03/08/2011

www.gupta-verlag.de/polyurethanes

New composite systems for automotive lightweighting and speciality coatings for wind turbine rotor blades

New systems enable serial production of lightweight structural automotive components
As composites are gaining importance in structural components, especially in lightweight automotive design, BASF is offering new solutions based on epoxy and polyurethane that are branded Baxxodur and Elastolit R, respectively. Both systems feature similar properties and can be selected individually to match the customer's application conditions and requirements.Lightweight structural automotive components can only be manufactured from composites based on continuous carbon or glass fibres. The RTM, or resin transfer moulding, process has become the established technology for producing these materials. In this process, multi-layered fibre-reinforced textile preforms are introduced into a heated mould on a press. The mould is closed and a liquid synthetic resin is injected under pressure that fully impregnates the filaments and then cures in a controlled reaction. Structural parts featuring superior mechanical properties, for example for vehicle chassis, require fibre levels in the range of 50 %. This adds to the requirements that the resin systems must meet.The two systems feature significantly reduced cycle times, with demoulding times of less than 5 min. Thus they resolve one of the critical issues that have to date prevented the use of high-performance composite plastic materials in automotive serial production. They function by innovative curing mechanisms. This means that they can be processed much longer than conventional products and still cure much faster if required. As a result, the fibres can be impregnated perfectly with these low-viscosity resins, which avoids the formation of "dry" areas that might negatively affect the mechanical properties of the finished component. On the other hand, the high speed of the complete reaction facilitates short cycle times. Both systems are self-releasing and suitable for processing on common high- and low-pressure equipment. Components made from these materials show good thermal and mechanical properties.The novel epoxy systems for the automotive industry are based on the same principle as the new epoxy systems BASF launched in 2008 for the production of wind turbine blades: the use of so-called latent curing agents offers users a significantly lengthened pot life while it reduces cycle times at the same time.Other polyurethane novelties
By combining fibre-reinforced structural components with lightweight polyurethane foam cores, you can achieve top-quality composite structures that feature very good specific component stiffness and good isolating properties - plus low weight. The specially developed Elastolit D systems are characterised by high compression strength and temperature resistance combined with low density.Fibre-reinforced components or composite mouldings for commercial vehicles, in particular, can be realised cost-effectively by open mould spray application used in the polyurethane composite spray moulding (PUR-CSM) process. In its Elastocoat C system, BASF has developed an in-mould coating material for use on commercial high-pressure CSM equipment. As well as high-quality fibre-reinforced composite parts, its applications include the reinforcement of metal faceplates or thermoforming film. With part-specific requirements determining the structure of the sandwich, compact and foamed polyurethane systems were developed that are reinforced as required by adding short or long glass fibres. Elastocoat C for CSM processing is solvent-free and stands out by its good mechanical properties, flow properties and ease of handling. A system based on renewables is available as an additional option.New coating materials:
Relest Wind RepKit - a new solution for rotor blade repairs
Through its Industrial Coatings Solutions business BASF supplies complete coating and repair solutions for wind turbines. Its blade coatings have been tried and tested in real life for decades. Flexible systems for plant maintenance are available today that avoid the expensive need to replace entire rotor blades and minimise turbine downtimes. At JEC 2011, BASF presents its new Relest Wind RepKit for onshore and offshore wind energy plants. Along with all the materials and tools necessary for rotor blade repairs, the kit also comprises an extensive application training seminar. The new Relest Wind RepKit has been designed for stationary use on the ground or on wind turbines.Relest Wind ProcessCoat - an efficient coating solution for rotor blades
Effective protection against erosion and UV radiation is essential in rotor blade coatings. It is the kind of protection that is provided by Relest Wind ProcessCoat, which was developed to meet these precise requirements and incidentally, by its low product use, helps to reduce rotor blade weight and optimise the process. Relest Wind ProcessCoat is just one of the products in BASF's coatings range for wind energy applications.

www.gupta-verlag.de/polyurethanes