Raising performance in wind industry - Highlight

Raising performance in wind industry - Highlight
Advanced Materials Raising performance in wind industry Quarter 1, 2014
Table of contents Advanced materials in wind turbines Tooling Shell manufacturing Bonding Manufacturing Composites process Araldite® for wet lay-up process Araldite® for infusion process Araldite® for prepreg process Bonding Araldite® structural adhesives Araldite® adhesives for repair and maintenance Advanced Materials 2
Advanced materials in wind turbines < Table of content Advanced materials > Manufacturing > Bonding > Tooling §  §  §  §  Seamless modeling pastes for master models Infusion systems Gelcoats Wet lay-up Mold Advanced Materials 3
Advanced materials in wind turbines < Table of content Advanced materials > Manufacturing > Shell manufacturing §  §  §  Bonding > Root Infusion systems Wet lay-up systems Prepreg systems Shell Advanced Materials 4
Advanced materials in wind turbines < Table of content Advanced materials > Manufacturing > Bonding > Shell manufacturing §  §  §  Root Infusion systems Wet lay-up systems Prepreg systems Spar Shell Advanced Materials 5
Advanced materials in wind turbines < Table of content Advanced materials > Manufacturing > Bonding > Bonding §  §  Structural adhesives Ancillary adhesives for assembly and repair Adhesives Advanced Materials 6
Advanced materials in wind turbines < Table of content Advanced materials > Manufacturing > Bonding > Shell manufacturing §  §  §  Root Infusion systems Wet lay-up systems Prepreg systems Girder Shell Advanced Materials 7
Advanced materials in wind turbines < Table of content Advanced materials > Advanced Materials Manufacturing > Bonding > 8
Three different processes < Table of content Advanced materials > Advanced Materials Manufacturing > Bonding > 9
Pastes for master model < Table of content Advanced materials > Manufacturing > Bonding > RenPaste® SV 4503-1 / Ren® HV 4503-1 RenPaste® 4666 / Ren® 4666 Typical applications Design and modeling Modeling and plugs Color Brown Dark grey 0.7 - 0.8 0.95 - 1.0 Mix ratio 100 : 100 100 : 100 Hardness shore D 55 - 60 60 - 65 Density g/cm3 CTE 10-6/K-1 100 - 105 75 - 80 HDT °C 45 - 50 50 - 55 / 80 after post-cure Compression strength MPa 10 - 12 20 Compressive modulus MPa 550 - 600 1 100 - 1 200 Flexural strength MPa 11 - 12 19 - 20 Linear shrinkage mm/m 1 0.4 Advanced Materials 10
Infusion systems with heat resistance 120-150°C < Table of content Advanced materials > Manufacturing > Bonding > RenLam® LY 113 / Ren® HY 98 RenLam® LY 120 / Ren® HY 99 Typical applications Mold production Mold production Process Wet lay-up / infusion Infusion Viscosity at 25°C mPa.s 300 300 - 350 Pot life 100 ml min 90 - 100 210 - 230 Demolding time h 12 at 23°C 24 at 40°C Cure cycle °C up to 120 up to 150 Ultimate Tg °C 120 - 125 153 - 158 Flexural strength MPa 127 - 130 120 - 126 Ultimate flexural elongation % 7.0 - 7.6 7.0 - 7.1 A selection of compatible coupling layers and surface coats are available Advanced Materials 11
Wet lay-up and infusion systems with heat resistance 180-200°C < Table of content Advanced materials > Manufacturing > Bonding > RenGel® SW 5200 / Ren® HY 5212 RenLam® LY 5210 / Ren® HY 5212 Araldite® LY 8615 / Aradur® 8615 Araldite® LY 8615 / XB 5173 Typical applications Mold production Mold production Mold production Mold production Process Wet lay-up Wet lay-up Infusion Infusion Viscosity at 25°C mPa.s Thixotropic 2 000 480 - 580 300 - 350 Pot life 500 ml h 10 12 14 - 16 (100 ml) 5 - 6 (100 ml) Demoulding time h 14 at 40°C 14 at 40°C 24 at 40°C 24 at 40°C Cure cycle °C up to 200°C up to 200°C up to 180°C up to 180°C Ultimate Tg °C 200 230 - 238 210 - 220 210 - 220 Flexural strength MPa 88 88 82 - 86 113 - 117 Ultimate flexural elongation % - - 2.7 - 3.7 4.1 - 5.1 Advanced Materials 12
Wet lay-up process < Table of content Advanced materials > Manufacturing > Bonding > Advantages §  §  §  Low investment cost Very easy process Every part possible Limitations §  §  Limited fiber content Laminate quality Advanced Materials 13
