Presentation in alphabetical order:
Chomarat unveils its new multiaxial NCF reinforcement for Thermoplastics, and Carbon Reinforcement for Wind Energy
Chomarat will present its latest innovations in Hall 5A, Booth J42
CHOMARAT, the composite reinforcement specialist group, is launching its multiaxial glass NCF for thermoplastic composites. The unique patented stitching yarn used can withstand processing temperatures to 400°C, making it an innovative industrial solution for thermoplastic composites and an alternative to the woven reinforcements used especially in the automotive sector. For the first time, CHOMARAT is also exhibiting a unidirectional carbon NCF reinforcement that is adapted to the productivity and performance requirements in the wind energy sector.
An innovative industrial solution to reinforce automotive thermoplastics
Thanks to a unique patented stitching yarn, the glass NCF reinforcement (G- PLY™) developed by Chomarat offers new possibilities in thermoplastic RTM and organosheet processes. “This is an especially innovative solution, utilizing stitching yarns that are compatible with processing temperatures to 400°C. These multiaxials improve the performance and provide a lot of construction freedom in terms of fibre orientation. These new design possibilities contribute to structural optimization. The quest for more lightweight vehicles, shorter cycle times and lower cost is a major issue for Thanks to a unique patented stitching yarn, the glass NCF reinforcement (G- PLY™) developed by CHOMARAT offers new possibilities in thermoplastic RTM and organosheet processes. “This is an especially innovative solution, utilizing stitching yarns that are compatible with processing temperatures to 400°C. These multiaxials improve the performance and provide a lot of construction freedom in terms of fibre orientation. These new design possibilities contribute to structural optimization. The quest for more lightweight vehicles, shorter cycle times and lower cost is a major issue for all builders,” explains CHOMARAT Automotive Market Manager Francisco De Oliveira.
This new heat-stable G-PLY™ reinforcement can withstand very high processing temperatures without deformation and provides optimal mechanical performance.
A Carbon Ud to reinforce extra thick wind turbine structures
For the first time, CHOMARAT is exhibiting an infusion-moulded laminate made with 150 plies of its new unidirectional carbon C-PLY™. This 600g/m², high-permeability NCF can be used to create extra-thick structures, in particular the wind-turbine blade stiffeners, or spar caps.
“Cost reduction is the challenge in the wind energy industry. Increasing the blade length by incorporating carbon stiffeners increases power, and so it also lowers the cost of the energy,” says CHOMARAT Wind Energy Market Manager Raphaël PLEYNET. The carbon UD developed by CHOMARAT provides a solution to achieve the goal to optimize the weight/power ratio. The UD’s high permeability reduces cycle times and lowers the blade production costs.
Professor Sung Ha from the University of Hanyang will give a conference on composite challenges in the wind energy sector at 11:30 am on Wednesday, 7 March 2018 at JEC World.
Established in 1898, CHOMARAT is an international industrial textile group, involved in three businesses: Composites Reinforcements, Construction Reinforcements, Coatings & Films–Textiles. The privately held company operates in France, Tunisia, the United States and China to service its global customers.
The firm leads a strong innovation strategy, rising to challenges, developing materials for the future. Hence, the Group invests in new technologies and enters into collaborative research programs with universities and technical centres worldwide.
Chomarat offers strong technical know-how and mastery of complex technologies in fields ranging from automotive, aerospace, sports, energy, marine, construction, and also in markets requiring creativity and expertise, like luxury goods.
Dornier at JEC World in Paris
Customized equipment for manufacturing semi-finished products
Fabrics, tapes, organic sheets: DORNIER presents machines and system solutions for efficiently manufacturing semi-finished composite fibre products at JEC World (March 6 – 8,2018) in Paris, France at Hall 6, Booth D43
DORNIER will present its Composite Systems® business unit at the JEC World composite materials exhibition. The machine builder continues to establish its reputation as a system partner for component, fibre and polymer manufacturers for all matters relating to machinery and systems for manufacturing semi-finished textiles made from high-performance fibres.
Handcrafted single-item production, small lots – these keywords still characterize the production of fibre-reinforced plastics (FRP) in all sectors which count on lightweight, fibre-based structural applications, including aerospace, automobile construction, machine-building, and even architecture. This is why textile research institutions and sector enterprises are pushing to develop reliable, economical processes for manufacturing FRP components on an industrial scale. Their efforts are concentrated on new developments and advancements of machinery used to make semi-finished goods from carbon, glass, aramide and basalt for composites.
