Processing Guidelines for CETEX Thermo-Lite PPS - TenCate

Processing Guidelines for CETEX
Thermo-Lite ® PPS (Polyphenylene Sulfide)
Uni-Tape Thermoplastic Composite Materials
Introduction: CETEX Thermo-Lite ® PPS thermoplastic uni-tape composite materials from
TenCate are processed by heating the material above the PPS melting point and molding it and
cooling it under pressure to the desired shape. Because no chemical change occurs to the PPS
matrix, processing is very rapid. The fast processing of CETEX Thermo-Lite materials is also
made possible because of the rapid crystallization rate of the PPS matrix. The key thermal
processing parameters are:
Melt Temperature 560�F (293�C)
Typical Processing Temperature 625�F (330�C)
Typical prepreg material forms that are supplied by TenCate are shown in the Table 1. These
materials are shown as examples and fiber type, resin type, fiber areal weight, and fiber/resin
contents can be varied depending on specific customer requirements.
TABLE 1: CETEX Thermo-Lite ® Prepreg Products
Product Description
PPS/Carbon Prepreg - AS-4C, 60% Fiber Weight, 150 FAW, 12" Wide
PPS/Carbon Prepreg - AS-4, 67% Fiber Weight, 145 FAW, 12" Wide
PPS/Carbon Prepreg - IM-2A, 66% Fiber Weight, 100 FAW, 12" Wide
CETEX Thermo-Lite prepregs have been fabricated into laminates and parts using a number of
different methods, including heated platen press molding, autoclave molding, matched die
compressions molding, thermoforming, roll forming, pultrusion, tape lay-up, and filament
winding. The most common methods of fabricating and finishing laminates and parts using
thermoplastic materials are described in this report. The parameters and methodologies outlined
in these processes should be used as guidelines in obtaining high quality structures. Careful
process experimentation will generally improve the results obtained for a specific application.
While the temperatures and pressures described in the following processes have been tailored to
PPS based CETEX Thermo-Lite materials, the general processes are applicable to a number of
other resin systems, such as Polyetherimide (PEI), Polyetheretherketone (PEEK), Polyamide
(PA), et al.
TENCATE ADVANCED COMPOSITES USA, INC. ISO 9001
18410 Butterfield Blvd. 2450 Cordelia Road AS 9100
Morgan Hill, CA 95037 Fairfield, CA 94534 USA Registered
Tel 408 776 0700 Tel 707 359 3400 www.tencate.com
Fax 408 776 0107 Fax 707 359 3459 E-mail: tcac-usa@tencate.com

Press Lamination: A laminate can be press molded from any CETEX Thermo-Lite prepreg by
stacking two or more plies in the desired orientation into a picture frame mold, transferring the
assembly to a heated platen press where it is brought to approximately 625-675�F (330-360�C) at
contact pressure until the material reaches temperature. The pressure should then be increased to
250 psi (1.7 MPa) and held for approximately 30 minutes. The assembly should then be quickly
transferred to a chilled platen press and cooled to room temperature while pressure is maintained.
Autoclave Lamination: Autoclave consolidation is used for fabricating laminates from any
Thermo-Lite prepreg tape. Individual layers are stacked in the desired orientation and vacuum
bagged (vacuum should be maintained throughout the entire process). A high temperature
bagging material, such as Kapton polyimide should be used. The assembly should then be placed
in the autoclave and brought to approximately 600-625�F (315-330�C), at which time the
pressure is increased from ambient to 100 psi (6.9 bar) and maintained for around 30 minutes.
The part should then be cooled to less than 200�F (93�C), at which time the pressure can be
dropped to ambient, the vacuum released, and the part brought to room temperature.
Thermoforming Laminates into Shapes: Thermoforming is used to convert a flat consolidated
continuous fiber reinforced laminate into a complex shape with no change in starting laminate
thickness. The laminate should be heated to around 625-650�F (330-345�C) in an infrared or
similar oven and then quickly transferred to a matched core/cavity mold where it can be formed
at 150-600 psi (10-40 bar). For optimum properties and formability, heating of the composite
laminate should take no longer than 8 minutes. Overall part production cycle times are between
2-10 minutes, depending on material thickness and part geometry. Production tooling consists of
machined aluminum halves, one that has a compliant layer of cast silicone, and an associated
laminate tensioning system to prevent wrinkling within the part being thermoformed.
Cutting and Machining: Thermoplastic composite laminates and thermoformed parts can be
machined with feed rates and tip speeds similar to those used when machining brass.
The following are some general guidelines:
Circular Saw: Diamond-grit-edge blade of 220 grit. Blade speed: 6000 fpm
(1830 mpm) with water or soap solution as coolant. Feed rates
depend on thickness.
Turning Operations: Cutting Speed: 350-400 fpm (105-120 mpm) for high speed tools,
1500-2500 fpm (180-455 mpm) for Stellite or carbide tools, and
2000-4000 fpm (600-1200 mpm) for diamond tools
Milling Operations: Tip speed: 250-450 fpm (75-135 mpm) for carbide and diamond tools
Plunge feed rate: 0.5-1 fpm (0.15-0.30 mpm)
Drilling Operations: Feed Rate: 0.008-0.016 in/rev (0.2-0.4 mm/rev)
Drill speed: 150-300 fpm (45-90 mpm)
Drill point angles: 60� for thin parts, 90� for thick parts
Clearance angle: 15�
Tapping: Tool rake of 0� to 5� negative
Shearing: Thicknesses up to 0.125 inch (3.2 mm)
TENCATE ADVANCED COMPOSITES USA, INC. ISO 9001
18410 Butterfield Blvd. 2450 Cordelia Road AS 9100
Morgan Hill, CA 95037 Fairfield, CA 94534 USA Registered
Tel 408 776 0700 Tel 707 359 3400 www.tencate.com
Fax 408 776 0107 Fax 707 359 3459 E-mail: tcac-usa@tencate.com

