ROHACELL General Review Aircraft Reid Averill Business Development

ROHACELL® General Review, Aircraft Reid Averill, Business Development Manager Rodrigo Marques Regional Business Development

1. Evonik supports the composite market 2. Overview of ROHACELL 3. New Product ROHACELL HERO 4. Shaping of ROHACELL 5. Conclusion Page 2

Evonik products and expertise in almost all composite sub-components Composite sandwich system – schematic view Thermosets Thermoplastics VESTAKEEP® VESTAMID® HTplus VESTAMID® L TROGAMID® Matrix Interface Fiber Foam cores Crosslinker ROHACELL® VESTAMIN® VESTANAT® JAYHAWK™ Dianhydrides VISIOMER® Foam Core Additives/rheological modifier AEROSIL® Dynasylan® TEGOMER ® 3 COMPIMIDE® CALIDUR® Thermoset modifier Adhesive / Sealant NANOPOX® ALBIDUR® P 84® Understanding all aspects of a complex system is important.

ROHACELL ® industry breakdown Wind Auto Lifestyle* Aircraft *Lifestyle: 4 sports equipment, medical tables, electronics, radomes

ROHACELL® locations Positioned to serve a global market Darmstadt Mobile Shanghai Mobile, Alabama (USA) Darmstadt (Germany) 5 Production: Casting·Foaming·Cutting·Shaping Sandwich Technology Center Production: Foaming·Cutting·Shaping Sandwich Technology Center Shanghai (China) Production: Cutting facility - in progress Sandwich Technology Center

Composite Sandwich Design Concepts 6

Aircraft Product Portfolio 7 ROHACELL® Product Processing Conditions Special Properties A 130°C / 0. 35 MPa Standard aircraft grade HERO 180°C / 0. 7 MPa Highest elongation at break HF 130°C / 0. 35 MPa High frequency transparency, designed for radome applications WF 180°C / 0. 7 MPa Most qualified aircraft grade RIST 180°C / 0. 7 MPa Designed for resin infusion, smaller cells RIMA 180°C / 0. 7 MPa Designed for resin infusion, smallest cells XT 220°C / 0. 7 MPa Usable with BMI resins EC 180°C / 0. 7 MPa Electrically conductive, designed for UAVs and other stealth applications

Advantages of Using ROHACELL • • 8 Compatible with all composite processes and thermoset resin systems • Prepreg/autoclave, RTM, infusion, Fiber Placement, etc. . • 100% closed cell foam no resin absorption through thickness • Outstanding Compressive creep resistance, compatible with 180 C and 0. 7 MPa cure cycles Complex shaping (Thermoforming/Thermoshaping and CNC machining) High strength to weight ratio Excellent electrical performance (Radome applications) Class A Surface finish No liquid moisture problem Full blown FAA qualification on WF grade Date | ROHACELL® HERO P

Electrical Properties of ROHACELL • • 9 ROHACELL’s electrical and mechanical properties make it an excellent core material for Radomes • ROHACELL performs superior to Honeycomb in hail strike performance • ROHACELL behaves isotropic electrically making it a much easier material to electrically model when compared to honeycomb Evonik also offer’s an electrically conductive grade of ROHACELL called EC for EM shielding and stealth applications Date | ROHACELL® HERO P

ROHACELL HERO The ROHACELL® HERO development challenge: Improve a proven, high performing foam sandwich core product for use in Class A and B parts. Add: High damage tolerance & visibility With: Greatly improved elongation at break Keep: All existing advantages Result: Reduced finished part costs 10 Pa

Increased elongation at break is key to meeting the damage requirement Tension Standard ROHACELL® products 3 -4 % 9 -10 % HERO offers the highest elongation at break of any ROHACELL® foam core product 11 Elongation

Introducing: ROHACELL® HERO New design opportunities Floor panels • carbon epoxy skin Empennage Leading and Trailing Edges VTP tip VTP panels Dorsal fin Spoilers / Ailerons Pylon Aft Secondary Structure Access Panels • carbon epoxy or thermoplastic skins Nose Landing Gear Doors • carbon fiber epoxy skins Flap Track Fairings • carbon/glass epoxy skins Main Landing Gear Doors Wing Leading and Trailing Edge Panels Access Panels Fuselage Belly Fairing • carbon/glass epoxy skins 12

