Aquacore - Advanced Ceramics Manufacturing

Transcription

ADVANCED CERAMICS MANUFACTURING
ADVANCED CERAMICS MANUFACTURING, founded in 2001, is an AS 9100 certified aerospace research
and development company, responsible for commercialization of products related to over 12 patents. Located
in Tucson, Arizona, the facility is over 20,000 sq. ft. and has a state-of-art machine shop, autoclave, wet-lab,
metrology lab, numerous ceramic firing ovens, QC lab, and two composite clean rooms. Voted in 2007 as top
10 defense contractor in Arizona and top 5 in Tucson, also winning notable R&D awards in 2001 and 2002.
ACM is a joint venture with the Tohono O‘odham tribe, San Xavier Development Authority, and is considered
an 8A Native American owned small business.
The evolution of Aqua Products has lead ACM into the commercialization of water-soluble mandrels used for
the production of complex hollow composite parts. The Fastcore & Rapidcore processes allow customers to
provide CAD drawings to ACM engineers, for the manufacture of disposable water soluble mandrels. The
water-soluble mandrels are environmentally friendly, with ceramic sediment being the only result from
washout. ACM can provide several levels of solutions to clients; from raw materials that can be cast into
mandrels, to mandrels shaped to the customer‘s required tolerances, or finished composite parts.
A Guide to Product Lines
Aquapour
-
Specification Sheet……………….pg. 2
Water Soluble Mandrel Process…..pg. 3
Instructions……………………..…pg. 4
MSDS……………………………..pg. 5-7
Aquacore
-
Specification Sheet………….…….pg. 8
Instructions………………………..pg. 9
MSDS……………………………..pg. 10-12
Aquacore Premium
MSDS……………………………..pg. 15-16
Aquafill
-
Instructions for Aquafill – 3 part….pg. 19
MSDS……………………………..pg. 20-21
Aquaseal
-
MSDS……………………………..pg. 23-24
Fastcore/Rapidcore
Instructions………………………..pg. 25-27
Request Sheet……………………..pg. 28
MSDS……………………………..pg. 29-30
Page 1 of 31
Page 2 of 31
Page 3 of 31
INSTRUCTIONS
Aquapour™ — WSC 4015
NOTE: CONTENTS SETTLES DURING SHIPPING
Mix Aquapour™ thoroughly before each use & before beginning Step1
1. Prep mold. We recommend a Lecithin based mold release. (e.g. Pam)
2. Combine Aquapour™ with water.
Recommended mixing ratio is: 55% Aquapour™ powder material to 45% water by weight.
3. Pour Aquapour™ into mold.
Working time is 5-10 minutes.
Vibrating the material while in wet form will help reduce bubbling. Pouring the material in a vacuum will also
reduce surface bubbling greatly. Material will set up in approximately 1 hour.
4. Remove mandrel from the mold — MUST be removed from mold prior to being dried. 5. Dry in a
convection oven.
We recommend the material be dried at 135°C (275°F) at 1.5 hours per inch of mandrel thickness.
The material can also be dried at temperatures below 135°C (275°F). However, drying time will be
increased. Aquapour™ is thermally stable and can withstand temperatures in excess of 200°C (392°F).
Drying times for Aquapour™ vary according to the part geometry and surface area. The more surface area
that is exposed the shorter the drying time.
Drying times will increase exponentially as the part geometry increases at 135°C (275°F).
6. Remove mandrel from oven.
To avoid cracking, we recommend turning the oven off with the mandrel inside and letting the mandrel
cool in the oven. This prevents thermal shock.
If tooling is necessary, we recommend Aquafill™ as a way to give the mandrel a smooth porcelain-like feel.
Aquafill™ can also be used to patch any defects or imperfections on mandrel.
7. Seal the mandrel. We recommend Aquaseal™, a water-soluble sealer. 8. Lay-up on
mandrel to make finished part.
Prep mandrel with desired release agent prior to lay-up.
Aquapour™ is compatible with the curing temperatures of all commercial pre-preg materials and
resins.
9. Wash away Aquapour™ from finished part.
The material can be washed away under a faucet or with a standard garden hose.
Heated water is not necessary but will drastically increase the wash out of the mandrel. Aquapour™ is
environmentally friendly so no special disposal procedures are needed.
