Painel Aeroespacial -2017 -...

Painel Aeroespacial -2017

Compósitos em SMC- Sheet Molding Compound :

Estrutura , propriedades e Aplicações

Palestrante: Everton Sterzo

A.Schulman Inc. in the World

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A. Schulman operate facilities in the Americas, Europe and Asia-Pacific regions. Its plants, offices and technical centers are strategically located to serve customer needs in markets throughout the world.

Rio Claro Plant

– Plant Size: 43.665,29 m²

– Built area: 8.821,13 m²

– Location: Meridian, 55

Distrito Industrial

Rio Claro – SP, Brasil

13505-610

– Inaugurated Date: 1997

– Associates: 65

Rio Claro Plant / Internal Area

Materials Engineered Tetrahedron

Chemical Structure

PropertiesProcess

Products / End Market

Chemical Structure - SMC & BMC

SMC & BMC Formulation

• Thermosetting resin - Unsaturated Polyester , Vinyl Ester , Epoxy, Phenolic

• Catalyst

• Inhibitor

• Mold Releases

• Crosslink Agents

• Reological additives

• Fillers

• Reinforcement ( Glass Fiber, Carbon Fiber ,etc)

Polymer Matrix

• Thermosseting Resin

• Basic Component that will be cure process

• Unsaturated Polyester

• Vinyl Ester

Chemical Structure - SMC & BMC

• Epoxy

• Phenolic

Chemical Structure - SMC & BMC

Polymer Matrix

• Thermosseting Resin

• Basic Component that will be cure process

Catalyst

• Increase reaction speed, Decrease activity energy , same Free Energy

Chemical Structure - SMC & BMC

• Inhibitor

Others Additives

• Mold Release

• Fillers = (o + A)eBP

Chemical Structure - SMC & BMC

• For SMC , BMC and Pultrusion, the reinforcement can be used in Chopped Strand,

continuous or mat shape.

Ingredientes %

Sílica (SiO2) 52 – 56

Óxido de Cálcio (CaO) 16 – 25

Alumina (Al2O3) 12 – 16

Óxido de Boro (B2O3) 5 – 10

Mágnésia (MgO) 0 – 5

Óxidos Alcalinos (Na2O e K2O) 0 – 2

Dióxido de Titânio (TiO2) 0 – 0.8

Óxido Férrico (Fe2O3) 0.05 – 0.4

Fluoreto (F2) 0 – 1.0

Composição do Vidro -E

• Reinforcement (Glass and Carbon Fiber)

Interface

Chemical Structure - SMC & BMC

BMC SMC Pultrusion Compression Mold Injection Mold

Process

WHAT IS BMC?

• Bulk Molding Compound (or Composite)

• Polyester resin, glass-fiber and fillers reinforced

thermoset molding compound

• Used on hot-tool press molding

• Specifically formulated for each end-use

application

• Contains 5 % to 30 % chopped strand

• Can be injection, compression or transfer

• Sheet Molding Compound (or Composite)

• Chemically-thickened, glass-fiber/Carbon-

reinforced thermoset molding compound

• Used on hot-tool press molding

• Specifically formulated for each end-use

application

• Contains ½ to 2 inch chopped glass roving

• Can be compression

WHAT IS SMC?

Press

WHAT IS PULTRUSION?

Pultrusion is a manufacturing process for producing continuous lengths of reinforced polymer structural shapes with constant cross-sections. Raw materials are a liquid resin mixture (containing resin, fillers and specialized additives) and flexible textile reinforcing fibers.

Properties

• Physical-chemical

• Thermal

• Mechanical

• Electrical

• Optical

What is a Thermoset?

A thermosetting polymer is a prepolymer in a soft solid or viscous

state that changes irreversibly into an infusible, insoluble polymer

network by curing.

.A thermoplastic polymer is a polymer that becomes pliable or

moldable above a specific temperature, and returns to a solid state

upon cooling. Most thermoplastics have a high molecular weight,

whose chains associate through intermolecular forces; this property

allows thermoplastics to be remolded because the intermolecular

interactions spontaneously reform upon cooling. In this way,

thermoplastics differ from thermosetting polymers, which form

irreversible chemical bonds during the curing process.

