Raising performance through composites tooling - Highlight

1. Advanced Materials Raising performance through composites tooling Quarter 4, 2012

2. Advanced Materials 2 Table of contents From design to manufacturing Link from design to composites manufacturing Design model Design model Master model Master model RenShape board materials for master model RenPaste seamless modeling paste for master model SMP vs. Board materials RenPaste solution for PEUGEOT Composite tools Composite tools Compared advantages RenLam, Ren and RenGel selection New development Araldite LY 8615 solution for AIRBUS

3. Advanced Materials 3 Link from design to manufacturing < Table of content Design model > Master model >From design to manufacturing > Composite tools >

12. Advanced Materials 12 Design model Design / styling model is mostly used by automotive, marine and aerospace industry. Design / styling model is involved in the very early stage of part manufacturing. Main features and benefits !! Not functional !! For design aesthetic !! Suitable for market research, mock-ups, and trading fare !! Full size or scale model !! CNC machined from CAD Huntsman offers solutions for manufacturing of design / styling model with its very low density board materials and seamless modeling pastes. < Table of content Design model > Master model >From design to manufacturing > Composite tools >

13. Advanced Materials 13 Master model Once a composite part has been designed and captured in a digital format, the CAD program can be used to create a master model, known in the marine and wind industry as plug, by using a CNC milling machine. Main features and benefits !! Physical standard for production of mold !! Composite mould for limited production !! Full size model Huntsman offers solutions for manufacturing of master model / master plug with its board materials and seamless modeling pastes. < Table of content Design model > Master model >From design to manufacturing > Composite tools >

14. Advanced Materials 14 RenShape board materials Board materials description !! Polyurethane or Epoxy based !! Available in standardized size and density !! Cut and bonded to molding blanks !! CNC machining from CAD < Table of content Design model > Master model >From design to manufacturing > Composite tools >

15. Advanced Materials 15 RenShape board materials Main features !! Very fine surface structure !! Excellent machinability !! Good dimensional stability !! High heat resistance Benefits !! Ideal for lay up tools for prepregs !! Low CTE !! Bonding with dedicated adhesives XB 5055 A+B RenShape BM 5055 CTE 40 10-6K-1 HDT 140C Hardness 75 Shore D Density 0.75 g/cm3 Compressive strength 75 MPa < Table of content Design model > Master model >From design to manufacturing > Composite tools >

16. Advanced Materials 16 RenPaste seamless modeling paste Seamless modeling paste description !! Epoxy based !! 2 components extrudable paste !! Hand or machine application !! Applied with a metering / mixing machine on substrate !! CNC machined from CAD after curing of the paste !! Once milled, no joints or voids are visible (seamless material) < Table of content Design model > Master model >From design to manufacturing > Composite tools >

17. Advanced Materials 17 RenPaste seamless modeling paste Main features !! Very fine and seamless surface !! Quick model build up !! Room temperature curing !! Heat resistance up to 55C Benefits !! Ideal for design and styling models !! Low density RenPaste SV 4503-1 / Ren HV 4503-1 < Table of content Design model > Master model >From design to manufacturing > Composite tools > CTE 100 10-6K-1 HDT 55C Hardness 60 Shore D Density 0.7 g/cm3 Compressive strength 15 MPa

18. Advanced Materials 18 RenPaste seamless modeling paste Main features !! Rapid cure at room temperature !! Excellent adhesion to EPS !! Rapid and easy machining !! Heat resistance up to 80C Benefits !! Ideal for master models / plugs and short production-run molds !! Programmable paste rheology (10 to 40 mm) !! High slump resistance RenPaste 4666 / Ren 4666 < Table of content Design model > Master model >From design to manufacturing > Composite tools > CTE 75 10-6K-1 HDT 95C Hardness 65 Shore D Density 0.95 g/cm3 Compressive strength 20 MPa