For additional assistance, please contact Advanced Ceramics Manufacturing at 520.547.0850
Page 4 of 31
MATERIAL SAFETY DATA SHEET
SECTION 1 — PRODUCT AND COMPANY IDENTIFICATION
Date
Manufacturers Name
Address
Hazard Ratings
May 28th 2009
Advanced Ceramics Manufacturing
7800A South Nogales Highway ● Tucson, AZ 85756
Health — 1
Flammability — 0
Reactivity — 0
Product Name
Formula
Synonyms
Chemical Name
Aquapour
Not available
None
Refer to Section 2
Product Information Telephone Number: 520.547.0850
Hazardous Materials Support Center: 800.554.9964
Chemtrec (Spill Related Emergencies): 800.424.9300
SECTION 2 — INGREDIENTS
Notes
Materials:
The formula is proprietary information and is the property of Advanced Ceramics
Manufacturing.
WT%
TLV (mg/m³)
PEL (mg/m³)
CAS Number
Zircon
Trace
5 as Zr (R)
5 as Zr (R)
Crystalline Silica (Quartz)
Trace
0.05 (R)
0.1 ( R )
7732-18-5
Graphite
Trace
2(R)
2.5 ( R )
7782-42-5
( T ) - Total
Established
( R ) - Respirable
( I ) - Inhalable
14940-68-2
( NE ) - Not
SECTION 3 — PHYSICAL DATA
Boiling Point
Specific Gravity
Vapor Density
Appearance & Odor
% Volatiles by Weight
N/A
(H2O = 1): 0.57
N/A
Solid powder with no detectable odor.
N/A
SECTION 4 — FIRE AND EXPLOSIVE DATA
Flash Point
Special Fire Fighting
Procedures
Stability
Conditions to Avoid
Auto ignition Temperature
Unusual Fire &
Explosion Hazard
Greater than 400ºC
N/A
Stable
None known
N/A
None
Page 5 of 31
SECTION 5 — HEALTH HAZARD INFORMATION
Eye Contact
Direct contact may cause irritation.
Skin Contact
Inhalation
Ingestion
Signs & Symptoms of
Exposure to Airborne Dust
Medical Conditions
Aggravated by Exposure
Acute Health Effects
Chronic Health Hazards
Details
Repeated exposure to dust may cause lung injury.
No known hazard
Continued and prolonged exposure to airborne dust concentrations in excess of the
PEL/TLV may result in cough, dyspnea, wheezing, or impaired pulmonary functions.
Overexposure would generally aggravate respiratory system dysfunctions.
Mists or dusts from dried product may cause irritation of mucus membranes and
eyes. Liquid may cause slight skin and eye irritation.
Prolonged exposure to mist of product sprayed or to dust from dried product may
result in pulmonary damage. Inhalation of crystalline silica dusts can cause silicosis.
IARC has determined there is sufficient evidence in humans for the carcinogenicity
of inhaled crystalline silica and so is categorized as a Group 1 carcinogen. NTP has
classified respirable crystalline silica as a known human carcinogen and ACGIH has
classified it as a suspected human carcinogen.
FIRST AID PROCEDURES
Eyes
Flush eyes with running water for 15 minutes — lift upper and lower eyelids.
Skin
Wash skin thoroughly with mild soap and water.
Inhalation
Ingestion
Medical Conditions
Carcinogenic Assessment
Move the exposed person to fresh air at once. If not breathing, initiate pulmonary
resuscitation. Get medical attention.
No known hazard.
Lung ailments
No components used in this formulation are listed as carcinogenic.
SECTION 6 — REACTIVITY DATA
Hazardous
Decomposition Products
Hazardous
Polymerization
Conditions to Avoid
Stability
Chemical Incompatibility
None are to be anticipated under normal or recommended handling and storage
conditions.
Stable and hazardous polymerization will not occur. When heated to decomposition
oxides of sulfur will be released.
None known.
Stable under normal conditions.
None known.
SECTION 7 — PRECAUTIONS FOR SAFE HANDLING AND USE
Steps to be Taken if Material is
Spilled or Released
Waste Disposal Method
Precautions to be taken in
Handling and Storing
Ventilation Requirements
Dry material can be shoveled up; liquid material can be removed with a vacuum
truck. Neutralize remaining traces with any dilute acid (hydrochloride, sulfuric, or
acetic acid (vinegar)) Flush spill area with water followed up by liberal covering of
sodium bicarbonate.
Not an RCRA Hazardous waste. Dispose of in accordance with applicable
federal, state and local regulations.
Keep from getting wet to preserve usefulness.
Maintain positive ventilation.
SECTION 8 — SPECIAL PROTECTION INFORMATION
Page 6 of 31
Respiratory Protection
Eye Protection
Skin Protection
Other Clothing & Equipment
Work/Hygiene Practices
Ventilation
A NIOSH approved respirator for toxic dust is recommended if the
PEL/TLV is exceeded.