For more than 40 years, weaving machines by Lindauer DORNIER GmbH are the benchmark for processing high-performance fibres like carbon. But, with the innovations of its Composite Systems® division the highly respected family business now also covers a large portion of the semi-finished goods production spectrum for FRP components as well. “At the JEC, we are going to demonstrate that the expertise we have acquired over decades in building machinery for producing semi-finished goods has also been applied to production equipment”, says Dr Josef Klingele, Product Manager for DORNIER Composite Systems®.
Weaving organic sheets from tapes
It is common knowledge in the industry that carbon fabrics for aircraft wings, car parts and medical technology all over the world are produced on DORNIER P1 roving weaving machines. But meanwhile the machine builder also serves the very vibrant tape market with its own production plant. The system is capable of producing dry and fully impregnated tapes in widths up to 600 mm and at speeds up to 30 m/min. Based on a special impregnation unit, the tapes now are impregnated with thermoplastic matrix material inline – previously this had to be done in a second step. The uniform and controlled alignment of the fibres for the impregnation process is realized by a complex spreading mechanism, also developed by DORNIER. “We obtain very high spreading values”, adds Dr Klingele.
The finished tapes – this is where the system concept of Composite Systems® applies – then can be further processed on DORNIER’s tape weaving machine. This for example allows to produce woven organic sheets, more economically than before. The reason: fibres and plastic are readily combined in the tapes, they no longer have to be processed separately in an expensive step to make the organic sheets. The advantages for semi-finished goods and component manufacturers thus are shorter cycle times and lower production costs.
Machines and systems to customer specifications
The experts at DORNIER can draw on decades of experience in developing customized systems when building machinery for semi-finished goods. “Composite components are subject to enormous constraints; no two machines for manufacturing semi-finished goods are the same”, explains Klingele. Producers of components, fibres or polymers often rely on in-house developments and modified machines. But they usually don’t have the system building experience they need. As they reach a dead end, they contact the machine builders, who can contribute more than just their CE certification expertise: “We have been building machines and systems with very high manufacturing depth for over 65 years – this vast knowledge cannot be acquired overnight.”
In order to meet customers’ requirements as completely as possible, DORNIER has established a technology centre where specific system concepts for manufacturing semi-finished goods are tested, and customer trials are conducted. For example on 3D weaving machines, which weave in all three spatial directions. The machine builder from Lake Constance, which invests eight percent of its annual turnover in research and development, with these units offers its pioneering response to the trend towards lightweight textiles for mobility. “In the future, 3D fabrics will become indispensable elements in cars and aircraft”, of that, Klingele has no doubt.
Lindauer DORNIER GmbH and its Weaving Machine, Specialty Machine and Composite Systems® divisions has earned its place as a global technology leader. In 2017, the German family enterprise employing more than 1,000 staff (including 63 trainees) and recorded an order intake of approx. 280 million Euros. The company set up the Composite Systems® division with the P1 Roving Weaving Machine, 3D Weaving Machine, Tape Production Line and Tape Weaving Machine as a collecting point for its decades of experience in the engineering weaving machines and building production plants for plastic films. The systems are configured according to customer specifications; consequently, the equipment of each machine varies – sometimes considerably – depending on the needs of the customer. All machines are manufactured in the production workshops at Lindau and Esseratsweiler in Germany. 90 % of the machines produced are exported.
Hexcel’s Product Innovations for Aerospace, Automotive, Wind Energy and Marine at JEC WORLD 2018
Hexcel (Hall 5, Booth J41) will display an array of product innovations for customer applications in aerospace, automotive, wind energy and marine markets.
Hexcel’s banner at the exhibit hall entrance features the Airbus H160 helicopter and A350 XWB aircraft, both with carbon fibre livery to acknowledge the high Hexcel composites content in both programs. Hexcel’s reinforcements, prepregs, adhesives and honeycomb materials were selected for the H160’s composite fuselage structures and main rotor blades, contributing to the lightweight fuel- saving design and performance optimization. Airbus has loaned Hexcel an H160 BLUE EDGE blade to display on the booth.
