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Faculty of Mechanical Science and Engineering Institute of Textile Machinery and High Performance Material Technology, Professorship of Textile Technology
Development of Spun Yarn Made from Recycled Carbon Fibers for Reuse in Load-Bearing Components
Hengstermann, Martin; Abdkader, Anwar; Cherif, Chokri
Institute of Textile Machinery and High Performance Material
Technology at TU Dresden
ITMA 2015 Speakers Plattform 15.-17.11.2015
Faculty of Mechanical Science and Engineering Institute of Textile Machinery and High Performance Material Technology, Professorship of Textile Technology
Page 2
1 Introduction
© techbeyond2020
Faculty of Mechanical Science and Engineering Institute of Textile Machinery and High Performance Material Technology, Professorship of Textile Technology
Page 3
1 Introduction – Different Spinning Machinery at ITM
Lab Ring Spinning Industrial Ring Spinning Rotor Spinning
AirJet J20V3 Texturing Machine DREF 2000/3000
Faculty of Mechanical Science and Engineering Institute of Textile Machinery and High Performance Material Technology, Professorship of Textile Technology
Page 4
1 Introduction – Special Textile Machinery for rCF
Special rCF Card Special rCF Draw Frame Special rCF Spinning Frame
Faculty of Mechanical Science and Engineering Institute of Textile Machinery and High Performance Material Technology, Professorship of Textile Technology
Page 5
2 Motivation
Carbon Fiber Waste
Faculty of Mechanical Science and Engineering Institute of Textile Machinery and High Performance Material Technology, Professorship of Textile Technology
Page 6
2 Motivation
1. Rising demand for carbon fiber and their applications
2. High amount of waste in the production and preforming
3. Increasing percentage of used carbon fiber
4. High purchase price of carbon fiber
5. Disposal problem of CF waste
Need for reuse of the used carbon fiber (rCF)
DFG Project CH 174/34-1
Source: AIRBUS S.A.S.
Source: BMW AG
Source: Carbon Composite e.V.
Source: ELG Carbon Fiber
Source: io9.com
Faculty of Mechanical Science and Engineering Institute of Textile Machinery and High Performance Material Technology, Professorship of Textile Technology
Page 7
2 Motivation
Schematic Yarn Structure
Carbon Staple Fiber
Thermoplastic Staple Fiber
Hybrid Yarn:
Staple Fiber Yarn:
Carbon Staple Fiber
Yarn Count:200-2000 tex
Schematic Yarn Structure
Faculty of Mechanical Science and Engineering Institute of Textile Machinery and High Performance Material Technology, Professorship of Textile Technology
Page 8
2 Motivation
Advantages and Challenges of rCF Yarn Production
+ Useful disposal of carbon fiber waste
+ Re-use for load-bearing components
+ Implementation as hybrid yarn for thermoplastic application
cheap and fast consolidation of CFRP
+ High mixing level of the rCF fiber and thermoplastic matrix
fiber allows optimum consolidation
+ Higher Drapeability with Carbon Staple Fiber Yarn in
Preforms
Brittle CF and lack of crimp problem. i.e. need improved
spinning process low fiber damage for high strength
CFRP
Faculty of Mechanical Science and Engineering Institute of Textile Machinery and High Performance Material Technology, Professorship of Textile Technology
Page 9
3 rCF Hybrid Yarn
Fabric Production
Mixing
Thermoplastic
fiber
rCF- Staple
fiber
Carding Drafting
Consolidation
Fiber Mix Carded WebDraw Frame
Sliver
Hybrid Yarne.g. UD-
WindingCFRP
Yarn
Formation
Faculty of Mechanical Science and Engineering Institute of Textile Machinery and High Performance Material Technology, Professorship of Textile Technology
Page 10
3 rCF Hybrid Yarn
Types of Fiber used in this Project:
1. Cut Primary Carbon Fiber
2. CF Waste of semi-finished products
manufacturing
3. CF Waste of pyrolyzed CFRP parts
4. Cut Primary PA6 Fiber
I. Material for Hybrid Yarn
Faculty of Mechanical Science and Engineering Institute of Textile Machinery and High Performance Material Technology, Professorship of Textile Technology
Page 11
Carbon Staple Fiber
I. Material for Hybrid Yarn
PA6 Staple Fiber
3 rCF Hybrid Yarn
Faculty of Mechanical Science and Engineering Institute of Textile Machinery and High Performance Material Technology, Professorship of Textile Technology
Page 12
Mix of rCF and PA6 fiber
II. Opening and Mixing rCF and PA6 fiber
3 rCF Hybrid Yarn
Faculty of Mechanical Science and Engineering Institute of Textile Machinery and High Performance Material Technology, Professorship of Textile Technology
Page 13
ITM Special rCF Card
Metallic Card Clothings
Roller Distances
III. Web Formation
3 rCF Hybrid Yarn
Carded rCF Web
Faculty of Mechanical Science and Engineering Institute of Textile Machinery and High Performance Material Technology, Professorship of Textile Technology
Page 14
rCF-Sliver Slivers with 30%, 50% and
70% vol. rCF
IV. Drawing to sliver
3 rCF Hybrid Yarn
Faculty of Mechanical Science and Engineering Institute of Textile Machinery and High Performance Material Technology, Professorship of Textile Technology
Page 15
→
rCF Hybrid Yarn
V. Spinning to Yarn
3 rCF Hybrid Yarn
Faculty of Mechanical Science and Engineering Institute of Textile Machinery and High Performance Material Technology, Professorship of Textile Technology
Page 16
Fiber Cross-Section
4 Testing rCF Hybrid Yarn
CF (small
white dots)
PA6 (big grey dots)
Very good
mixing of fiber
Faculty of Mechanical Science and Engineering Institute of Textile Machinery and High Performance Material Technology, Professorship of Textile Technology
Page 17
Yarn strength
4 Testing rCF Hybrid Yarn
60 mm cut rCF
Faculty of Mechanical Science and Engineering Institute of Textile Machinery and High Performance Material Technology, Professorship of Textile Technology
Page 18
Consolidated Plate
Hot Press with Vacuum
UD-Winding Frame
4 Testing rCF Hybrid Yarn
Consolidation
Faculty of Mechanical Science and Engineering Institute of Textile Machinery and High Performance Material Technology, Professorship of Textile Technology
Page 19
Draw Frame Sliver with
100% rCF
Card Sliver with 100% rCF
100% rCF Yarn, 880tex
5 100% rCF Yarn (Cut Fiber)
Faculty of Mechanical Science and Engineering Institute of Textile Machinery and High Performance Material Technology, Professorship of Textile Technology
Page 20
6 Outlook
Pending Investigations:
• Twist of rCF Yarns
• Spinning of 100% rCF Yarns (Pyrolysis)
• Improving Matrix Fiber
• Testing of Carbon Fiber Characterization
• Yarn Simulation
Further Investigations:
• Industrial Production of rCF yarns
• Manufacturing of semi finished parts and CFRP
Source: RJTA Vol. 15 No. 1 2011
Faculty of Mechanical Science and Engineering Institute of Textile Machinery and High Performance Material Technology, Professorship of Textile Technology
Thank you for
your kind attention!
We would like to thank German Research Foundation (DFG)
for the financial support for this reasearch work !
Contact: [email protected]
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