Safety glasses or goggles.
Rubber gloves should be worn to prevent excessive or repeated skin contact.
Work clothing or coveralls to minimize skin contact.
Avoid creating dust.
Provide ventilation to maintain a dust level below the PEL/TLV.
SECTION 9 — TRANSPORT INFORMATION
U.S.A. DOT
General
Not regulated.
Non-hazardous; non-restricted.
SECTION 10 — SPECIAL PRECAUTIONS
TSCA Listing
All ingredients are on the TSCA inventory, or exempt.
May contain trace amounts of crystalline silica (quartz). In the event a dust cloud is
created the exposure limits are as follows:
The information contained herein is believed to be accurate. However, it is provided solely for the customer's consideration,
investigation and verification. Advanced Ceramics Manufacturing hereby specifically disclaims any and all warranties, express or implied,
regarding the accuracy and completeness of such information, and makes no representations with respect thereto.
Page 7 of 31
Page 8 of 31
INSTRUCTIONS
Aquacore™ — WSC 1024
The ACM water-soluble mandrel material, Aquacore™, has been formulated with a minimum amount of water to
enable it to be easily formed into complex shapes. Aquacore™ comes ready to use, no additional water is needed
for production.
If Aquacore™ has notably separated; we recommend placing the product in a shallow trough or bucket
and kneading it by hand until thoroughly mixed.
Aquacore™ is porous and may need to be sealed. Aquaseal™, a water-soluble and thermally stable
sealer, is recommended for sealing the mandrel. No special disposal procedures need to be followed for the
washed mandrel material, as it is completely environmentally friendly. Aquacore™ is compatible with the curing
temperatures of all commercial pre-preg resins.
NOTE: Mix Aquacore™ thoroughly before beginning Step 1
1. Form material into the desired shape by packing into a mold or shaping it by hand.
2. Remove material from mold.
3. Dry material in a convection oven at 125°C (257°F).
The material can also be dried at temperatures below 125°C (257°F). However,
Aquacore™ is very thermally stable and can withstand temperatures in excess of 195°C
(383°F).
Drying times for Aquacore™ vary according to the part geometry and surface area.
For example, a cylinder measuring 2 inches in diameter and 6 inches in length will require
approximately 1.5 hours of drying time at 125°C (257°F) or approximately 2 hours at 95°C
(203°F). Objects much larger in diameter are also dried at the same
temperatures. Drying times will increase at approximately 1 hour per inch in diameter at 125°C
(257°F) and at 1.5 hours per inch in diameter at 95°C (203°F).
To avoid cracking, we recommend turning the oven off with the mandrel inside and
letting the mandrel cool in the oven. This prevents thermal shock.
4. Once dried, lay up composite material around Aquacore™ and cure according to the
specifications of the material.
5. After cure, simply wash with tap water to remove the mandrel particulate.
For additional assistance, please contact Advanced Ceramics Manufacturing at 520.547.0850.
Page 9 of 31
Date
Manufacturers Name
Address
Hazard Ratings
October 14, 2008
Health — 1
Flammability — 0
Reactivity — 0
Product Name
Formula
Synonyms
Chemical Name
AQUACORE™
Not available
None
Refer to Section 2
Product Information Telephone Number: 520.547-0850
Notes
Materials:
Water Soluble Binder
Ceramic Microspheres
Aquacore™ has no known hazardous properties. The formula is proprietary information
and is the property of Advanced Ceramics Manufacturing.
WT%
TLV (mg/m³)
1%-30%
10%-90%
NE
10 ( I ) / 3 ( R )
( T ) - Total
Established
( R ) - Respirable
PEL (mg/m³)
CAS Number
NE
15 ( T ) / 5 ( R )
( I ) - Inhalable
66402-68-4
( NE ) - Not
Boiling Point
Specific Gravity
Vapor Density
Appearance & Odor
N/A
(H2O = 1): 0.54
[at 250 psi/1.72 MPa Compaction]
N/A
White solid with no detectable odor.
N/A
Flash Point
Procedures
Stability
Conditions to Avoid
Noncombustible
N/A
Stable
None Known
N/A
Unusual Fire &
Explosion Hazard
N/A
Eye Contact
Page 10 of 31
Skin Contact
Inhalation
Ingestion
Signs & Symptoms of
When machining in the cured state, repeated exposure to dust may cause
delayed lung injury.
No known hazard.
May result in cough, dyspnea, wheezing, or impaired pulmonary functions.
Medical Conditions
N/A
Routes of Exposure
N/A
Effects of Overexposure
N/A
Eyes
Skin
Inhalation
Ingestion
Medical Conditions
Remove to fresh air.
