raising performance in aerospace - quarter 1,...

Advanced Materials

Raising performance in aerospace production, maintenance and repair

Quarter 1, 2015

Advanced Materials 2

Table of contents

Bonding solutions for production, maintenance and repair

Applications in aerospace

Panel forming and bonding

Edge fill and close-out: NEW Epocast 1645 FR A/B

Insert potting and panel reinforcement

Laminating and repair

Composites bonding Choosing adhesives for composites assembly

Araldite® 2015 for dynamic loading

Araldite® 2031 for toughness

Araldite® AW4858 / HW4858 for toughness and resilience

Araldite® AW4859 / HW4859 for high temperature resistance

Araldite® 2048 for high flexiblility

Epibond® 100 A/B for high shear and peel strength

Araldite® 420 A/B for toughness and resilience

Adhesives overall comparison

FST adhesives Epibond® 8000 FR A/B

Araldite® 1570 FST A/B

FST syntactic Epocast® 1622 FST A/B

Advanced Materials

Bonding solutions for aerospace production, maintenance and repair

3

Insert bonding with Epocast®

syntactics

Edge close-out with Epocast® syntactics

Panel bonding with Araldite®

epoxy adhesives

Insert potting with Epocast® and

Uralane® adhesives

Skin repair with Araldite® and Epocast®

epoxy adhesives

Panel forming with Epocast® syntactics

Component bonding with Araldite®, Epibond® and Uralane® adhesives

< Table of content Bonding solutions > Composites bonding > FST adhesives > FST syntactic >

Panel and core reinforcement with Epocast® syntactics

Advanced Materials

Main applications in aerospace

4

Panel forming and bonding > Edge fill and close-out >

Laminating and repair > Insert potting and panel reinforcement >


Advanced Materials

Panel forming and bonding Component bonding

5

Panel bonding with CG 1305 A/B Araldite® 1570 FST A/B Epibond® 100 A/B Epibond® 8000 FR A/B

Panel forming with Epocast® 1618 D/B Epocast® 1622 FST A/B CG 1305 A/B

Component bonding with Araldite® EP 1000 A/B Araldite® 420 A/B Epibond® 8000 FR A/B Uralane® 5774 A/C


Advanced Materials

Panel forming and bonding Component bonding

6

Syntactics

Features and benefits

PF Epocast® 1618 D/B Flame-retardant, pumpable, low-density epoxy syntactic

PF PB

CG 1305 A/B Flame-retardant, pourable, medium-density epoxy syntactic

PF Epocast® 1622 FST A/B Medium-density, FST, pumpable epoxy syntactic

Adhesives


CB Araldite® 420 A/B

Multi-purpose, toughened, high-strength epoxy adhesive

CB Uralane® 5774 A/C High peel strength, bonds dissimilar substrates (metals and plastics), self extinguishing, polyurethane adhesive

CB Araldite® EP 1000 A/B Nano-toughened, chemical resistant, high-strength and high-temperature epoxy adhesive

PB Araldite® 1570 FST A/B Halogen-free, flame retardant, room temperature curing epoxy adhesive

PB CB

Epibond® 8000 FR A/B Nano-toughened, pumpable, high-peel, FR epoxy adhesive

PB Epibond® 100 A/B High dry-wet Tg, toughened, structural epoxy adhesive


PF: panel forming PB: panel bonding CB: component bonding

Advanced Materials

Edge fill and close-out

7

Edge fill / close-out with Epocast® 1645 FR A/B Epocast® 1618 D/B Epocast® 1628 A/B Epocast® 1633 A/B Epocast® 1622 FST A/B Araldite® 1641 A/B


Advanced Materials

Products


NEW Epocast® 1645 FR A/B Ultra-low density, FR, easy to process epoxy syntactic

Epocast® 1618 D/B Flame-retardant, pumpable, low-density epoxy syntactic

Epocast® 1633 A/B Extrudable, low-density, FR, fast cure epoxy syntactic

Epocast® 1628 A/B Extrudable, ultra-low density, FR, room-temperature cure epoxy syntactic

Araldite® 1641 A/B Ultra-low density, vibration damping, non-sagging epoxy syntactic

Epocast® 1622 FST A/B Medium-density, FST, pumpable epoxy syntactic

Edge fill and close-out

8


Advanced Materials

NEW Epocast® 1645 FR A/B

9

Two-parts, ultra-low density, 1 year shelf life, epoxy syntactic Application

Aerospace and transport interior, reinforcement and edge close-out applications in honeycomb panel structures.