Thermoplastic

Heat

Thermosetting

What is a Thermoset?

Cooling

What is a Thermoset?

Thermoplastic Thermosetting

Mechanical Properties – BMC/SMC

0

50

100

150

200

250

300

350

400

450

10 15 20 25 30 35 40 45 50 55 60 65

Tensile PropertiesTe

nsi

leSt

ren

ght

(Mp

a)

Fiber content(%)

BMC

SMC

Special Materials

-CF SMC

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Materials properties Comparision

*This table uses steel as a standard by which all other processes are compared. **Costs may vary.

Propriedades x

MateriaisStamped Steel SMC/BMC Thermoplastic CF SMC Aluminum

Part

ConsolidationBaseline Excellent Excellent Excellent Very Good

Comparable

Mass100 60-75% 70% <60% >80%

Corrosion

ResistanceBaseline Superior Superior Superior Poor

Tooling Cost 100% 40% 60% 40% 115%

CLTE 100% 100-130% 600-1000% 100-130% 170-200%

HDT N/A Baseline Poor Baseline N/A

Thermoset Composite Materials

70

140

280

350

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*This table uses steel as a standard by which all other processes are compared. **Costs may vary.

CF SMC TDS

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CF SMC TDS

*This table uses steel as a standard by which all other processes are compared. **Costs may vary.

A.Schulman Laboratory

What is the SMC advantages?

• High Heat Resistance- HDT and Tg

• Dimension Stability– Lower CLTE

• Flame Retardant

• Low Smoke Emission

• Excellent Chemical Resistance

• Excellent Creep Resistance – Little to No Creep

• Tailored Glass Transition Temperatures

• Formulations which are Easily Customizable to your Application

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Why SMC?

• Part Consolidation

• High yield

• Easy handling

• Excellent properties

• Formulations which are Easily Customizable to your Application

• Low Cost

AppliancesMotorcycle AutomotiveIndustrialAgricultural Electrical AerospaceTruck

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Products/ End Market

• BMC Applications

BMC (Headlamps)

Products/ End Market

Valve Cover

Products/ End Market

• BMC Applications

BMC - Sewing Machine

Products/ End Market

• BMC Applications

Electrical Parts

Products/ End Market

• BMC Applications

SMC - Sheet Molding Compounds

Products/ End Market

Electrical

SMC - Sheet Molding Compounds

Products/ End Market

GrillGrill

SMC - Sheet Molding Compounds

Products/ End Market

Ford Troller – Structural SMC

SMC - Sheet Molding Compounds

Products/ End Market

Ford Troller – Class A SMC

SMC - Sheet Molding Compounds

Products/ End Market

Rear Floor - Renault

SMC - Sheet Molding Compounds

Products/ End Market

Empilhadeira - Nacco

SMC - Sheet Molding Compounds

Products/ End Market

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Quantum Composites material is usedextensively in tertiary and secondary

structure applications where net shape

compression molding can provide cost

and weight reduction benefits over

aluminum and other metals including cost

reduction over prepreg materials.

Aircraft companies have increased their

reliance on compression molded Lytex®

components as overall composite usage

has increased in the next generation

aircraft with higher carbon and glass fiber

composite content.

UnderGwingThermalpanel

Inboard trackfairing

Flap trackcones

LYTEX® 9063

Inboard fanduct fairing

Trailingedge fairing

Lytex is usually chosen because of its much lower part cost versus a prepreg part. A key benefit that Lytexoffers is the ability to easily mold in ribs, bosses and changes in thickness.

Hundreds of part numbers are compression molded using Lytex materials in complex geometries for

commercial aircraft

Lytex® Parts used on Commercial Jets

Products/ End Market

Seat Components

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Products/ End Market

Oxygen Canister Container for Long Haul(Boeing and Airbus) and other Regional Aircra0

Aerospace

Products/ End Market

ISO/ TS 16949:2009 ISO 9001:2008

Certificates

Certificates : ISO 140001:2004

Thank you !!!!

Everton SterzoQuality & Development ManagerEngineered Composites

A. Schulman, Inc. ║ T: 55 (19) 35261229 // C: 55 (19) 9 98172600