Functionalization of CFRP surfaces by TP films

F. Weiland, M&P Research and Projects, 11.9.14

Content

• Motivation: Project MAI Fo • Materials • Applications and results

– Corrosion protection – Non structural bonds – Structural bonds

• Outlook

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Thermoplastic films offer an endless variety of surface functions - Protection (thermal, mechanical) - Interfaces (for assembly) - Optical (illuminated, signal) - Integration of circuits and sensors and many more Films on a part surface… - concentrate the functions were needed without

influencing the component performance itself - M&P of the component itself can remain widely unchanged - Supplier capabilities can be integrated more easily into value creation chain

Motivation

By understanding and managing the application of films, numerous functions become available for the CFRP engineer

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Project MAI Fo

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Project name MAIfo: „Entwicklung von Prozessketten zur Herstellung teilfolierter Faserverbundbauteile“

Projekt coordinator Airbus Helicopters

Budget 2,35 Mio €

Duration 01.05.13 - 30.04.16

Partner BMW, BASF, LCC, AHD

MAI Fo: AHD application targets

Three film functions are targeted within MAI-Fo

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complexity

Targeted maturity (within MAI Fo)

TP film selection

Criteria • Interphase formation • Solubility with resin systems

HEXCEL M18/1 and RTM6 • Tg > 200

C • Resistance against media No solubility: PI, TPI Tg too low: SRP, PSU, COC Films not manufacturable: PPC, PBI, PAI n.a. yet: HTS

Go on with: PEI, PES, PPSU (PPE)

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[Plastics Technology]

Applications

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Org

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Corrosion protection

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• Assembly of frame segments by aluminium brackets

• difference of electrochemical potenital causes contact corrosion

• State of the art: protection by paint

Intermediate steps

grinding

cleaning

Primer and paint application

Cutting, layup, compaction

a/c cycle

rework

drying

old/new approach for frame manufacturing

Film preparation

Film application

Frame assy Lower frame

bracket

rivet

film

Potential process time savings: 7.5%

part

man

ufac

ture

A

pply

pro

tect

ion

Salt spray testing

PEI film suitable as corrosion protection

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• Salt spray test: • 5% NaCl spray • 2024 aluminium alloy,

chromated …after 1000h:

• No protection: Corrosion on aluminium plate

• Protective paint: No corrosion • PES sample: showed degradation

in salt spray • PEI sample: No corrosion

PEI

No protection Paint

PES

Non structural bonding

Whole process chain through connection of MAI projects

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• 1000+ click bonds and electrical supports per h/c • adhesive joints, manual application Film integration and welding on TP surface:

Projects MAI Fo and MAI Plast (AGI)

material process part w/

film surface

joining Characterisation of assembly

testing

@ Airbus Group Innovation

40 mm

Cost saving potential for click bond application

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Marking

Cleaning substrate

Cleaning C-B

adhesive

curing

Primer

Grinding of substrate

Cutting, layup

a/c cycle

rework

Film preparation

Film application

Welding

Old/new approach for click bond attachment

Bas

e pa

rt m

anuf

actu

re

Clic

k bo

nd a

pplic

atio

n

time

- 14% - 31%

Adhesive bonding

Welding easy accesible c/b

Welding all accesible c/b

Time consumption click bond application

Interphase formation, PES and PEI

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• Both PEI and PES form interphases and bond to epoxy prepreg and infusion resin during cure cycle (180

C)

• interphase formation takes place below Tg

• Interphase thickness is between 30 µm und 50 µm • Interphase formation mechanisms and means to influence

the formation is investigated at LCC Presentation tomorrow • Translation into consequences for a serial application

is done between LCC and the industry partners

Prepreg-PEI Prepreg-PES RTM-PES

Mechanical Characterisation

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Substantial increase of GIC for PEI confirmed

[AHD/LCC]

Outlook

• Corrosion protection: Technology assessed beneficial from technical and economical point of view: Certification aspects for coming h/c programs to be evaluated

• Non-structural bonds: high cost saving potential identified and promising mechanical strength confirmed further mechanical characterization and concentration of welding technologies

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Potential of TP films for cost saving and function integration could be confirmed and will be further pushed towards a serial application at Airbus Helicopters

Thank you for the attention

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