No known hazard.
N/A
Hazardous
conditions.
Hazardous
Polymerization
conditions.
Conditions to Avoid
Stability
None known.
None known.
Spilled or Released
Shovel or scoop into container for use, if possible, or disposal.
Not a listed toxic chemical under SARA Title III, 302, 304 or 313.
Keep container closed to avoid dry out.
Eye Protection
Skin Protection
Ventilation
Use of a Class NIOSH N95 respirator where dust is generated is recommended.
Chemical resistant safety glasses or goggles as a minimum.
U.S.A. DOT
General
Not regulated.
Page 11 of 31
TSCA Listing
Page 12 of 31
Page 13 of 31
INSTRUCTIONS
Aquacore™ Premium — WSC 6001
The ACM water-soluble mandrel material, Aquacore™ Premium, has been formulated with a minimum amount of
water to enable it to be easily formed into complex shapes. Aquacore™ Premium comes ready to use, no additional
water is needed for production.
If Aquacore™ Premium has notably separated; we recommend placing the product in a shallow trough
or bucket and kneading it by hand until thoroughly mixed.
Aquacore™ Premium is porous and may need to be sealed. Aquaseal™, a water-soluble and thermally
stable sealer, is recommended for sealing the mandrel. No special disposal procedures need to be followed for the
washed mandrel material, as it is completely environmentally friendly. Aquacore™ Premium is compatible with the
curing temperatures of all commercial pre-preg resins.
NOTE: Mix Aquacore™ Premium thoroughly before beginning Step 1
1. Form material into the desired shape by packing into a mold or shaping it by hand.
2. Remove material from mold.
3. Dry material in a convection oven at 125°C (257°F).
The material can also be dried at temperatures below 125°C (257°F). However,
Aquacore™ Premium is very thermally stable and can withstand temperatures in excess of
195°C (383°F).
Drying times for Aquacore™ Premium vary according to part geometry and surface
area. For example, a cylinder measuring 2 inches in diameter and 6 inches in length will require
approximately 1.5 hours of drying time at 125°C (257°F) or approximately 2 hours at 95°C
(203°F). Objects much larger in diameter are also dried at the same temperatures. Drying times
will increase at approximately 1 hour per inch in diameter at 125°C (257°F) and at 1.5 hours per
inch in diameter at 95°C (203°F).
To avoid cracking, we recommend turning the oven off with the mandrel inside and
letting the mandrel cool in the oven. This prevents thermal shock.
4. Once dried, lay up composite material around Aquacore™ Premium and cure according to
the specifications of the material.
5. After cure, simply wash with tap water to remove the mandrel particulate.
Page 14 of 31
Date
Manufacturers Name
Address
Hazard Ratings
March 21, 2006
Health — 1
Flammability — 0
Reactivity — 0
Product Name
Formula
Synonyms
Chemical Name
AQUACORE™ PREMIUM
Not available
None
Refer to Section 2
Notes
AQUACORE™ PREMIUM has no known hazardous properties. The formula is proprietary
information and is the property of Advanced Ceramics Manufacturing.
Boiling Point
Specific Gravity
Vapor Density
Appearance & Odor
N/A
(H2O = 1): 0.59
N/A
N/A
Flash Point
Procedures
Stability
Conditions to Avoid
Noncombustible
N/A
Stable
None known
N/A
Unusual Fire &
Explosion Hazard
N/A
Eye Contact
Skin Contact
Inhalation
Ingestion
Signs & Symptoms of
Medical Conditions
When machining in the cured state, repeated exposure to dust may cause
delayed lung injury.
No known hazard.
N/A
Page 15 of 31
Routes of Exposure
N/A
N/A
Eyes
Skin
Inhalation
Ingestion
Medical Conditions
No known hazard.
N/A
Hazardous
conditions.
Hazardous
Polymerization
conditions.
Conditions to Avoid
Stability
None known.
None known.
Spilled or Released
Shovel or scoop into container for use, if possible, or disposal.
Not a listed toxic chemical under SARA Title III, 302, 304 or 313.
Eye Protection
Skin Protection
Ventilation
Use of Class M respirator where dust is generated is recommended.
U.S.A. DOT
General
Not regulated.
TSCA Listing
Page 16 of 31
Page 17 of 31
INSTRUCTIONS
Aquafill™ — WSF 5003
Shelf Life: 30 days from DOM
Aquafill™ has been specially formulated to fill, patch or bond the water-soluble mandrel materials Aquacore™,
Aquacore™ Premium and Aquapour™. Once applied, Aquafill™ will give the surface of the mandrel a smooth
porcelain-like feel.