Target: Meet customer’s requirement for damage detectability (Class A & B parts) Design load requirements Typical impact damage If General Visual Inspection selected If Detailed Visual Inspection selected k*Limit Load (1<k<1. 5) Ultimate Load UL Required damage C-scan LL Limit Load Hole Diameter TBD BVID (DVI) DVI (Detailed Visual Inspection) 13 BVID (GVI) GVI (General Visual Inspection) Large VID Walk-around Inspection Increasing damage size

Impact damage visibility test Testing target: ROHACELL® HERO Sandwich Density 75 kg/m³ Prove that a ROHACELL® HERO sandwich provides the same damage visibility after an impact as a honeycomb sandwich For more information, please refer to test report. NOMEX Honeycomb Sandwich Density 48 kg/m³, Cell size 3. 2 mm Testing conducted at Fraunhofer IWM, 2013 14

Impact-Depth [mm] Impact @ -55°C Impact depth after 48 hours Foam-Sandwich after 48 h 4. 0 3. 5 3. 0 2. 5 2. 0 1. 5 1. 0 0. 5 0. 0 Honeycomb-Sandwich after 48 h BVID (DVI) > 0. 3 mm 0 3 6 9 12 Impact-Energy [J] 15 15 18 21

NDT results Impact 10 J @ 23°C – cut specimen Foam Sandwich 16 Honeycomb Sandwich

NDT results Impact 35 J @ -55°C – cut specimen Foam Sandwich 17 Honeycomb Sandwich

ROHACELL® HERO solves a known honeycomb in-service problem Water ingress in honeycomb Damaged and undamaged areas of honeycomb collect water, porosity in the skins, or leakage paths (cracks in resin or potting) Effects include 1. Increase of mass Part weight increase Higher fuel consumption Water Ingress 2. CTE (water converts into ice resulting in expansion) Damage increase Disbond failure 3. Repair Cost and weight Trailing edge screws Lightening protection strips Author: Martin Oehike Manager: Dr. Eckart Nast/ Lufthansa Technik AG 18 4. Additional service costs for airlines AOG time to replace parts Spare part cost

ROHACELL HERO Freeze Thaw Test 1) Impact simulates open damage 3) Damage size evaluation by a US scan Reference defect (PTFE foil) 2) Water is injected into impact areas and then cooled to 18 °C US scans of impacted panel CM-VTS 2 before freeze/thaw cycles 30 mm panel 71 ROHACELL®, 2. 6 mm CFRP 19 Source: Testing conducted by OEM

Damage size evaluation Damage size [US scan] US scan after 6, 30 and 60 cycles proves no damage growth. Reason: ROHACELL® can absorb the change in volume during the liquid to solid transition phase of water. Collar 6 30 cycle 60 Further testing by an OEM confirms HERO solves the water ingress and freeze damage problems exhibited by honeycomb! 20

Single Cantilever Beam test vs of climbing drum peel test (G 1 C Determination) Correct Testing Solution: Single Cantilever Beam (SCB) test is the recommended test method for face sheet bonding to core Energy required to propagate crack 21 DIN 53292 – Not applicable The climbing drum peel test (DIN 53292) for a foam sandwich is not an applicable test method. DIN 53292 will not show damage behavior if damage already exists.

Effective skin to core bonding analysis with fracture toughness test (SCB) 1. Part design determines skin-stiffness, stress leads to compressive strength in the skins (LL). 2. Worst case debonding area due to: Ø Impact (according to part requirements) determines damage size. G 1 3. FEM shows local buckling and the G 1 kinetic energy during special load case Ronald Krueger ICASE, Hampton, Virginia Process failure 4. If G 1 < G 1 C, the crack will not open (no crack growth) Source: NASA/CR-2002 -211628 ICASE Report No. 2002 -10/ Ronald Krueger ICASE, Hampton, Virginia 22 G 1= f (~damage size, skin stiffness and in-plane compression)

SCB test gives fracture toughness e. g. G 1 23

Fatigue testing ROHACELL® WF has a long and successful history of usage in aircraft, with more than 25 years in service. Test procedure (ASTM C 393) 24 Evaluation of the Foam Core Shear Fatigue Performance; Marianne John, IWM Halle

HERO outperforms WF Honeycomb in comparison 1. 00 0. 90 0. 80 Cycled fatigue specimens failed due to core shear cracking �max/�UL [-] 0. 70 0. 60 0. 50 0. 40 0. 30 0. 20 0. 10 0. 00 1 E+00 ~ +52% CFRP/71 HERO Sandwich CFRP/71 WF Sandwich** CFRP/NOMEX ECA 3. 2/48 L* CFRP/NOMEX ECA 3. 2/48 W* 1 E+01 1 E+02 1 E+03 1 E+04 Load cycles [-] 1 E+05 1 E+06 1 E+07 25 * Fatigue Crack Initiation and Propagation in Sandwich Structures, Magnus Burmann, Report No. 98 -29, 1998, KTH **Burman M. and Zenkert D. , “ Fatigue of Foam Core Sandwich Beams, Part 2: Damaged Specimens” International Journal of Fatigue, Vol. 19, No. 7, pp. 563 -578, 1997