Araldite® composite resin systems for wet lay-up process < Table of content Manufacturing > Advanced materials > TYPICAL KEY DATA Bonding > PROPERTIES OF THE CURED, NEAT FORMULATION Glass transition temperature Gel time Mix viscosity Cure cycle Conditions at 80°C at 25°C at 23°C Unit min mPa.s Araldite® LY 3505 / Hardener XB 3403 36 - 48 Araldite® LY 3505 / Hardener XB 3404-1 Araldite® LY 3505 / Aradur® 3405 Mechanical properties Tg DSC Cure cycle Tg DSC Flexural modulus Ultimate elongation G1C days °C h °C MPa % J/m2 300 - 400 8 49 - 53 4 at 60°C + 6 at 80°C 78 - 83 3 100 - 3 300 10.5 - 13 250 - 280 11 - 18 550 - 800 8 48 - 52 4 at 60°C + 6 at 80°C 76 - 81 3 450 - 3 600 6.5 - 9.5 160 - 200 5 - 11 1 000 - 1 200 8 55 - 60 4 at 60°C + 6 at 80°C 87 - 92 3 450 - 3 600 7.0 - 9.0 150 - 190 4 at 60°C + 6 at 80°C 92 - 98 3 100 - 3 400 9 - 11 130 - 170 Standard products Higher viscosity for vertical applications Araldite® LY 1556 / Aradur® 3405 6-9 1 500 - 1 800 All these composite resin systems are Germanischer Lloyd (GL) certified Advanced Materials 14
Infusion process < Table of content Advanced materials > Manufacturing > Bonding > Advantages §  §  §  §  §  Void free laminates Short cycle time High quality reproducibility Hygienic process Price versus quality Limitations §  Cutting and handling of dry fibers Advanced Materials 15
Araldite® composite resin systems for infusion process < Table of content Advanced materials > Manufacturing > TYPICAL KEY DATA Bonding > PROPERTIES OF THE CURED, NEAT FORMULATION Glass transition temperature Gel time Mix viscosity Cure cycle Tg DSC Conditions at 80°C at 25°C at 50°C Unit min mPa.s h °C Araldite® LY 1564 / Aradur® 3486 33 - 43 200 - 300 15 Araldite® LY 1564 / Aradur® 3416 20 - 27 200 - 320 Araldite® LY 1564 / Aradur® 3487 18 - 25 Araldite® LY 1568 / Aradur® 3489 Araldite® LY 1568 / Aradur® 3492 Mechanical properties Cure cycle Tg DSC Flexural modulus Ultimate elongation G1C h °C MPa % J/m2 66 - 70 8 80 - 84 2 900 - 3 050 10.5 - 12.5 260 - 310 15 68 - 73 8 80 - 85 2 900 - 3 050 10 - 12 260 - 310 220 - 320 15 68 - 73 8 81 - 86 2 950 - 3 100 10 - 12 255 - 305 43 - 46 200 - 300 15 61 - 65 8 77 - 80 2 910 - 3 010 9 - 10 170 - 210 23 - 25 250 - 350 15 74 - 78 8 80 - 85 2 900 - 3 100 7 - 7.5 210 - 230 at 80°C All these composite resin systems are Germanischer Lloyd (GL) certified Advanced Materials 16
Prepreg process < Table of content Advanced materials > Manufacturing > Bonding > Advantages §  §  §  §  Well defined resin content Excellent fiber wet out Clean handling Hygienic process Limitations §  §  §  More expensive product Storage Impregnated waste Advanced Materials 17
What is a B-stage < Table of content Advanced materials > Manufacturing > Bonding > Chemical B – stage §  §  Chemical pre-reaction of the matrix system (adduct, pre-polymerization) Degree of conversion always below the gelation point of the system Advanced Materials 18
What is a B-stage < Table of content Advanced materials > Manufacturing > Bonding > Physical B – stage (1) Hot melt §  “Melting” of a high viscous system mix (1 or x component) at elevated temperatures in order to decrease the viscosity during the period of the impregnation process (hot melt process) Advanced Materials 19
What is a B-stage < Table of content Advanced materials > Manufacturing > Bonding > Physical B – stage (2) Solvent containing systems §  §  Formulation of high viscous system mix in solvent in order to enable fiber impregnation Evaporation of the solvent after impregnation process using a drying tower Advanced Materials 20
Araldite® composite resin systems for prepreg process < Table of content Advanced materials > Manufacturing > Bonding > Tack, reactivity adjustable, long shelf life, curable from 80 - 90°C TYPICAL KEY DATA PROPERTIES OF CURED, NEAT FORMULATION Glass transition temperature Mechanical properties Tg max DSC Flexural modulus Elongation at break G1C Mix viscosity B stage Shelf life Cure cycle Conditions at 25°C at 23°C at 23°C at 120°C Unit mPa.s h weeks h °C MPa % J/m2 Araldite® LY 1556 / Aradur® 1571 / Accelerator 1573 / Hardener XB 3403 *** 4 000 - 6 000 24 - 48 >6 2 105 - 110 2 900 - 3 100 7 - 10 130 - 170 Resin XU 3508 / Aradur® 1571 / Accelerator 1573 / Hardener XB 3403 (tough system) 6 650 - 7 100 24 >4 4 120 - 125 2 650 - 2 800 5.5 - 8.0 850 - 915 *** Germanischer Lloyd (GL) certified Advanced Materials 21