Once the mandrel is dried, there may be small defects on the surface of the mandrel formed by air
bubbles in the material. Apply Aquafill™ to the mandrel to patch these defects.
Tips for Applying Aquafill™
Aquafill™ has been pre-mixed and is ready to use.
The best method of applying the material is using a rubber squeegee commonly used in auto body
applications.
Simply spread Aquafill™ on the mandrel in a very thin coat making sure to fill in all
imperfections on the surface.
If applied too thick, the surface may be bumpy, or it may result in decreased mandrel solubility. Aquafill™
can be sanded to a smooth finish once it has dried.
Allow at least 30 minutes between coats. Aquafill™ does not need to be dried in an oven, simply allow
to air dry.
The washout time for Aquafill™ is slightly longer than that of Aquacore™, and Aquapour™. The edges of
the mandrel may need additional soaking time of about 15 minutes before coming out of the finished part.
The material can be washed away under a faucet or with a standard low-pressure garden hose.
No special procedure is needed the disposal of the product; Aquafill™ is completely
environmentally friendly.
Page 18 of 31
INSTRUCTIONS
Mixing & Using 3-Part Aquafill™ — WSF 5003
Shelf Life: 30 days from DOM
Kit contains three parts: Part A, Part B and Part C.
To Mix:
1. Place all of Part A in mixing bucket
2. Add all of Part B and slowly mix for 5 minutes
3. Add all of Part C and mix well until a smooth, even consistency is achieved
- approximately 12-15 minutes
For smaller batches, follow above steps using:
40% of Part A by weight, 40% of Part B by weight and 20% of Part C by weight
Aquafill™ has been specially formulated to fill, patch or bond the water-soluble mandrel materials
Aquacore™, Aquacore™ Premium and Aquapour™. Once applied, Aquafill™ will give the surface of the mandrel a
smooth porcelain-like feel.
Once the mandrel is dried, there may be small defects on the surface of the mandrel formed by air
bubbles in the material. Apply Aquafill™ to the mandrel to patch these defects.
Tips for Applying Aquafill™
The best method of applying the material is using a rubber squeegee commonly used in auto
body applications.
Simply spread Aquafill™ on the mandrel in a very thin coat making sure to fill in all
imperfections on the surface.
If applied too thick, the surface may be bumpy, or it may result in decreased mandrel
solubility. Aquafill™ can be sanded to a smooth finish once it has dried.
Allow at least 30 minutes between coats. Aquafill™ does not need to be dried in an oven,
simply allow to air dry.
The washout time for Aquafill™ is slightly longer than that of Aquacore™, and Aquapour™.
The edges of the mandrel may need additional soaking time of about 15 minutes before coming out of
the finished part.
The material can be washed away under a faucet or with a standard low-pressure garden
hose. No special procedure is needed the disposal of the product; Aquafill™ is completely
environmentally friendly.
For additional assistance, please contact Advanced Ceramics Manufacturing at 520.547.0850.
Page 19 of 31
Date
Manufacturers Name
Address
Hazard Ratings
March 21, 2006
Advanced Ceramics Manufacturing, LLC.
Health — 0
Flammability — 0
Reactivity — 0
Product Name
AQUAFILL™
Formula
Not available
Synonyms
Chemical Name
None
Refer to Section 2
Notes
Aquafill™ has no known hazardous properties. The formula is proprietary
information and is the property of Advanced Ceramics Manufacturing
Boiling Point
Specific Gravity
Vapor Density
Appearance & Odor
212°F/100°C
(H2O = 1): 1.0
N/A
White paste with no detectable odor.
N/A
Flash Point
N/A
Procedures
N/A
Stability
N/A
Conditions to Avoid
N/A
N/A
Unusual Fire &
Explosion Hazard
N/A
Eye Contact
Skin Contact
Inhalation
Ingestion
N/A
No known hazard.
Signs & Symptoms of
N/A
Medical Conditions
N/A
Page 20 of 31
No specific information available.
Routes of Exposure
N/A
Eyes
Skin
Inhalation
Ingestion
Medical Conditions
If dry sanded, provide ventilation to maintain a dust level below the PEL/TLV.
N/A
No components used in this formula are listed as carcinogenic.
Hazardous
Hazardous
Polymerization
Conditions to Avoid
Stability
conditions. During decomposition the toxic fumes of carbon monoxide, carbon dioxide,
nitrogen oxides, aldehydes, carboxylic acids, and smoke.
conditions.
None known.
Avoid strong oxidizing agents.
