Convegno AIRET Compositi per un Trasporto

Transcription

INTERNAL
Convegno AIRET
Compositi per un Trasporto Aereo più Sicuro,
Efficiente e Rispettoso dell’Ambiente
L’Utilizzo dei Materiali Compositi
in Alenia Aermacchi
by
Michele Iannone
Rimini – 7 settembre 2012
Il materiale contenuto in questa presentazione (Materiale) è di proprietà di Alenia Aermacchi S.p.A. (Alenia). È vietato qualsiasi utilizzo del Materiale se non
preventivamente autorizzato da Alenia per iscritto. Le informazioni riportate nel Materiale hanno solo un fine illustrativo. Alenia non dà garanzia di validità dei
contenuti e non sarà responsabile di utilizzi abusivi del Materiale. © Alenia Aermacchi – Tutti i diritti riservati
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I Materiali Compositi in Alenia Aermacchi
Alenia
Aermacchi,
leader
nazionale
dell’industria aeronautica, pone in primo piano
nella sua strategia lo sviluppo di nuove
tecnologie per il mantenimento e l’incremento
della competitività sul mercato.
La tecnologia delle strutture innovative in
composito è sempre stata fra quelle
identificate come prioritarie.
Convegno AIRET – Rimini 7/9/2012
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Un Minuto di Storia
• B767 Alettoni, Timone, Spoilers, Elevatore
• MD 80 Alettoni e Timone
• MD 11 Winglet
• AMX Impennaggi
• B777 Outboard Flap
• ATR 42/72 Timone ed Elevatore
• ATR 42/72 Deriva e Stabilizzatore Orizzontale
• EF 2000 Pannelli di Fusoliera e Ala
• B787 Stabilizzatore Orizzontale e Barili Fusoliera
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Programma Boeing 767 – Parti in Composito
Alenia Aermacchi ha partecipato fin dalla fine degli anni ’70, con responsabilità di
progettazione e produzione, al programma di questo jet commerciale wide-body
della Boeing di grande successo con parti in composito per circa il 6% delle strutture.
> Flaps
> Slats
> Ailerons
> Spoilers
> Elevators
> Rudder
> Radome
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La Famiglia ATR
Aereo regionale da trasporto con bimotore turboprop progettato e fabbricato da Alenia
Aermacchi in a joint venture 50/50 con EADS. ATR42 (42-50 seats) and ATR72 (64-74
seats) sono molto apprezzati da passeggeri e airlines per gli elevati standard di confort, i
bassi costi operativi e la semplicità di manutenzione.
L’ATR ha abbondantemente superato i 1000 velivoli ordinati.
> Vertical fin
> Rudder
> Horizontal stabilizer and elevator
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ATR 42/72 Timone ed Elevatore
• Struttura tipo Sandwich con Skin
(Configurazione Pannellizzata/Full Depth)
Carbon/Epoxy
ATR 42/72 Deriva e Stabilizzatore
• Struttura tipo laminato con pannelli cobondizzati e con
cassone integrale cocurato multispar (Tecnologia Patented)
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ATR 42/72 HORIZONTAL STABILIZER AND VERTICAL FIN
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Boeing 787 “Dreamliner”
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Boeing 787 “Dreamliner”
Un nuovo aereo super efficiente ad alta tecnologia
Il 787-8 Dreamliner trasporta 210 - 250 passeggeri su rotte
da 8,000 a 8,500 miglia nautiche (da 14,800 to 15,700 km),
mentre il 787-9 Dreamliner trasporterà 250 - 290
passeggeri su rotte da 8,600 a 8,800 miglia nautiche ( da
15,900 a 16,300 km).
Primo volo nel 2010, prima consegna al cliente nel 2011.
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Boeing 787, partecipazione Alenia Aermacchi
• Due barili di fusoliera (sez. 44 e 46), realizzati come
“one piece barrel” con automated fiber placement con
stringer a forma di “hat” cocurati
• Ordinate di fusoliera per Resin Film Infusion
• Stabilizzatore orizzontale multispar “one piece”
cocurato
Nel 787 la parte di struttura realizzata in composito
supera il 50%
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Prospettive Future
E’ in valutazione la realizzazione di un nuovo velivolo
regionale nella fascia dei 90 posti, ad integrazione del
successo dell’ATR.
Il velivolo dovrebbe confermare le parti in composito
realizzate sull’ATR, con possibilità di ulteriori soluzioni in
