Smart Tooling Options for November 20, 2017 Resin Transfer ... · 11/20/2017 · Resin Transfer...

Smart Tooling Options for Resin Transfer Molding (RTM)

Composite Fabrication

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November 20, 2017

A disruptive tooling solution that enables

fabrication of composite products with

higher through-put, improved quality and

lower cost

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SMART TOOLING IS …

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Smart Tooling Technology Overview

…An aerospace-grade, rigid epoxy at room temperature…

…And a flexible, though tough elastomer when heated above activation temperature

It’s a Shape Memory Polymer that behaves like…

Smart Caul Mandrel VARTM

Spintech, LLC. proprietary information 4

• Carbon reinforced, net-shaped, High Tg, Smart Caul Mandrel for inner mold line part control

- Carbon reinforced Smart Caul Mandrel is rigid to 250F and CTE matched to final part

• Rigid Smart Caul Mandrel for over-braided or broad good dry fiber layup

• Vacuum bag over Smart Caul Mandrel and VARTM resin into preform

- VARTM directly onto Smart Caul Mandrel for higher fiber content part

• Smart Caul Mandrel rigid to support cure temperatures up to 250F, then during 350F post cure step transitions to elastomeric for extraction

- Many qualified infusion resin systems are already compatible with 250/350F cure cycles

High Temp Caul Material – Purple Line in Graph to Right

Blue Region – High Temp Caul Rigid Operating Temperatures Red Region – High Temp Caul Elastic Operating Temperatures

Features/Benefits Part inner mold line (IML) control Lowest cost manufacturing option

presented Low capital requirement Medium fiber volume (15 Psi

compaction Compatible with complex part

shapes

Smart Caul Mandrel Match Die Tooling RTM


High Temp Caul Material – Purple Line in Graph to Right Blue Region – High Temp Caul Rigid Operating Temperatures

Red Region – High Temp Caul Elastic Operating Temperatures

• Carbon reinforced, net-shaped, High Tg, Smart Caul Mandrel for inner mold line part control

- Carbon reinforced Smart Caul Mandrel is rigid to 250F and CTE matched to final part

• Metal RTM mold on part outer mold line (OML) for OML part control

• Rigid Smart Caul Mandrel for over-braided or broad good dry fiber layup

• Resin Transfer Mold (RTM) into dry fiber preform between Smart Caul Mandrel and RTM clamshell mold

• Smart Caul Mandrel rigid to support cure temperatures up to 250F, then during 350F post cure step transitions to elastomeric for extraction

- Many qualified infusion resin systems are already compatible with 250/350F cure cycles

Features/Benefits Part IML and OML control Compatible with complex part

shapes Low pressure RTM

Smart Caul Bladder RTM


Low Temp Caul Material – Green Line in Graph to Right Blue Region – High Temp Caul Rigid Operating Temperatures Red Region – High Temp Caul Elastic Operating Temperatures

• Net shaped Smart Caul Bladder is rigid for lay-up at room temperature

• Smart Caul Bladder and dry fiber preform are loaded into OML control RTM mold

• Dry fiber preform is infused using RTM (Smart Caul Bladder can either be rigid or elastic, transition temperature at 170F)

• Once infusion is complete the cure cycle is started and Smart Caul Bladder transitions to elastomeric , 200F

• Once elastic a cavity pressure of 90 Psi is applied to expel excess and compact laminate

• Cure is complete with Smart Caul Bladder in elastomeric state compacting laminate

• Once cure is complete Smart Caul Bladder is extracted while above activation

Features/Benefits Part outer mold line (OML)

control High fiber volume (90 Psi

compaction) Compatible with complex part

shapes Low pressure RTM

Smart Caul Mandrel VARTM Demonstration

VARTM Demonstration


- Using existing tooling created in the likeness of the F-35 main inlet duct, Smart Tooling manufactured a carbon reinforced, high temperature Smart Mandrel

- The Smart Mandrel was “over-braided” with stock braided carbon fiber - Fiber weights were logged - Spintech used existing braid, no specific efforts were made to achieve a target fiber

angle, part thickness, or fiber density

VARTM Demonstration Cont.


- The demonstration article used 3 layers of carbon braid: 6”ID +/- 45 deg biaxial 4.84 ft/lb, 19 oz/sq

- The dry fiber pre-form was VARTM infused with Epon 862 onto the rigid Smart Mandrel and cured initially at 250F to set the shape of the laminate

- After completion of the 250F cure the infusion media was removed from the Smart Mandrel and the part and Smart Mandrel were heated to 350F to post cure the part and soften the Smart Mandrel for extraction

VARTM Demonstration Results


Additional Part Images


VARTM Part Fiber Volume


Smart Caul Weight: 0.5538 Kg

Smart Caul & Lay-up Weight: 0.8505 Kg

Dry Fiber Weight: 0.2967 Kg

Final Part Weight (w/ Caul): 0.9856 Kg

Final Part Only Weight: 0.4318 Kg

Resin Weight: 0.1351 Kg

Fiber Volume by Weight: 68.71% Fiber

Fiber Density = 1.76 g/cm^3 Volume of fiber = 168.57 cm^3 Resin Density = 1.17 g/cm^3 Volume of Resin = 115.05 cm^3 Fiber volume = 59.43*% * No measurement or offset of void content included in FV calculation

Part Fiber Volume Calc.