Spilled or Released
Mop up and place in a closed container and hold for waste disposal, or reuse.
Eye Protection
Skin Protection
Ventilation
A NIOSH approved respirator for toxic dust is recommended if the PEL/TLV is
exceeded.
Safety glasses or goggles.
U.S.A. DOT
General
Not regulated.
TSCA Listing
Page 21 of 31
INSTRUCTIONS
Aquaseal™ — WSS 3818
Aquaseal™ has been specially formulated to seal the water-soluble mandrel materials Aquacore™, Aquacore™
Premium and Aquapour™.
Form the mandrel material into the desired shape and dry it in a convection oven to cure. Once the
mandrel is dried and cooled, apply Aquaseal™ to seal the product prior to usage. It will take 3-4 coats to acquire the
desired finish.
NOTE: Aquaseal™ is not to be used on mandrel
prior to drying in convection oven
Tips for Applying Aquaseal™
Shake sealer well before applying it to the mandrel, as settling is common.
Aquaseal™ can be sprayed or brushed onto the mandrel.
Aquaseal™ can be sprayed on with an airless sprayer.
Aquaseal™ can be applied with any brush suitable for latex
or water-based paint.
It will take several coats to obtain the desired finish on the
mandrel material.
Recommendation: Spray the first coat onto the mandrel and allow to dry. Once the first
coat is dry, you can continue to spray or brush the additional coats.
Drying times for Aquaseal™ vary according to humidity and room temperature. It will be
necessary to apply 3-4 coats. We have added an environmentally safe dye to aid in detecting how
well the sealer is applied.
Allow approximately 30 minutes drying time in an oven at 100ºF between coats for
sealer to dry properly.
To remove, simply wash out mandrel material and sealer with tap water. Room
temperature water will remove sealer, but heated water will significantly increase the wash out
process.
Aquaseal™ takes slightly longer to dissolve than the mandrel, but still requires only
water. Soaking in water for 15 minutes will loosen sealer. No special procedure is needed for the
disposal of the product; Aquaseal™ is completely environmentally friendly.
Page 22 of 31
Date
Manufacturers Name
Address
Hazard Ratings
March 21, 2006
Advanced Ceramics Manufacturing, LLC.
Health — 0
Flammability — 0
Reactivity — 0
Product Name
Formula
Synonyms
Chemical Name
AQUASEAL™ 3818
Not available
None
Refer to Section 2
Notes
Aquaseal™ 3818 has no known hazardous properties. The formula is proprietary
Boiling Point
Specific Gravity
Vapor Density
Appearance & Odor
212°F/100°C
(H2O = 1): 1.0
<1
Blue or clear liquid with slight sweet odor.
75-85
Flash Point
N/A
Procedures
N/A
Stability
N/A
Conditions to Avoid
N/A
N/A
Unusual Fire &
Explosion Hazard
Solid active ingredient heated in open flame can produce potentially toxic
substances.
Eye Contact
Skin Contact
Inhalation
Ingestion
N/A
No known hazard.
Signs & Symptoms of
N/A
Medical Conditions
N/A
Page 23 of 31
Routes of Exposure
N/A
Eyes
Skin
Inhalation
Ingestion
Medical Conditions
No specific information available, but unlikely route of exposure.
N/A
Hazardous
Hazardous
Polymerization
Conditions to Avoid
Stability
Small amounts of hydrogen chloride.
conditions.
None known.
None known.
Spilled or Released
Soak up with inert absorbent such as sand, earth or vermiculite and put in closed
container for prompt disposal.
Eye Protection
Skin Protection
Ventilation
No special respiratory requirements — unlikely route of exposure.
N/A
U.S.A. DOT
General
Not regulated.
TSCA Listing
General
Avoid freezing temperatures. Heating solid active ingredients above 500°F may
cause formation of potentially toxic substances. Wash hands thoroughly after handling.
Do not smoke while using, nor contaminate with tobacco products.
Page 24 of 31
Instructions for Fastcore & Rapidcore Mandrels
!!! MOST IMPORTANT !!!
FASTCORE MANDRELS ARE EXTREMLY WATER SOLUBLE AND THEREFORE HAVE TO BE
KEPT DRY AT ALL TIME!!!
OPEN THE MANDREL-PACKAGE ONLY JUST PRIOR TO THE LAYUP!
A Fastcore mandrel consists of two components. The internal body is a highly porous water soluble ceramic
material and the exterior is a sealer. The sealer could be either a Teflon-tape film or Aquaskin. The Aquaskin is
also water soluble, although designed as to be less soluble than the internal ceramic to allow for handling and
the application of mold release.
