Making the world lighter. High-performance foam cores for sandwich structures

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Agnes Blankenship
6 years ago
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1 ROHACELL Making the world lighter High-performance foam cores for sandwich structures

Lightweight composite sandwich constructions with ROHACELL Evonik, the creative industrial group from Germany, is one of the world leaders in specialty chemicals.

With ROHACELL structural foam lightweight sandwich structures can be realized resulting in super-light structures that display high shear and pressure resistance, even at elevated temperatures.

ROHACELL, PMI-based structural foam has been used in fiber reinforced composite technology for more than 30 years.

2 Lightweight composite sandwich constructions with ROHACELL Evonik, the creative industrial group from Germany, is one of the world leaders in specialty chemicals. Its activities focus on the key megatrends health and nutrition, resource efficiency and globalization. Evonik is active in over 100 countries around the world. With ROHACELL structural foam lightweight sandwich structures can be realized resulting in super-light structures that display high shear and pressure resistance, even at elevated temperatures. Light and strong The principle of increasing stiffness of a composite structure by means of sandwich construction is well established. ROHACELL, PMI-based structural foam has been used in fiber reinforced composite technology for more than 30 years. And it is by no coincidence that ROHACELL is still a leader in the area of high performance lightweight sandwich construction today. ROHACELL s success is attributed to the following: Excellent mechanical properties over a wide temperature and density range. High temperature resistance up to 220 C (428 F) Excellent compressive creep behavior up to 180 C (356 F) and 1.0 MPa (145 psi) Excellent dynamic strength and fatigue behavior Cell size options for process method optimization 2

The optimum product to realize your success ROHACELL grades ROHACELL IG/IG-F ROHACELL SL ROHACELL HERO ROHACELL A ROHACELL WF* ROHACELL RIST* ROHACELL RIMA* ROHACELL XT* ROHACELL HP* ROHACELL S

curing up to 125 C and 0.35 MPa aircraft applications, curing up to 180 C and 0.

g, 32 kg/m³, 180 C and vacuum good fire behavior, railcars, ship, smaller aircraft absorbs electromagnetic waves at radar frequencies antennas, radomes, medical wind turbine blades Used mainly in

specific strength Outstanding creep compression resistance Antennas and radomes Dielectric properties close to air High specific properties while maintaining transparency Tightest dimensional

consumption and CO 2 emission Extended range and thermal insulation for EV s Medical technology No inclusion due to homogeneous structure Stable and reliable process Lightweight and handy imaging

3 The optimum product to realize your success ROHACELL grades ROHACELL IG/IG-F ROHACELL SL ROHACELL HERO ROHACELL A ROHACELL WF* ROHACELL RIST* ROHACELL RIMA* ROHACELL XT* ROHACELL HP* ROHACELL S ROHACELL EC ROHACELL HF ROHACELL WIND-F sporting goods, medical, automobile applications sporting goods, automobile applications highest elongation, minimized resin absorption aircraft applications, curing up to 125 C and 0.35 MPa aircraft applications, curing up to 180 C and 0.7 MPa designed for Resin Infusion, STructural application designed for Resin Infusion, Minimized Resin Absorption extended temperature, curing up to 190 C and 0.7 MPa highest creep resistance, e.g, 32 kg/m³, 180 C and vacuum good fire behavior, railcars, ship, smaller aircraft absorbs electromagnetic waves at radar frequencies antennas, radomes, medical wind turbine blades Used mainly in aircraft * HT grade available Added Value with ROHACELL Aerospace applications Stable, uniform and reliable during fabrication Reduced fabrication time Co-curing, no core stabilization required High specific strength Outstanding creep compression resistance Antennas and radomes Dielectric properties close to air High specific properties while maintaining transparency Tightest dimensional tolerances for optimum antenna performance Automotive industry Efficient thermoshaping process Short cycle times by RTM or with thermoplastic layers Effective light weight design Reduction of fuel consumption and CO 2 emission Extended range and thermal insulation for EV s Medical technology No inclusion due to homogeneous structure Stable and reliable process Lightweight and handy imaging beds High quality X-ray/CT image with minimal patient radiation exposure due to low Al-equivalent Railcars Low energy consumption and high accelerations due to lightweight structure Good FST properties (no smoke, no toxic gasses) Extended passenger space Sports and leisure Lightweight design resulting in top performance and endurance High specific mechanical properties Design freedom 3

efficiently in your design work. We support you in developing automation concepts with ROHACELL.

