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Rcf Hamburg

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JosephHeil

This document discusses research into recycled carbon fiber composites conducted by the Institute for Maintenance Science and Technology. It summarizes their work with partners to develop recycling techniques for carbon fibers from aircraft and other composites. Their research demonstrated that recycled carbon fibers can be used to create new composites through vacuum assisted resin transfer molding and bulk molding compounds that exhibit comparable mechanical properties to virgin carbon fiber composites. The document outlines the recycling process and results of testing recycled carbon fiber composite materials and properties.

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Institute for Maintenance Science and TechnologyRecyCled Carbon Fiber CompositesJoseph Heil, Dr. Jerry Cuomowww.imst.usCarbon Fibre Recycling and ReuseNovember 4, 2009
OutlineIMST Composite Sustainment ActivitiesPartners in Carbon Fiber RecyclingRecycled Carbon Fiber CompositesVacuum Assisted Resin Transfer Molding (VARTM)Bulk Molding Compound (BMC)Injection MoldingMechanical Properties of Recycled Carbon Fibers2
Composites Sustainment ActivitiesReverse EngineeringNDIAtmospheric PlasmaCarbon Fiber RecyclingComposites ManufacturingRepair TechnologiesEconomic DevelopmentTraining ActivityTechnical Support3
Recycled Carbon Fiber NetworkThe Boeing CompanyPete George & Bill CarberryNC Polymer Center of ExcellenceQuantum CompositesRecycled Carbon Fiber, LtdAdherent Technologies, Inc ANEA/ KarborekFirebird Advanced MaterialsPenn Compression MoldingBulk Molding Compounds, Inc.4
Recycled Carbon Fiber CompositesVacuum Assisted Resin Transfer Molding (VARTM)AS4 LaminatesIM7 LaminatesBulk Molding Compound (BMC)Injection Molding5
Vacuum Assisted Resin Transfer Molding6Mechanical Property Testing:TensionCompressionFlexure Recycled AS4 laminates
Recycled IM7 laminates
Virgin IM7 laminatesVARTM Mechanical Properties: IM7 Laminates7VARTM Set 1 (AS4 fibers) UTS Retention: 13%-33%Compression: 58%-86%VARTM Set 2 (IM7 fibers)UTS Retention: 40%-44%Compression: 72%-74%Strength RetentionTensile: 40%-44% Compressive: ~73%
VARTM Mechanical Properties: IM7 Laminates8
VARTM Key PointsLeaving the weave intact during recycling allows for laminate construction of RCFRPReduced tensile strength of fibers & possible poor resin to fiber adhesion resulted in weak laminatesVARTM allows for quick & easy comparison of different recycling treatments 9
Recycled Carbon Fiber CompositesVacuum Assisted Resin Transfer Molding (VARTM)Bulk Molding Compound (BMC)Injection MoldingFuel Cell Plates @ BMCICircuit Breaker Panel @ Penn Compression Molding10
Bulk Molding Compound Panels11Fabrication: 2wt% loading of milled AS4 fibers in vinyl ester resin
3000psi molding pressure
160oC for 60sMechanical Testing:Tensile ASTM D3039Flexure ASTM D790
Mechanical Testing of BMC Panels12 86% UTS retention
99% Flexure retention
Comparable to 5wt% loading glass/polyester
Greater strength retention at shorter fiber length Bulk Molding of Circuit Breaker Panel13 ~12wt% AS4 fiber, 3袖m particle size
Six combinations of pressure and time
Difficult to wet out fibers
~65 wt% phenolic resin
Added resin lowered viscosity
Excess amount of flash BMC Key PointsMilled RCF provide adequate reinforcement strength for BMC applicationsBMCs made with RCF could replace glass compounds with higher loadingOptimal fiber wetting & BMC viscosity are most likely obtained with ~50wt%-55wt% resin 14
Recycled Carbon Fiber CompositesVacuum Assisted Resin Transfer Molding (VARTM)Bulk Molding Compound (BMC)Injection MoldingProcess of Making CFRPFiber HistoryExtrusion CompoundingInjection Molding TrialsMechanical Testing15
From Junk to Recycled Carbon Fiber CompositesHow do I get a CFRP?Recycle the FiberAnalyze fiber propertiesMix with resinMoldTest Composite properties16
End of Life Parts Shredded and Sorted at Huron Valley Fritz West in Tucson, ArizonaReclamation of Fiber by Recycled Carbon Fiber, Ltd Birmingham U.K 350F Cure Epoxy with AS4 FiberControl Unsized AS4Reclamation of Fiber by Adherent Technologies Albuquerque, NM Characterizationby NC State with Direction and Oversight by Boeing Fiber History17
Extrusion Compounding18cCarbon FiberbaCFRP PelletsH2SO4 + H2O2Ceramic FilterH2SO4 + H2O2waste
Injection Molding Trials19
Mechanical Testing Results 20Tensile: ASTM D 638Flexure: ASTM D 790
Impact Tests21PC Control: 60ft-lb/in
Injection Molding Key PointsA clean fiber supply is neededChemicals left over from recycling can impede bonding to resinFiber does not flow freelyExcellent mechanical propertiesFuture work: engineering thermoplastics22

