reset re-use of thermoplastic composite · pre-selection of different waste stream conditioning of...

This project has received funding from the Clean Sky 2 Joint Undertaking under the European Union’s Horizon 2020 research and innovation

programme under grant agreement No 686636

RESET Re-use of Thermoplastic Composite

Claudia Aguilar, Leitat



Outline

Background and objectives

Definition of Material

Characterization

Process development

DEMONSTRATION-Development of prototype demonstrator

by injection moulding

-Life Cycle Assesment (LCA)

CONCLUSIONS



Objectives

DEVELOPMENT OF AN INNOVATIVE RECYCLING PROCESS OF THERMOPLASTICS USED IN AERONAUTIC

The recycled material will be used as raw material to produce new parts for aircrafts

Up to 70% of recycled material will be used to produce a new family of composites materials

COMPLETE CHARACTERIZATION OF THE NEW COMPOSITES –DEVELOPMENT OF NEW PROTOTYPES

BASED ON CRYOGENIC GRINDING PROCESS



Pre-selection of different

waste stream

Conditioning of waste material

Development of new

composites

Manufacture of

demonstrators

PEEK and PPS waste from

aircraftsMilling process

Definition of the particle size

Data sheet of the waste material

Polymer waste management

Development of new rCFRP by extrusion

process

ISO tests samples of new rCFRP by injection

moulding

Technical data Sheet

New Engineering thermoplastics

3 new pieces for aircraft made with new rCFRP


http://www.google.es/url?sa=i&rct=j&q=&esrc=s&source=images&cd=&cad=rja&uact=8&ved=0CAcQjRw&url=http://www.flightglobal.com/news/articles/aviation-industry-under-pressure-to-reduce-landfill-waste-from-scrapped-351597/&ei=g7kSVZeoCsv3UtqugpgI&bvm=bv.89184060,d.d24&psig=AFQjCNHbjFc9hYWwD9gyAieDBgO8XLDZSw&ust=1427376873054401

http://www.google.es/url?sa=i&rct=j&q=&esrc=s&source=images&cd=&cad=rja&uact=8&ved=0CAcQjRw&url=http://www.flightglobal.com/news/articles/aviation-industry-under-pressure-to-reduce-landfill-waste-from-scrapped-351597/&ei=g7kSVZeoCsv3UtqugpgI&bvm=bv.89184060,d.d24&psig=AFQjCNHbjFc9hYWwD9gyAieDBgO8XLDZSw&ust=1427376873054401

http://www.google.es/url?sa=i&rct=j&q=&esrc=s&source=images&cd=&cad=rja&uact=8&ved=0CAcQjRw&url=http://www.recyclingtoday.com/afra-aircraft-recycling-demolition-aels.aspx&ei=u7kSVf-BO8OAUdK9gvAE&bvm=bv.89184060,d.d24&psig=AFQjCNEWvhbnuJT_AElXl0gMsW2q0DYIaQ&ust=1427376920119602

http://www.google.es/url?sa=i&rct=j&q=&esrc=s&source=images&cd=&cad=rja&uact=8&ved=0CAcQjRw&url=http://www.recyclingtoday.com/afra-aircraft-recycling-demolition-aels.aspx&ei=u7kSVf-BO8OAUdK9gvAE&bvm=bv.89184060,d.d24&psig=AFQjCNEWvhbnuJT_AElXl0gMsW2q0DYIaQ&ust=1427376920119602

http://www.google.es/url?sa=i&rct=j&q=&esrc=s&source=images&cd=&cad=rja&uact=8&ved=0CAcQjRw&url=http://www.amazon.com/Robust-Process-Development-Scientific-Molding/dp/1569905010&ei=OsISVc6CMMj3ULeVhJAD&bvm=bv.89184060,d.d24&psig=AFQjCNEvMkFN5KCUW_KmZecpeFZInCwSqA&ust=1427379076563965

http://www.google.es/url?sa=i&rct=j&q=&esrc=s&source=images&cd=&cad=rja&uact=8&ved=0CAcQjRw&url=http://www.amazon.com/Robust-Process-Development-Scientific-Molding/dp/1569905010&ei=OsISVc6CMMj3ULeVhJAD&bvm=bv.89184060,d.d24&psig=AFQjCNEvMkFN5KCUW_KmZecpeFZInCwSqA&ust=1427379076563965