4 We support you. We support your use of ROHACELL in all composite manufacturing processes. Low viscosity resin RTM closed mold LRI single side mold For the best possible support of our customers, the ROHACELL solution center offers you a variety of options to incorporate ROHACELL efficiently in your design work. We support you in developing automation concepts with ROHACELL. Sandwich Technology Center We can support your prototype fabrication, small production runs, and can conduct sandwich structure testing and experiments, e.g., thermoforming, liquid composite molding and autoclaving etc.. We are able to demonstrate the use of ROHACELL using traditional and non-traditional techniques. In addition, we offer samples and customer product training. Take advantage of our knowhow: We can help you with Reducing cycle time in production Selection of right shaping method (thermoforming and/or CNC machining) Stable and reliable curing process Cost saving concepts Shorter development cycles 4

5 Mid and high viscosity resin Prepreg RFI single side mold Press-Mold closed mold Feeding system skins and ROHACELL Cutting Heating Vacuum thermoforming Cooling Trimming and cutting Handling by robotics Removing Increase your efficiency Utilize the advantages of ROHACELL for your lightweight constructions and optimize your processes. Stay cool The benchmark is 180 C (356 F) and 1.0 MPa (145 psi). ROHACELL can reduce the curing process to a single step. With its high thermal stability and creep compression strength the structural foam sets new standards in processing. Reduce your lay-up efforts Shortened lay-up time helps achieve cost savings of up to 50 % in comparison to the honeycomb structure. Design without limits Design and produce composite components with the greatest of ease. With ROHACELL you can optimize integral construction. Whether by thermoforming or high-speed CNC machining, ROHACELL eliminates geometric challenges by combining creativity and mechanical effectiveness. 5

ROHACELL SHAPES Department The ROHACELL SHAPES department produces high precision shaped foam cores to any geometry you may require.

6 Our competences in Shapes Engineering service ITAR certified facility at ROHACELL production site in Mobile, AL, USA only Ftp site data transfer CAD data transfer to CNC

Thermoforming tool concept CNC machining 4 axis/5 axis Quality management First Article Inspection (FAI) reporting Certificate of conformity for each delivery Digital

6 ROHACELL SHAPES Department The ROHACELL SHAPES department produces high precision shaped foam cores to any geometry you may require. This can be done by CNC machining and/or thermoforming. 6 Our competences in Shapes Engineering service ITAR certified facility at ROHACELL production site in Mobile, AL, USA only Ftp site data transfer CAD data transfer to CNC data 2D/3D Generating CNC data Prototype and serial production Pre-process management Moisture/environmental management Drying Heat treatment Thermoforming Cold/hot forming Thermoforming tool concept CNC machining 4 axis/5 axis Quality management First Article Inspection (FAI) reporting Certificate of conformity for each delivery Digital measurement with FARO arm Process control documentation Reproducible quality Logistics Just in time delivery Ready to use and clearly labeled shapes Optimized packaging concept Your benefits Focus on your core business No bound capital, no scrap parts Reduce your finished part cost up to 30 % Decrease lead time by not using a CNC machining third-party

7 ROHACELL contacts all over the world Germany Global office phone Belgium, Netherlands Ron van Hoorn phone ron.vanhoorn@evonik.com France, Spain Laurent Miotto phone laurent.miotto@evonik.com Italy Alessio Redolfi phone alessio.redolfi@roehmitalia.it United Kingdom Hameem Yasin phone hameem.yasin@evonik.com Israel Aviad Aronson phone aviad@ornigon.com USA/Canada (Eastern), South America Reid Averill phone reid.averill@evonik.com USA/Canada (Western), Mexico Blake Juhl phone blake.juhl@evonik.com Brazil Fabio Tufano phone fabio.tufano@evonik.com China Jacky Yang phone jacky.yang@evonik.com India Pratik Bhatnagar phone pratik.bhatnagar@evonik.com Japan Teiji Ito phone t.ito@evonik.daicel.com South Korea David Baek phone david.baek@evonik.com You can find further contact persons at > contact. Darmstadt Mobile Shanghai Highest quality standard We have an integrated management system in place to meet global customer requirements and ensure that the highest quality standards are maintained. Our system is ISO 9001: 2008, ISO 14001: 2004, BS OHASAS 1800:2007 and EN 9100: 2009-certified and is regularly optimized. Our US location can produce ITAR related projects. 7

8 This information and all technical and other advice are based on Evonik s present knowledge and experience. However, Evonik assumes no liability for such information or advice, including the extent to which such information or advice may relate to third party intellectual property rights. Evonik reserves the right to make any changes to information or advice at any time, without prior or subsequent notice. Evonik disclaims all representations and warranties, whether express or implied, and shall have no liability for, merchantability of the product or its fitness for a particular purpose (even if Evonik is aware of such purpose), or otherwise. EVONIK SHALL NOT BE RESPONSIBLE FOR CONSEQUENTIAL, INDIRECT OR INCIDENTAL DAMAGES (INCLUDING LOSS OF PROFITS) OF ANY KIND. It is the customer s sole responsibility to arrange for inspection and testing of all products by qualified experts. Reference to trade names used by other companies is neither a recommendation nor an endorsement of the corresponding product, and does not imply that similar products could not be used. Evonik Resource Efficiency GmbH High Performance Polymers Kirschenallee Darmstadt Germany phone fax rohacell@evonik.com Evonik Foams Inc Industrial Road Theodore, AL USA phone fax rohacell.usa@evonik.com Evonik Specialty Chemicals (Shanghai) Co., Ltd. 55 Chundong Road Xinzhuang Industry Park Shanghai China phone rohacell@evonik.com 07/GR/500/en

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