Celstran Thermoplastic Composites

The Material of Great Inventions

Daniel Grauer David Almond

Ticona a global company with proximity to local customers

Leading global supplier of engineering polymers Sales: 1.109 bill. US dollars (2010) Globally positioned with regional subsidiaries or dealer networks

Approx. 1630 employees ensure success of the company

Excellent technical services Broad expertise in application development Responsible Care (Environment, Health and Safety), ISO 14001 Quality management certifications (ISO 9001, ISO/TS 16949, VDA 6.3)

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The history of Ticona

*1961

*1999

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Global network strong global presence

Production and compounding plants Sales offices

Oberhausen, Germany

Winona, Minnesota Florence, Kentucky Bishop, Texas Shelby, North Carolina Wilmington, North Carolina (Fortron Industries) *

Kelsterbach, Germany

Nantong, China

Nanjing, China

Suzano, Brazil

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Celstran Thermoplastic Composites

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Celstran CFRTP Evolution

Step 1 Step 2 Step 3 Step 4

Short fiber granule fiber length = 0.20.4 mm

Wire-coated or co-mingled fibers

Fully impregnated long fiber granule fiber length = 1125 mm

Fully impregnated continuous fiber reinforced tape

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Celstran CFRTP Our Strengths

Ticona is a world leader in thermoplastic fiber impregnation technology Ticona is a world leader in thermoplastic resin technology Ticona has brand equity in engineering materials markets Our strengths are our resin fiber range, our size and experience in engineering thermoplastics, and our impregnation quality

Celstran
C F R T P = Continuous = Fiber = Reinforced = Thermo= plastic

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Celstran Why CFRTP?

Pros
CFRTPs can extend the range of physical properties attainable with reinforced thermoplastic materials by up to an order of magnitude. Extend the range of CFRTPs commercially available to include most significant resins, fibers and additives. Improve the range of useful, economical fabrication methods. Combination of easy processing of TPs with performance of composite materials.

Cons
Consolidation and fabrication methods are not well established relative to traditional thermoplastic or thermoset processing. Range of commercially available materials has been relatively limited.

Polyolefins-GF or PEEK-CF

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Celstran CFRTP and Ticona

Outstanding mechanical/thermal performance

Best fiber impregnation

Ultimate resin/fiber range

Large projects confidence Help customers to develop their new products

Ability for customized products

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Celstran Broad Portfolio

Resins
PEEK PEI PAA/PPA PA (6,66,46,12) PPS PBT/PET PC PCABS ABS PPO TPU POM PEHD TPE/TPO/TPV PP

Fibers
Carbon Fiber Aramid S-Glass E-Glass ECR-Glass Stainless Steel

Additives
Custom Color UV Stabilization Heat Stabilization Impact Enhancement Surface Appearance Flow Enhancement Paint Adhesion Conductive Particle Low Emission Lubricity/Wear Enhancement

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Celstran

Broad Possibilities
Pellets
( 1112 mm) 1 ( 25 mm) Custom

Undirectional fiber-reinforced tapes

Glass-fiber tapes: 12 mm (slit tape) 20 mm (slit tape) 25 mm (slit tape) 50 mm (slit tape) 152 mm (6) 178 mm (7) 203 mm (8) Custom Carbon-fiber tapes: 12 mm (slit tape) 20 mm (slit tape) 25 mm (slit tape) 50 mm (slit tape) 152 mm (6) Custom

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Celstran Fiber Impregnation

Transfer from pellet knowledge into CFRTPs
Impregnation of Each Filament

Fully impregnated long fiber granule

Celstran Impregnation Process

Fully impregnated continuous fiberreinforced tape

Very Good Properties for New Applications

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Celstran Benefits of Thermoplastic Composites

1. Take advantage of the full strength of the reinforcing fibers 2. Extend LFRTP mechanical specific properties by up to an order of magnitude 7. All the well-known benefits of thermoplastics Post-processable High-toughness

3. Safe, efficient, environmentally friendly

4. Modern design 5. For a wide range of different market segments 6. New applications for Celstran

Light-weight
Recyclable Environmental resistance Rapid processing Indefinite shelf life Large range of fibers and matrices

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2 F6 -C 66 58 PA F -C 66 0 PA F5 -C 66 PA F60 G SAB F50 G S0 AB F5 I-G 50 PE CF EK PE F50 C SPP F50 G SPP F60 -A U TP F5 0 -C U TP F70 -G U TP F50 C APA F60 G 60 PA 6 F C 60 PA F5 -C M 0 PO F6 -G M PO F5 5 G T0 PB F7 0 F7 PP -G H D PE -G

120

100

80

60

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Celstran CFRTPs Tensile Modulus

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Products

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[GPa]

2 F6 -C 66 8 PA F5 -C 66 0 PA F5 -C 66 PA F60 G SAB F50 G S0 AB F5 I-G 0 PE F5 -C EK PE F50 C SPP F50 G S0 PP F6 -A U TP F5 0 -C U TP F70 -G U TP F50 C APA F60 G 60 PA F6 C 60 PA F5 -C M 0 PO F6 -G M 5 F5 PO PB PP H G T0 F7 -G D PE -G

0 F7

2500

2000

1500

Celstran CFRTPs Tensile Strength

1000

500

Products

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[MPa]

Celstran Tg of Different Polymers

250 200 Tg [C] 150 100 50 0 50 100

POM TPU PE PP PA 6 PBT P A 66 PPS PP A P EI PEE K

P o l y m e rs

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Celstran Thermal key points of different polymers

