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Fortron PPS

for Thermoplastic Composites


2013 Celanese PPS-014 AM 10/13

Contents

Introduction to Ticona
Fortron PPS
Chemistry
Properties
Applications
Fortron PPS Composites
Background
Processing Options
Properties
Applications
Summary

2013 Celanese PPS-014 AM 10/13

Fortron PPS for Thermoplastic Composites

Celanese Maintains Leading Position in


Engineered Materials

Service temperature

Engineering Polymers

High-Performance
Polymers (HPP)
(TI1 > 150C)

Engineering
Polymers (ETP)
(TI1 90 150C)

Basic
Polymers

LCP

Vectra /Zenite

PPS

Fortron

PCT

Thermx

PET

Impet

PBT

Celanex

PBT Alloy

Vandar

TPC-ET

Riteflex

POM

Hostaform/Celcon

UHMW-PE

GUR

Long Fiber and


Continuous Fiber
Reinforced Thermoplastics*

Amorphous

LFRT

Celstran, Factor
Compel

CFR-TP

Celstran Tapes,
Rods and Profiles

Partially crystalline

TI1 = Temperature Index


* with Matrix Polymers: PP, PA, PPS, PBT, POM and others on request
2013 Celanese PPS-014 AM 10/13

Fortron PPS for Thermoplastic Composites

Fortron PPS
Summary Structure and Properties
Semicrystalline
Tg 85C, TM 285C
Density 1.35 g/cm

Inherently Flame Retardant:


UL94-V0, LOI > 45
Chemical Resistance

Dimensional Stability
Fuels, oils, solvents
Water-glycol

Easy to Process
Injection molding

Polyphenylenesulfide (PPS)

Extrusion

Poly(thio 1,4 - phenylene)

2013 Celanese PPS-014 AM 10/13

Fortron PPS for Thermoplastic Composites

Fortron PPS

Semi-crystalline thermoplastic polymer, perfectly suited


for parts that have to withstand the high mechanical and
thermal requirements which require
A high melting point range between 280 and 290C
Inherently flame resistant
Excellent resistance to chemicals, oils and fluids
An ideal alternative to conventional materials such as
thermosetting polymers and metals
High hardness and stiffness and superb long-term creep
under load properties
Ease to injection mold, blow mold and machine
Weight reduction combined with high dimensional stability
2013 Celanese PPS-014 AM 10/13

Fortron PPS for Thermoplastic Composites

Fortron PPS Has No Known Solvent


Below 200C
Chemical resistance with minimal attack or swelling even at

elevated temperatures
Resists: acids/bases pH 2 to 12
Resists: strong bleaches
Resists: auto fluids coolants,
transmission & brake
Resists: gas & alternate fuels
(methanol, ethanol)
Resists: hydrolysis

2013 Celanese PPS-014 AM 10/13

Fortron PPS for Thermoplastic Composites

Fortron 0214C1
Matrix Material for Composites
Linear, unmodified PPS polymer
High molecular weight / high viscosity: 140 pas
For extrusion and injection molding applications
Specified for aircraft applications
In use at Airbus and Boeing
VIAM qualification
Federal state unitary enterprise All Russian Scientific Research
Institute of Aviation Materials
Tested in regards to flammability, smoke density and smoke

toxicity:

ABD0031
FAR/JAR 25.853
New: DIN 5510 and ISO 5659

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Fortron PPS for Thermoplastic Composites

Fortron PPS 0214C1 Smoke Density


Tested with 2 mm Plaques
Smoke density according to Airbus Standard ABD0031
Non-flaming Max. Value: 0, Average: 0
DS max. @ 4 min: 0; ABD and FAR Passed

Flaming Max. Value: 32 (6 min.), Average: 23 (6 min)


DS max. @ 4 min: 15; ABD and FAR Passed

Tox-Test (ABD0031):
ABD / FAR passed

Value

Max. Value in ppm

Hydrogen Cyanide HCN:

NF: 0 F: 0

150

Carbon Monoxide CO:

NF: 0 F: 10

1000

Nitrous Gases NO-NO2:

NF: 0 F: 0

100

Sulfur Dioxide/Hy. Sulfide SO2 - H2S:

NF: 0 F: 10

100

Hydrofluoric Acid HF:

NF: 0 F: 0

100

Hydrochloric Acid HCl:

