From the Sector

STAMFORD, February 26, 2018 - at JEC World 2018, taking place in Paris March 6-8, Hexcel will display an array of product innovations for customer applications in aerospace, automotive, wind energy and marine markets.
Hexcel’s banner at the exhibit hall entrance features the Airbus H160 helicopter and A350 XWB aircraft, both with carbon fiber livery to acknowledge the high Hexcel composites content in both programs. Hexcel’s reinforcements, prepregs, adhesives and honeycomb materials were selected for the H160’s composite fuselage structures and main rotor blades, contributing to the lightweight fuel-saving design and performance optimization. Airbus has loaned Hexcel an H160 BLUE EDGE blade to display on the booth.

Among the Aerospace promotions at Hexcel’s booth are carbon-reinforced 3D printed parts, made from Hexcel’s HexAM™ additive manufacturing technology that uses PEKK ultra-high performance polymers. Hexcel acquired this technology from Oxford Performance Materials in December 2017 to provide a weight-saving solution for intricate parts in highly demanding aerospace, satellite and defense applications. HexPEKK™ structures offer significant weight, cost and time-to-market reductions, replacing traditional cast or machined metallic parts with a new technology.

Aircraft engines benefit from a number of Hexcel technologies that will be promoted at JEC 2018, including HexShield™ honeycomb that provides high temperature resistance in aircraft engine nacelles. By inserting a thermally resistant material into honeycomb cells, Hexcel provides a core product with unique heat-shielding capabilities that allows for the potential re-use of material after a fire event.
Another honeycomb innovation from Hexcel is Acousti-Cap® broadband noise-reducing honeycomb that significantly improves acoustic absorption in aircraft engine nacelles. The acoustic treatment may be positioned at a consistent depth and resistance within the core, or can be placed in a pattern of varying depths and/or resistances (Multi-Degrees of Freedom and 3 Degrees Of Freedom), offering an acoustic liner that is precisely tuned to the engine operating conditions. These technologies have been tested at NASA on a full engine test rig and meet all 16 design conditions without trade-offs. An example of this technology will be on display at JEC 2018.

Rounding off the aircraft engine exhibits is a CTi fan blade for new generation lightweight turbofan engines from Rolls-Royce, manufactured from Hexcel’s HexPly® M91 high toughness and impact-resistant epoxy prepreg. Hexcel supplies HexPly® M91 as slit tape for the automated lay-up of the complex aerodynamic shape, with a constantly changing thickness across the blade length. The blade which is thinner and lighter than titanium fan blades is currently undergoing flight tests.
Hexcel’s HiTape® and HiMax™ dry carbon reinforcements that were developed for the automated lay-up of preforms for resin-infused aerospace structures will be promoted at the show. Two demonstrator parts, one made with HiMax™ and one with HiTape®, were both infused with HexFlow® RTM6 resin to demonstrate the potential benefits of an integrated design for aircraft skins, spars and stiffeners that meets OEM requirements for production rate increases and cost effectiveness.

Hexcel is also introducing its new range of HiFlow™ advanced liquid resins for aerospace structures manufactured by liquid molding technologies. Based on novel proprietary chemistry, the new resin family will enhance the performance of composites and ease processing when combined with HiTape® and HiMax™ dry carbon reinforcements. HiFlow™ HF610 is the first resin in the range.
Hexcel’s range of high performance adhesives has expanded considerably following the company’s acquisition of Structil last October. Hexcel is relaunching the acquired products under the new HexBond™ brand name at JEC World. This fast-growing range of pastes, liquid shim and film adhesives has a wide spectrum of operating temperatures and is in qualification with a large number of aerospace and industrial OEMs.
In the Planet Aerospace area at JEC, Daher and Hexcel will jointly display an aircraft spar manufactured from HexPly® M56 prepreg. Hexcel’s Neil Parker and Daher R&T Director Dominique Bailly will give a joint presentation focusing on the materials used and the benefits for the finished part. The aircraft spar was designed and manufactured by Daher using Hexcel’s HexPly® M56 prepreg, in slit tape format, that was developed for automated deposition and out-of-autoclave curing. The spar was manufactured using only the vacuum bag process and demonstrates very low porosity levels. It is currently undergoing testing and validation through CORAC funding.