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Rcf Hamburg

  • 1. Institute for Maintenance Science and TechnologyRecyCled Carbon Fiber CompositesJoseph Heil, Dr. Jerry Cuomowww.imst.usCarbon Fibre Recycling and ReuseNovember 4, 2009
  • 2. OutlineIMST Composite Sustainment ActivitiesPartners in Carbon Fiber RecyclingRecycled Carbon Fiber CompositesVacuum Assisted Resin Transfer Molding (VARTM)Bulk Molding Compound (BMC)Injection MoldingMechanical Properties of Recycled Carbon Fibers2
  • 3. Composites Sustainment ActivitiesReverse EngineeringNDIAtmospheric PlasmaCarbon Fiber RecyclingComposites ManufacturingRepair TechnologiesEconomic DevelopmentTraining ActivityTechnical Support3
  • 4. Recycled Carbon Fiber NetworkThe Boeing CompanyPete George & Bill CarberryNC Polymer Center of ExcellenceQuantum CompositesRecycled Carbon Fiber, LtdAdherent Technologies, Inc ANEA/ KarborekFirebird Advanced MaterialsPenn Compression MoldingBulk Molding Compounds, Inc.4
  • 5. Recycled Carbon Fiber CompositesVacuum Assisted Resin Transfer Molding (VARTM)AS4 LaminatesIM7 LaminatesBulk Molding Compound (BMC)Injection Molding5
  • 6. Vacuum Assisted Resin Transfer Molding6Mechanical Property Testing:TensionCompressionFlexure Recycled AS4 laminates
  • 7. Recycled IM7 laminates
  • 8. Virgin IM7 laminatesVARTM Mechanical Properties: IM7 Laminates7VARTM Set 1 (AS4 fibers) UTS Retention: 13%-33%Compression: 58%-86%VARTM Set 2 (IM7 fibers)UTS Retention: 40%-44%Compression: 72%-74%Strength RetentionTensile: 40%-44% Compressive: ~73%
  • 10. VARTM Key PointsLeaving the weave intact during recycling allows for laminate construction of RCFRPReduced tensile strength of fibers & possible poor resin to fiber adhesion resulted in weak laminatesVARTM allows for quick & easy comparison of different recycling treatments 9
  • 11. Recycled Carbon Fiber CompositesVacuum Assisted Resin Transfer Molding (VARTM)Bulk Molding Compound (BMC)Injection MoldingFuel Cell Plates @ BMCICircuit Breaker Panel @ Penn Compression Molding10
  • 12. Bulk Molding Compound Panels11Fabrication: 2wt% loading of milled AS4 fibers in vinyl ester resin
  • 14. 160oC for 60sMechanical Testing:Tensile ASTM D3039Flexure ASTM D790
  • 15. Mechanical Testing of BMC Panels12 86% UTS retention
  • 16. 99% Flexure retention
  • 17. Comparable to 5wt% loading glass/polyester
  • 18. Greater strength retention at shorter fiber length Bulk Molding of Circuit Breaker Panel13 ~12wt% AS4 fiber, 3袖m particle size
  • 19. Six combinations of pressure and time
  • 20. Difficult to wet out fibers
  • 21. ~65 wt% phenolic resin
  • 22. Added resin lowered viscosity
  • 23. Excess amount of flash BMC Key PointsMilled RCF provide adequate reinforcement strength for BMC applicationsBMCs made with RCF could replace glass compounds with higher loadingOptimal fiber wetting & BMC viscosity are most likely obtained with ~50wt%-55wt% resin 14