composito (fusoliera).
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Dal punto di vista del rispetto dell’ambiente la
riduzione di peso produce un significativo
effetto di riduzione di risparmio di carburante e
di produzione di COx a parità di distanza e di
peso trasportato.
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Ulteriori miglioramenti dal punto di vista
dell’ambiente:
-Riciclaggio dei materiali compositi
-Polimerizzati
-Non Polimerizzati
-Impiego di resine termoplastiche
-Impiego di fibre naturali
-Protezioni superficiali “verdi”
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Conclusioni
I materiali compositi hanno avuto un ruolo
fondamentale in Alenia Aermacchi, e si prevede
che possano avere un ruolo anche più
importante in futuro, contribuendo alla difesa
della competitività dell’azienda sul mercato, ed
apportando
benefici
crescenti
all’impatto
ambientale dei velivoli ad ala fissa.
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14
Composite surface preparation
Maurizio Foppa Pedretti for AIRET – September 2012
Background
Composites are used in aerospace
since a long time but mainly for secondary
parts
Nowadays, thanks to new technical
developments, composites are starting to
gain primary parts
The surface preparation becomes a critical
operation to avoid breaking the mechanical
skills of the material itself
Background
Background
Targets
Surface roughness
Homogeneous coverage
No parts damaging
This is what can be
matched with Airblasting
technologies
PRODUCTION STEPS
Solvant
Degreasing
Sanding
Solvant
Degreasing
Mastic
applying
Soft
Sanding
Painting
Control
Methodology
The preparation is mainly done by hand
with sander machine.
This solution is very empiric
non repeatable
Present risk for the part itself
(Fiber damaging)
Very long operation
Parameters
Type of media (nature, size,
shape)
Dry or wet process
Angle
Distance
Pressure
Shotflow rate
Exposure time
Automatic or manual processing
Control
Water drip flows out
Water diffusion
Bad result
Good result
Plastic media
Plastic media blasting is
qualified to do some composite
surface preparation for
airframes
Currently used for delacquing,
plastic media is adapted to
clean up the surface from
moulding products and dust
Monitoring
Shotflow
monitoring by
weighing
system to
shotflow
regulation in
closed loop
application
Surface
preparation
on large
composite
panels
before
painting with
plastic media
40/60 type II
Grade B
Pressure
blasting
application
Surface
preparation
on
helicopter
blades
before
painting with
plastic media
20/40 type II
Pressure
blasting
Conclusion
A method qualified for composite surface
preparation
Nevertheless, This technical occurs warm
up of the surface which can affect the
material
The aggression of the media on the surface
can do deep damage to the material
The electrostatic effect of the media
Microscopic analysis
Reference
Drystrip 40/60
Drystrip 20/30
Process : Pressure dry
All Views are x500
Aluminium Oxide
Aluminium oxide is
qualified to do some
composite surface
preparations
Aluminium oxide is
currently used for
metallic based parts
This solution is proofed
since a long time in
aerospace
Monitoring
Application
Surface
preparation
on large
blades with
f220
aluminium
oxide
Suction
blasting
Application
Surface
preparation
of liquid
tanks with
f220
aluminium
oxide
Suction
blasting
Reference
F220
F120
Process : injection dry
All Views are x500
Conclusion
Aluminium oxide is qualified to do some
composite surface preparations
Nevertheless, this method occurs warm up
of the surface which can affect the
material
risk of inclusions
Sensitive process due to very fine
aluminium oxide F320 or more
The aggression of the media can do deep
damage to the material
Electrostatic effect
Wetblasting
Developments on
wetblasting method
have been done and
qualifications are on
processing
Wetblasting
The water is acting as
a protection cover on
the surface of the
material to avoid
inclusions and fibres
damages
Water
Composite
Process
Filter unit
Concentration
between 20 to
25%
Pressure 2 to 3
bars