19. Advanced Materials 19 Critical properties of master model RenPaste products are ideally dedicated for rapid production of large model / tool requiring seamless finish with easy repair and present additional advantages during processing to reduce wastage and to be easy machined. SMP vs. Board materials < Table of content Design model > Master model >From design to manufacturing > Composite tools >

20. Advanced Materials 20 Design model of show car Peugeot Flux Made by D3 design studio with RenPaste 4666 / Ren 4666 Benefits !! Optimal reproduction of contours allowed by the programmable rheology and surface quality !! Short lead time due to fast cure and machining RenPaste solution for PEUGEOT < Table of content Design model > Master model >From design to manufacturing > Composite tools >

21. Advanced Materials 21 Composite tools Composite mold / tool describes a form with convex respectively concave shape and will be used to fabricate the final composite part with a concave respectively convex finished surface. Main features and benefits !! Production of composite parts !! Manufactured by wet-lay up, infusion and prepreg Depending on size, geometry, temperature resistance and durability requirement, Huntsman offers solutions for manufacturing of composite mold / tool with its product range of laminating systems, laminating pastes and gelcoats. < Table of content< Table of content Design model > Master model >From design to manufacturing > Composite tools >

22. Advanced Materials 22 Compared advantages Typical and critical properties Material Density Thermal conductivity Coefficient of thermal expansion Temperature resistance Cost (2) Durability (3) SMP (1) +++ - - - ++ - GFRP ++ - ++ + ++ - CFRP +++ - +++ + + - Aluminum + +++ - + ++ + Stainless steel - ++ + ++ +++ +++ Invar 36 - + ++ ++ - +++ < Table of content< Table of content Design model > Master model >From design to manufacturing > Composite tools > (1) Direct to mold (2) Manufacturing cost not included (3) Number of manufactured composite parts / production cycle

23. Advanced Materials 23 Compared advantages Benefits !! Low cost tooling method !! CTE of composite tooling compatible with laminate !! Low density easier to handle than metal !! By damage, fast and economical production of new tool Challenges !! Withstand severe temperature / pressure !! Durability !! Heatable < Table of content< Table of content Design model > Master model >From design to manufacturing > Composite tools >

24. Advanced Materials 24 RenLam, Ren and RenGel selection Standard epoxy systems for composite mold manufacturing Product designation Application Process Viscosity Pot life Demolding time Tack time* Cure cycle Ultimate Tg Ultimate flexural elongation Conditions 25C 250 ml, 25C 25C Unit mPa.s min h C C % RenGel XD 4615 / Ren HY 5159 surface coat brush roll thixotropic 25 - 30 1* up to 120 120 - 130 - RenGel P99 / Ren HY 5159 coupling coat brush roll thixotropic 30 12 up to 100 120 - RenLam LY 113 / Ren HY 98 laminating system wet lay-up infusion 300 90 - 100 12 (23C) up to 120 120 - 125 7.0 7.6 < Table of content< Table of content Design model > Master model >From design to manufacturing > Composite tools >

25. Advanced Materials 25 RenLam, Ren and RenGel selection High performance epoxy systems for composite mold manufacturing < Table of content< Table of content Design model > Master model >From design to manufacturing > Composite tools > Product designation Application Process Viscosity Pot life Demolding time Tack time* Cure cycle Ultimate Tg Ultimate flexural elongation Conditions 25C 500 ml, 25C 40C Unit mPa.s h h C C % RenGel SW 5200 / Ren HY 5212 surface coat brush roll thixotropic 10 (250 ml) 24 (25C)* up to 200 200 - RenLam LY 5210 / Ren HY 5212 laminating system wet lay-up 2 000 12 14 up to 200 230 - 238 - RenLam LY 5210 / Ren HY 5213 laminating system wet lay-up 1 800 2 - 2.5 14 up to 180 170 - 180 - Araldite LY 8615 / Aradur 8615 laminating system infusion 480 - 580 14 -16 (100 ml) 24 up to 180 210 - 220 2.7 - 3.7 Araldite LY 8615 / XB 5173 laminating system infusion 300 - 350 5 - 6 (100 ml) 24 up to 180 210 - 220 4.1 - 5.1