Araldite® structural adhesives for shell and shear web bonding < Table of content Advanced materials > Product Manufacturing > Mix ratio Conditions Bonding > Pot life LSS* Typical Tg Gap filling Cure cycle Key features 23°C, 100 g Unit v/v min MPa °C mm h Araldite® AW 4856 GB / Hardener HW 4856 GB 100 : 50 240 - 280 20 - 25** 75 - 85 up to 50*** RT or 5 h at 70°C Outstanding impact and fatigue resistance No slumping on vertical surfaces up to 50 mm Araldite® AW 4856 GB / Hardener HW 4856 fast GB 100 : 50 30 - 40 20 - 25** 75 - 85 Up to 50*** RT or 5 h at 70°C Outstanding impact and fatigue resistance No slumping on vertical surfaces up to 50 mm All these composite resin systems are Germanischer Lloyd (GL) certified * LSS: lap shear strength on EP GRP induced stresses in thick joint Advanced Materials ** Substrates delamination or failure *** Bond line thickness of 20-25 mm is recommended to avoid exothermic effect as well as excessive 22
Araldite® structural adhesives < Table of content Advanced materials > Mix ratio Conditions Manufacturing > Pot life Bonding > LSS* Typical Tg Gap filling Cure cycle Key features 23°C, 100 g Unit v/v min MPa °C mm h Araldite® AV 4076-1 / Hardener HV 5309-1 1:1 50 - 65 20 - 24 70 - 80 2-5 RT or 4 h at 60°C Root joint steel insert bonding Araldite® 2015 1:1 45 - 60 15 - 18 70 - 80 2-7 RT or 4 h at 60°C Bonding of lightning conductor, monitor sensors, ideal for dissimilar substrates Araldite® 2031 1:1 50 - 65 20 - 24 70 - 80 2-5 RT or 4 h at 60°C For insert or composite (CFRP, GRP) bonding Araldite® 2014-1 2:1 50 - 65 15 - 18 75 - 85 5 RT or 4 h at 60°C Bonding tip, control shaft components, high temperature and chemical resistance, ideal for metals Araldite® AW 5047-1 / Hardener HW 5067 100 : 45 65 - 80 20 - 22 70 - 80 < 0.5 1h at 80°C Liquid system, ideal for metal bonding, temperature resistant up to 180ｰC Araldite® AW 4510 / Hardener HW 4511 2:1 85 -100 14 - 16 110 - 125 10 2h at 110°C Non sagging paste, for gap filling or vertical application, high temperature resistance * LSS: lap shear strength on aluminum Advanced Materials 23
Araldite® adhesives for repair and maintenance < Table of content Advanced materials > Mix ratio Conditions Manufacturing > Pot life Bonding > LSS* Typical Tg Gap filling 23°C, 100 g Cure cycle Key features at 23°C Unit v/v min MPa °C mm h Araldite® 2021 1:1 5 - 15 20 - 22 65 - 80 3-5 1 Very fast setting, tough adhesive for rapid fixing and filling of small voids Araldite® 2022 1:1 10 - 20 20 - 22 65 - 80 3-5 2 Medium open time and fast curing tough adhesive for field/ workshop operations Araldite® 2048 10 : 1 10 - 20 20 - 22 65 - 75 5-8 1 Rapid attachment of parts, high flexibility and gap filling adhesive Araldite® 2047-1 10 : 1 15 - 25 10 - 14 70 - 80 3-5 2 Rapid attachment of parts, multipurpose adhesive, ideal for dissimilar substrates Araldite® 2029 1:1 35 - 45 20 - 24 25 - 35 3-5 12 Medium open time adhesive, filling holes, high flexibility and strength Araldite® 2012 1:1 5-8 16 - 18 40 - 50 Self levelling 8 Fast setting, general purpose, self levelling epoxy adhesive Araldite® AW 2101 / Hardener HW 2951 1:1 4-8 18 - 20 40 - 50 4-5 8 Fast setting and multipurpose gap filling epoxy adhesive * LSS: lap shear strength on aluminum - A selection of wet lay up laminating systems is available Advanced Materials 24
Keep our products at your fingertips View the brochure on SlideShare Download our mobile apps on your smartphone With this brochure get an overview of our comprehensive range of tooling, composites and repair solutions for the wind industry. With these apps select immediately the right: §  Araldite® industrial adhesive for your specific need §  Araldite® composite formulated system for your process / application Access the product description or send us an email to request the technical data sheet. Araldite® - Adhesives (Europe) Download on iPhone | Android Huntsman - Composite resins (Europe) Download on iPhone | Android Advanced Materials 25
For more information www.huntsman.com/advanced_materials advanced_materials@huntsman.com Europe Huntsman Advanced Materials (Switzerland) GmbH Klybeckstrasse 200 P.O. Box - 4002 Basel Switzerland Tel. +41 61 299 20 41 Fax +41 61 299 20 40 Advanced Materials 26
Legal Disclaimer Copyright © 2014 Huntsman Corporation or an affiliate thereof. All rights reserved. The use of the symbol ® herein signifies the registration of the associated trademark in one or more, but not all, countries. While the information and recommendations included in this publication are, to the best of Huntsman’s knowledge, accurate as of the date of publication, nothing contained herein is to be construed as a representation or warranty of any kind, express or implied. Advanced Materials

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