LIFE11 ENV/IT/000095 Carbon Fiber Reuse through Epoxy Special - PowerPoint PPT Presentation

LIFE11 ENV/IT/000095 Carbon Fiber Reuse through Epoxy Special Impregnation Coordinating Beneficiary: Afros SpA Associated Beneficiary: Cannon Ergos SpA LIFE11 ENV/IT/95 – CRESIM 2016 D. Pigliafreddo Afros Spa

Cannon Group LIFE11 ENV/IT/95 – CRESIM 2016 D. Pigliafreddo Afros Spa

Composite Materials Biphasic material composed by: Matrix (Polyurethane, Epoxy …) Reinforcement (Glass Fiber, Carbon Fiber , Kevlar…) Advantages of composites: Reinforcement Arrangement: Lightness Unidirectional • • Strength Fabric (woven) • • Structural Efficiency Mat (non-woven) • • LIFE11 ENV/IT/95 – CRESIM 2016 D. Pigliafreddo Afros Spa

Recycling Design Re-use Manufacture Circular Economy Repair Retailer Consumer At the end of 2015 new EU strategic plan (roadmaps): Efficiency and productivity wastes (even CF) become resources LIFE11 ENV/IT/95 – CRESIM 2016 D. Pigliafreddo Afros Spa

Carbon Fibre Utilization Forecast 250000 200000 150000 100000 50000 0 2011 2012 2013 2015 2020 2024 by 2020 > 150.000 t/year • «Circular Economy» politics: • Limitations in CF landfilling • High increase in the amount of recycled material in the final product • LIFE11 ENV/IT/95 – CRESIM 2016 D. Pigliafreddo Afros Spa

Carbon Fibre Utilization Forecast Global carbon fibre demand forecast, in metric tonnes Market 2015 2020 2024 Trend per year Recreational 14.800 16.740 18.620 + 2.6% Aerospace 15.460 22.100 21.650 + 3.8% Industrial 52.800 118.490 178.920 + 14,5% Total 83.060 157.330 219.190 + 11.4% 75% of the world’s carbon fibre is consumed by the industrial sector • carbon fibre growth will occur with 14,5% CAGR (compound annual growth • rate) The total carbon fibre growth will be around 11,4% • LIFE11 ENV/IT/95 – CRESIM 2016 D. Pigliafreddo Afros Spa

Carbon Fibre Utilization Forecast Global carbon fibre supply forecast, in metric tonnes Year Nameplate Capacity Actual Output (est.) 2015 143.590 93.170 2020 180600 129.960 Around 2020 carbon fibre demand will exceed supply From previous slide: • Demand 2015 83.060 tons vs supply 2015 93.170 tons • Demand 2020 157.330 tons vs supply 2020 129.960 tons • LIFE11 ENV/IT/95 – CRESIM 2016 D. Pigliafreddo Afros Spa

Carbon Fibre Utilization Forecast Possible solution Virgin Fibre Recycled Fibre LIFE11 ENV/IT/95 – CRESIM 2016 D. Pigliafreddo Afros Spa

The CRESIM Project Targets: prototyping and launching an industrial process to re-use the recycled CF sensitive cost saving • to demonstrate an important benefit for the ambient reducing • dangerous wastes and carbon footprint Achievements: It has been demonstrated that re-using recycled carbon fiber can be created parts with acceptable mechanical properties It is possible to impregnate and easily produce parts with recycled • carbon fiber LIFE11 ENV/IT/95 – CRESIM 2016 D. Pigliafreddo Afros Spa

Recycled Carbon Fibre When we refer to industrial (automatic) production processes for CFRP , we have to consider HP RTM , High Pressure Resin Transfer Moulding for the injection process LIFE11 ENV/IT/95 – CRESIM 2016 D. Pigliafreddo Afros Spa

Recycled Carbon Fibre When we talk about industrial (automatic) production processes for CFRP , we have to consider HP RTM , High Pressure Resin Transfer Moulding for the injection process ? What happens if we try to use a regular HP-RTM injection on Recycled Carbon Fibre? LIFE11 ENV/IT/95 – CRESIM 2016 D. Pigliafreddo Afros Spa

Recycled Carbon Fibre Some companies are already able to eliminate the resin from CF scraps: Pyrolysis • Chemical dissolving • Through dry fibers coming from not yet wetted waste • Production of felt formed with recycled chopped fibres Afros Contacts in the CF and R-CF world

The CRESIM Plant LIFE11 ENV/IT/95 – CRESIM 2016 D. Pigliafreddo Afros Spa

The CRESIM Plant LIFE11 ENV/IT/95 – CRESIM 2016 D. Pigliafreddo Afros Spa

The CRESIM Plant Preforming Press LIFE11 ENV/IT/95 – CRESIM 2016 D. Pigliafreddo Afros Spa

The CRESIM Plant 7 Axis Robot LIFE11 ENV/IT/95 – CRESIM 2016 D. Pigliafreddo Afros Spa

