Advanced composites microwave processing offers increased industry benefits
For the first time, the HEPHAISTOS CA1 (VHM 100/100), a large revolutionary microwave system, has been successfully simulated using standard 3D numerical methods (FDTD Finite Difference Time Domain) to design moulds, accelerate curing of thermosets and achieve welding process for thermoplastic products in full industrial detail. The work has been supported by a European-funded project (www.mu-tool.com) involving suppliers to the automotive and aerospace industries. HEPHAISTOS technology, invented by Lambert Feher, has been used for curing composite products at TWI since 2009.
Efficient and sustainable uses of resources continually drive the development of new lightweight solutions in nearly all market segments, especially in the transportation industry. Materials such as commodity metal alloys are being replaced by polymer composites, which add value to their greater functional properties and efficient manufacturing processes. Development work at TWI’s Cambridge laboratories has identified high-frequency technology as offering unique advantages in product quality, productivity and automation, energy efficiency and price leverage, compared with thermal processing that will increase the industrial volume production of advanced composites. These composite materials offer a high, lightweight exploitation potential as well as efficient recycling potential of the valuable components.
The HEPHAISTOS microwave oven’s unique interior geometry, together with its waveguides, allows fast and even heating of the part to be cured, and demonstrates that microwave field patterns are more even at small dimensions. In comparison with alternative methods, HEPHAISTOS makes it possible to process higher-quality cured composite components and, at the same time, to increase productivity with optimised energy efficiency.
The TWI HEPHAISTOS facility is available at TWI’s laboratories in Middlesbrough for aerospace and automotive composite engineering as well as product development. Starting from the lab-scale, TWI can also offer world-leading computational methods, design of composite parts, technical development for high-frequency systems and composite technologies, experimental prototyping and testing as well as consulting on the industrial capitalisation of applying new production technologies.
To find out more about this opportunity, please contact us.
Photo caption: (A) Microwave field distribution within HEPHAISTOS-cavity, with large tool and carbon fibre reinforced plastic sample.
Photo caption: (B) Cross section of microwave field distribution – the rectangular carbon fibre reinforced plastic sample gains homogeneous heating in the tool as the fields follow the shape. TWI’s tool design is successfully applied for arbitrary 3D contours.
About TWI
TWI is one of the world’s foremost independent research and technology organisations, with expertise in solving problems in all aspects of manufacturing, fabrication and whole-life integrity management technologies.
Established at Abington, Cambridge, UK in 1946 and with facilities across the globe, the company has a first class reputation for service through its teams of internationally respected consultants, scientists, engineers and support staff, whose knowledge and expertise is available to its Members as and when they require.
The company employs nearly 800 staff, serving 700 Member companies across 4500 sites in 80 countries. TWI also houses a professional institution, The Welding Institute, with a separate membership of over 6000 individuals.
TWI, Granta Park, Abington, Cambridge CB21 6AL. Tel: 01223 899000. Fax: 01223 892588. E-mail: twi@twi.co.uk. Web: www.twi.co.uk
12 November 2013 catherine.condie@twi.co.uk
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