Technical data

!! Ultra-low density of 0,48

!! 90% compressive strength in 1 day at RT

!! Room temperature or heat (3 hours at 50°C) cure

!! Excellent tolerance with off ratio

!! Flame Retardant (meets FAR 25.853a)

!! Easy 1:1 pbw / pbv mix ratio with color mix indicator

!! 12 months shelf life at RT

Gel time, 100g at 23°C 65 min

Tg 50°C

Compressive strength at 23°C 20 MPa

Compressive strength at 150°C 3,5 MPa

LSS, Al / Al at 23°C 7,5 MPa

Compressive modulus at 23°C 1300 MPa

Shore D hardness 55 - 60

CTE 42 !m / (m.°C)


Advanced Materials


10

Insert potting with Epocast® 1617 A/B Epocast® 1618 D/B Epocast® 1633 A/B Epocast® 1622 FST A/B


Panel and core reinforcement with Epocast® one-part mixed frozen syntactics Epocast® 1645 FR A/B

Advanced Materials


11

Products


PCR Eposert® Pre-formed, cured, customizable epoxy syntactic insert

PCR Epocast® one-part mixed frozen syntactics

High-compressive strength, medium- to high-density, frozen epoxy syntactics, FR versions available

PCR NEW Epocast® 1645 FR A/B Ultra-low density, FR, easy to process epoxy syntactic

IP Epocast® 1618 D/B Flame-retardant, pumpable, low-density syntactic

IP Epocast® 1617 A/B Flame-retardant, low-density, room temperature-cure epoxy syntactic

IP Epocast® 1633 A/B Extrudable, low density, FR, fast-cure epoxy syntactic

IP Epocast® 1622 FST A/B Medium-density, FST, pumpable epoxy syntactic


PCR: panel and core reinforcement IP: insert potting

Advanced Materials


12

Skin repair / laminating with Epocast® 50 A1 / 946 or 9816 Epocast® 52 A/B Epocast® 54 A/B Araldite® LY 5052 / Aradur® 5052

Repair mis-drilled hole with Epocast® 1635 A/B

General repair with Araldite® AV 8574 / HV 8574


Advanced Materials


13

Laminating and repair systems


Epocast® 50 A1 / 946 or 9816 Flame-retardant, low-viscosity, epoxy laminating system

Epocast® 52 A/B CACRC qualified, high-strength, high-temperature, good hot / wet strength, chemical-resistant, epoxy laminating system

Epocast® 54 A/B FR, high compressive strength and modulus, fast-setting epoxy laminating system

Araldite® LY 5052 / Aradur® 5052 Low-viscosity, high-strength multi-purpose epoxy laminating system

Repair systems


Epocast® 1635 A/B

High-density, high-strength, high-temperature epoxy syntactic repair material

Araldite® AV 8574 / HV 8574 High-temperature, chemical-resistant, RT curing epoxy adhesive


Advanced Materials

Epocast® 52 A/B

14

First wet lay-up system qualified according to the Commercial Aircraft Composite Repair Committee (CACRC) standard AMS 2980 for the structural repair of carbon epoxy airframe components Application

Manufacturing and repair of composites parts.


Technical data

!! Good wetting

!! Low viscosity, 5.500 mPa.s at RT

!! Good adhesion property

!! Good hot / wet strength, service temperature 150°C

!! Excellent resistance to aircraft fluids and moisture

LSS at RT on Alu/Alu 17 MPa

LSS at 150°C on Alu/Alu 13.5 MPa

Tg (cure: 3h at 55°C)

133°C

Tg (cure: 3h at 55°C + 1h at 175°C)

155°C

Specification

AIMS 08-01-002, IPS 08-01-002-01, BMS 8-301



Choosing adhesives for composites assembly

Adhesives are the 1st class choice !! Assembly of similar and dissimilar substrates !! Weight reduction compared to other mechanical

assembly !! Reduce the stress concentration !! Superior fatigue resistance !! Easily processable (manually / automatically) !! No damage to the substrates (no holes) !! Sealed joints !! Compensation of dimensional tolerances !! Aesthetic aspect

Requirements for composites bonding !! Good adhesion to the substrates !! High mechanical resistance !! High peel resistance !! High temperature resistance !! High toughness !! Good chemical / environmental resistance !! Low temperature cure



Araldite® adhesives

Epoxy adhesives Main benefits !! Excellent adhesion to metals

and thermoset composites !! High strength and high stiffness !! High creep resistance !! High fatigue resistance !! High temperature resistance