NF: 0 F: 0

150

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Fortron PPS for Thermoplastic Composites

Fortron 0214C1 Flammability


Tested With 2 mm Plaque
Vertical Burning Test 12 s ABD0031
Total burn time: 12 s
Flame extinguish time: 0 s
No. of particles: 0
Ignited particles: 0
Total burn length: 5 mm

Vertical Burning Test 60 s ABD0031


Total burn time: 60 s
Flame extinguish time: 0.6 s
No. of particles: 2.4
Ignited particles: 1.4
Total burn length: 44 mm

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Fortron PPS for Thermoplastic Composites

Internal UL Flammability Testing

Material

Part Thickness

Unaged Sample
Rating

Aged Sample
Rating

Unfilled Fortron PPS


Control

3.0mm (0.12)

V-0*

V-0*

1/32

V-0

V-2

1/64

V-2

V-2

3.0mm (0.12)

V-0*

V-0*

1.5mm (0.059)

V-0*

V-0*

1/32

No V-Rating

V-2

1/64

No V-Rating

No V-Rating

Unfilled PEEK
Control

Thin PEEK samples failed to achieve a V-Rating because of long burn

times and cotton ignition


Thin PPS parts have V-0 equivalent burn times but molten polymer drips
can ignite the cotton = V-2 Rating
*Data as reported by Underwriters Laboratory

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Fortron PPS for Thermoplastic Composites

10

Fortron PPS Dimensional Stability

Extremely low moisture absorption 0.02%


Minimal effect of temperature
CLTE 19 x 10-6 /C (6165A4)
Precision molding
Low shrinkage - 0.3% (6165A4)
Creep resistance

For Precision Parts Even at Elevated Temperatures


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Fortron PPS for Thermoplastic Composites

11

Low PPS Water Absorption


Results in Dimensional Stability
1.25

0.16
0.14
0.12

(%)

0.10
0.08
0.06
0.04
0.02
0
PPS

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PEI

Fortron PPS for Thermoplastic Composites

PEEK

12

Top Fortron PPS Segments


Semicon

Industrial

EE & Sensors

Fibers

Composites

Automotive

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Fortron PPS for Thermoplastic Composites

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Fortron PPS
Automotive: Under the Hood
Throttle Body 1140L4

Inlet Tank for CAC 1140L4

Water Pump 6165A6, 1140L6

Crankshaft Flange 4332L6

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Water Pump Impeller 1140L4

Fortron PPS for Thermoplastic Composites

14

Fortron PPS
Automotive: Fuel Applications
Fortron PPS was selected for:
Fuel Injection Rail

Resistance to all sorts of fuels including auto

oxidized fuels up to 120C


Excellent mechanical and impact strength at
elevated temperatures
Inherently flame resistant (UL 94 V-0)
Lower specific gravity than metal
Simplified fabrication by eliminating
secondary operations

Fuel Pump Parts

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15

Fortron 1140L4
Water Pump Impellers
The challenge:
Improve pump efficiency
Decrease water pump cost
Improve fuel efficiency (Lower HP
requirements)

The innovation:
Exotic blade shapes improve
pump efficiency by 10-20% vs.
sheet metal
Fortron PPS has required
chemical / hydrolysis resistance
to OAT coolants
Excellent fatigue properties
withstand pressure cycles
Excellent erosion resistance

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Fortron PPS Industrial

Gas Furnace Tray

Chemical
Metering Pump

Instant Hot
Water Heater

Medical Forceps

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Washing Machine
Light Fixture

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Fortron PPS
Extrusion: Film, Fiber, Netting, etc.
Aircraft Composite

High Tenacity Monofilament


Filter Netting

Stock Shapes

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Fortron PPS for Thermoplastic Composites

CPI Filter

18

Fortron PPS
for Thermoplastic Composites
May 2012
2013 Celanese PPS-014 AM 10/13

Why Thermoplastic Matrix Composites?