Among the Aerospace promotions at Hexcel’s booth are carbon-reinforced 3D printed parts, made from Hexcel’s HexAM™ additive manufacturing technology that uses PEKK ultra-high performance polymers. Hexcel acquired this technology from Oxford Performance Materials in December 2017 to provide a weight-saving solution for intricate parts in highly demanding aerospace, satellite and defense applications. HexPEKK™ structures offer significant weight, cost and time-to-market reductions, replacing traditional cast or machined metallic parts with a new technology.
Aircraft engines benefit from a number of Hexcel technologies that will be promoted at JEC 2018, including HexShield™ honeycomb that provides high temperature resistance in aircraft engine nacelles. By inserting a thermally resistant material into honeycomb cells, Hexcel provides a core product with unique heat-shielding capabilities that allows for the potential re-use of material after a fire event.
Another honeycomb innovation from Hexcel is Acousti-Cap® broadband noise-reducing honeycomb that significantly improves acoustic absorption in aircraft engine nacelles. The acoustic treatment may be positioned at a consistent depth and resistance within the core, or can be placed in a pattern of varying depths and/or resistances (Multi-Degrees of Freedom and 3 Degrees Of Freedom), offering an acoustic liner that is precisely tuned to the engine operating conditions. These technologies have been tested at NASA on a full engine test rig and meet all 16 design conditions without trade-offs. An example of this technology will be on display at JEC 2018.
Rounding off the aircraft engine exhibits is a CTi fan blade for new generation lightweight turbofan engines from Rolls-Royce, manufactured from Hexcel’s HexPly® M91 high toughness and impact- resistant epoxy prepreg. Hexcel supplies HexPly® M91 as slit tape for the automated lay-up of the complex aerodynamic shape, with a constantly changing thickness across the blade length. The blade, which is thinner and lighter than titanium fan blades, is currently undergoing flight tests.
Hexcel’s HiTape® and HiMax™ dry carbon reinforcements that were developed for the automated lay-up of preforms for resin-infused aerospace structures will be promoted at the show. Two demonstrator parts, one made with HiMax™ and one with HiTape®, were both infused with HexFlow® RTM6 resin to demonstrate the potential benefits of an integrated design for aircraft skins, spars and stiffeners that meets OEM requirements for production rate increases and cost effectiveness.
Hexcel is also introducing its new range of HiFlow™ advanced liquid resins for aerospace structures manufactured by liquid molding technologies. Based on novel proprietary chemistry, the new resin family will enhance the performance of composites and ease processing when combined with HiTape® and HiMax™ dry carbon reinforcements. HiFlow™ HF610 is the first resin in the range.
Hexcel’s range of high performance adhesives has expanded considerably following the company’s acquisition of Structil last October. Hexcel is relaunching the acquired products under the new HexBond™ brand name at JEC World. This fast-growing range of pastes, liquid shim and film adhesives has a wide spectrum of operating temperatures and is in qualification with a large number of aerospace and industrial OEMs.
In the Planet Aerospace area at JEC, Daher and Hexcel will jointly display an aircraft spar manufactured from HexPly® M56 prepreg. Hexcel’s Neil Parker and Daher R&T Director Dominique Bailly will give a joint presentation focusing on the materials used and the benefits for the finished part. The aircraft spar was designed and manufactured by Daher using Hexcel’s HexPly® M56 prepreg, in slit tape format, that was developed for automated deposition and out-of-autoclave curing. The spar was manufactured using only the vacuum bag process and demonstrates very low porosity levels. It is currently undergoing testing and validation through CORAC funding.
Hexcel’s Automotive promotions at JEC World 2018 include a new prepreg for composite leaf springs, HexPly® M901. In contrast to steel leaf springs used for suspension on vans, trucks and SUVs, newer composite versions offer many advantages including weight savings of up to 70%, high corrosion resistance, optimized system integration and superior performance. Hexcel’s HexPly® M901 prepreg raises the bar further, reducing mould cure time below 15 minutes, a 50% reduction compared to standard industrial prepregs. HexPly® M901 provides 15% higher mechanical performance, with enhanced fatigue properties. It also operates at high temperatures, providing a Tg of up to 200°C following a post cure. Hexcel’s expertise in manufacturing heavy weight glass UD prepregs, with fibre areal weights of up to 1600gsm, allows the company to offer a highly cost- competitive solution for the rapid manufacture of these safety critical components.