Mandrels sealed with Aquaskin are usually used in composite applications up to 250F. Teflon tape is
recommended for applications above 250F and up to 350F.
Fastcore mandrels arrive in a sealed bag for the purpose of keeping the mandrel protected from ambient
humidity and natural skin moisture. The vacuum bag does not protect the mandrel from impact damage.
The mandrel should be maintained in the vacuum bag until the time of lay-up. The mandrel may be stored
indefinitely in the vacuum bag, but should be stored in a cool location.
The mandrel is labeled. The label includes Mandrel ID, PO and most important a weight factor in Grams. This
value is the weight of the complete mandrel including package. As the mandrel arrives ensure that the mandrel
did not pick up any moisture by simply weighing the complete package and comparing the factor with the
weight factor written on the bag of the mandrel.
Talk to an ACM- Sales representative if you have any more questions regarding shipping and handling of the
Fastcore mandrel.
MOLD RELEASE
Page 25 of 31
Mold release such as FreKote 700-NC® may be used to create a non tacky surface between the applied
composite and the Fastcore mandrel sealed with Aquaskin. ACM does not specifically endorse any brand of
mold release, and customer feedback has shown Aquaskin sealer is amendable to mold releasing with many
materials depending on process requirements.
Note: The Aquaskin material will soften with increased temperature. Accordingly, heat should not be applied to
flash solvent or mold release. Room temperature application of mold release and any de-bulking is suggested. It
is important to always minimize contact of mandrel with solvent as they may lead to a failure of the mandrel
during processing.
Mandrels sealed with Teflon tape may not require further release materials.
CURING
Temperature
The Fastcore mandrels are designed to operate in a range of operating conditions. Be sure that your specific
mandrel has been approved for the desired processing conditions before continuing.
Utilization of thermal cure processes such as pre-preg or high temp resins may require several hours of the
mandrel at desired temperature.
To ensure a successful composite part, the placement of thermal couples is important. Proper placement will
ensure the mandrel is not over heated and able to maintain proper dimensional properties.
NOTE: Overheating of the mandrel may result in distortion of the finished composite part.
Thermal couples should ideally be placed between the applied material and the mandrel. This will ensure that
the applied material is able to reach the measured temperature.
The thermocouple should never be placed into the mandrel as the Fastcore will act to insulate the ovens thermal
gradient and force the controller to drastically overshoot the desired set point.
Unless otherwise stated the Fastcore mandrel should never be heated above 350‘F.
Non-Uniform thermal gradients in the user‘s autoclave or oven may cause damage to the mandrel if the critical
temperature is exceeded. High temperature mandrels are suggested to be cured at 340‘F to allow for fluxuation
up to 350‘F. Please contact your ACM-Sales representative if you need further assistance regarding thermal
processing.
Pressure
Consolidation of composites is essential to developing full strength. Accordingly the majority of processes
require the composite laid up mandrel to undergo various pressures and temperatures as discussed above.
Page 26 of 31
Again it is important that the mandrel that is provided is qualified for the specific process. Fastcore mandrels
may be prepared using a variety of mandrel-materials to reach the desired properties for each specific
application process.
Please check to ensure that your processing conditions are compliant which the Fastcore mandrel provided.
The application of pressure to the mandrel is very similar to any other material. Ramp rates and cycle times are
defined by the composite system and should follow the manufactures‘ specification.
However due to the hygroscopic (Water Loving) nature of the water soluble Fastcore material constant attention
must be given to ensure the mandrel comes in contact with as little moisture as possible.
In addition it is important to maintain full vacuum throughout the processing cycle on the mandrel to ensure that
if any residual moisture is released during the process that it is able to be removed from the system by way of
the vacuum.
NOTE: Always keep the vacuum operating during composite curing.
REMOVAL
To clean out the mandrel, simply apply tap water to an exposed surface of the mandrel.
Some Washout Tips:
If a Fastcore mandrel with Aquaskin sealer has been used, mechanically break the surface of the Aquaskin, thus
exposing the more porous ceramic core. Remove the core with agitation, leaving only the Aquaskin layer
residing in the composite. Next just allow the part to soak overnight, this will increase the speed of wash-out
and minimize the labor in the Aquaskin removal process. The use of high pressure and/or warm/hot water also
increases the speed of material removal.
If a Fastcore mandrel has been provided with Teflon Tape, simply washout the core material and then pull out
the complete Teflon tape. This process can be simplified when applying water between the composite part and
the Teflon coating.
The mandrel material is a green product, and is environmentally friendly; nevertheless the ceramic material will
clog drains. Therefore, we recommend capturing the ceramic and disposing of the material in a dumpster.
