Processes contd Filament Winding Processes contd Dry Layup

Processes ─ cont’d Filament Winding

Processes ─ cont’d Dry Lay-up bafore infusion

Processes ─ cont’d Infusion (in process)

Structural composites : A solution provider In the fastest growing energy supply To reinforce our commitment and dedication to the wind turbine industry, the composites adhesives and resins systems have been consolidated into the Structural Composites business unit to provide a total technical solution. We are now offering the added value of combined application expertise, understanding of the whole manufacturing process and development services, to meet the most demanding requirements of our customers.

Structural composites in wind turbine industry applications Inner (root) section Manufacture and assembly of main structural composite parts § § § Shells Girders Shear webs/stiffeners Spars Root section Spar Solid laminate Sandwich panel Assembly bondline Shear web

Temp °C Overall blade manufacturing process Process time Mould preparation and resin application according to the used process Adhesive application Blade demoulding

Structural composites Resins & adhesives RESINS: 1. ü PROCESSES Processes comparison 2. ü ü ü WET LAY UP PROCESS Process Systems and advantages New development 3. ü ü ü RESIN INFUSION Process Systems and advantages New development 4. ü ü ü PREPREG Process Systems and advantages New development 5. RESIN SELECTION GUIDE ADHESIVES: 6. ü ü ü 7. BONDING Process Quality of bonded joint Adhesive selection Blade assembly adhesives systems New development Bonding systems chemistry in comparison CONCLUSION

3 different processes Mixing epoxy system Fabrics impregnation and wet laminate build-up Vacuum bagging WET LAY-UP Mould preparation Build-up of dry reinforcement for Vartm processing Mixing epoxy system Infusion under vacuum RESIN INFUSION Prepreg laying & compaction PREPREG Vacuum bagging Curing Demoulding & finishing

Principle of wet lay-up process Easiest way to produce composite parts. With the use of vacuum bagging technology the laminate quality is improved. Features ü Easy to teach ü Low tooling cost

Wet lay-up system: Araldite® LY 3505 / Hardener XB 3403 / XB 3404 -1 / Aradur® 3405 80 Pot life (100 g 23°C) 600 / 720 min Pot life (100 g 23°C) 80 / 100 min Pot life (100 g 23°C) 26 / 36 min Pot life (100 g 23°C) 260 / 300 min Pot life (100 g 23°C) 100 / 130 min LY 3505/XB 3403 (100: 35) LY 3505/XB 3404 -1 (100: 35) LY 3505/ Aradur® 3405 (100: 35) LY 3505/XB 3403/XB 3404 -1 (100: 17. 5) LY 3505/XB 3403/ Aradur® 3405 (100: 17. 5)

Wet lay-up: New systems in development Low viscosity and non aggressive system with: • Long pot life hardener • Fast hardener

Principle of resin infusion process (Vartm) Process to produce parts with dry fabrics impregnated under pressure and heat using a reactive liquid resin. Avoids waste of impregnated fabrics. Features ü High resin mechanical properties (due to elevated temperature cure) ü Good health and safety and clean lay-up

Resin infusion system Araldite® LY 1564 / Aradur® 3486 / Aradur® 3487 Pot life (100 g 23°C) 560 / 620 min Pot life (100 g 23°C) 130 / 160 min Pot life (100 g 23°C) 380 / 430 min LY 1564/ Aradur® 3486 (100: 34) LY 1564/ Aradur® 3487 (100: 34) LY 1564/ Aradur® 3486/ Aradur® 3487 (100: 17)

Resin infusion: New systems in development System with : • Long pot life • Fast cure

Principle of prepreg process Production of high quality parts in a press or autoclave supported by heat and vacuum. Features ü Well defined resin content ü Clean handling ü Excellent fibre wet out ü Logistic

Prepreg: New systems in development Hot melt system with long shelf life and low exotherm • Cure at 85°C 4 -6 h • Fast cure up to 120°C 1 -2 h

Bonding process Preparation of parts Adhesive mixing & dispensing Positionning of parts According to assembly sequence Closing mould with upper part shell and compressing Curing Demoulding Finishing operations Completed blade

Bonding process MIXING AND APPLYING ADHESIVE ON UNDER PART IN THE MOULD CLOSING MOULD, COMPRESSING & CURING APPLYING ADHESIVE ONTO THE BONDED AREAS & ASSEMBLING ALL PARTS (SPAR, SHEAR WEB, …) DEMOULDING & FINISHING

Blade assembly New adhesives in development New adhesives generation ü Toughened system ü 65 -70°C post cured 20

General committment • Technical support – – Selection of matrix Selection of adhesive Testing and verification Process trials and application support – General problem solving • Training/seminars – Composites, matrix and processes – Structural bonding • Chemistry, formulations, materials and composite knowhow 21