Joining: Thermoplastic composites can be joined via mechanical fasteners, adhesive bonding, or
fusion welding.
Strong adhesive bonds are possible with epoxy adhesives when PPS surfaces are cleaned with a
suitable degreasing solvent (i.e. MEK), grit blasted with #100 or #200 Aluminum Oxide,
re-cleaned and flame or corona treated. Grit blasting may be omitted if surface cleaning
effectively removes residual release agents, oils, or other impurities. Epoxy films or pastes with
cure temperatures up to 350�F (177�C), polyurethanes, acrylics, and cyanoacrylates are effective
adhesives depending on specific requirements. The following adhesives represent a starting point
in the search for an appropriate adhesive. Once specific application information is known,
however, an appropriate adhesive manufacturer should be contacted.
TABLE 2: Adhesive Examples
1. Cytec
� FM300 (350�F Epoxy Film), 300�F Service
� FM300-2 (250�F Epoxy Film), 300�F Service
� FM87-1 (250�F Epoxy Film), 250�F Service
� FM73 (250�F Epoxy Film), 180�F Service
2. Henkel
� Hysol EA9394 (RT Cure, 2-Part Epoxy Paste), 250�F Service
� Hysol EA9346 (250�F Cure, 1-Part Epoxy Paste), 250�F Service
� Hysol EA9330 (RT Cure, 2-Part Epoxy Paste), 100�F Service
3. Vantico
� Epibond 1545 (150�F Cure, 2-Part Epoxy Paste), 150�F Service
� XMH 8680 (RT Cure, 2-Part Polyurethane Paste), 120�F Service
Painting: CETEX Thermo-Lite ® PPS composite surfaces can be painted with a variety of
products. It is recommended that a paintable (non-silicone) mold release be used, if possible,
during the molding of all surfaces to be painted. If a silicone or Teflon mold release is used
during molding, laminate and part surfaces may require abrasion prior to painting. In all cases,
surfaces must be wiped with a suitable solvent (e.g. MEK, DuPont 3919S) to remove oils,
release agents, or other impurities.
Health & Safety: Health and safety information on handling and processing TenCate Thermo-
Lite composite materials is described in a Material Safety Data Sheet available from TenCate
Advanced Composites USA, Inc. To obtain this or any other information about TenCate PPS
thermoplastic composite materials, contact: TenCate Advanced Composites USA, Inc. and
Phoenixx TPC, Inc. at the addresses and telephone numbers below.
TENCATE ADVANCED COMPOSITES USA, INC. ISO 9001
18410 Butterfield Blvd. 2450 Cordelia Road AS 9100
Morgan Hill, CA 95037 Fairfield, CA 94534 USA Registered
Tel 408 776 0700 Tel 707 359 3400 www.tencate.com
Fax 408 776 0107 Fax 707 359 3459 E-mail: tcac-usa@tencate.com