The partnership is creating a new materials sub-facility called the Materials Solutions Network which will drive composite manufacturing into a physics-based exact science that can be predicted and modelled allowing faster implementation of low-cost, short-term and limited-life technologies.

It is hoped the new facility will allow breakthroughs in materials, processes and designs for aerospace and military components. The ability to process material models faster than ever will enable shorter times toward certification of new materials and difficult processing methods such as additive manufacturing.

The beamline will allow manufacturers and researchers to observe materials in real-time and at atomic scale for structural components such as the stationary section of a rotary system for DOD technologies or additively manufactured articles for limited life applications.

Obtaining tangible measurement data such as material structure in regards to gaps and interfacial quality is now a reality. Problems and processes can be eliminated sooner and refined for quality control and consistency.

Traditionally, composites manufacturing is mainly done by hand. Hence, the processing is as much art as it is science. Predictive modelling relies on numerous assumptions and experimental data. Reproducibility is low and ever-changing to new and improved material.

This development pushes a real-time, high-resolution understanding of the manufacturing of composites. The research reveals processing effects and variations on thermoplastic and thermoset composites during consolidation processes such as stamping and additive manufacturing.

Two new X-ray beamlines – a structural materials beamline (for which higher-energy X-rays are required to penetrate, e.g., metals) and a functional materials beamline (with lower energies for polymers and composites) are housed at the facility.

The structural materials beamline uses high energy X-rays to understand the evolving internal structure of metals, ceramics and composites during service and processing conditions.

The functional materials beamline is designed for analysis of soft materials, such as organic molecule and polymer-based materials and composites used in lightweight structural components and organic electronics, during processing and under real-life load conditions.

The X-ray beam at the functional materials beamline is only one-hundredth of the width of a human hair and can probe interfaces between the matrix and the carbon fibre, between layers of printed composites and of bonded structures. Images can be taken at fractions of a second to enhance quality control in revealing behaviour during processing. The beamline allows quick switching between different operating modes, such as small-angle X-ray/wide-angle X-ray scattering, phase contrast imaging and X-ray computed tomography.

Partnerships between the Department of Defense, industry and academia to address DOD challenges in materials discovery, processing and manufacturing of disruptive technologies will enable advances in materials and designs for a multitude of military components.

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The company is investing heavily in thermoplastic composites technology development and has joined the research centre based in the Netherlands as a tier 1 member, which grants Solvay access to the centre’s research and the ability to steer on fundamental development activities, which are complementary to Solvay’s internal research such as forming and over-moulding, cost-effective manufacture of large structures, material performance and sustainability.

The ThermoPlastic composites Research Center (TPRC) is a consortium of industrial and academic members active in the thermoplastic composites industry. We believe in thermoplastic composites as the material for lightweight manufacturing in large volumes. Our primary aim is to enable more widespread use of thermoplastic composites by eliminating technological barriers.

Solvay’s research and innovation experts will work hand in hand with the TPRC on selected projects where we see joint benefits. Solvay and the TPRC are both committed to increasing the adoption of TPC by the aerospace and automotive industries and our membership will strengthen our ability to contribute to industry developments Dr Jim Pratte, Senior Research Fellow for Solvay Composite Materials Global Business Unit

Solvay recently opened a Product Development Center in Alpharetta USA and Customer Engagement Center in Brussels which will work closely with the TPRC as we start engaging in joint collaboration projects.

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CFRP materials, both thermoplastic and thermoset, are created when thousands of carbon filament threads are bundled together before being combined with a matrix to form a composite material. A ply or layer is made to the specified size and orientation, and then more layers are added until the piece has the necessary properties to support the loads it will carry. The resulting material is composed of approximately 60% fibres and 40% resin.

Thermoplastic CFRP has superb fatigue and damage tolerance properties, along with shorter manufacturing cycles and lower moisture absorption. It can even be welded, which cannot be done with thermoset-type CFRP.

According to Airbus researchers the key difference between thermoplastic and thermoset CFRP is what happens during their individual curing processes. When you put ‘raw’ thermoset material into an autoclave and ‘cook’ it, there’s a chemical reaction, the actual chemical composition of the material changes however with thermoplastic composites, you can melt a finished piece and reshape it and it still has the same chemical composition.

This difference makes thermoplastic composites very attractive. Why? Because Airbus and its suppliers produce literally hundreds of tonnes of scrap thermoplastic composites each year, With thermoset, you would need to burn the resin, and all you end up with are the fibres the remaining 40% of resin is lost. With thermoplastic composites, the scrap produces the same amount of recycled material, which could be used in a variety of structural and interior applications.

Thermoplastic-type composites also do not require curing in an autoclave and can be stored at ambient temperature without need of a freezer equating to significant reductions in energy costs. Thermoset composites have become more prevalent in the air transport sector over the years because it is perceived, sometimes incorrectly, to be cheaper.

There are many suppliers of thermoset, which drove down the cost, but now, there are more and more thermoplastic composites manufacturers entering the market, so prices are coming down. Still, even before the A350 XWB, Airbus had more than 1,500 reference parts made from thermoplastic composites and its use will continue to grow.

The post Why Airbus Are Focusing on Thermoplastic Composites appeared first on Composites Today.

Manufactured using advanced compounding techniques that maximise fibre integrity, the company say these new ultra performance structural compounds achieve strength and stiffness properties higher than previously available products. Combining the higher mechanical properties and lower densities of carbon fibre with the excellent thermal and chemical resistance provided by using high temperature resin systems allows these injection mouldable thermoplastic materials to close the performance gap between plastics and metals.

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Products are available in high temperature resin systems with carbon fibre reinforcement loadings from 20-40% to provide performance options that meet a broad range of requirements for demanding applications in energy, industrial, aerospace, automotive, and medical markets that previously required aluminum, zinc, and magnesium metals.

Matt Torosian, High Temperature Product Manager at RTP Company said;

These materials will allow more product designers to take advantage of the design freedoms plastics offer. That translates into weight reduction opportunities, having the ability to overcome design limitations through part consolidation and optimisation, and to reduce manufacturing cost and shorten production time by obtaining net shape parts through a one-step injection molding process that eliminates secondary operations.

In addition to structural characteristics, RTP Company can incorporate other capabilities during compounding, such as wear and friction resistance at high pressure/velocity ratios without needing external lubricants. PEEK, PEI, and PPS materials are inherently flame retardant and often chosen for their low burning toxicity, but flame retardants can also be added to PPA to increase product safety.

Ultra Performance Structural Compounds and all other products from RTP Company are available and supported worldwide through their global facilities that provide technical support from design through finished part production.

For more information on this product, you can download their product bulletin here.

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