900 13,900

Toho Tenax Japan, Japan 6,400 6,400 6,400 6,400 6,400

Toho Tenax Europe, Germany 5,100 5,100 5,100 5,100 5,100

Toho Tenax America, USA 2,400 2,400 2,400 2,400 2,400

Mitsubishi Rayon, Japan 7,400 7,400 10,800 10,800 10,800

Japan Pyrofil 5,400 5,400 8,800 8,800 8,800

Grafil, USA Grafil 2,000 2,000 2,000 2,000 2,000

Chinese Manufacturers 7,650 15,650 18,650 18,650 18,650

Hengshen Fiber Material 1,000 3,000 6,000 6,000 6,000

Zhongfu-Shenying [CNBM] 3,000 4,000 4,000 4,000 4,000

Jilin Tangu Carbon Fiber C., Ltd. [Jilin Qifeng Chemical Fiber] - 3,500 3,500 3,500 3,500

Weihai Tuozhan Fiber [150T[3K] et 2000T[12k]] 2,150 2,150 2,150 2,150 2,150

Sinosteel Jiangcheng Carbon Fiber 500 2,000 2,000 2,000 2,000

Dalian Xingke Carbon Fiber 1,000 1,000 1,000 1,000 1,000

Formosa Plastics Group, Taiwan Tairyfill 8,750 8,750 8,750 8,750 8,750

Hexcel, USA HexTow 7,000 8,400 9,800 11,200 11,200

USA 6,350 7,750 7,750 10,550 10,550

Spain 650 650 650 650 650

Cytec, USA Thornel 3,000 2,000 2,000 4,000 4,000

Dow-AKSA, Turkey Aksaca 3,500 3,500 3,500 3,500 3,500

Kemrock, India 2,000 2,500 4,000 4,000 4,000

Hyosung, Republic of Korea Tansome 500 2,500 2,500 6,500 6,500

Taekwang Industrial, Republic of Korea Acepora 500 2,000 2,000 2,000 2,000

Composite Holding Company - - 1,500 1,500 1,500

OJSC NPK Khimpromengineering [ArgonБZUKM], Russia ? ? ? ? ?

Alabuga-Colokno, Republic of Tatarstan - - 1,500 1,500 1,500

Rostec, Russia - 300 300 300 300

Total [small tow] 71,800 87,700 103,500 111,900 111,900

Output [coefficient 0.7] 50,260 61,390 72,450 78,330 78,330

(Source : JEC magazine No.88)

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Nameplate capacities, large tow[metric tonnes] Brand 2012 2013 2014 2015 2016

Toray Group - 17,300 21,300 26,300 26,300

Ex-Zolteck, Hungary Panex - 9,000 9,000 10,000 10,000

Ex-Zoltek, USA Б Mexico Panex - 6,000 8,000 10,000 10,000

Ex-Zolteck, china Panex - 2,000 4,000 6,000 6,000

Japan Torauca - 300 300 300 300

SGL Group Sigrafil - 9,000 9,000 9,000 9,000

Muir of Ord, UK - 4,000 4,000 4,000 4,000

Evanston, USA - 2,000 2,000 2,000 2,000

Moses Lake, USA - 3,000 3,000 3,000 3,000

Bluestar Sigrafil - 3,700 3,700 3,700 3,700

China - 3,200 3,200 3,200 3,200

UK - 500 500 500 500

Kemrock, India Tairyfill - - 1,500 1,500 1,500

Mitsubishi Rayon, Japan HexTow - 2,700 2,700 2,700 2,700

Total [large tow] - 32,700 38,200 43,200 43,200

Output [coefficient 0.9] - 29,430 34,380 38,880 38,880

(Source : JEC magazine No.88)

PAN-based carbon fiber [both small and large tow] 2012 2013 2014 2015 2016

Total nameplate capacities 71,800 120,400 141,700 155,100 155,100

Total output 50,260 90,820 106,830 117,210 117,210

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Project Objectives

Development of Fundamental Technology of Carbon

Materials with world-class competitive Cost

Development of Core technology and

Commercialization

Integration of Carbon Industries and R&BD support

Infrastructure

Project Overview

Hosted of Ministry of Knowledge Economy(MKE)