Air
pressure
Nozzle
Mixture
Pump
Controls
Concentration
Calibration
Reference
Aluminium oxide
2 bar
3 bar
4 bar
Conclusion
Water doesn't generate any
temperature upgrade
The water is acting as a
protection cover on the
surface of the material to
avoid inclusions
The coverage is homogeneous
The process can support air
pressure variation without
any damage
Qualified in other industries
THANK YOU FOR YOUR ATTENTION
Maurizio Foppa Pedretti
Managing Director
RÖSLER ITALIANA S.R.L.
Via E. Vittorini 10/12
20863 Concorezzo (MB)
www.rosler.it
tel: +39 039 611521
fax: +39 039 6115232
Carbon preform concept , RTM process, applications
for carbon component construction
WHY RTM
AUTOCLAVE vs RTM vs SMC
Lamiflex RTM concept is for
high performance carbon parts
Vol % > 50%
Productivity 100100-200 p/y
WHY RTM
AUTOCLAVE:
Low production rate
High mechanical performance
One side net shape
Simple moulds
RTM:
Medium production rate
Twice side net shape
Complex moulds
SMC:
High production rate
Medium mechanical performance
Twice side net shape
Medium complex moulds
WHY RTM
AUTOCLAVE:
Manual lamination - quality of the part is linked to the operator
RTM:
Automation carbon preform
(Core of the RTM – how to make the preform..!!!)
(Lamiflex proposes a new patent system for complex frames)
SMC:
High level of automation
WHY RTM
RTM is a good production system for:
Medium production
100-500 / year (for one mould)
Medium component dimensions
from 1000mm to 3000mm
E from 70 to 140 GPa
Sigma from 400 to 900 MPa
All surfaces tool side
for a perfect assembling parts
Complex Shapes
Depending of the preform technology
If the component has these requirements RTM
is a good solution
Lamiflex RTM know how
Lamiflex use RTM process from 20 years in particular for radiology table top and
head rest applications (Siemens).
FEM simulation
RTM production
Critical and structural medical component with high level of
control in term of raw material, process parameters, NDA
and XX-ray image quality
QUALITY CONTROL SIEMENS
Lamiflex use RTM process from 20 years in particular for radiology table top
and head rest applications (Siemens).
Lancing wheel for weaving looms
Metallic inserts co-molded
Dynamic component with 200G of acceleration / 0,05 sec
Lamiflex develop for Alenia an infusion carbon tool with thermal control for “T”
stringer production (IMAC PRO program).
4000mm
200°C
+/- 5°C
length
curing temperature
temperature control
FRAMES structural concept
A new approach of a preform making and RTM molding
Typical autoclave approach:
Ribs elimination
Corners elimination
(too complex)
(complex deformation for pre-pregs)
corner
rib
RTM approach:
Same external geometry of the aluminum
frame…this concept is the core of the
development.
AW CARBON PREFORM
Using multi-axial carbon reinforcement and unidirectional it
is possible to make the preform
Carbon preform for
the frame
Carbon preform for the
complete frame
Good manipulation
Binder treatment
Packaging with vacuum bag
FROM AW project TO the CONCEPT for
STRUCTURAL frames
The RTM project is applicable for a huge range of geometries…using the same
concept.
STRUCTURAL frames
concept.
STRUCTURAL frames
concept.
BUTT-JOINT
.
New patented concept system for carbon preforming
BUTT-JOINT
New patented concept system for carbon preforming
MATERIAL TESTING
- Test mechanical test : traction and flexion
- Aging
- Water absorption
- DSC and DMA
- Surface analysis
- Fatigue test on progress
- Fiber content
MATERIAL PROPERTIES
790
730
=
=
Tg (°C)
=
Fiber content (%vol)
14
0.32
310°C (DMA)
51%
11
10
0
1010
10-1
109
)
G (GPa)
ν
10
G" ( )
[P a]
σ (MPa) traction =
σ (MPa) flexion =
LME10521_350_1a
G' ( )
[Pa]
68
42
tan_delta (
[]
E (GPa) traction =
E (GPa) flexion =
10-2
8
10
10
7
0.0
50.0
100.0
150.0
200.0
Temp [°C]
250.0
300.0
350.0
10
400.0
-3
F.E.M. traction test analysis
28000N traction test
Stress concentration at the breaking point
for 28000N
CARBON RTM mould
Lamiflex is able to project and build RTM carbon tool (HEXTOOL) with thermal
control system
Cable for power
control
Carbon mould
control box
CARBON RTM mould
