“COMPOSITE INTERMEDIATES“ Emphasized on High performance materials
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- 2. “COMPOSITE INTERMEDIATES“ Emphasized on High performance materials Dr. Milind Khandwe President Technology & Innovation Hindoostan Technical Fabrics Limited. Sir Vithaldas Chambers,16 Mumbai Samachar Marg, Fort, Mumbai 400 001,India. Tel: +91-022-2204 0846 Fax: +91-022-2283 3841 mkhandwe@hindoostantech.com 11/15/2012 2
- 3. India Composite Industry : Preview Indian Composite Industry: • Composites prodn : Approx. 200,000 MT (USD 2.5 Billion) (2011) • 95% dominated by GF and natural fiber based Composites. • CFRP (Advanced Composites) share is less than 1% • Over 1200 composites making companies. • Growth rate : 22% CAGR (last 5 yrs) • Target : 0.75 Million MT by 2015. Source : All India Reinforced Plastics Manufacturers Association and Teijin India 11/15/2012 3
- 4. Profile • Highest quality composite woven fabrics and intermediate manufacturer from Carbon Fiber and Para Aramide in India • HTFL is a part of the Thackersey group, established in India in 1873 which has been manufacturing quality textiles for over a century. • Partners with Toho Tenax -Teijin Group Japan • Under the partnership, Toho Tenax will supply its proprietary Tenax carbon fiber to Hindoostan Technical Fabrics for weaving and processing into quality textiles. The two companies will jointly market products to manufacturers of composite materials and reinforced sheets 11/15/2012 4
- 5. Locations • Mumbai • Karad The Hindoostan Technical Fabrics The Hindoostan Technical Fabrics Limited Limited Sir Vithaldas Chambers 16, Plot No D-1 MIDC, Industrial Area Mumbai Samachar Marg, Mumbai - 400 Village, Taswade, Tal Karad, 001. India Dist. Satara . 415109 . Karad Telephone : +91 022 2204 0846 Fax : +91 022 2283 3841 Tel. 2164 2581 91 E-mail : contact@hindoostantech.com The Hindoostan Technical Fabrics Limited R&D Centre BTRA Campus LBS Marg, Ghatkopar Mumbai 11/15/2012 5
- 6. Plant And Machinery • Dedicated land area and building as per Japan standard specified by collaborator • Imported Machineries from Germany and Japan • Integrated with Vision inspection and reporting system • Other equipments specific to handling carbon fabric 11/15/2012 6
- 7. What We Can Do • Capability to weave fabrics from Carbon, Aramide, Basalt fiber, silica fiber to meet customer specifications. • Initial weaving capacity of 20-25 tons per annum, with capability to expand to 100 tons p.a within existing building. • Qualified and experienced workforce from the technical textile weaving along with assistance and training from consultants worldwide. • Stress on Quality, following international weaving and packing quality standards. 11/15/2012 7
- 8. Target Markets • Sports and recreations • Construction Reinforcement • Defence • Energy Sector • International (export) • Aerospace • Automotive 11/15/2012 8
- 9. R&D Centre structure • In The premises of BTRA, Ghatkopar Mumbai • Pilot scale facility to simulate production conditions • Chemical analyses lab • Physical testing lab • Instrumentation Lab • Library 11/15/2012 9
- 10. Production Unit Expansion • Prepregging Machine capable of handling thermoset as well as thermoplastic systems • Coating and lamination machine capable of handling solvent and water based polymeric formulations • Hotmelt coating for handling TPU,TPO and other advanced thermoplastics prepregs 11/15/2012 10
- 11. Quality Assurance Facility Plan • Establishment of NABL accredited lab • Regular quality checks on incoming , in-process and finished product properties • Trained and accredited manpower development • Maintaining latest Aerospace and building defence standards of technical textile and composite products • State of the art instrumentation facility creation 11/15/2012 11
- 12. Material Converting Capability • Polymers - PVC, PU,TPO, Acrylics, Silicone, Epoxy, synthetic Rubber and other high-performance polymers. • Textiles –Carbon , Basalt, Polyester, Polyamide, Polyaramid, Glass, Silica, Polypr opylene, Silk, Viscose, Cotton and blends. • Films – Polyester, Polyimide, Polypropylene, PTFE, FEP, PVF, PVC, PU, P BT (including membranes). • Foils – Aluminium, Copper, Zinc. • Paper – Aramid, Glassine, , Ceramic. • Nonwovens – Needle punch, Spun laid, Chemical /Thermal bonded, air laid , wads of various fibers. 11/15/2012 12
- 13. What Is Carbon Fiber? Definition：Fiber which consists of more than 90% Carbon 11/15/2012 13
- 14. Carbon Fiber ●Mechanical property -Lower density than Metal -High tensile strength / modulus -High fatigue resistance, ●Chemical/Physicochemical property -Good chemical stability -Low linear expansion coefficient, good dimensional stability ●Electric property -Electric conductivity -X-ray penetrability -Electromagnetic waves shield 11/15/2012 11/15/2012 14 14