Melt processible
Can be reformed
Near infinite shelf life
No refrigeration needed
Common generalized attributes:
Good in fatigue
Insensitive to moisture
Tough

Higher temperature

Damage tolerant

Excellent FST

Good chemical compatibility in aircraft fluids

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Why Thermoplastic PPS Composites


vs. Thermoset Composites?
Improved Properties

Improved Processing

Tougher, good fatigue performance


4x tougher than toughened epoxies

Eliminate bagging materials and labor


May also eliminate kitting and debulking
steps and equipment

Damage tolerant

Eliminate autoclave possible


Cost, space and bottleneck issues

Insensitive to moisture
High-temperature performance
Very low flammability, smoke, toxicity
Low residual stress in molded parts
Excellent chemical resistance

Rapid processing vs. thermosets


Can be reformed
Simple, longer lasting tool
Fusion bonding eliminates fasteners and
adhesives

Reduces cost and weight

Green processing
Recyclable

2013 Celanese PPS-014 AM 10/13

No VOCs in processing

Less process scrap

Fewer process energy requirements

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21

Thermoplastic Composite Matrix


Cost Advantage
100

Processing
Material

System Cost in %

80

60

The material cost for a

thermoplastic matrix might be


equal or even higher
Lower cost for handling,
processing, and assembly can
lead to a substantial advantage in
total cost

40

20

0
Conventional

Thermoplastic

Even the High Cost Thermoplastic Polymers Offer Improved Cost Savings
vs. Epoxy Based Composites
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Thermoplastic Composite Value Chain

Raw
Materials
Fibers

E Glass

S2 Glass

Carbon/
Graphite
Aramid/Kevlar
Polymer
Boron/Ceramic
Resins
PEEK

PPS
PEI
Nylons
PP
Etc

Intermediate
Products
Film
Fabric
Prepreg
Dry Powder

Fabrication
Processes

End Users

Pultrusion

Sheets

Lamination

Rods

Molding
Oven

Pipes/Tubes
Beams

Slurry

Match

Shapes

Hot Melt

Bladder

Structures

Liquid

Comingle

Fiber Placement
Filawinding
AFP

Tows
Fabric

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Fortron PPS for Thermoplastic Composites

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Example for Value Chain in


Aircraft Industries

Plastic
Pellets

Film
Producer

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Producer of
Composites

ThermoFormingProcess

Fortron PPS for Thermoplastic Composites

Assembling

Aircraft

24

Station 1: Film Production

Fortron PPS
Pellets

Starting Product:

Film Production

PPS Pellets
Temperature stability
High level of hardness and
impact strength
Excellent resistance
to chemicals
Broad temperature range
Inherent flame resistance

Station 1 Lipp-Terler GmbH in


Gaflenz near Linz, Austria. The
pellets are converted into films
with a thickness of 50 to 200 m.
The film leaves the special plant in
rolls of 100 kg in a flawless state,
crystal clear and with the required
characteristics with regard to
strength and dimensional stability.

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Station 2: Composite Production

Fortron PPS Film


e. g. Carbon Fiber

Starting Product:
Basic Matrix of
PPS / Carbon Fiber Fabric

Laminate Production
Station 2 Ten Cate Advanced
Composites BV, Nijverdal, Netherlands. The
carbon fiber fabric and PPS film are bonded
together in a press, under high pressure
and high temperature, into high-strength,
dimensionally stable and resistant
composites in the desired layer thickness.
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Station 3: Thermoforming

Positive Form
Composite
Plate

Starting Product:
Negative Form

Composite plates
in the required size

Shaping
Station 3 Fokker Special
Products, Hoogeveen, Netherlands.
The composite plates are preheated and subsequently shaped
into the desired form under
pressure and high temperature.

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Station 4: Assembly

Front Wing Portion

Starting Product:
Front wing portion
(Weight of the parts is
20 percent less than
aluminum)

Assembly
Station 4 Airbus
The completed construction
element is mounted at the
intended location.

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Technology Breakthrough: Fixed Wing


Leading Edge Airbus
Welded structure

Low weight and low cost monolithic design

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29

Fortron PPS
Success in the Aviation Industry
Safe, efficient, environmentally friendly
Modern design
Licensed for aircraft construction
New applications from Fortron PPS

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Fortron PPS for Thermoplastic Composites

30

Thermoplastic Composite Processing


Technologies
Pultrusion
Continuous laminating
Compression molding
Thermoforming
Automated tape laying/fiber placement
Bladder molding