(up to 190°C) !! Excellent chemical resistance

and long-term durability !! Low shrinkage over curing

Methacrylate adhesives Main benefits !! Excellent adhesion to metals,

thermoset composites and most thermoplastics

!! Good adhesion with minimum surface preparation

!! Tolerant to mix ratio variations !! Mechanical properties from

rigid to flexible !! Wide spectrum of available

reactivity !! Optimum ratio open time /

cure time !! Good chemical resistance

and long term durability !! Possibility for hardener

lacquer and no mix methods

Polyurethane adhesives Main benefits !! Excellent adhesion to most

composite materials and plastics !! Good adhesion to metals !! Mechanical properties from

rigid to flexible !! High fatigue resistance !! Good long-term durability

Wide spectrum of available

lacquer and no mix methods



Araldite® 2015

2K epoxy adhesive (1:1 v/v) Main properties

!! High mechanical performance !! Gap filling !! Toughened !! Bonds well dissimilar substrates

Benefits !! Ideal for dynamic loading !! Good thermal resistance (Tg " 65°C) !! Good impact resistance



Araldite® 2031


!! High mechanical performances !! Mat black !! Toughened !! Multipurpose

Benefits !! Ideal for big parts !! Good thermal resistance (Tg " 65°C) !! Good adhesion to polyamide



Araldite® AW 4858 / HW 4858


!! High LSS on metal and FRP !! High peel resistance, toughened !! Shiny black, gap filling !! Multipurpose

Benefits !! Ideal for big CFRP parts assembly (open time > 60 min) !! Outstanding resilient bondlines !! Ideal for dissimilar substrates bonding, impact resistant



Araldite® AW 4859 / HW 4859


!! High LSS on metals and FRP !! Toughened !! Black, gap filling !! Multipurpose

Benefits !! Resistant up to 145°C (Tg " 125°C) !! Outstanding combination of high toughness and high mechanical performance !! Outstanding chemical resistance



Araldite® 2048

2K MMA adhesive (10:1 v/v) Main properties

!! High LSS on metal and most of thermoplastics !! Gap filling !! Flexible (>90% elongation) !! Multipurpose

Benefits !! Quick setting !! Ideal for composite / thermoplastic assemblies !! Good balance of flexibility and temperature resistance (Tg " 65°C)



Epibond® 100 A/B


!! High shear and peel strength !! High dry/wet Tg !! Gap filling

Benefits !! Good chemical and environmental resistance !! High impact resistance !! Service temperature up to 150°C


Advanced Materials

Epibond® 100 A/B

23

Two-part, heat-curing epoxy adhesive for structural bonding of composites Application

Primary and secondary bonding of composites and dissimilar substrates where high service temperatures and elevated hot/wet Tg performance is needed. Suitable for carbon fiber, glass reinforced composite, PEEK and aluminum.

Features and benefits Technical data

!! Service temperatures up to 165°C

!! Moderate cure cycle / variable handling

!! Long working time of 100-120 min allows for large composite part assembly

!! Variety of handling strengths vs. time allow flexibility of process

!! Extrudable, gap filling

!! No bagging or autoclave steps (out of autoclave process compatible)

!! Easy process by hand or cartridge (2:1 Mix ratio)

!! Retention of properties under demanding high hot / wet conditions

Cure schedule 1h at 65°C + 5h at 93°C

LSS at RT on Alu/Alu (phosphoric acid anodized)

34 MPa

LSS at 93°C on Alu/Alu (phosphoric acid anodized)

23 MPa


7 MPa

LSS at RT on GRP/GRP 24 MPa

LSS at RT on PEEK/PEEK (abraded + nitrogen)

11 MPa

LSS at 150°C on PEEK/PEEK (abraded + nitrogen)

6.5 MPa


Advanced Materials

Araldite® 420 A/B

24

Two-part, toughened epoxy adhesive for structural bonding Application

Bonding of composite aeroplane parts (wing sections). Aircraft interior furnishings, such as wardrobes, stowage bins, toilet modules, produced from honeycomb. Bonding of metallic inserts.


Technical data

!! Dark green liquid

!! Very high shear and peel strength adhesive

!! Extremely tough and resilient

!! Good moisture resistance

!! Easy to use

!! RT cure

!! Service temperature 70°C

Cure schedule 16h at 40°C

LSS at RT

Aluminum (sandblasted) 23 MPa

Steel (sandblasted) 27 MPa

CFRP (abraded) 35 MPa

GRP (abraded) 31 MPa

Tg (DMA) 56°C

Specification

ASNA 4125, Issue B (Airbus)