VARTM Part Surface Roughness


• 1” gauge section, drag profilometer used • Tested “flat” sections only on duct • Results are typical of multiple test sections • Areas measured were between layers of Airtech Tooltech CS5 film. (Release film was used on

first article. Expected flight articles would use liquid mold release product or homogeneous film barrier)

Smart Caul Bladder RTM Demonstration


16 Spintech, LLC. proprietary information


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The tool was infused vertically (big diameter to small diameter) using these parameters: - Resin temperature: 125F - Part Temperature: 178F (Smart Caul still in rigid state) - Infusion Pressure: Vacuum only on part cavity & 3 Psi in Smart Caul

cavity. Pressure increased on both part cavity and infusion cavity during infusion to keep resin flow rates. Final infusion pressure and caul pressure were 34 Psi.

- Cure: Once infusion complete, increase oven temperature to 265F, when Smart Caul temperature reached 200F, increased pressure to 75 Psi, vented excess resin out, closed inlet & outlet, then increased pressure to 90 Psi for cure, 250F for 4 hours.

- Cured part and Smart Caul demolded from tool together then heated to 350F for post cure and Smart Caul extraction.

Spintech, LLC. proprietary information

Results


Fiber Volume Fraction

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Fiber Content by Weight: 67.90% Fiber



Part Vacuum Integrity

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Time Vacuum Value Drop

0 Minutes -28.79 in-hg N/A

5 Minutes -28.78 in-hg +0.01

10 Minutes -28.76 in-hg +0.03

20 Minutes -28.73 in-hg +0.06

30 Minutes -28.72 in-hg +0.07


Smart Caul Bladder Demonstration Pricing


INDIRECT COSTS

Consumables $/mo

resuable vacuum bags, kitting materials, Super 77, epoxy edge wipe, solvents for cleanup 100% 1,500.00$ 1,500.00$

PPE 100% 500.00$ 500.00$

trim bits 100% 500.00$ 500.00$

Production facility ($/mo) 20' x 90' facility @ $8/sf/yr 100% 1,200.00$ 1,200.00$

Utilities WAG 100% 500.00$ 500.00$

Environmental/Process Monitoring ($/mo) $15000 over 5 yrs 100% 250.00$ 250.00$

Fabric trimming station $5000 over 5 years 100% 83.33$ 83.33$

APT ($/mo) $12000 over 5 yrs 100% 200.00$ 200.00$

Vacuum system cost ($/mo) $16000 over 5 yrs 100% 266.67$ 266.67$

Resin metering and mixing equipment $5000 over 5 years 100% 83.33$ 83.33$

Misc workstation $5000 over 5 years 100% 83.33$ 83.33$

Trim and drill station $5000 over 5 years 100% 83.33$ 83.33$

Quality workstation $5000 over 5 years 100% 83.33$ 83.33$

Misc tools $3000 over 3 years 100% 83.33$ 83.33$

Repair and Maintenance WAG 100% 1,000.00$ 1,000.00$

Unknowns % of total above 10% 641.67$

Total Indirect Costs 7,058.33$ 7,058.33$

Total Capitilization 71,000.00$

Material details

Carbon mass % 68%

Resin mass % 32%

Part trim excess (%) 5%

Mass carbon /part+exc (lb) 3.82

Mass resin /part+exc (lb) 1.80

Total mass / part+exc (lb) 5.61

Volume of parts attempted/month 43

Scrap carbon 3%

Scrap mat 0%

Scrap resin 61%

Carbon need (lbs/mo) 169

Resin need (lbs/mo) 124

Carbon price ($/lb) 21.29$

Resin price ($/lb) 7.50$

Total carbon cost ($/mo) 3,599$

Total resin cost ($/mo) 933$

Total matl cost ($/mo) 4,532$

Total consumable cost ($/unit) 70.00$

Total consumable cost ($/Mo) 3,010.00$

Rate/Month: 42 units Part Weight: 5.436 lbs. Part Price: $1,056.62 Part Price/lb.: $197.65

Cost Model Includes: Direct materials, direct labor, equipment amortized over 5 years production, indirect facilities & overhead, SG&A, fringe, misc. manufacturing overhead, scrap, and markup. Assumes tooling capitalized separately

Smart Caul Mandrel RTM Demonstration


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The tool was infused vertically (big diameter to small diameter) using these parameters: - Resin temperature: 125F - Part Temperature: 178F (Smart Caul in rigid state) - Infusion Pressure: Vacuum only on part cavity & 3 Psi in Smart Caul

cavity. Part was infused using only vacuum - Cure: Once infusion complete, increase pressure on resin and pressure

on inside of caul to 45 Psi to create hydrostatic force. Then, increase oven temperature to 255F for cure, 255F for 4 hours.



Results



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Smart Caul Bladder RTM Demonstration (Filament Wound)

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The tool was infused vertically (big diameter to small diameter) using these parameters: - Resin temperature: 125F - Part Temperature: 178F (Smart Caul in rigid state) - Infusion Pressure: Vacuum only on part cavity & 3 Psi in Smart Caul

cavity. Part was infused using only vacuum - Cure: Once infusion complete, increase pressure on resin and pressure

on inside of caul to 45 Psi to create hydrostatic force. Then, increase oven temperature to 255F for cure, 255F for 4 hours.



Results



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Smart Tooling Options for November 20, 2017 Resin Transfer ... · 11/20/2017 · Resin Transfer...

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Transcript of Smart Tooling Options for November 20, 2017 Resin Transfer ... · 11/20/2017 · Resin Transfer...