Expected RESET

output material




Definition of material waste

- Scrap material from part manufactures

Characterization and conditioning of the waste material

Specification of the recycled material

- Supplier: Tencate

- Reference: Cetex PPS

- Matrix content:

- Resin content by volume 50 %

- Resin content by weight 43 %

- Mass of fabric 280 g/m²

- Mass of fabric + resin 486 g/m²

- Reinforcement architecture (fabric/tape): Carbon T300 3K 5HS

-



- Previous treatment of residues

Characterization and conditioning of the waste material

The proposed strategy is the treatmentof the residues through a priorconditioning by a cryogenic grindingprocess.

Different parameters were taken into account: -Milling speed -Sieve size

Chopped into small fragments-Particle size up to 2,5 mm (determined by laser diffraction).



Characterization of the conditioned PPS/CF scrap: Fibres up to 300 µm of length

Diameter vary from 5 µm to 9 µm- SEM:

Figure 7. SEM micrographs 1000xfrom milled PPS scrap

Figure 8. SEM micrographs 1000xfrom milled PPS scrap

Figure 9. SEM micrographs 1000x from milled PPS scrap



Development of a new family of composites based on PPS/CF scrap

Preparation of the new

composites by means of melt

extrusion

•Extruder configuration

• Screw speed

•Temperature profile

•Residence time

Taking into account the parameters listed below



Characterization of the new family of composites based on PPS/CF scrap

- TGA

Tmax (°C)

PPS virgen 511

Composite 1 553

Composite 2 550

Composite 3 553



Mechanical Properties: Tensile test

Effect of the recycling

Process over the mechanical

Properties

Young´s modulus of the composites are comparable with the commercial countertype Larton K/30

4

32

25

30 30

22

25

29

0

5

10

15

20

25

30

Te

nsi

le m

od

ulu

s (G

Pa

)

Tensile modulus

PPS/rCF fr

om p

repe

gs *

Larto

n K/3

0

RTP 1

387

C (P

PS-CF-4

0)

PPS virg

in

PPS/rCF fr

om fi

nish

ed p

arts

*

Com

posite

1

Com

posite

2

Com

posite

3



Mechanical Properties: Flexural properties



Properties

Enhancement in stress at break

66

190 185

200191

203216 213

0

50

100

150

200

Com

posite

3

Com

posite

2

Str

ess a

t b

rea

k (

MP

a)

Stress at break

PPS virg

in

RTP 1

387

C (P

PS-CF-4

0)

Larto

n K/3

0

PPS/rCF fr

om p

repe

gs *

PPS/rCF fr

om fi

nish

ed p

arts

*

Com

posite

1






Properties

Enhancement in strain at break

2

0,8 0,8

1,19 1,19

4,37 4,4

4,08

0

1

2

3

4

Com

posite

3

Com

posite

2

Str

ian

at b

rea

k (%

)

Strian at break

Com

posite

2

Com

posite

1

PPS/rCF fr

om fi

nish

ed p

arts

*

PPS/rCF fr

om p

repe

gs *

Larto

n K/3

0

RTP 1

387

C (P

PS-CF-4

0)

PPS virg

in






Properties

Elasticity´s modulus of the composites are comparable with the commercial countertype Larton K/30

4

28

23

27

29

20

2526

0

5

10

15

20

25

30

Mo

du

lus

of e

lsa

ticity

(G

Pa

)

Modulus of

elasticity






Properties

Enhancement in flexural strength

66

269278

310325

301

346 351

0

50

100

150

200

250

300

350F

lexu

ral s

tre

ng

ht (M

Pa

)

Flexural strenght

PPS virg

in

RTP 1

387

C (P

PS-CF-4

0)