Temperature mould control
Carbon tool with automatic temperature control system
CARBON RTM mould
Temperature mould control
set point 2°C
° /min
/min
Temperature of the
preform in 5 position
Heating rate from 0,1
0,1°
°C/min
/mintoto 80
80°
°C/min
/min
FRAME from CARBON MOULD
FIRST MOULDED PART
Preform
Moulded part
FRAME from CARBON MOULD
SEM surface analisys
Thanks
Lamiflex Spa
Member of
Via De Angeli 51
24028 Ponte Nossa BG
Tel 035.700011
Lombardy Aerospace Clusters
robertooppio@lamiflex.it
Business Development Manager
mauromaggioni@lamiflex.it
R&D Responsible
INJECTING FIRE RESISTANCE
Convegno Airet
Rimini 07.09.2012
Lorenzo Musiani
Agenda
Solving Industry challenges in Interior composites
Processing conditions
Mechanical & thermal properties
Fire resistance
Aerospace standard
Railway standard
Conclusion
Solving Industry challenges
in Interior composites
User-friendly system
→ 2-component liquid system
→ RT transportation and storage
User-friendly process
→ RTM & infusion
→ Low temperature injection
Fire resistant unfilled system
→ Inherently flame retardant
(no flame retardant filtration)
→ High Tg
→ High ILSS
New development
Araldite® LME 10521
LME 10522
Solving Industry challenges
in Interior composites (cont’d)
“Wet process for
weight savings”
Structural applications
→ Alternatives to Aluminum
Non & Semi Structural applications
→ Alternatives to phenolics, filled
polyester, halogenated epoxy
New development
Araldite® LME 10521
LME 10522
Processing conditions
LME 10521
LME 10522
Araldite®
LME 10521
LME 10522
Mix ratio (wt)
80
20
80 / 20
Viscosity (mPas) / 25ºC
200
13000
700
Products
Mould temp (ºC)
50 – 80
Viscosity (mPa.s)
1200
1000
Low temperature
RTM & Infusion
impregnation
800
600
400
200
0
20
25
30
35
40
45
50
55
60
Temperature (℃
℃)
65
70
75
Processing conditions (cont’d)
Pre-cure:
RTM: 4H80°C ↔ 2H90°C depending on part size
Infusion: 4H80°C
5
80°C
90°C
100°C
120°C
4
Viscosity (Pa.s)
3
2
1
0
0
10
20
30
40
50
60
70
Time (min)
→ Snap cure behavior: latency followed by sudden increase in viscosity
Processing conditions (cont’d)
After pre-cure (RTM & Infusion):
2H180°C (in the mould)
1H120°C (in the mould) + 2H180°C (oven)
Cure cycle
ILSS (MPa)
Carbon Fabric *
4H80ºC
1H120ºC
4H80ºC
1H120ºC
2H180ºC
56.5
64.1
* Hexcel G0926
88% of ultimate value
Mechanical & thermal Properties
Standard
Araldite®
LME 10521
LME 10522
2H90°C
1H120°C
2H180°C
Cure cycle
Neat resin
Tensile Modulus (MPa)
Tensile Strength (MPa)
3000
ISO 527
Elongation at break (%)
DRY DMA Tg onset (ºC)
K1C (MPa.√m)
G1C (J/m2)
53
2
ISO 6721
260
0.88
ISO 13586
273
Mechanical & thermal Properties
(cont’d)
Standard
Araldite®
LME 10521
LME 10522
2H90°C
1H120°C
2H180°C
Cure cycle
CFRP UD *
Tensile Modulus (GPa)
Tensile Strength (MPa)
126
AITM 1.0007
Elongation at break (%)
DRY DMA Tg onset (ºC)
1.1
ISO 6721
ILSS (MPa) / 23ºC
ILSS (MPa) / 120ºC
ILSS (MPa) / 160ºC
* Hexcel G1157
1600
260
97
ASTM D2344
65
55
Fire Resistance
Aerospace standard
Fiber type
Carbon Fabric*
Resin Vol %
Glass Fabric**
50
Thickness (mm)
0.3
Test
Standard
Criteria
Specified
Values
2
0.3
Araldite® LME 10521 / LME 10522
Vertical Burn 12s
AITM 2.0002B
Burn length (mm)
After flame time (s)
Drip flame time(s)
203
15
5
122
0
0
-
48
15
0
Vertical Burn 60s
AITM 2.0002A
Burn length (mm)
After flame time (s)
Drip flame time(s)
152
15
3
158
0
0
47
6
0
65
0
0
Heat Release
AITM 2.0006
HRR max* (kW/m2)
HR**(kW.min/m2)
65
65
63.64
(at 18s)
32.13
86.66
(at 54s)
88.93
43.93
(at 15s)
24.9
Toxicity
(flaming mode)
AITM 3.0005
Components toxicity
level
ppm
Smoke
AITM 3.0005
after 4 min
200
PASS
23
12
* Hexcel G0926, ** Hexcel G1157
→ LME 10521 / 10521 suitable for non visible parts where Heat Release is not
required. Development is ongoing to improve.
16
Fire Resistance (cont’d)
Railway standard EN 45545-2
Fiber type
Industrial Glass Fabric
Resin Vol %
50
Thickness (mm)
Test
Standard
1.15
Specified Value
Criteria
4.15
Araldite®
Min /
Max
HL1
HL2
HL3
LME 10521
LME 10522
Spread of flame
ISO 5658-2
CFE
(kWm-2)
Min
20
20
20
24.5
HL3
35.5
HL3
Heat release
ISO 5660-1
50 kWm-2
MARHE
Max
-
90
60
75
HL2
74
HL2
Ds(4)
Max
