SAMPE Journal - July/August 2011 - 13
• Ceramic tooling will use approx. 10-12 KW/ sq.m of surface x 2 hours of full power during process, e.g. for 16 sq.m tool, usage will be 12 x 2 x 16 = 384 KW.hrs. • A 16 sq.m Invar tool in an oven would use approx. 350KW x 3 hours = 1050 KW.hrs • A 16 sq.m Invar tool in an autoclave would use approx. 500KW x 3 hours of full power = 1500 KW.hrs The total amount of energy used per cure cycle is substantially less than that in an oven (63% less) or autoclave (85% less), yielding lower costs and environmental benefits with each cure cycle.
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Conclusions A novel tooling solution for out-of-autoclave processing of both thermoset and thermoplastic composites has been presented. The tooling is a ceramic cement material, reinforced with a carbon-fabric thermoplastic composite, and heated electrically with embedded electrical heating tape. The tooling is lightweight, strong and durable, with low coefficients of thermal expansion in the plane of the tool, and is capable of being heated to 200°C in less than 10 minutes. Special surface sealing and repair solutions have been developed to make the tool surface sufficiently vacuum tight. Though the ceramic is heat stable to 1000°C, the expected upper temperature limit of the tooling is governed by the thermoplastic polymer used to bind the reinforcing fibres to the ceramic cement. In the case of a carbon fibre/PEEK reinforcement, the tooling has an expected upper temperature limit of approximately 300°C. The new tooling technology has been used to successfully manufacture a 12.6 metre wind turbine blade in an in-situ polymerized glass/ PBT material, and in a “VOC-free” glass-fibre epoxy material, both processed at temperatures around 200°C. Advantages of the tooling for large composite structures such as wind turbine blades include reduced process cmyk cycle times, and labour content, as well as “one-shot” manufacturing of the blades. Finally, an aerospace 180°C-cure
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carbon-fibre/epoxy prepreg was successfully manufactured on a section of the tooling. Economic comparisons with aerospace-standard Invar metal tooling indicate that capital investment savings of up to 85% could be envisaged when compared with autoclave
Table 4. Running costs of electrically-heated ceramic tooling compared to other solutions.
SAMPE Journal, Volume 47, No. 4, July/August 2011
13
SAMPE Journal - July/August 2011
Table of Contents for the Digital Edition of SAMPE Journal - July/August 2011
SAMPE Journal - July/August 2011
Contents
President’s Message
Technical Director’s Corner
Electrically-Heated Ceramic Composite Tooling for Out-of-Autoclave Manufacturing of Large Composite Structures
SAMPE 2011–A Review
SAMPE 2011 Photo Gallery
SAMPE Tech 2011 Conference
SAMPE Tech 2011 Exhibition
Europe News & Views
SAMPE Europe’s SETEC 2011, Leiden
SAMPE Europe’s SEICO 2012, Paris
SAMPE China 2011
12th Japan International SAMPE Symposium and Exhibition – JISSE-12
SAMPE Books & CD’s Order Form
SAMPE Proceedings
SAMPE Journal Editorial Calender
The SAMPE Foundation
Welcome SAMPE’s Newest Members
Rapid/Affordable Composite Tooling Strategies Utilizing Fused Deposition Modeling
Corporate Partners
Industry News
SAMPE 2012 Call for Papers
SAMPE 2012 Exhibition
Materials & Products
SAMPE Asia 2012|Kuala Lumpur, Malaysia
LTM205 OOA Materials for Novel Prepreg Formats for Cauls and Tooling Manufactured from Very Low CTE CB1100 Ceramic Tooling Block
Advertiser’s Index
Resource Center
SAMPE LinkedIn Communities
Industry Events Calendar
Chapter Meetings Dates and Contacts
SAMPE Journal - July/August 2011 - SAMPE Journal - July/August 2011
SAMPE Journal - July/August 2011 - Cover2