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Part Complexity

Process Cost vs. Part Complexity


for Continuous Fiber Reinforced Parts

In-Situ
Filament Winding,
Tape Placement

Continuous
Molding

Pultrusion

Diaphragm
Forming

Prepreg Molding
Compression Molding,
Autoclave
Sheet Forming:
Stamping,
Roll Forming

Relative Cost
Source: Composite Market Reports

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32

Continuous Fiber TPC Processes


Rods/Profiles/Sheets
Pultrusion
Continuous/Semi-continuous molding
Batch molding (press, autoclave)
Tubes/Pipes
Fiber/Tape placement (In situ)
Table roll/oven molding (2 Step)
Table roll/bladder molding (2 Step)
Complex Geometries (draws, bends, etc.)
Automated tape lay-up/fiber placement
Mold processing (compression, bladder)
Diaphragm, matched metal, thermoforming/folding, et al

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Fortron PPS for Thermoplastic Composites

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Additional Thermoplastic Composite


Manufacturing Processes

Automated Dynamics
Fiber Placement

Lingol Thermoforming

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FiberForge Compression Molding

Fortron PPS for Thermoplastic Composites

34

Advantages of Thermoplastic Composite


Automation Processes
Accurate fiber placement at any angle
Material savings
Labor savings
Quality improvement
Automatic debulking
Reduced manufacturing space
Reduced assembly costs

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Fortron PPS for Thermoplastic Composites

35

Environmental Attributes for


Thermoplastic Composites
Reduced Energy Requirements
Reduced Scrap and Reusability/Repairability
Reduced VOCs and Toxic Cure By-Products

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Reduced Scrap and


Reusability/ Repairability
Thermosets

Thermoplastics

Prepreg Shelf Life

No Prepreg Shelf Life

Scrap Ends in Landfill

All Scrap can be Reused


e.g., Pelletized for Injection Molding

Rework can be Difficult

Rework is easier since Thermoplastics

can be Melted and Reformed

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Fortron PPS for Thermoplastic Composites

37

Reduced Process Energy Example


for TP vs TS Composites
Thermosets

Thermoplastics

Assemble part in tool

Assemble part in tool

Match Mold Process Cycle (1+ hours)

Stamp /Thermoform Cycle (minutes)

Cool, removal

Subsequent part can be stamped

immediately

Additional Savings:
No Need for Prepreg Freezers
Reduced Facility HVAC Costs

Energy Required Per Part Can Be Less Than a Factor of 10 for TP vs. TS
with Match Metal Molding of Simple Parts
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Fortron PPS for Thermoplastic Composites

38

Reduced VOCs and Toxic Products


Thermosets

Thermoplastics

Prepregs usually Contain Solvents

Prepregs Do Not Contain Solvents

(VOCs) for Tackiness


Cure By-Products can be Complex
Organic Compounds
Halogenated Additives Are Typically
Used to Reduce Flammability

No Cure By-Products
No Halogenation Necessary for Most

High

Performance Thermoplastics

Excellent FST Performance

But Toxicity is Increased

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Fortron PPS for Thermoplastic Composites

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Thermoplastic Composite Properties

Tg, C

High Load
Continuous use
Temperature, C

Approx.
Resin Cost,
$/lb

Approx. Carbon
Reinforced
prepreg Cost, $/lb

Fortron PPS

90

85

5.00

30.00

PEI

217

115

10.00

45.00

PEEK

143

138

60.00

90.00

Fortron PPS High-Performance, Low-Cost Solution


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Fortron PPS for Thermoplastic Composites

40

Fortron PPS Carbon Fiber Composite


Properties Thermo-Lite 1466P
Physical Property Data
Fiber Type

AS-4

Resin Type

PPS

Fiber Weight %

663

Resin Weight %

343

Fiber Volume %

593

Resin Volume %

413

Fiber Areal Weight

150 g/m2

Total Areal Weight

227 g/m2

Density

0.58 lb/in3 (1.61 g/cm3)

Thickness/Ply

0.0056 (0.14 mm)

Tape Width

12 (30.5 cm)

Mechanical Property Data1


Laminate Property
Fiber Orientation
0
Tensile Strength Ksi (MPa)
90
0
Tensile Modulus Msi (GPa)
90
Compression Strength Ksi (MPa)
0
Compression Modulus Msi (GPa)
0
Flexural Strength Ksi (MPa)
0
Flexural Modulus Msi (GPa)
0
Shear Strength (4 Point) Ksi (MPa)
0
1