Larto

n K/3

0

PPS/rCF fr

om p

repe

gs *

PPS/rCF fr

om fi

nish

ed p

arts

*

Com

posite

1

Com

posite

2

Com

posite

3






Properties

Enhancement in deformation

2

1 1 1

2 2 2

0,0

0,5

1,0

1,5

2,0D

efo

rma

tion

(%

)

Deformation

PPS virg

in

Larto

n K/3

0

PPS/rCF fr

om p

repe

gs *

PPS/rCF fr

om fi

nish

ed p

arts

*

Com

posite

1

Com

posite

2

Com

posite

3






Properties

Enhancement in the impact strength

4,5

6,11

6,556,8

Larton K/30 Composite 1 Composite 2 Composite 3

0

1

2

3

4

5

6

7Im

pa

ct s

tre

ng

th (

KJ/

m2)

Impact strength



Determination of burning behaviour of interiormaterials.

Classification of the material : DNI (does not ignite)

According to the formula; B = (s / t) x 60

-Composite 1

-Composite 2

-Composite 3



Demonstration

Thermoplastic bracket

Name of the piece: Bracket

Volume of the piece: 65 cm3

Nominal thickness 10 / 6 / 5,5 / 3 mm

Projected area: 71,1 cm2

Inyectora prevista: 60 Tn



Demonstration

Thermoplastic cleat

Name of the piece: Thermoplastic cleat

Volume of the piece: 22,3 cm3

Nominal thickness 3 mm

Projected area: 51,1 cm2

Inyectora prevista: 40 Tn



Demonstration

Case 1: Case 2:

BRACKET: study of the position of the injection point



Demonstration

Case 2:

BRACKET: study of the position of the injection point



Demonstration

Case 1: Case 2:

CLEAT: study of the position of the injection point



Demonstration

Case 2:

CLEAT: study of the position of the injection point



Life cycle assessment




Goal and ScopeThe functional unit has been defined as 1 kg of recycled thermoplastic composite

to be employed by the aircraft manufacturing industry




Goal and Scope

Assumptions considered

- The transportation of waste from France and crude polymer from China

has not been considered. The impact associated to the transport are

very high and it doesn’t let assess the specific impacts of recycling

processes. The transportation of release agent which is used in the

thermoforming process is neither considered because the specific origin

is not known.

- The lifespan of the manufactured pieces from the recycled composite

thermoplastic is unknown. For that reason, it is assumed to be the

same as the lifespan of an aircraft (25 years).




Goal and Scope

Assumptions considered

- The two technologies have been implemented in France and in Spain

but the LCA study considers that both processes have been developed

in the same country (in Spain). This fact allows the comparison

between the environmental performance of the recycling technologies,

independent of the sustainability of the energy matrix in each country.

The difference between the energy matrix in these countries causes

different impacts because the source of the energy is not the same.

That assumption allows comparing.

- The recycled waste contains around 40% of carbon fibres and 60% of

PPS. The same percentages have been considered for PEEK analysis.




Injection

moulding

Results: 50% of waste and 50% of crude polymer

Thermoforming



Life cycle assessment Results: Carbon footprint related to waste contained and technology



Life cycle assessment Results: comparative of impact (Carbon Footprint) the four demonstrators




Results: PEEK versus PPS

PEEK manufacturing process generates halogenated organic and dust

(PM 2,5) emissions. On average, PPS represents around 46% less

environmental impacts than PEEK.



Conclusions

Development and

characterization of

prototype demonstrators

by injection moulding

and thermoforming

The mechanical properties of the

material are comparable with the

commercial countertype and

composites prepared with

recycled carbon fibre

In this work, laminates of PPS

and carbon fibre were recycled

by means of cryogenic grinding

process.

The recycled composites were

compounded with virgin PPS to

obtain composites up to70% of

recycled material



THANKS FOR YOUR ATTENTION

www.leitat.org

[email protected]

reset re-use of thermoplastic composite · pre-selection of different waste stream conditioning of...

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