350 300 250 200 150 100 50 0 50 100

Temp. in C

POM

HDPE

PP

PA 6

PBT Polymers

PA 66

PPS
Tg Tm

PEI
Ts

PEEK

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Celstran Comparison of Density

4 3.5 3
Density [g/cm3]

2.5 2 1.5 1 0.5 0

Polymers

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Celstran Comparison of Density

D e n sity vs. S tr e n g t h o f V a r i o u s M a t e r i a ls 2000 1800
Tensile strength [MPa] PEE K - C F 5 0 PP S - C F 5 0 Ep o x y - CF 6 1 PO M-CF 5 0

1600 1400 1200 1000 800 6 0 0 PBT- GF5 5 400 200 0 1

A l u m i n u m a ll o y , 6 0 6 1 - T 6 PP - G F 7 0 PO M- G F 6 0 Ep o x y - GF 4 5

S t e e l A I SI 1 0 4 5

PP S - G F 5 0

A l a ll o y 2 0 2 4 - T 3 C a s t Ir o n g r a d e 2 0

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D e n s it y [ g/c m ]

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Celstran What are the Target Markets?

Aircraft

Energy

Sport/ Leisure

Celstran

Piping

Building/ Construction

Transportation

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Celstran CFR-TP processing

Automated tape lay-up/consolidation
Winding Tape placement Double belt press Press consolidation Continuous press consolidation

Press consolidation

Fluid heat transfer under vacuum (Quickstep) Partial reinforcement

Injection molding incorporation Compression molding incorporation Extrusion incorporation

Sandwich structures

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Thank you very much for your attention

Ticona GmbH Daniel Grauer Product Management Celstran EU Professor-Staudinger-Strasse D-65451 Kelsterbach Germany www.ticona.com

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Backup

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Weight Reduction Why?

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Celstran Thermosets vs. Thermoplastics

Alternative technologies (instead of tapes) Thermosets
Wet winding Injection/Infusion of resin (dry winding/dry laying) Hand-laminating of wave SMC Pultrusion

Thermoplastics
TWINTEX Organoblech Dry winding (pipes) Consolidation by heating in a centrifuge (discontinuous process, developed at KLuB Darmstadt) Consolidation by heating and enlarge spike (continuous process, developed at KLuB Darmstadt) Pultrusion

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Celstran Thermosets vs. Thermoplastics

Critical points in process Thermosets Emission Exact mixture Hazardous waste

Thermoplastics
Pressure, temperature and speed at the consolidation point have to be coordinated, controlled and documented

Trapped air can normally not be eliminated by vacuum

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Celstran Thermosets vs. Thermoplastics

Recycling Thermosets
No chance to invert the cross- linking reaction

Thermoplastics
Melting after molding possible No system to recycle long fibers but make short fibers

Producing short fiber-reinforced recyclate after use

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Celstran Thermosets vs. Thermoplastics

Characteristics Thermosets
Has to be molded in one step Post-processing: Only machining processing possible Winding: Only geodetic ways

Thermoplastics
Elastic Thermo-deformable Very good surface roughness by centrifugal technique High impact resistance High elongation at fracture Good buckling and upsetting performance Creep In endless fiber-reinforced materials, the force is hold by the fibers. So the creep is not as important as in other thermoplastic parts. In contrast to thermosets, there is creep.

Exothermic reaction

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Celstran Thermosets vs. Thermoplastics

Handling Thermosets
Limited storage time for prepregs Dust masks are necessary because of emission Material is liquid, so every tool or work surface has to be cleaned extensively Low viscosity (easy fiber impregnation)

Thermoplastics
Unlimited storage time Prepregs have to be heated to be as flexible as the thermoset prepregs or dry fibers

Hand-lamination is impossible
High viscosity

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Celstran Thermosets vs. Thermoplastics

Cost of processing and machine acquisition Thermosets
Much hand work Hand-lamination Resin injection/infusion

Thermoplastics
Fiber and tape placement of thermoplastics are new technologies New processes have to be developed

Long cycle time because of hardening State of the art

Fewer steps to get a finished product

Less experience in processing

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Celstran Thermosets vs. Thermoplastics

Thermosets
Chemical crosslinking reaction for part manufacture Irreversible Storage in freezer for preforms Limited shelf time Part assembly Conventional nuts, bolts, screws Smell/odor

Thermoplastics
Part manufacture by physical phase transition solid-liquid-solid Wide range of different polymers PP to PEEK Repeatable Unlimited storage at room temperatures Part assembly Conventional nuts, bolts, screws Welding Environmentally friendly

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Celstran Granule/Tape Cross Section

Transfer experience from pellets into tapes

Pellet

Tape

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Celstran Fiber/Matrix Adhesion in REM

Celstran good adhesion Bad adhesion (fiber pullout)

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Celstran Comparison of Density

D e nsit y vs. M o d u l u s o f V a r i o us M a t e r i a ls 160 140
Tensile modulus [GPA] Ep o x y -CF 6 1

120 100 80 60 40 20 0 1 1.2 1.4 1.6 1.8 2

D e n s it y [ g /c m ]
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P EE K - C F 5 0

PP S - C F 5 0 PO M- CF 5 0 A l a ll o y 2 0 2 4 - T 3 A l u m i n u m a ll o y , 6 0 6 1 - T 6 PO M- GF 6 0

PP - G F 7 0

Ep o x y - G F 4 5

PBT- GF 5 5

PP S - G F 5 0

2.2

2.4

2.6

2.8

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