Test Data
297 (2,045)
7.2 (50)
18.5 (127)
1.3 (8.8)
162 (1,117)
17.2 (118)
243 (1,672)
16.3 (112)
11.1 (77)

Typical mechanical properties at room temperature, dry condition

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Fortron PPS Carbon Fiber Composite


Properties Thermo-Lite 4268P
Physical Property Data
Fiber Type
Fiber Weight %
Fiber Volume %
Fiber Areal Weight
Density
Thickness/Ply

E-Glass
683
533
260 g/m2
0.072 lb/in3 (2.0 g/cm3)
0.0076 (0.19 mm)

Resin Type
Resin Weight %
Resin Volume %
Total Areal Weight

PPS
323
473
382 g/m2

Tape Width

12 (305 mm)

Mechanical Property Data1


Laminate Property
Tensile Strength Ksi (MPa)
Tensile Modulus Msi (GPa)
Open Hole Tensile Strength Ksi (MPa)
Open Hole Tensile Modulus Msi (GPa)
Compression Strength Ksi (MPa)
Compression Modulus Msi (GPa)
Open Hole Compression Strength Ksi (MPa)
Open Hole Compression Modulus Msi (GPa)
In Plane Shear Modulus (Iosipescu) Ksi (MPa)
In Plane Shear Modulus (Iosipescu) Msi (GPa)
Flexural Strength Ksi (MPa)
Flexural Modulus Msi (GPa)
Shear Strength (4-point) Ksi (MPa)
1

Fiber Orientation
0
45
90
0
45
90
0/ 45/ 90
0/ 45/ 90
0
0
0/ 45/ 90
0/ 45/ 90
0
0
0
0
0

Test Data
162 (1,118)
19.5 (135)
6.7 (46)
6.3 (44)
2.1 (14.5)
2.0 (13.8)
30 (207)
2.7 (18.6)
161 (1,111)
6.0 (41)
44 (304)
3.4(23.5)
8.9 (61)
0.8 (5.5)
174 (1,201)
6.2 (43)
9.1 (63)

Typical mechanical / physical properties

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42

Fortron PPS Carbon Fabric Composite


Physical Property Data
Physical/Thermal (nominal values)

T300 5HS/pps with double sided Amcor foil

Mass of fabric

8.26

oz/yd2

280

g/m2

Mass of fabric + resin

14.33

oz/yd2

486

g/m2

Resin content by volume

50

50

Resin content by weight

43

43

Moisture pick up

0.1

0.1

0.0122

In

0.31

mm

Specific gravity

96.7

lb/ft3

1.55

g/cm3

Tg (DSC) (amorphous)

194

90

Tg (DSC) (crystalline)

248

120

TM

536

280

Ply thickness

High Quality prepreg made by film infusion of fabric


Excellent wetout of fabric by resin
Reproducible and uniform
No shelf life
* TenCate

CETEX Data CETEX is a registered trademark of TenCate Advanced Composites, BV

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Fortron PPS Carbon Fabric Composite


Mechanical Property Data*
Mechanical Properties 73F (23C)/50% RH

7781/PPS

Tensile strength warp

49.3

ksi

340

MPa

Tensile strength weft

48.3

ksi

333

MPa

Tensile modulus warp

3.1

Msi

22

GPa

Tensile modulus weft

2.9

Msi

20

GPa

Compression strength warp

61.6

ksi

425

MPa

Compression strength weft

42.8

ksi

295

MPa

Compression modulus warp

3.7

Msi

26

GPa

Compression modulus weft

3.5

Msi

24

GPa

Flexural strength warp

74.2

ksi

511

MPa

Flexural strength weft

56.6

ksi

390

MPa

Flexural modulus warp

3.3

Msi

23

GPa

Flexural modulus weft

2.9

Msi

20

GPa

In plane shear strength

11.6

ksi

80

MPa

In plane shear modulus

538.5

ksi

3714

MPa

Open hole tensile strength

23.0

ksi

158

MPa

Open hole compression strength

26.5

ksi

183

MPa

Compression after impact

24.8

ksi

171

MPa

Bearing strength yield

46.1

ksi

318

MPa

Bearing strength ultimate

74.8

ksi

516

MPa

* TenCate

CETEX Data

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T300 3K Carbon Fabric/Fortron PPS