26. Advanced Materials 26 New development Application !! Large-scale mold for composite !! Suitable for various production process Main features and benefits !! Low viscosity !! Long pot life !! High heat resistance !! Low temperature gelation and demolding (40C) !! Free-standing post-cure possible !! No need of surface coat Mid Tg infusion RenLam LY 120 / Ren HY 99 < Table of content< Table of content Design model > Master model >From design to manufacturing > Composite tools > Viscosity at 25C 40 10-6K-1 Pot life at 25C 230 min Gel time at 40C 100 min Ultimate Tg 155C Ultimate elongation 7%

27. Advanced Materials 27 New development Compared properties vs. other mid Tg competitive system Pot life comparison (min) RenLam LY 120 / Ren HY 99 shows an excellent balance between long pot life, low viscosity and high heat resistance. < Table of content< Table of content Design model > Master model >From design to manufacturing > Composite tools >

28. Advanced Materials 28 New development Compared properties vs. other mid Tg competitive system Viscosity comparison (mPa.s) RenLam LY 120 / Ren HY 99 shows an excellent balance between long pot life, low viscosity and high heat resistance. < Table of content< Table of content Design model > Master model >From design to manufacturing > Composite tools >

29. Advanced Materials 29 New development Compared properties vs. other mid Tg competitive system Tg comparison (C) RenLam LY 120 / Ren HY 99 shows an excellent balance between long pot life, low viscosity and high heat resistance. < Table of content< Table of content Design model > Master model >From design to manufacturing > Composite tools >

30. Advanced Materials 30 New development New infusion and new prepreg epoxy system Application !! Mold for production of high heat resistant composite parts !! Serial and prototype production Evident durability improvement vs. current laminating system Durability comparison (number of cycles**) * Combined with RenGel SW 5200 / Ren HY 5212 ** Rating based on vacuum permeability, Heat resistance and ILSS after thermal ageing 1 cycle: heating 25-180C (3C/min) + 2h at 180C + cooling 180-25C + 1h at 25C < Table of content< Table of content Design model > Master model >From design to manufacturing > Composite tools >

31. Advanced Materials 31 Composite mold for Airbus A350 - Lower panel section 11-12 of the fuselage Produced by LOIRETECH (France) with Araldite LY 8615 / Aradur 8615 Process Infusion Benefits Easily processable and suitable for large molds production !! Long work life and infusion at low temperature (23-40C) !! Demolding after low temperature precure (35-40C) High perfomance !! Tg > 180C after post curing !! Withstand more than 300 production cycles (Airbus 10-4 mbar.l/s mold leak requirement / CETIM) Araldite LY 8615 solution for AIRBUS < Table of content< Table of content Design model > Master model >From design to manufacturing > Composite tools >

32. Advanced Materials 32 Keep our products at your fingertips View the brochures on SlideShare With these brochures get an overview of our comprehensive range of tooling solutions for master models and composites production. Download our mobile apps on your smartphone With these apps select immediately the right: !!Araldite industrial adhesive for your specific need !!Araldite composite formulated system for your process / application Access the product description or send us an email to request the technical data sheet. Araldite - Adhesives (Europe) Download on iPhone | Android Huntsman - Composite resins (Europe) Download on iPhone | Android

33. Advanced Materials 33 For more information www.huntsman.com/advanced_materials [email protected] 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

34. Legal Disclaimer Copyright 2012 Huntsman Corporation or an affiliate thereof. All rights reserved. The use of the symbol herein signifies the registration of the associated trademark in one or more, but not all, countries. While the information and recommendations included in this publication are, to the best of Huntsman s knowledge, accurate as of the date of publication, nothing contained herein is to be construed as a representation or warranty of any kind, express or implied.

Raising performance through composites tooling - Highlight

Technology

long pot life

master model

composite tools

development compared properties

seamless modeling pastes

high heat resistance

heat resistance

manufacturing