600
300
150
373
Smoke density
and toxicity
EN ISO 5659-2
50 kWm-2
HL1= Tramway
HL2= TGV, suburb trains
HL3= Subway, Tube, Eurostar
TBD
HL1
VOF4
(min)
Max
1200
600
300
779
CITG
(8 min)
Max
1.2
0.9
0.75
0.13
TBD
HL3
→ LME 10521 / 10521 suitable
for at least HL1 type train. Larger
thickness assessment ongoing.
Conclusion
Araldite® LME 10521 / 10522 at a glance…
Key features:
Processable at low temperature by Infusion and RTM
Inherently flame retardant
High mechanical and thermal properties
Enables weight savings through:
Replacement of Aluminum in structural applications
Alternative to phenolics, filled polyester, halogenated epoxy
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For more information
www.huntsman.com/advanced_materials
advanced_materials@huntsman.com
Europe
Huntsman Advanced Materials (Switzerland) GmbH
Klybeckstrasse 200
P.O. Box - 4002 Basel
Switzerland
Tel. +41 61 299 20 41
Fax +41 61 299 20 40
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AIRET:
Compositi per un trasporto aereo più sicuro,
efficiente e rispettoso dell’ambiente
“ Macchine specialistiche per processo RTM “
Relatore:
Mauro Farnese
AIRET - Compositi per un trasporto aereo più sicuro, efficiente e rispettoso dell’ambiente
MVP Italia: Leader nella distribuzione e realizzazione di
macchine e impianti per la miscelazione e dosaggio
di resine pluricomponenti
MVP Italia Composite technologies srl
MVP Italia : chi siamo
MVP Italia
 Azienda commerciale strutturata in Divisioni
 Distribuzione di prodotti industriali ad alta tecnologia.
MVP Italia e' in grado di offrire ai clienti :
 consulenza tecnica per la scelta del componente più idoneo
 fornitura con relative certificazioni
 magazzino parti di ricambio
 assistenza tecnica per riparazione, revisione e addestramento operatori.
MVP Italia distribuisce i seguenti marchi :
 MVP - Magnum Venus Plastech
 Sealant Equipment (Nordson Company)
 Meter Mix
 Gama
 RST5
 Kilfrost
Macchine per resine poliesteri
• Macchine RTM
Macchine per resine poliuretaniche
• Idraulica ad alta pressione
• Rapporto variabile
Macchine per resine pluricomponenti
• Pompe ad ingranaggi a rapporto variabile
Macchine per adesivi strutturali
Valvole erogatrici per mono e
bicomponenti
Detergente a base acqua
Fluidi De/Antighiaccio per Aeronautica e Piste
RTM
Principali famiglie di resine:
 Resine poliesteri
 Resine vinilesteri
 Resine epossidiche
Per ciascuna di queste famiglie ci sono macchine
specializzate ed accessori per l’RTM
 Macchine con pompe a pistoni
 Macchine con pompe ad ingranaggi
 Accessori
Principi di dosaggio
Pompa a pistoni
Pompa ad ingranaggi
Accessori
Piston Pump Benefits:
• Cost effective solution.
• More adaptable for use in hazardous or
“zoned” areas.
(i.e. can be totally pneumatically operated)
• Higher potential pressures can be created.
• Higher viscosity handling capability.
• More suitable for adhesives & abrasive
materials
• Ideal for precise metered shot applications.
Patriot Pro Innovator
(polyester / vinylester)
•
•
•
•
•
•
Highly accurate
Patriot Mix/Meter
Technology
Operated solely
through pneumatics
Increased efficiency
Improved product
quality
Mould pressure
guard
Recirculation control
Gear Pump Benefits:
•
•
•
•
•
•
•
•
Constant material flow rate.
Less moving/wearing parts.
Low retained capacity/volume in pump.
Low air entrapment
Relatively compact in size.
Rotary rear seal for longevity.
Electrically driven / variable ratio.
Longer material hose length capability.
Mixer Valves: (typical)
• MV601 & MV801 “Snuff-Back” valve
Reverse shut-off creating slight suction on mixer
• TSV601 & TSV801 “Tip-Seal” valve
Forward shut-off preventing run on from mixer
(sometimes incorporates “three-ported”
high-ratio outlet to deliver hardener component
directly in centre of material flow path)
Standard Options
Heating (Reservoirs, Pumps & Hoses)
•
•
•
•
•
•
Can
Can
Can
Can
Can
Can
reduce viscosity to aid pump loading.
reduce viscosity to increase output rate.
reduce viscosity to help fill component.
help mixing (brings viscosities closer)
accelerate cure time.
give better surface finish to end product.