The CRESIM Plant 6 Axis Robot LIFE11 ENV/IT/95 – CRESIM 2016 D. Pigliafreddo Afros Spa

The CRESIM Plant Dosing Units LIFE11 ENV/IT/95 – CRESIM 2016 D. Pigliafreddo Afros Spa

The CRESIM Plant Heated Mould LIFE11 ENV/IT/95 – CRESIM 2016 D. Pigliafreddo Afros Spa

The CRESIM Plant 1000 tons Press LIFE11 ENV/IT/95 – CRESIM 2016 D. Pigliafreddo Afros Spa

The CRESIM Plant - Preforming Heating system + dedicated preformer For medium-high degree of threedimensionality • Heating of CF • Thermoplastic sizing Proper tensioning • Adjustable grippers • Preforming mould • • Cooling down of the part • Geometrical stability LIFE11 ENV/IT/95 – CRESIM 2016 D. Pigliafreddo Afros Spa

The CRESIM Plant – 7 Axis Robot • Pick And Place Of The Dry Carbon Fiber • Automated Extraction Of The Finished Part LIFE11 ENV/IT/95 – CRESIM 2016 D. Pigliafreddo Afros Spa

The CRESIM Plant – 6 Axis Robot • 6 Axis Robot programmed to follow specific trajectories over the mould • Automatic Lay Down of the Resin through LLD Mixing Head LIFE11 ENV/IT/95 – CRESIM 2016 D. Pigliafreddo Afros Spa

The CRESIM Plant – Dosing Unit Cannon E-System High Pressure DU for HP-RTM 2 to 3 components • • Accurate metering • Reliability (closed loop control) Data tracking • Temperature control • Thermoregulators • • Insulation LIFE11 ENV/IT/95 – CRESIM 2016 D. Pigliafreddo Afros Spa

The CRESIM Plant – Mixing Head LN EPX Series Typically for Gap Injection and HP-RTM Minimized footprint • • Premixing of the releasing agent • Integrated mould fixing screws Liquid Lay Down Kit For open mould technologies Spatula-shaped dispensing blade • • Laminar flow of resin LIFE11 ENV/IT/95 – CRESIM 2016 D. Pigliafreddo Afros Spa

The CRESIM Plant - Press Dedicated 1000 tons Press Standard design 4 columns press Platen dimensions 2500 x 1500 mm • • Accessibility to working area • Active parallelism control Shuttling system • Auxiliary hydraulic controls • LIFE11 ENV/IT/95 – CRESIM 2016 D. Pigliafreddo Afros Spa

Gap Injection The process : Semi-closed mould • Injection • • Spreading of resin into the gap • Closing and curing The resin has to travel under pressure only in the vertical direction Less pressure in the mould • • Smaller presses LIFE11 ENV/IT/95 – CRESIM 2016 D. Pigliafreddo Afros Spa

Gap Injection The process : Semi-closed mould • Injection • • Spreading of resin into the gap • Closing and curing The resin has to travel under pressure only in the vertical direction Less pressure in the mould • • Smaller presses LIFE11 ENV/IT/95 – CRESIM 2016 D. Pigliafreddo Afros Spa

Liquid Lay Down Spraying (first technology used) Disadvantages: Lack of accuracy • • Lack of cleanliness • Air trapping The spatula releases a thin homogeneous film Evolved in… of liquid reacting resin onto the mat and the Liquid Lay Down process distribution can be very well controlled by the performed thanks to the programmable robot installation of a multi channel spatula-shaped blade LIFE11 ENV/IT/95 – CRESIM 2016 D. Pigliafreddo Afros Spa

Lab Trials and Testing Omega Shaped Mould for study and tuning of impregnation technologies Liquid Lay Down or Gap Injection R-CF V-CF LIFE11 ENV/IT/95 – CRESIM 2016 D. Pigliafreddo Afros Spa

Mechanical Characterization Two configurations • stacks of R-CF mats • sandwiches composed by a core of R-CF and virgin fabric as external layers Mat of R-CF has properties about half those of the virgin CF Sandwich of fabric + R-CF is the most interesting application, being the mechanical properties comparable with those of CF fabric LIFE11 ENV/IT/95 – CRESIM 2016 D. Pigliafreddo Afros Spa

Applications Modular Parabolic Antenna in CF Parabolic Dish sector in Recycled Carbon Fiber material, impregnated through the Liquid Lay Down method LIFE11 ENV/IT/95 – CRESIM 2016 D. Pigliafreddo Afros Spa

Applications R-CF Skateboard (inserts) From impregnated mat… …to product LIFE11 ENV/IT/95 – CRESIM 2016 D. Pigliafreddo Afros Spa

New developments Robot Arm New processes for industrial parts are under (hollow body) development • The arm of a pick and place robot perfect for moving under high acceleration and speed rate • The part is produced pressing R-CF mat around a central solid part LIFE11 ENV/IT/95 – CRESIM 2016 D. Pigliafreddo Afros Spa