- 15. What Is Aramid Fiber? 11/15/2012 15
- 16. Aramid Fiber Structures TECHNORA : co-poly-(paraphenylene/3,4'- Molecular structure made of oxydiphenylene terephthalamide) linked Benzene rings and amide bonds Para-type Meta-type TWARON : poly-(paraphenylene terephthalamide) (PPTA) TEIJINCONEX : poly-(metaphenylene isophthalamide) (MPIA) http://www.teijin-aramid.com 11/15/2012 11/15/2012 16 16
- 19. Comparison 11/15/2012 11/15/2012 19 19
- 20. Technical Requirements: Fiber And Fabric Properties • Fiber must be purchased to a specification tied to either the prepreg or fabric specification. • Not only should mechanical properties such as tensile strength, modulus and elongation be part of the batch acceptance testing, but the size type and level must be specified as well as tow bundle count and twist. • Fiber specification should define the average values and ranges for all critical mechanical and physical properties • Fabric specification should establish the critical fiber properties, fabric areal weight and fabric style. • Physical characteristics such as width, tracer type and spacing, alignment, openness, yarn count per inch should be defined. 11/15/2012 20
- 21. Weave Type-Plain The plain weave consists of yarns interlaced in an alternating fashion one over and one under every other yarn. The plain weave provides good fabric stability but is generally the least pliable. 11/15/2012 21
- 22. Twill Weave The twill weave is more pliable than the plain weave and has better drapability while maintaining more fabric stability than a four or eight harness satin weave. The weave pattern is characterized by a diagonal rib created by one warp yarn floating over at least two filling yarns. 11/15/2012 22
- 23. Eight Harness Satin The eight harness satin is similar to the four harness satin except that one filling yarn floats over seven warp yarns and under one. This is a very pliable weave and is used for forming over curved surfaces 11/15/2012 23
- 24. Four Harness Satin (Crowfoot) The four harness satin weave is more pliable than the plain weave and is easier to conform to curved surfaces typical in reinforced plastics. In this weave pattern there is a three-by-one interfacing where a filling yarn floats over three warp yarns and under one. 11/15/2012 24
- 25. Basket The basket weave is similar to the plain weave except that two or more warp yarns and two or more filling yarns are alternately interlaced over and under each other. The basket weave is more pliable, flatter and stronger than the plain weave, but is not as stable. 11/15/2012 25
- 26. Products we will offer • Thermosetting prepregs. • Preformable Fabrics. • Thermoplastic prepregs. • UD for construction industry. • 0 - 360 degree multilayer laminates. • Mixed fabrics with carbon, aramid, basalt, silica, UHMWPE, special polyolefins etc. 11/15/2012 26
- 27. What are Prepregs • A prepreg consists of a combination of a matrix (or resin) and fiber reinforcement. It is available in ready to use form in the component manufacturing process. • It is available in : – Unidirectional (UD) form i.e. fibers laid in one direction of reinforcement – Woven Fabrics in several directions of reinforcement as per weaving pattern and axial pattern – Nonwoven and/or chopped fibers i.e. random reinforcement 11/15/2012 27
- 28. Finished Prepregs 11/15/2012 28
- 29. Classes of Prepregs • Thermosets- basic and High performance application based on thermosetting systems • Thermoplasts- basic and high performance application based on thermoplastic polymers • Thermosets are in use for many years and knowledge and data are available • Thermoplasts systems can meet productivity requirements and can be higher volume alternatives intensively used by leading international companies. • Industry needs more development effort on Thermoplasts 11/15/2012 29
- 30. Advantages of Prepregs • The most important objectives of high performance and cost can be met. • Weight performance ratio can be achieved. • Reduced number of parts in complex design. • Best control of fiber and resin ratio. • Good ageing characteristics. • Reduced energy consumption. • Predetermined balance of mechanical properties. 11/15/2012 30
- 31. Unidirectional Prepregs • Unidirectional reinforcements include tapes, tows, unidirectional tow sheets and rovings • Fibers in this form are all aligned parallel in one direction and uncrimped providing the highest mechanical properties. • Composites using unidirectional tapes or sheets have high strength in the direction of the fiber. Unidirectional sheets are thin and multiple layers are required for most structural applications. 11/15/2012 31