Residual strength test – 71 HERO Shear strength [Mpa] 1. 4 1. 2 1. 0 0. 8 0. 6 0. 4 0. 2 0. 0 uncycled 55% UL, after 5 Mio. cycles Fatigue loaded specimen of 55% UL with 5 Mio. load cycles failed in the same force range as the uncycled specimen (= quasi-static test) 26

Proven stability at high temperatures and pressures Compressive creep [%] Compressive Creep 180°C/ 0. 7 MPa 130°C/ 0. 35 MPa Curing conditions (2 h) Out-time investigation at 23°C/50%RF and 27°C/70%RF is running. 27

Lay-up / process / part cost e s B ne i s u as c s Lower part cost and weight (up to -25%) Easy handling Stable curing process Fewer production steps 28 Ready-to-use parts

Demonstrator and evaluation part: Nose Landing Gear (NLG) Door Foam / Infusion This foam sandwich part was originally constructed as a 71/200 WF core in infusion technique for Do 728. Now, it is optimized for 71 HERO/dry fabrics and stay in infusion technique. Honeycomb / Prepreg Baseline for the comparison is an NLG door similar to the A 320 design and a process using Nomex honeycomb (64 kg/m³, 4, 8 mm) and prepreg (Fibredux 913 C-926 -40%). Foam / Prepreg Additionally, we compare the foam with an Autoclave (Prepreg) process in a situation where honeycomb is replaced by foam, but the process stays the same. 29 Date | ROHACELL® HERO Partners

Cost advantage results: Save 21 – 25 % by using foam Cost comparison NLG door 120 100 Cost share [%] 100 80 75 75 79 Honeycomb/Prepreg design 60 Foam/Infusion design Foam/Prepreg design 44 40 35 40 34 25 20 0 Material cost 30 Date | ROHACELL® HERO Labor 55€/h Machine + Labor 85 €/h Labor + Machine cost Total cost

Weight advantage results: Save 19 % Weight comparison NLG door 120 100 81 81 Weight [%] 80 60 40 No adhesive film Honeycomb/Prepreg Foam/Prepreg No need for potting Foam/Infusion 20 0 31 Date | ROHACELL® HERO Pa

ng I D N ni hi ac M na l g 2 shot curing Fi n io in ou ld em D us In f n ki io n at p tu rs ne in g/ in ur C up te gr in 5 La y e se 7 or n Core handling C in g n n ki rs ou te ki ki rs te ou n tc he s Pa ou ol To g in ld ou em D C ur p La yu m tio ra ic time each step [h] 8 or ef Pr pr ep a ab r p tu se /F eg ep r e Pr in g ol To or C g tin ut 32 C The time advantage: Where are the main differences? Comparison of time by process step 10 9 Prepreg instead of infusion Honeycomb/Prepreg Foam/Prepreg 6 Foam/Infusion Core handling 4 3 2 1 0

Shaped ROHACELL® profiles 33 Pa

Shaped ROHACELL® profiles 34 Pa

HERO outperforms honeycomb Damage visibility 4 - Superior 3 - Excellent 2 - Very good 1 - Good Part 0 - Unacceptable 4 cost 3 Honeycomb HERO Water ingress 2 1 0 Surface quality 35 Date | ROHACELL® HERO Part weight

Conclusion 36 Solve Honeycomb problems No water problem, better fit to CRFP Efficient part production Reduce manufacturing costs Robust damage behavior Meet industry requirements for damage tolerance and visibility Excellent mechanical properties and fatigue behavior Produce reliable structural components with long service life Qualification AIRBUS Spec. and MIL-PRF-46194 a are in progress ROHACELL® HERO

ROHACELL® Sales and technical support Reid Averill Technical Sales Manger ROHACELL North America Phone +49 6151 18 -3570 Mobile 901. 651. 7675 reid. averill@evonik. com Blake Juhl Director of Sales and Marketing ROHACELL North America Mobile 801. 495. 9403 blake. juhl@evonik. com 37 Date | ROHACELL® HERO Pa

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