Please contact Advanced Ceramics Manufacturing at 520-547-0850 with any concerns or questions.
Page 27 of 31
Request Sheet for Fastcore & Rapidcore Mandrels
File Preparation
All files must be in the form of either “.IGS or .STP” for proper communication of data to our software
platform. Please ensure that the units are also provided for which the part is measured. Files may be transferred
by email info@acmtucson.com . In the event that the file is of proprietary nature please make sure to annotate
the file name accordingly with the term ―confidential‖.
Example ―Airbus Part 34d-cx CONFIDENTIAL.igs‖
All confidential files will be stored in a secure location and destroyed at the request of the customer.
Customers who are in need of further protection can make other arrangements such as contract or PIA
agreements. DO NOT FORGET – ACM is AS9100B CERTIFIED – and therefore required to have
documentation control and customer property logs in house.
Processing Information
Complete processing parameters are required to ensure mandrel success:
Desired Mandrel Tolerances:
______________________ (Ex +/- 0.015 Inch)
Mandrel Usage Process:
______________________ (Closed mold, RTM, Vacuum, Wet layup etc)
Mandrel Processing Temperature: ______________________ (C) Maximum Mandrel Temperature
Mandrel Processing Pressure:
______________________ (Psi/MPa) Maximum Mandrel Pressure
Processing Duration:
______________________ (‗Hr) Total Time Exposed to Above Condition
Sealing Method
Customers are encouraged to try the two current sealing methods prior to Rapid Core to select the desired
surface finish and removal properties. Current methods include a high temperature Teflon tape sealer or
complete water soluble sealer Aquaskin.
Desired Sealing Method:
______________________ (Aquaskin/Teflon Tape)
Note: Be sure to review the Fastcore/Rapidcore mandrel instruction sheet for proper
handling of water soluble mandrels.
Page 28 of 31
t: 520.547.0850 ● f: 520.547-0851 ● www.acmtucson.com
Date
Manufacturers Name
Address
Hazard Ratings
November 1, 2010
Health — 2
Flammability — 0
Product Name
Formula
Synonyms
Chemical Name
Reactivity — 0
FastCore & RapidCore
Not available
None
Refer to Section 2
Product Information Telephone Number:
520.547-0850
Chemtrec (Spill Related Emergencies):
800.424.9300
Notes
Fastcore & RapidCore has no known hazardous properties. The formula is proprietary
Boiling Point
Specific Gravity
Vapor Density
Appearance & Odor
N/A
(H2O = 1): 0.54
N/A
N/A
Flash Point
Procedures
Stability
Conditions to Avoid
Noncombustible below 500'F
N/A
Stable
material may act as an oxidizer due to the presence of small amounts of caustic.
Autoignition Temperature
N/A
Unusual Fire &
Explosion Hazard
N/A
Eye Contact
Skin Contact
Inhalation
Ingestion
Signs & Symptoms of
Medical Conditions
When machining in the cured state, repeated exposure to dust may cause . Special
consideration should be given to avoid dust.
delayed lung injury. Presence of Crystiliine Silica may be possible as the product is derived
No known hazard.
N/A
Page 1
MSDS Aqua_MASTER
Routes of Exposure
N/A
N/A
Eyes
Skin
Inhalation
Ingestion
Medical Conditions
Never give anything by mouth to an unconscious person. Do not induce vomiting if
swollowed.Give large glasses of water or milk. Seek medical attention.
N/A
Hazardous
None are to be anticipated under normal or recommended handling and storage conditions.
Hazardous
Polymerization
None are to be anticipated under normal or recommended handling and storage conditions.
Conditions to Avoid
Stability
Storing with acids or metals
Acids
Spilled or Released
Dry material can be shoveled up, liquid material can be removed with a vacuum truck.
Neutralize remaining traces with any dilute inorganic acid (hydrochloride, sulfuric or acetic
acid). Flush spill area with water followed up by liberal covering of sodium bicarbonate.
All clean-up material should be removed for proper treatment or disposal . Spills on other than
pavement (e.g. dirt or sand) may be handled by removing the affected soil and placing in
approved containers.
Eye Protection
Skin Protection
Ventilation
Use of a Class M respirator where dust is generated is recommended.
U.S.A. DOT
General
Not regulated.
TSCA Listing
investigation and verification. Advanced Ceramics Manufacturing hereby specifically disclaims any and all warranties, express or implied
Page 2
MSDS Aqua_MASTER
Page 31 of 31

Aquacore - Advanced Ceramics Manufacturing

Transcription

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