Period : ‘11 ~ ’15yr (5yr)

Total Budget : 177M USD

(Government 130, Local 11, Private 25)

Project Budget

Sum Central Local Private

R&D 152 78 0 74

Test-Bed 25 19 6 0

Sum 177 97 6 74

[USD] (M USD)

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Large Tow Carbon Fiber

Low Cost Carbon Fiber

Intermediate Product and Application

Carbon Fiber(Coal Tar Pitch )

Carbon Fiber

http://www.newpower.co.kr/eng/index.php

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Convergence Technology Center

Testing Center Light Weight Metal

Carbon Fiber Manufacturing

PAN Fiber Manufacturing

SMC Manufacturing

Light Weight Metal (Mg/Al Parts Development)

Abrasion Resistance Material Technology Development

Manufacturing Support Center

Joint Venture 1, 2

R&D Application Center

Global Carbon Plaza (Global Joint R&D)

Carbon Valley in Jeonju city

Carbon Technical Education Center

Business Incubator

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2003

2006

2013

2003. 3. Establishment of JMC

2004. 3. Awarded First-Class of Promotion of local Industries Competition (MOTIE)

Awarded President of Best practices for Regional Innovation

2006. 11. Held the First International Carbon Festival

2011. 6. Built up Carbon Precursor & Fiber production system (200 mT/yr)

2013. 5. Changed to Korea Institute of Carbon Convergence Technology

2009. 12. Awarded MKE of Best practices for Regional Innovation

2005. 10.

2010. 10. Opened Int’l Carbon R&D center and Signed MOU (USA, Germany, Japan)

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○ Aerospace Structural Testing & System Integrations

○ Assembly & Design : Auto fiber placement & Microwave curing technology

○ Advanced Material (Composites) Machining Centre

○ Nuclear Manufacturing Centre

The AMRC Composite Centre hosts world-class design, manufacturing and machining

facilities for all types of composite materials. (UK Sheffield)

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Overview

AS IS

High Cost of Carbon Fiber

Low Productivity

: Hand lay- up, Autoclave

Recycle : Thermoset

Cost down

Productivity

Cycle time

Recycle

CF cost down

Melt Spinning

OoA Process (RTM, Compression)

& Fast Curing Process

Thermoplastic

Increasing

Productivity

COST

DOWN

Fast, Stable, Uniform Manufacturing

Advanced Process : Microwave curing process

Trend of Carbon Fiber Composites

Preforming

Automation

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Objective

To develop a new low cost manufacturing process

- AFP(Auto Fiber Placement) process

- Microwave curing process

Compared with conventional manufacturing process

- Cycle time, energy consumption, mechanical properties.

To proposal the new technology of CFRP Process

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CF Prepreg Hand lay-up

Conventional

Process

Advanced

Process

Microwave

Autoclave

AFP CF Tape

The manufacturing process

• UD, 600mm

• Epoxy resin 32%

• UD, 6.5mm(1/4") • Epoxy resin 32%

• Automated Dynamics • Heating : hot gas

• LBBC Autoclave • 1m x 2m • up to 400℃, 200bar

• Vötsch(Germany) • 1.8m x 2.m • up to 450℃

1st STEP Raw Materials

2nd STEP Preforming

3rd STEP Curing

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Matrix

MANUFACTURING PROCESS

Remark Curing

Preforming

Autoclave

(AC)

Microwave

(MW)

Oven

(OV)