Standard Options
Stirring
• Prevents filler fallout.
• Keeps S.G. constant.
(When fitting heating to a reservoir, this normally
reduces the viscosity therefore allowing the fillers to fall
out of suspension more readily)
Standard Options
Level Sensing
• High-level sensors are normally fitted with the
automatic bulkfeed system, and will give a visual &
audible alarm if the bulkfeed supply runs out.
• Low-level sensors give visual and audible alarm.
Standard Options
Vacuum
• Normally required when encapsulating electronic
components within a Vacuum Chamber
• Adds a considerable cost to the machine depending
upon the exact vacuum requirements (i.e. high-vac or
low-vac)
Standard Options
Hardened Parts
• Normally required when processing heavily filled
materials.
(Thermally conductive materials, etc...)
• Includes hardened gear pumps, pump tubes/piston
rods & mixer valve spools.
Standard Options
Auto-Bulkfeed
• Requires electronic high-level sensors with auto
transfer pump start/stop sequencing.
This also gives an indication of when the bulkfeed
container has run low.
• Machines can also be gravity fed directly from suppliers
containers.
Standard Options
Anti-Gel Timer
• Required to automatically dispense a shot to “purge”
the mixer nozzle, therefore giving an extended mixer
nozzle life.
• Anti-Gel countdown time and shot volumes can also be
pre-set on machine.
Standard Options
Shot Counter / Repeater (Piston Pumps)
• Required to dispense several pre-set metered shots into
the component.
This option is normally only used when dispensing into
large components with a small shotting machine.
It reduces the chances of underfilling, or overfilling a
component.
MVP Italia srl
Ringrazia per la vostra attenzione
Tel. : +39 02 48401180
Fax : +39 02 48401212
E-mail : info@mvpitalia.com
Web
: www.mvpitalia.com
Heraeus Noblelight
turnkey heating solutions for industrial applications
Peter Funk | HNG-IPVA | September 2012 | All rights and any changes reserved, see last page of this presentation
Who we are
Heraeus is a globally active precious metals and
technology Group with firm roots in Germany.
The company has been family-owned for over 160
years.
We operate in global niche markets
Over 13,300 employees in more than 120
companies
Product revenue 2011: €4.8 billion
Precious metals trading revenue: €21.3 billion
Facts and Figures 2011
Heraeus Group
Product revenue in € million
4.840
Precious metals revenue in € million
21.343
Employees at year-end
13.323
Business Groups
Product revenue in € million
Employees
Precious Metals
1.949
2.614
Materials and technologies
1.645
3.102
Sensors
408
3.030
Dental products
306
1.421
74
208
Quartz glass
348
1.489
Specialty light sources
103
728
Biomaterials and medical products
As of December 31, 2011
Our global presence
With 121 locations and 25 dedicated development centers,
Heraeus is active all over the world.*
The Americas (19)
Brazil (3)
Canada (1)
Mexico (2)
Puerto Rico (1)
USA (12)
Europe (61)
Asia (36)
Austria (1)
Belgium (1)
Czech Republic (1)
France (4)
Greece (1)
Hungary (1)
Ireland (1)
Italy (3)
Poland (2)
Portugal (1)
Russia (2)
Spain (2)
Sweden (2)
Switzerland (3)
The Netherlands (3)
Turkey (2)
Ukraine (1)
United Kingdom (7)
China (15)
Hong Kong (1)
India (3)
Indonesia (2)
Japan (4)
Korea (5)
Singapore (2)
Taiwan (2)
The Philippines (1)
Thailand (1)
South Africa (2)
•
Australia (3)
*Map shows number of locations as of December 31, 2011
Specialty Light Sources – Heraeus Noblelight
Is among the market and technology leaders
worldwide for special lamps and modules with
wavelengths from ultraviolet to infrared for industrial,
scientific, and medical applications
Manufactures specialty light sources for analytical
measurement technology and the printing industry,
infrared emitters for industrial heating processes, arc
and flash lamps, and products for water and surface
disinfection, air treatment, and sun simulation with a
high level of vertical integration
Heraeus Noblelight GmbH
What can we provide to our clients?
Scope of delivery Heraeus Noblelight
Material testing