Composite Property Data*
160
-55C

140

23C

120

80C

100
80
60
40
20
0
Tensile
Strength

Compressive
Strength

Flexural
Strength

In Plane
Shear

Open Hole
Tensile

Open Hole Compression


Compressive After Impact

Values are in ksi


Warp direction data
Average values - Tested per Mil-R-17
* TenCate

CETEX Data

Steady and Stable Across Use Temperature


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T300 3K Carbon Fabric/


Fortron PPS Composite Property Data*
10
9

-55C

23C

80C

6
5
4
3
2
1
0
Tensile Modulus, msi

Compressive Modulus,
msi

Flexural Modulus, msi In Plane Shear Modulus,


msi

Values are in msi


Warp direction data
Average values - Tested per Mil-R-17
* TenCate

CETEX Data

Steady and Stable Across Use Temperature


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Working Together
in the Aviation Industry

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Technology Validation Carbon/PPS:


Fokker 50 Undercarriage Door
Final step in a dedicated 10-year program
Press-formed ribs and spars
Welded assembly
Qualified carbon / PPS material
Certified by the

Airworthiness Authorities
Flown on a KLM aircraft for 3.5 years

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Technology Breakthrough: Fixed Wing


Leading Edge Airbus A340-500/600
Welded structure

Low weight and low

cost monolithic design


Strong partnering with
Airbus UK and TenCate
Technology is now
state of the art
current application Airbus A380

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Metal Substitution with Linear PPS Composite


Resulted in 2050% Lighter Components

KB WP: 18m, 2.5 tons

Keel Beam Application

Main Ribs (L&R)

Multi-technology concept
Panels and spars
Thermoset Prepreg lay-up
TP ribs and angles
Aluminum and titanium brackets

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A330/340 Family: Common Aileron


A318
A319
A320
A321
A330-200
A330-300
A340-300
A340-500

240 Parts per Airframe

A340-600
A380-800

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Airbus A340 500/600 Aileron


Thermoplastic Composite Parts

Edge Ribs
Main Ribs

Edge Rib

Leading Edge
Ribs, Angles & Panels

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Airbus A340 500/600


Thermoplastic Composite Components
Part Description: Panel of the Pylon Forward
Second Structure 22 per
Aircraft
Dimensions:

L = 700 1400 mm
W = 200 400 mm
Thickness 2.8 mm
Double-Curvature Shape

Material:

PPS / Carbon Fiber


Bronze Mesh Top-layer for EMI
Shielding

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Leading Edge Airbus A380

8 assemblies / wing
Wing length: 26 meters
16 segments, 52-meter length
400 kg total weight

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Weight Reduction The Vision


Fortron PPS in Aircraft Interior
46% Lighter Seat Parts Due to
Metal Substitution
Aluminum
Fortron

280 g
150 g

Product innovations for Composites

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Weight Reduction The Vision


Linear PPS for Aircraft Interiors
Fortron PPS is the prime candidate for several

aircraft interior efforts


Applications include seat frames,
brackets, beams, ducts
Lower cost vs. PEI and PEKK

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240 CETEX Parts in Ailerons

Common Aileron for


A330-340 Family

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Summary

Fortron PPS is a demonstrated, producible, low-cost, high-

performance thermoplastic for composite applications


Aircraft interior and exterior applications
Down hole applications
Corrosion resistant environments
High-temperature usage
The low-cost, green alternative
Industrial thermoplastics composites manufacturing is a

demonstrated production process


Proven success in aerospace
Ticona technical personnel will work with you to meet your

composites needs

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Contact Information

Disclaimer
This publication was printed on 1 October 2013 based on
Celaneses present state of knowledge, and Celanese
undertakes no obligation to update it. Because conditions of
product use are outside Celaneses control, Celanese makes
no warranties, express or implied, and assumes no liability in
connection with any use of this information. Nothing herein is
intended as a license to operate under or a recommendation
to infringe any patents.
Copyright 2013 Celanese or its affiliates.
All rights reserved.

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Fortron PPS for Thermoplastic Composites

59

Thank you.
For more information:
1-800-833-4882
info-engineeredmaterials-am@celanese.com
celanese.com/engineered-materials

2013 Celanese PPS-014 AM 10/13

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