Sample

Hand lay-up

(HND) HND-AC HND-MW HND-OV

AFP AFP-AC AFP-MW AFP-OV

SPECIMEN ID DESCRITION Remark

HND-AC Hand lay-up + Autoclave curing process

HND-MW Hand lay-up + Microwave curing process

HND-OV Hand lay-up + Oven curing process

AFP-AC AFP + Autoclave curing process

AFP-MW AFP + Microwave curing process

AFP-OV AFP + Oven curing process

3 types curing process + 2 types of preforming

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Advantages

High deposition rates

High accuracy

High complexity components achievable

Reduced need for vacuum de-bulking

Disadvantages

Typically expensive equipment

Expensive material due to secondary slitting

Limited in process inspection technologies available

Auto Fiber Placement(AFP)

Carbon Fiber slit tows (MTM44-1, UMECO)

Hand lay-up

AFP Process

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Microwave Curing

Vacuum bag for microwave cure Microwave System

Microwave Heating (2.45 GHz, magnetron)

Non contacting heating

High speed heating and cooling

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NDI Test

C scan Conditions

: scan machine is a Vertical 1 Channel,

2 Axis Jet Rig Scanner, the machine

works by ultrasonic transmission.

NDI Results

- All specimens have no defects

in the hand lay-up, automatic placement

and all curing process. Tested by Composites Testing Laboratory(Ireland)

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Compressive Test

Test Method : ASTM D6484

(Open hole compressive test)

Test Speed : 2mm/min

Hole diameter : 6.35mm

Test Results

• HND-AC is the highest value

• AFP is lower value than that of HND

• AFP-MC is 80% value(HND-AC : 100%)

200

300

400

HND-AC HND-MC HND-OV ATP-AC ATP-MC ATP-OV

before after

OHC failure

MPa

HND-AC HND-MC HND-OV AFP-AC AFP-MC AFP-OV

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ILSS

Test Method : ASTM D2344

Test Speed : 1.0mm/min

Radius of the loading nose : 3mm

Radius of the supports : 3mm

Test results

12mm

20mm

6mm

3mm

0

25

50

75

100

HND-AC HND-MC HND-ON ATP-AC ATP-MC ATP-ON

• HND-AC & AFP AC are highest value

• AFP is similar to that of HND

• AFP-MC is 80% value(HND-AC : 100%)

MPa

HND-AC HND-MC HND-OV AFP-AC AFP-MC AFP-OV

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Modal analysis

Material : Carbon Fabric prepreg(2x2 twill weave)

Natural frequency

Mode #1

(Torsion mode)

Mode #2

(Bending mode)

Mode #3

(Panel main mode)

66 Hz 130 Hz 273 Hz(target : 266Hz↑) *ref : original : 87Hz

#1

#3 #2

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Product : Acoustic Cover

Hand lay-up + Microwave AFP + Microwave

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Test Conditions : C-scan, 10 MHz Probes with water jet coupling.

scanning rate 200mms-1, raster pitch 0.2mm

Tested by NCCEF in Manchester University

NDI

※ NCCEF(National Composites Certification and Evaluation Facility)

HND-AC HND-OV HND-MW

AFP-AC AFP-OV AFP-MW

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ACURSTIC COVER

: PA6 , G/F 7% & M/F 30%

CFRP ACURSTIC COVER

: Epoxy/CF Fabric Prepreg Lay-up

& MW curing

Prototype of Acoustic Cover : Microwave process

Weight Reduction : 40%

Good mechanical and acoustic properties in the automobile

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Acoustic Cover : Testing

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developed new low cost manufacturing process of CFRP

- speed up CFRP process

＠ automation & MW process : 7.5hr, hand lay-up & autoclave : 14.5hr

- reduced CFRP production costs & increase energy efficient : 60~70%

- increase product quality by homogeneity

Compared the properties of MW process and Autoclave process

- mechanical strength of MW is 80% that of autoclave but higher than that of

oven process.

- MW process is possible to alternative process of autoclave for aerospace

and automobile industries.

Conclusion

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Acknowledgements

Dr. J. Lee & R. Scaife

International R&D Fund of Jeonju City in Korea

Project Funding

Cooperate with AMRC with Boeing (UK)

Cooperate with Sheffield University (UK)

Cooperate with SSANGYONG MOTOR(KOREA)

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