Hexcel is constantly seeking ways to ensure that customers obtain the maximum benefit from composites and has recently acquired state-of-the-art simulation technology that accurately predicts how HiMax™ non-crimp fabrics will drape in a mould. Working in collaboration with Nottingham University Hexcel has created a car seat shell, for which the material selection was optimized using this new drape simulation technology. Visitors to Hexcel’s stand at JEC will see an on-screen demonstration that illustrates how the simulation tool operates, predicting process and performance and ensuring that the optimum fabric architecture is quickly identified, reducing the need for expensive trial programs.
Hexcel’s HexMC®-i 2000 carbon fibre/epoxy moulding compound has been successfully used by Audi to manufacture a high-performance engine cross brace. HexMC®-i is a fast curing high-performance moulding material, suitable for the series production of complex shaped parts and providing excellent mechanical properties. The Audi cross brace covers the engine, providing torsional stiffness for enhanced drive dynamics.
Hexcel’s product offering for customers in the Marine industry has expanded following the acquisition of Formax in 2016 and Structil in 2017. At JEC World, Hexcel will promote its enhanced portfolio of carbon fibres, prepregs, woven reinforcements and multiaxial fabrics for builders of racing catamarans and luxury yachts.
Marine customers have supplied a number of parts for display to illustrate their expertise in manufacturing composite structures from Hexcel materials. These include part of a Diam 24 yacht mast made by ADH Inotec from Hexcel’s HexPly® M79 fast curing, low temperature cure prepreg. ADH Inotec purchased the prepreg from Composites Distribution, a Hexcel Official Distributor that also supplied HexPly® M9.6 prepreg to Lorima for the Outremer 5X catamaran mast section on display. Part of Lorima’s 42m wing mast for a multihull racing boat made with HexPly® prepreg from Vert-Le-Petit (formerly Structil) will complete the marine display.
Hexcel’s innovations for Wind Energy include Polyspeed® pultruded laminates for load-carrying elements in wind blades. These continuous cross-section profiles, made from a polyurethane matrix reinforced with unidirectional carbon fibre, provide consistently high mechanical properties, including high stiffness, fracture toughness and shear strength, combined with low weight and durability. Visitors to Hexcel’s stand will see a 2m diameter coil of pultruded carbon laminate that contains 255m of material in a single roll. This technology offers an economical way of reinforcing large-scale composite structures such as wind turbine blades.
Hexcel will also launch its surface finishing prepreg for wind turbine blades and components. This provides a tough, durable and ready-to-paint blade surface without the use of gel coat and results in faster blade manufacture, saving time in production and reducing material costs. The benefits of the new surfacing prepreg will be demonstrated via a wind blade exhibit that has been given four different treatments across the blade surface. These include a section with gel coat, a section of standard prepreg without gel coat, and a section where a fleece has been added to improve surface quality but still requires preparation before painting due to pin holes. The final section made with new HexPly® XF2P surfacing prepreg has a ready-to-paint surface, straight from the mold, without any requirement for gel coat, fleece or finishing operations.
Hexcel Corporation is a leading advanced composites company. It develops, manufactures and markets lightweight, high-performance structural materials including carbon fibres, specialty reinforcements, prepregs and other fibre-reinforced matrix materials, honeycomb, adhesives, engineered core and composite structures for use in commercial aerospace, space and defense and industrial applications.
KARL MAYER Technische Textilien presents innovative solutions relating to the topic of reinforcement layer fabrics
The company KARL MAYER Technische Textilien GmbH, a competent and committed partner of the composite industry, will also be exhibiting at the upcoming JEC World to take place from 6. to 8. March 2018 in Paris. This machine manufacturer invites the trade fair visitors to come and see its Stand Q58, Hall 5, in Paris Nord Villepinte Exhibition Center. Here the company will be displaying its high-performance composite machines, namely: the COP MAX 4 as a flexible all-round model for producing multilayered, multi-axial structures with angles ranging between maximum +20° and -20° and the COP MAX 5 especially designed for processing carbon fibres. The COP MAX 5 can manufacture layer fabrics with a very low weight per unit area; the machine works, either with an on-line or an off-line feeding system of the fibre material. For the spreading of the fibre tapes for the off-line version, KARL MAYER Technische Textilien can offer the fibre spreading unit UD 700. Information on the high-performance machines is available as video presentation, print media to read, and also during discussions with the KARL MAYER specialists. One main focus will be on the topic of glass layers with defined carbon fibre reinforcements. The tailor-made reinforcement textiles are produced on multi-axial machines with filler thread shogging device during the so-called „VARIOLAYING“ procedure.