Hexcel’s Automotive promotions at JEC World 2018 include a new prepreg for composite leaf springs, HexPly® M901. In contrast to steel leaf springs used for suspension on vans, trucks and SUVs, newer composite versions offer many advantages including weight savings of up to 70%, high corrosion resistance, optimized system integration and superior performance. Hexcel’s HexPly® M901 prepreg raises the bar further, reducing mold cure time below 15 minutes, a 50% reduction compared to standard industrial prepregs. HexPly® M901 provides 15% higher mechanical performance, with enhanced fatigue properties. It also operates at high temperatures, providing a Tg of up to 200°C following a post cure. Hexcel’s expertise in manufacturing heavy weight glass UD prepregs, with fiber areal weights of up to 1600gsm, allows the company to offer a highly cost-competitive solution for the rapid manufacture of these safety critical components.

Hexcel is constantly seeking ways to ensure that customers obtain the maximum benefit from composites and has recently acquired state-of-the-art simulation technology that accurately predicts how HiMax™ non-crimp fabrics will drape in a mold. Working in collaboration with Nottingham University Hexcel has created a car seat shell, for which the material selection was optimized using this new drape simulation technology. Visitors to Hexcel’s stand at JEC will see an on-screen demonstration that illustrates how the simulation tool operates, predicting process and performance and ensuring that the optimum fabric architecture is quickly identified, reducing the need for expensive trial programs.
Hexcel’s HexMC®-i 2000 carbon fiber/epoxy molding compound has been successfully used by Audi to manufacture a high-performance engine cross brace. HexMC®-i is a fast curing high-performance molding material, suitable for the series production of complex shaped parts and providing excellent mechanical properties. The Audi cross brace covers the engine, providing torsional stiffness for enhanced drive dynamics.

Hexcel’s product offering for customers in the Marine industry has expanded following the acquisition of Formax in 2016 and Structil in 2017. At JEC World, Hexcel will promote its enhanced portfolio of carbon fibers, prepregs, woven reinforcements and multiaxial fabrics for builders of racing catamarans and luxury yachts.
Marine customers have supplied a number of parts for display to illustrate their expertise in manufacturing composite structures from Hexcel materials. These include part of a Diam 24 yacht mast made by ADH Inotec from Hexcel’s HexPly® M79 fast curing, low temperature cure prepreg. ADH Inotec purchased the prepreg from Composites Distribution, a Hexcel Official Distributor that also supplied HexPly® M9.6 prepreg to Lorima for the Outremer 5X catamaran mast section on display. Part of Lorima’s 42m wing mast for a multihull racing boat made with HexPly® prepreg from Vert-Le-Petit (formerly Structil) will complete the marine display.

Hexcel’s innovations for Wind Energy include Polyspeed® pultruded laminates for load-carrying elements in wind blades. These continuous cross-section profiles, made from a polyurethane matrix reinforced with unidirectional carbon fiber, provide consistently high mechanical properties, including high stiffness, fracture toughness and shear strength, combined with low weight and durability. Visitors to Hexcel’s stand will see a 2m diameter coil of pultruded carbon laminate that contains 255m of material in a single roll. This technology offers an economical way of reinforcing large-scale composite structures such as wind turbine blades. Hexcel will also launch its surface finishing prepreg for wind turbine blades and components. This provides a tough, durable and ready-to-paint blade surface without the use of gel coat and results in faster blade manufacture, saving time in production and reducing material costs. The benefits of the new surfacing prepreg will be demonstrated via a wind blade exhibit that has been given four different treatments across the blade surface. These include a section with gel coat, a section of standard prepreg without gel coat, and a section where a fleece has been added to improve surface quality but still requires preparation before painting due to pin holes. The final section made with new HexPly® XF2P surfacing prepreg has a ready-to-paint surface, straight from the mold, without any requirement for gel coat, fleece or finishing operations.

The AZL will continue its collaboration on composites in buildings and infrastructure after completing an initial market and technology study which identified new potentials for composite technologies in buildings and infrastructure markets. The aim of the new AZL Workgroup which will meet for the first time on January 25th, 2018 is to jointly develop new applications and to support the business development for composites in these two growing markets. The meeting is open to interested companies from the composite industry as well as the building and infrastructure markets.

The aim of the initial workgroup meeting will be to turn insights from the study into a long-term workgroup collaboration and to define topics and initiatives for the joint cooperation in the field of process and manufacturing technologies, fire safety regulations, materials as well as standards and norms. Industrial keynote presentations will introduce these action fields and will provide an insight into building and infrastructure applications for composites. The meeting will furthermore provide a platform to network with companies along the entire composite value chain.