- 32. Preformable fabrics • Special resin treated fabrics with low resin content • Can be preformed in to a shape at moderate temperatures • Allow free flow of resin system in infusion process 11/15/2012 32
- 33. Multilayer Laminates • Unidirectional spread carbon fabrics stabilized with resin systems • Unidirectional spread carbon fabrics oriented in 0-360 degree as per customer requirement • Woven Nonwoven Laminates ready to use for composite manufacturing • Fabric /Film/ core laminates 11/15/2012 33
- 34. Impediments in Epoxy Prepreg usage • In the case of Thermosets storage and transportation requires low temperature approx -18o C • Most of the materials are imported hence time required for shipments and custom clearance are prohibitive • Import restrictions due to country specific policies • In the case of Thermoplasts converting technology is not developed 11/15/2012 34
- 35. Types of Matrix Resin -Thermosets • Types – Polyester and vinyl esters – Epoxy including UV curable – Cyanate esters – BMI – Phenolics • The resin types are selected and formulated as per end application specifications 11/15/2012 35
- 36. Types of Matrix Resins Thermoplasts • Types – PP – PA – TPU – TPO – PEEK • Advantages- flexibility in formulation and compounding to achieve desired performance, also excellent fiber wet out can be achieved • Impediments- High experimentation time, low industrial awareness in prepreg (intermediate) usage 11/15/2012 36
- 37. Thermoplastic Prepregs source: net images 11/15/2012 37
- 38. Thermoplastic components source: net images 11/15/2012 38
- 39. UD for construction industry • Can be used to strengthen reinforced concrete structures, brickwork and timber for flexural and shear loads due to: – Loading increases. – Damage to structural parts. – Changes in structural system. – Design or construction defects. – Earthquake/seismic requirements. 11/15/2012 39
- 40. Operational Issues • Limited skilled manpower availability. • Most of the composite expertise available are in the area of engineering of finished products. • The industrial requirement of multidisciplinary manpower i.e. a composite knowledge of Textile, Polymer, Converting ( coating Lamination, compounding) is generated by experience not by education. 11/15/2012 40
- 41. Manufacturing Machinery issues • Indian machinery manufactures do not invest in sophisticated converting machinery development due to limited knowledge and market • Imported machinery cost for high performance product manufacturing, is prohibitive to small investors and machinery cost is more because of knowledge component not because of the component or equipment used 11/15/2012 41
- 42. Testing and Quality assurance issues • Country specific standards (IS standards) development need special attention and efforts. • Test housed are relatively slow in getting experience due to limited testing sample quantum. • In process and finished product quality assurance can not be dependent on test housed Like ATIRA, BTRA. 11/15/2012 42
- 43. Application- Aerospace source:http://www.mechanicalengineeringblo g.com/tag/powder-metallurgy/ 11/15/2012 43
- 44. Application- Wind Energy (3) SHEAR (1) ROOT (2) SPAR (4) SHELL (5) SURFACE WEB Structural Structural Structural Structural Coatings Adhesive Adhesive Core Core Structural Infusion Infusion Infusion Fillers Adhesive Prepreg Prepreg Prepreg Fillers Finishing & Infusion Repair Prepreg Finishing & Repair source: net images 11/15/2012 44
- 45. Application- Railway, Marine, Automobiles source: net images 11/15/2012 45
- 46. Application- Sports source: net images 11/15/2012 46
- 47. Conclusions • Indigenous source is available to design customer specific fabric using high performance yarns • A wide variety of resin selection is possible to design specific component in prepreg form • Thermoplastic prepregs will meet futuristic industry requirement • Preformable and laminated option available to composite manufacturers 11/15/2012 47
- 48. Conclusions • Policy related issues needs attention by Defence and aerospace users • Raw Material issues in terms of storage, availability, formulation knowhow, needs to be resolved • Machinery related issue requires attention from engineering industry • Testing standards need to be indigenized at least for Basic composite systems based on high performance materials • Graduate Manpower generation requires by implementing new courses in Technological Institutes like IIT, NIT or engineering Institutes • Diploma level manpower can be generated in Polytechnic Institutes or CIPET or TRA’s 11/15/2012 48
- 49. Thank You 11/15/2012 49