Preliminary tests with customers‘ material
IR emitter development and assembly

Numeric analysis (ray tracing, computational
fluid dynamics)
System project planning and construction

Analysis of heat processes

Embedding in existing equipment

Handling and transport system
Component and system assembly

Customer-specific
Installation / commissioning
Application Center
Heraeus Application Centers can
carry out trials to determine the most
suitable emitter for the customers
application:

Is my material suitable for infrared?

Which type of emitter / wavelength
provides optimum output for the
process?

Can I integrate infrared into my process
reasonable?
Numerical Ray Tracing Analysis
dynamic process
optimize for conveyed substrate:
1.0 m2 size,
13 emitter, 2 different types in 3
zones
usual basic setup:
1.0 m2 size,
11 emitter, all same power
batch process
optimize for batch process:
1.0 m2 size,
zones
Numerical Ray Tracing Analysis
dynamic process
optimize for conveyed substrate:
1.0 m2 size,
zones
batch process
optimize for batch process:
1.0 m2 size,
zones
CFD Computational Fluid Dynamics
CFD Computational Fluid Dynamics
Infrared heat
Basics
Heat transfer via ...
vibration
induction
convection
contact
electron beam
infrared radiation
Advantage of infrared radiation
Heat is transmitted straight to the substrate

No carrier gas required, in contrast to convection
Fast response

Tungsten or carbon filaments react within seconds

Closed loop control possible

High energy efficiency
Ideal for vacuum

No power losses by convection
Spectral power distribution
Spectral Radiation Distribution
at the same electrical power
ratings
1200 °C
Infrared radiation
reflection / r
infrared radiation
absorption / 
absorption
transmission / 
+r+=1
Heraeus Noblelight Infrared Products
Infrared Emitters
Short wave
Fast response
medium wave
Carbon
round
Carbon
twin
Medium
wave
Max. Power/m2
200 kW
150 kW
100 kW
150 kW
60 kW
Filament temperature °C
1800
-2400
1400
-1800
1200
1200
800
-950
1s
1-2s
1- 2 s
1- 2 s
1- 4 min
Reaction time
Infrared modules and systems
Heraeus Noblelight and Composites
Individual solutions for lightweight materials
Infrared and composites  Where is infrared needed?
raw material
fiber
carbon/glass
Only for carbon fiber
thermoplastic
matrix
thermoset
matrix
semifinished
part
finished
product
finished
product
Understanding the process
Infrared application in the value chain of FRP

Drying of sizing

Pre-heating of fiber fabrics in RTM

Melting of thermoplastic matrices like PEEK, PPS, PP, PA6…

Melting of hybrid yarns

Heating of organic sheet materials for forming processes e.g. vacuum molding or
stamping

Pre-heating or pre-curing of thermo setting matrices prior to curing in an autoclave

Curing under vacuum bagging films

…
thermoset matrix  finished product
Resin infusion molding

pre-heating  fabrics (glass or carbon)

curing

annealing
RTM (Resin Transfer Molding)

pre-heating  fabrics (glass or carbon)

Annealing
Pre-preg

tape laying

de-bulking
Fiber winding

pre-heating roving's

curing
thermoset matrix  semifinished part
Pre-forming
Pultrusion
SMC (Sheet Molding Compound)
thermoset matrix  finished product
Injection molding with organo-sheets
Forming processes

vacuum molding

stamping

diaphragm forming

…
Heraeus Noblelight / CFK Valley Stade
Heraeus Noblelight as a member of the CFK Valleys Stade
Heraeus Noblelight und der Carbon Composites e.V. (CCeV)
Heraeus Noblelight as a member of Carbon Composites e.V. (CCeV)
Government funded research project
Heraeus Noblelight is a partner of the research project funded by the German
government “Energieeffizientes Pultrusionsverfahren zur Herstellung von
Faserverbundbauteilen mit thermoplastischer Matrix in
Serienanwendungen“ (acronym: TPult)
Target: Developing and Use of specially adapted IR-heating systems to the
respective heat demand. In this case:

Drying of sizing

Melting of hybrid yarns

Pre-heating of consolidated composite tube prior to thermoforming process
Massimo Bianchi
Heraeus spa
Via dei Chiosi 11
20040 Cavenago Brianza MB
Sales Manager
IR-Division of Heraeus Noblelight
Phone +3902957591
mobile +393355642422
massimo.bianchi@heraeus.com
www.heraeus-noblelight.com/infrared
Peter Funk
Heraeus Noblelight GmbH
Industrial Process Technology
Reinhard-Heraeus-Ring 7
63801 Kleinostheim
Germany
Phone +49 6181 / 35 - 8483
Fax + 49 6181 / 35 - 16 8483
peter.funk@heraeus.com
www.heraeus-noblelight.com/infrared
Disclaimer
This presentation including all its parts (e.g. photographs, diagrams, drawings etc.) is protected by
copyright. Any exploitation outside the close limits of the Copyright Act is inadmissible and
punishable, unless pre-approved by Heraeus. This applies in particular to photocopies,
publications, translations as well as storage and processing in electronic systems.
All data in this presentation were thoroughly ascertained by Heraeus. However, Heraeus does not
assume any liability for their correctness or completeness.
The data are based on conditions of use and environmental influences assumed by Heraeus. They
cannot be adopted indiscriminately, but require prior verification for the respective use of the
customer.
Exclusively Heraeus’ General Terms of Delivery shall apply to all deliveries of Heraeus for
commercial transactions with business enterprises.
FLY-BAG Blastworthy flexible
composite luggage container for
aircraft cargo holds
D’Appolonia S.p.A., Sächsisches Textilforschungsinstitut e.V.,
Blastech Ltd., Consorzio Cetma, Carmel Cargo Network BV,
Meridiana S.p.A., Danmarks Tekniske Universitet, APC Composit AB
Alessandro Bozzolo, D’Appolonia S.p.A.
7 September 2012, Rimini, Italy
FLY-BAG Blastworthy flexible composite luggage container for aircraft cargo holds
Cargo plane bombing plot October 30th 2010
• Two bombs
travelled from
Yemen to Dubai
and the UK
• Also onboard
passenger flights
• Around 400 g of
PETN each
PROTECTION MEASURES ARE NEEDED
Explosions in aircraft cargo holds
PROTECTION MEASURES ARE NEEDED
HULDs: past attempts
• Since the Lockerbie disaster in
1988, development of HULDs
• Never gained wide market
acceptance:
–
–
–
–
Too heavy
Too bulky
Too expensive
Easily damaged during use
and/or by environment
• Only for wide bodies!
A NEW APPROACH IS NEEDED
FLY-BAG: Blastworthy textile-based
luggage containers for aviation safety
Project Type: Collaborative project – Small of medium-scale focused research
project
Call:
FP7-AAT-2007-RTD-1
Topic:
7.1.5 PROTECTION OF AIRCRAFT AND PASSENGERS
7.1.5.1 Aircraft Security
AAT.2007.5.1.1.Aerostructures
Start date:
December 2008
End date:
February 2011
Coordinator: Donato Zangani, D’Appolonia S.p.A.
The Consortium
D’Appolonia S.p.A.
Italy
Sächsisches
Textilforschungsinstitut e.V.
Germany
Blastech Ltd.
UK
Consorzio CETMA
Italy
Cargo Network
The
Netherlands
Meridiana S.p.A.
Italy
Danske Tekniske Universitet
Denmark
APC Composite AB
Sweden
Result
We have developed and successfully tested a
blast-resistant
flexible
composite
luggage
container “FLY-BAG” for the protection of aircrafts
from on-board explosions from explosives hidden in
luggage in the cargo hold
FLY-BAG
Composite structure infusion @ APC, Sweden
FLY-BAG
Installation trials into Meridiana Airbus A319
The FLY-BAG is not...
• The FLY-BAG container is not a ULD (although extending
the concept to a ULD version is straightforward)
• It is more like “a bag full of bags”
• It stays inside the cargo hold of the airplane (non-ULD
version), hence no degradation problems
• It does not require any modification to the hold
equipment/structure
• It does not require any special machinery or skill
• When not in use, it is simply folded and kept in the hold,
thanks to its flexible composite structure
The FLY-BAG is...
•
•
•
•
•
•
Lightweight (65 kg) ≤ standard Al LD3-45 ULD (85 kg)
Blast resistant
(Relatively) inexpensive: target cost ≤ 2.000 €
Easy to install and use
Durable: target working life (foreseen) at least 3 years
Slim – payload is unaffected when in use, when folded it
fits in a 30x40x80 cm case
• Suitable both for narrow- and wide-bodies; presently
developed with focus on narrow bodies
The FLY-BAG Approach
• Use a flexible composite multilayer structure
• Use advanced concepts of progressive failure/energy
absorption
• Use advanced materials (including anti-blast fabrics,
composites, and nanomaterials)
• Follow functional requirements from the aviation sector
Blast events
• Four possible causes of damage:
– High speed fragments ejection
– Shock peak pressure (duration: few ms)
– Quasi static pressure (duration: few s)
– Fire/heat
MULTILAYER CONFIGURATION
Multilayered composite structure
1. Gas/heat resistant and
flame retardant
2. Inner deformation and
energy absorbing layer
3. Reinforcing and splinter
protection layer
4. Defined outer deformation
Joined by stitching + resin infusion
Composite reinforcement concepts
Controlled deformation
Energy absorption
Dynamic burst test of flexible
composite layer with seam
Shock-holing tests on composite floor
panels
Explosive charge
not shown for
confidentiality
reasons
Blast Test of LD3-45 ULD
WOULD MOST LIKELY LEAD TO FUSELAGE COLLAPSE
FLY-BAG blast test with the same explosive
charge that destroyed the ULD
THE FLY-BAG SURVIVES SUBSTANTIALLY INTACT!
FLY-BAG blast test with the same explosive
charge that destroyed the ULD
THE FLY-BAG SURVIVES SUBSTANTIALLY INTACT!
FE simulation of blast in cargo hold
Watch the full length video at
http://www.euronews.net/2011/01/25/bomb-proof-textiles-take-off/
FLY-BAG Awards
From FLY-BAG to FLY-BAG2
• FLY-BAG has demonstrated the feasibility of a textilebased blast resistant container, but:
– For a specific configuration (narrow-body, the container stays
in the hold)
• No use for wide bodies
• No use against suicide bombers
– We only blast-tested it in open air
– The interaction with airframe is only known from simulations,
not tested
FLY-BAG2
• For addressing these issues, a new European Project, called FLYBAG2 has been proposed and approved by the EC
–
–
–
–
–
–
Project Type:
Call:
Topic:
Start date:
Duration:
Coordinator:
Collaborative Project
FP7-AAT-2012-RTD-1
AAT.2012.5.1-1. Aerostructures
August 2012
3 years
Alessandro Bozzolo, D’Appolonia S.p.A.
University
of Patras
FLY-BAG2
FLY-BAG LRBL
FLY-BAG ULD
LEAST RISK BOMB
LOCATION
CARGO COMPARTMENTS
Thank you for your attention!
• Contact us at www.fly-bag.net
– Watch the full length promo video
– Join the Community
• For direct inquiries:
alessandro.bozzolo@dappolonia.it
samuele.ambrosetti@dappolonia.it
donato.zangani@dappolonia.it

Convegno AIRET Compositi per un Trasporto

Transcription

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