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3m — Technical Presentation (October 2014)
19 slides from 3m's technical presentation, October 2014
Slide 1: Composite Erosion Protection Films
Composite Erosion Protection Films Presented at CAMX 2014 Ryan Marx | October 2014
Slide 2: Outline
Outline: Erosion of aircraft components Types of erosion protection Co-curable Erosion Films (CEFs) • Rain erosion resistance • Grit erosion resistance • Flow characteristics • Rheological characterization • Flow during cure • Peel adhesion to epoxy film adhesive
Slide 3: Erosion of Aircraft Components
Erosion of Aircraft Components • 2 Main types of erosion damage • Solid particle erosion (sand, dust, or grit) • Rain erosion • Fiber reinforced polymeric composites are especially susceptible to erosion damage • Impacts cause the matrix resin to crack and debond at fiber interfaces, causing rapid d
Slide 4: Types of Erosion Protection
Types of Erosion Protection Metallic systems (titanium, nickel, aluminum) Polymeric systems • Paints • Sprayable polyurethane coatings • Polyurethane Tapes Rain Grit Impact Weight Temperature UV Application Application Upfront VOCs / Tapered Key Erosion Erosion Density Repairability to complex Corro
Slide 5: Co-curable Erosion Films (CEFs)
Co-curable Erosion Films (CEFs) What are CEFs? • Erosion resistant polyurethane films with processing temperatures up to 400 °F and service temperatures up to 250 °F • Able to be co-cured with composite parts or post bonded with structural adhesives (built-in erosion protection) • Unique flow charac
Slide 6: Rain Erosion Resistance
Rain Erosion Resistance Glass fiber composite airfoils begin eroding within the first minute of testing Paint provides minimal protection from rain erosion Glass fiber composite Co-curable erosion film provides about 7x – 10x improvement in rain erosion resistance relative to paint for a comparable
Slide 7: Rain Erosion Resistance
Rain Erosion Resistance Doubling the thickness of the CEF (0.305 mm vs 0.152 200 Rain Erosion Resistance - CEF Comparison mm) results in ~4x improvement in rain erosion 180 resistance (135 min vs 35 min) Rain Erosion Time to Failure (min) 160 • Performance enhancement is also achieved by 140 135 sta
Slide 8: Rain Erosion Resistance
Rain Erosion Resistance Rain erosion resistance of the co-curable erosion films is independent of cure cycle Rain Erosion Resistance - Cure Cycle Dependence Cure Cycles (0.152 mm thick CEF) 1) Vacuum pressure of 91.4 kPa with a 2.8 °C/min ramp to 50 82 °C, hold for 60 minutes, then a 2.8 °C/min ramp
Slide 9: Grit Erosion Resistance
Grit Erosion Resistance Grit Erosion Resistance (Wear Through) Co-curable erosion films provide a 14000 12966 much higher level of resistance to Mass of Al2 O3 to break through film (g) 12000 grit erosion (90° and 30°) than glass fiber epoxy composite or paint 10000 8000 5391 6000 4000 3280 1892 200
Slide 10: Grit Erosion Resistance
Grit Erosion Resistance 90° Grit Erosion Resistance (Wear Loss) Co-curable erosion films show 0.80 minimal to no erosion loss at a 90° 0.70 angle 0.620 0.60 Material Volume Loss (ml) 0.50 0.40 0.30 0.20 0.083 0.068 0.10 0.000 0.000 0.000 0.00 Procedure: Samples tested in a modified grit blaster at 7
Slide 11: Grit Erosion Resistance
Grit Erosion Resistance 30° Grit Erosion Resistance (Wear Loss) At a 30° angle, the CEF shows 0.18 similar erosion resistance as a 0.16 0.152 thermoplastic polyurethane and 0.14 better than aluminum, titanium, or a 0.124 thermoset polyurethane Material Volume Loss (ml) 0.12 0.106 0.10 0.087 0.091 0.
Slide 12: Flow Characteristics
Flow Characteristics Co-curable erosion films exhibit enough flow during a cure to effectively take on the surface texture of the tool or caul sheet and have seamless transitions, yet boundary fidelity is maintained 0.305 mm black CEF Gray 0.152 mm 3M CEF co- cured on 0.305 mm black CEF with carbon
Slide 13: Rheological Characterization
Rheological Characterization • The thermoplastic PU and the CEF Parallel Plate Rheology begin to differ around 110 °C as Storage Modulus the thermoplastic PU begins to 10 melt Storage Modulus (MPa) 1 • The thermoset PU and the CEF 0.1 have a similar storage modulus 0.01 (elastic nature) over the 120
Slide 14: Rheological Characterization
Rheological Characterization Parallel Plate Rheology • The thermoset PU displays a Loss Modulus lower loss modulus than either 10 the CEF or thermoplastic PU over the 120 °C to 180 °C range. 1 Loss Modulus (MPa) • The thermoplastic PU and the 0.1 CEF display a similar loss modulus (viscous nature) o
Slide 15: Surface Area Expansion
Surface Area Expansion Surface Area Expansion After Cure • The thermoplastic PU melts 120% exhibiting a high surface area Surface Area Expansion After Cure expansion 100% 121 °C Cure Cycle • Thermoset PU and CEF exhibit 80% similar flow at both temperatures 177 °C Cure Cycle with the CEF flowing sli
Slide 16: Peel Adhesion
Peel Adhesion Floating Roller Peel Adhesion - 121 °C Cure • Thermoset PU and thermoplastic PU failed 50 adhesively at urethane/adhesive interface Floating Roller Peel Adhesion (N/mm) 40.8 • CEF failed cohesively in urethane layer 40 30.0 • Thermoplastic PU melted and flowed out of 30 bond 20 16.2 Fl
Slide 17: Conclusions
Conclusions • Performance benefits of co-curable erosion films • Rain and grit erosion resistant • Lighter than metallic systems • More consistent weight than spray systems • Excellent adhesion to epoxy systems • Process benefits of co-curable erosion films • Decreased cycle time by incorporating wi
Slide 18: Thank you.
3M Science. Applied to Life.” Thank you.
Slide 19: Product use and technical information notice
Please ensure products meet all applicable specifications, standards, maintenance manual requirements for the platform being worked on and validate aircraft approvals against current technical documentation. Technical Information: The technical information, recommendations and other statements conta