Dr. Amer Affan, CEO and founder of AFFAN Innovative Structures based in Dubai is in charge of various composite projects for buildings such as the Museum of the Future in Dubai: “We have been utilizing structural composites in construction since 2010. Composites is a truly high-tech material compared with the traditional building materials (steel, concrete, timber and aluminum) but it is still to be recognized as such in the conservative and price-sensitive building industry. AZL, particularly its location at the RWTH Aachen University and its partner companies, offers a good platform to progress the use of composites in construction.”

AZL together with more than 25 companies just completed the Joint Market and Technology Study on “New Potentials for Composite Technologies in Buildings and Infrastructure” establishing a broad knowledge on business opportunities for composite technologies in these two growing markets. In a structured approach, the study determined the key segments as well as the technologies/applications with the highest market and technological potential. Analyses of 20 market segments, investigation of 438 applications, technology analyses of 25 highlight components and 11 detailed business cases were elaborated throughout the study. Additional to requirement analyses for materials and production technologies, new concepts for efficient profitable production technologies and cost engineering analysis were developed. With the workgroup, the AZL will take this initiative a step further with the aim to build a long-term cooperation platform for composites in buildings and infrastructure markets.

Justin Jin, CEO of the Korean company AXIA Materials participated in the study and is part of the AZL Partner Network: “As producer of large thermoplastic composite sheets and composite SIP (Structural Insulated Panel), we are eager to drive composites in B&I applications with the best efficient way. The AZL study on Buildings and Infrastructure provided us a great networking with key players in this business field and opportunities to strengthen our products with the key elements from partners. The study also gave us a proper market understanding including market size/volume in numbers to prove the value of this technology to building industry. We are looking forward to following up on these first insights and to realize applications with the AZL and its partners.”

Besides the networking options, the meeting will offer the opportunity to get an insight into the activities of the AZL Network consisting of nine research institutes at the RWTH Aachen Campus and more than 80 companies from 21 countries. During an optional guided tour, participants will visit selected institutes at the RWTH Aachen Campus. The meeting is open to all interested companies and free of charge.

More Information on Meeting and the Study
Information on AZL activities in the field of buildings and infrastructure:
www.azl-lightweight-production.com/composites-buildings-infrastructure
Details and registration to first Workgroup Meeting on January 25th, 2018:
http://www.azl-lightweight-production.com/termine/1st-workgroup-meeting-buildings-infrastructure

• CHOMARAT signs a new distribution agreement with VELOX for its range of carbon reinforcements

The international textile group CHOMARAT announced the signing of a distribution agreement with VELOX, a European distributor in the market for composite materials. The partnership agreement covers the distribution of CHOMARAT reinforcements for high-performance (carbon) composites, in France, Italy, and the United Kingdom, as well as the distribution of CHOMARAT’s complete range of carbon and glass reinforcements in Turkey.

Stepping up the distribution of CHOMARAT´s carbion ranges in Europe

This new partnership will enable CHOMARAT to extend its network in France, Italy and the United Kingdom for its carbon fabric and multiaxial ranges, by offering its customers optimum, locally based services in line with the Group’s development strategy for high-performance composites in Europe.

CHOMARAT’s compete glass and carbon range is now distributed in Turkey

One component of the agreement deals with the distribution of CHOMARAT’s complete range of glass and carbon reinforcements in Turkey, where the composite market is booming, in particular in the transportation sector. Relying on VELOX’s strong foothold in the Turkish market, CHOMARAT will build up its flagship ROVICORE™ line, the first glass-fibre-reinforced sandwich reinforcement, which was designed and developed by CHOMARAT for closed-mould processes. “The idea is to step up our glass activities and still offer our customers more flexibility over the entire range of our reinforcements,” explains Vincent CHOLVY, in charge of the Turkish market at CHOMARAT.

VELOX secures its position as an “innovation distributor”

By distributing CHOMARAT’s high-performance composites, Velox will develop its offering in the transportation, sports & leisure and boating sectors. According to Serge GRADYS, Manager of the VELOX Composites Business, “in Europe, the distribution of the CHOMARAT range of carbon multiaxial range with C-WeaveTM and C-PlyTM, gives us a real competitive advantage and enables us to maintain our position as an innovation distributor. The same is true for the carbon and glass ranges distributed in Turkey!”

Archroma, a global leader in color and specialty chemicals, has partnered with the popular color inspiration site Design Seeds, on a series of seasonal stories featuring colors found in the Color Atlas by Archroma®. Design Seeds founder Jessica Colaluca and the site have more than 1,250,000 followers combined across social media platforms, and Design Seeds itself gets around 300,000 viewers every month.