Performance on composites Lap shear strength at 23°C (MPa) - ISO 4587


Lap shear strength at 23°C (MPa) - ISO 4587



Performance* versus temperature Lap shear strength (MPa) - ISO 4587

* Lap shear strength on aluminum


Lap shear strength (MPa) - ISO 4587



Performance on metals Lap shear strength at 23°C (MPa) - ISO 4587


Lap shear strength at 23°C (MPa) - ISO 4587



Strength on aluminum : comparison to epoxy adhesive references Peel strength (N/mm) / Lap shear strength (MPa) / Service temperature (LSS > 5 MPa)

(1) 2K rigid epoxy - RT cure (2) 1K epoxy - 180°C cure


Peel strength (N/mm) / Lap shear strength ( ) / Service temperature (LSS > 5 )



Assembly of composites : main properties overview Product designation LSS performance Peel performance Thermal

resistance Chemical resistance

Elongation at break

Handling time RT curing

Araldite® 2015

Araldite® 2031

Araldite® AW 4858 / Hardener HW 4858

Araldite® AW 4859 / Hardener HW 4859

Epibond® 100 A/B

Araldite® 2048

Araldite® 420 A/B

Ideal Recommended



Selection for specific requirements

High service temperature !! Araldite® AW 4510 / Hardener HW 4511

1/3 of initial LSS retained at 180°C

Fast curing epoxy !! Araldite® AW 2101 / Hardener HW 2951

5 min gel time - 60 min handling time

High performance structural PU !! Araldite® 2029-1

combination of high LSS on composites and flexibility - 40% elongation


Advanced Materials

Epibond® 8000 FR A/B

31

Two-parts, FR / FST interior epoxy adhesive Application

Bonding interior honeycomb panels, metals and composite materials as well as insert bonding. Use anywhere FST / FR properties* are desired such as aerospace and transport interiors.


Technical data

!! One system for both FR and FST: meets requirements of FAR 25.853

!! Rigid adhesive with high lap shear strength

!! Accelerated cure at RT, allows high shop productivity

!! Extrudable, gap filling, suitable for overhead application

!! RT or heat cure

!! Easy process by hand or cartridge, 2:1 mix ratio

Cure schedule 1.5h at 55°C Cure time to 10 MPa at RT < 4h

LSS at RT on Alu/Alu (phosphoric acid anodized)

27 MPa


6 MPa

Flammability CFR 25.853 appendix F, part 1

FST properties FAR 25.853 appendix F


* Except for OSU heat release

Advanced Materials

Araldite® 1570 FST A/B

32

Two-parts, flame retardant epoxy adhesive Application

Bonding of Aircraft interior - flooring parts. PE foam to phenolic GRP bonding in cargo areas.


Technical data

!! Outstanding FST properties (complying with FAR 25.853)

!! Semi-rigid adhesive with high elongation at break

!! Long pot life at RT

!! Suitable for structural application on metal or plastic substrates

!! Non halogenated

!! Dark grey paste

Cure schedule 16h at 40°C Cure time to 10 MPa at RT: 10h

Pot life ca 2,5h

LSS at RT on Alu/Alu (chromic acid etched)

18 MPa

LSS at RT on CFRP/CFRP 17 MPa

LSS at RT on PPS/PPS (polyphenylene sulphide)

9.5 MPa

LSS at RT on PC/PC 4 MPa

LSS at RT on PEEK/PEEK (plasma)

5.5 MPa

Specification

AIMS 10-04-006 (Airbus), FAR 25.853


Advanced Materials

Epocast® 1622 FST A/B

33

Two-parts, low density, fast, epoxy syntactic with high compressive strength Application

Aerospace and transport interior potting of fasteners, panel joining, reinforcement and edge closeout applications in honeycomb panel structures. Emphasis on applications requiring low density, high compressive strength and FR / FST properties.


Technical data

!! Low density of 0,77

!! High compressive strength of 59 MPa

!! Extrudable, gap filling

!! Room temperature (3 to 5 days) or heat (3 to 5 hours at 55°C) cure

!! Fast gel time of 15 min, allows for higher shop productivity

!! FR / FST properties (meets FAR 25.853)

!! Easy process by Semco® cartridge, 100:11.5 parts by weight mix ratio

Cure schedule 5h at 55°C

Tg 80°C

Insert pull-out strength at 23°C 1300 N



Compressive modulus at 23°C 2.5 GPa

LSS, Al / Al at 23°C 12 MPa

Shrinkage 0.4 %

CTE below / above Tg 40 / 80 !m / (m.°C)



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For more information

www.huntsman.com/advanced_materials [email protected]

Europe Huntsman Advanced Materials (Switzerland) GmbH Klybeckstrasse 200 P.O. Box - 4002 Basel Switzerland Tel. +41 61 299 1111 Fax +41 61 299 1112

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