  • 24. Recycled Carbon Fiber CompositesVacuum Assisted Resin Transfer Molding (VARTM)Bulk Molding Compound (BMC)Injection MoldingProcess of Making CFRPFiber HistoryExtrusion CompoundingInjection Molding TrialsMechanical Testing15
  • 25. From Junk to Recycled Carbon Fiber CompositesHow do I get a CFRP?Recycle the FiberAnalyze fiber propertiesMix with resinMoldTest Composite properties16
  • 26. End of Life Parts Shredded and Sorted at Huron Valley Fritz West in Tucson, ArizonaReclamation of Fiber by Recycled Carbon Fiber, Ltd Birmingham U.K 350F Cure Epoxy with AS4 FiberControl Unsized AS4Reclamation of Fiber by Adherent Technologies Albuquerque, NM Characterizationby NC State with Direction and Oversight by Boeing Fiber History17
  • 27. Extrusion Compounding18cCarbon FiberbaCFRP PelletsH2SO4 + H2O2Ceramic FilterH2SO4 + H2O2waste
  • 29. Mechanical Testing Results 20Tensile: ASTM D 638Flexure: ASTM D 790
  • 31. Injection Molding Key PointsA clean fiber supply is neededChemicals left over from recycling can impede bonding to resinFiber does not flow freelyExcellent mechanical propertiesFuture work: engineering thermoplastics22
  • 32. OutlineIMST Composite Sustainment ActivitiesPartners in Carbon Fiber RecyclingRecycled Carbon Fiber CompositesMechanical Properties of Recycled Carbon FibersT300 & AS4T800sInterfacial Shear Strength23
  • 33. TensileStrength24T300AS4Source material: uncured trim scrap recovered by RCF, LtdSource material: EOL scrap recovered by RCF, LtdFavorable strength retention at shorter gauge lengthsElastic Modulus25T300AS4Source material: uncured trim scrap recovered by RCF, LtdSource material: EOL scrap recovered by RCF, LtdSource material: EOL scrapSource material: uncured trim scrapFibersremain stiff after recyclingT800s Tensile Strength26
  • 35. Single Fiber Composite Test28Reasons for increased adhesion:Surface chemistry
  • 36. Surface roughnessCTS lab CTS Virgin UCTS CTS PilotVirginRCF-UTSVirgin EOL EOL-OENEA/ KarborekRCF, LtdRCF, LtdFibers show excellent retention or increase in IFSSConclusionsMultiple demonstrations of Recycled Carbon Fiber Reinforced Plastics (RCFRP) has been shownRCFRP have comparable properties to virgin CFRP in many casesRCFRPs can be tailored for strength and/or stiffnessMaintaining fiber orientation during recycling is beneficial for future processing of RCFThere are numerous opportunities to sell RCFRPs29
  • 37. AcknowledgmentsBrian Allen, Myles Connor, Brad Hartman, Davis Litzenberger, IMSTTom Hunter, Firebird Advanced MaterialsPete George & Bill Carberry, The Boeing CompanyIntertechPira30

Editor's Notes

  • #12: 5x6x1/8 Molding done at BMCI-=>Chicago, IL largest manufacturer of thermoset bulk moldingcompounds in North America
  • #29: Performed at Cornell University under direction of Dr. Netravali