SAMPE Journal - July/August 2011 - Contents
SAMPE Journal - July/August 2011 - 2
SAMPE Journal - July/August 2011 - President’s Message
SAMPE Journal - July/August 2011 - 4
SAMPE Journal - July/August 2011 - Technical Director’s Corner
SAMPE Journal - July/August 2011 - Electrically-Heated Ceramic Composite Tooling for Out-of-Autoclave Manufacturing of Large Composite Structures
SAMPE Journal - July/August 2011 - 7
SAMPE Journal - July/August 2011 - 8
SAMPE Journal - July/August 2011 - 9
SAMPE Journal - July/August 2011 - 10
SAMPE Journal - July/August 2011 - 11
SAMPE Journal - July/August 2011 - 12
SAMPE Journal - July/August 2011 - 13
SAMPE Journal - July/August 2011 - 14
SAMPE Journal - July/August 2011 - 15
SAMPE Journal - July/August 2011 - SAMPE 2011–A Review
SAMPE Journal - July/August 2011 - SAMPE 2011 Photo Gallery
SAMPE Journal - July/August 2011 - SAMPE Tech 2011 Conference
SAMPE Journal - July/August 2011 - SAMPE Tech 2011 Exhibition
SAMPE Journal - July/August 2011 - Europe News & Views
SAMPE Journal - July/August 2011 - 21
SAMPE Journal - July/August 2011 - SAMPE Europe’s SETEC 2011, Leiden
SAMPE Journal - July/August 2011 - 23
SAMPE Journal - July/August 2011 - SAMPE Europe’s SEICO 2012, Paris
SAMPE Journal - July/August 2011 - 25
SAMPE Journal - July/August 2011 - SAMPE China 2011
SAMPE Journal - July/August 2011 - 27
SAMPE Journal - July/August 2011 - 12th Japan International SAMPE Symposium and Exhibition – JISSE-12
SAMPE Journal - July/August 2011 - SAMPE Books & CD’s Order Form
SAMPE Journal - July/August 2011 - SAMPE Proceedings
SAMPE Journal - July/August 2011 - 31
SAMPE Journal - July/August 2011 - SAMPE Journal Editorial Calender
SAMPE Journal - July/August 2011 - The SAMPE Foundation
SAMPE Journal - July/August 2011 - Welcome SAMPE’s Newest Members
SAMPE Journal - July/August 2011 - 35
SAMPE Journal - July/August 2011 - 36
SAMPE Journal - July/August 2011 - Rapid/Affordable Composite Tooling Strategies Utilizing Fused Deposition Modeling
SAMPE Journal - July/August 2011 - 38
SAMPE Journal - July/August 2011 - 39
SAMPE Journal - July/August 2011 - 40
SAMPE Journal - July/August 2011 - 41
SAMPE Journal - July/August 2011 - 42
SAMPE Journal - July/August 2011 - 43
SAMPE Journal - July/August 2011 - 44
SAMPE Journal - July/August 2011 - Corporate Partners
SAMPE Journal - July/August 2011 - Industry News
SAMPE Journal - July/August 2011 - 47
SAMPE Journal - July/August 2011 - SAMPE 2012 Call for Papers
SAMPE Journal - July/August 2011 - SAMPE 2012 Exhibition
SAMPE Journal - July/August 2011 - Materials & Products
SAMPE Journal - July/August 2011 - 51
SAMPE Journal - July/August 2011 - SAMPE Asia 2012|Kuala Lumpur, Malaysia
SAMPE Journal - July/August 2011 - 53
SAMPE Journal - July/August 2011 - LTM205 OOA Materials for Novel Prepreg Formats for Cauls and Tooling Manufactured from Very Low CTE CB1100 Ceramic Tooling Block
SAMPE Journal - July/August 2011 - 55
SAMPE Journal - July/August 2011 - 56
SAMPE Journal - July/August 2011 - 57
SAMPE Journal - July/August 2011 - 58
SAMPE Journal - July/August 2011 - 59
SAMPE Journal - July/August 2011 - 60
SAMPE Journal - July/August 2011 - 61
SAMPE Journal - July/August 2011 - Advertiser’s Index
SAMPE Journal - July/August 2011 - 63
SAMPE Journal - July/August 2011 - Resource Center
SAMPE Journal - July/August 2011 - 65
SAMPE Journal - July/August 2011 - 66
SAMPE Journal - July/August 2011 - 67
SAMPE Journal - July/August 2011 - 68
SAMPE Journal - July/August 2011 - 69
SAMPE Journal - July/August 2011 - 70
SAMPE Journal - July/August 2011 - SAMPE LinkedIn Communities
SAMPE Journal - July/August 2011 - Chapter Meetings Dates and Contacts
SAMPE Journal - July/August 2011 - Cover3
SAMPE Journal - July/August 2011 - Cover4
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