“Archroma Color Management and Design Seeds is a match made in heaven,” said Colaluca. “I had declined partnering with brands or incorporating sponsored content on the site for over seven years until I met the incredible folks at Archroma. Beyond our obvious shared passion for color, we share a dedication to empowering designers. And as a designer, I fell in love with the Color Atlas. It is a brilliant system overflowing with modern color.”

Through the site, Colaluca provides daily color stories, utilizing dynamic, thought-provoking images. In a new Design Seeds feature sponsored by Archroma she creates ‘seasonal atlas’ which offers storied vignettes of creative color and inspiration. Color Atlas by Archroma® codes are provided for all colors in the inspiration resource. The ‘seasonal atlas’ is catalogued on the Design Seeds site, distributed at trade shows and is available for download.

“It’s critical to designers working in today’s global fashion industry to select color that is achievable from the very start of a project,” says Chris Hipps, Global Director, Archroma Color Management. “Here at Archroma, our suite of color tools, from the Color Atlas to our online Color Search tool to our industry-renowned Engineered Color Standards, are all designed to help designers capture their inspiration, and ensure that their color choices remain consistent across global production processes.”

“We brainstormed on how to enhance what we can offer creatives through our partnership and that is when the concept of the ‘seasonal atlas’ was born. Through Archroma’s sponsorship, I am able to create the expanded inspiration resource on the site. And by featuring Color Atlas codes, folks are getting a gorgeous color match from concept to execution which I believe no other system can provide,” adds Colaluca.

When creating Design Seeds, Colaluca mixes each color swatch individually. She uses digital software much as she had gouache paint back in the early days of her career. For the seasonal atlas she then works with the Archroma team to translate her collection into selections from the 4,320 swatches in the six-volume Color Atlas. Fans of any color story can then refer to the Archroma color number which references swatches in the Color Atlas. Each color is readily available as an Engineered Color Standard and the digital reflectance data. All colors are also supported in Color Atlas Online (coloratlas.archroma.com) with dye formulas on multiple substrates, Hex, CMYK, sRGB values and a selection of surrounding similar Colors.

Am 11. Mai 2017 wurden wieder zwei von insgesamt fünf Förder- und Kreativitätspreisen 2017 des VDMA Fachverbandes Textilmaschinen an Nachwuchswissenschaftler des Institutes für Textilmaschinen und Textile Hochleistungswerkstofftechnik (ITM) der TU Dresden verliehen. Die Preise sind mit 8.000 Euro dotiert und gingen an Frau Dr.-Ing. Cornelia Sennewald für ihre Dissertation zum Thema „Generative Struktur-, Technologie- und Webmaschinenentwicklung für unikale zellulare 3D Strukturen in Leichtbauweise “ und an Herrn Philipp Kempert für seine Studienarbeit „Entwicklung eines Schützenwechselsystems für Spulenschützen-Bandwebmaschinen zur Herstellung hochkomplexer 3D-Gewebe“.

Im Rahmen der prämierten Dissertation entwickelte Frau Dr.-Ing. Cornelia Sennewald eine neue Webtechnologie für die Fertigung völlig neuer zellularer 3D Drahtstrukturen. Die besondere Leistung besteht in der Entwicklung von Lösungen für die Verarbeitung von steifen Drahtmaterialien nach einem äußerst effizienten textilen Fertigungsverfahren. Die einzigartigen Strukturen zeichnen sich bei geringem Gewicht durch exzellente Werkstoffkennwerte aus. Sie bieten eine hervorragende Basis für neue Lösungen im Metallleichtbau, für crashsichere Leichtbauteile, aber auch für Hochleistungsbeton.
Herr Kempert leistete mit seiner ausgezeichneten Studienarbeit in Zusammenarbeit mit dem deutschen Maschinenbauer MAGEBA Textilmaschinen GmbH & Co KG einen wesentlichen Beitrag zur Automatisierung von Spezial-Webmaschinen für die Verarbeitung von Hochleistungsfaserstoffen, insbesondere von Carbon-Fäden. Mit diesen Spezial-Webmaschinen können komplexe 3D-Strukturen für Faserkunststoffverbunde gefertigt werden, die bisher in aufwändigen manuellen Arbeitsschritten gefertigt werden. Die vollständige Automatisierung ist eine wesentliche Grundlage für die Überführung der Forschungsergebnisse in die Industrie, wie die Automobilindustrie, der Maschinenbau und Sportgerätehersteller.