CYCOM 2040 EPOXY PREPREG

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CYCOM

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2040 is a very tough modified epoxy resin system with exceptional high temperature

performance. It is suitable for highly stressed components exposed to elevated temperature environments

(under bonnet/engine bay) including impact/crash structures. A two hour cure at 180°C (356°F) generates

a Tg of over 200°C (392°F)* and offers excellent mechanical properties at both ambient and elevated

temperatures.

CYCOM 2040 is available on woven and unidirectional carbon, glass and man-made fibres.

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E AT U R E S

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E N E F IT S

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Very tough resin system

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>200°C (392°F) glass transition temperature following 180°C (356°F) cure *

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Excellent mechanical properties

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High levels of mechanical property retention at elevated temperatures

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Controlled flow

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Excellent cured surface quality

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Low cured resin density (1.21g/cm³)

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Free-standing post curable to 200°C (356°F) for maximum temperature performance

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Shop life of 21 days at ambient [23°C (73°F)]

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Available in a wide range of fibres and fabric weaves

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U GGE S T E D

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P P L I C AT I ON S

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Primary vehicle structures including chassis, engine frames suspension components and

aerodynamic wings

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Impact structures including nose cone, side and rear

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Components requiring operating temperatures up to 200°C (392°F)

*

NOTE:

Tg data is not applicable for U.S. export control classification or licensing.

For export-related information please contact us.

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TE C H N I C A L DA T A SH E E T A E C M - 0 0 0 4 9 RE V: 0 2 7 MA R C H 2 0 1 2 2 www.cytec.com

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H AR AC T E R IS T IC S

Table 1 | Physical Characteristics

Shelf life 1 year when stored at less than -18°C (0°F) Tack Life Up to 21 days at 24°C (75°F)

Shop Life Up to 21 days at 24°C (75°F) Cured Resin Density 1.21 g/cm³

Table 2 | Resin Viscosity Characteristics

Minimum Viscosity (poise) 160 Minimum Viscosity Temp, °C(°F) 150 (302)

Gel Temp, °C(°F) 167 (333)

Gel Time (minutes) 58

Figure 1 | Viscosity trace of CYCOM 2040

Ramp rate = 2°C/min. Minimum viscosity = 159.6 poise.

0.0 10.0 20.0 30.0 40.0 50.0 60.0 _70.0 102 103 104 105 106 107 40.0 60.0 80.0 100.0 120.0 140.0 160.0 180.0 time [min] Et a* ( ) [P ] G ' ( ) [ dy n/ cm ²] G " ( ) [ dy n/ cm ²] T em p ( ) [° C ] G' / G" Crossover Point:(58.4mins,166.5°C) Eta* = 159.64 [P] time = 49.9 [min] temp = 149.6 [°C]

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Glass Transition Temperature *

Figure 2 | Typical DMA trace for CYCOM 2040 following a 2hr @ 180°C cure

Figure 3 | Typical DMA trace for CYCOM 2040 following a 2hr @ 180°C cure and 2hr @ 200°C post cure

*

NOTE:

Tg data is not applicable for U.S. export control classification or licensing.

For export-related information please contact us.

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Table 3 | Mechanical Properties of CYCOM 2040 Unidirectional Tape

Properties 2040-36%T800-140 2040-36%M55J-140 RT DRY Actual 53.2% VF RT DRY Normalized 60% VF 150°C (302°F) Actual 53.2% VF 150°C (302°F) Normalized 60% VF RT DRY Actual 52.4% VF RT DRY Normalized 60% VF 150°C (302°F) Actual 52.4% VF 150°C (302°F) Normalized 60% VF 0° Tensile

Strength, MPa (ksi) Modulus, GPa (msi)

2400 (348) 160 (23) 2570 (373) 172 (25) 2133 (309) 150 (22) 2406 (349) 170 (25) 1622 (235) 297 (43) 1853 (269) 339 (49) 1449 (210) 283 (41) 1656 (240) 323 90° Tensile

Strength, MPa (ksi) Modulus, GPa (msi

51.4 (7.5) 7.5 (1.09) - - 45.8 (6.6) 5.9 (0.86) - - 35.1 (5.1) 5.62 (0.81) - - 26.9 (3.9) 4.74 (0.69) - - 0° Compression

1304 (189) 133 (19) 1471 (213) 150 (22) 1073 (156) 143 (21) 1210 (176) 161 (23) 600 (87) 263 (38) 695 (101) 305 (44) 495 (72) 246 (36) 573 (83) 285 (41) 90° Compression

271.2 (39) 9.3 (1.35) - - 123.3 (18) 7.1 (1.03) - - 190.6 (28) 6.08 (0.88) - - 93.9 (14) 5.75 (0.83) - - 0° Flexural

1688 (244) 141 (21) 1904 (276) 159 (23) 1408 (204) 160 (23) 1588 (230) 181 (26) 972 (140) 233 (34) 1104 (160) 265 (38) 873 (127) 251 (36) 992 (144) 285 (41) 90° Flexural

110.3 (16) 7.0 (1.01) - - 87.2 (13) 6.8 (0.99) - - - - - - - - - - Poisson’s Ratio 0° 90° ±45° 0.32 0.01 0.85 - - - 0.41 0.03 0.91 - - - - - 0.90 - - - - - 0.96 - - - Interlaminar Shear

Strength, MPa (ksi) 96.9 (14.1) - 62.4 (9.0) - 67.4 (9.8) - 47.9 (6.9) -

In Plane Shear

126.6 (18.4) 3.3 (0.48) - - 86.6 (12.6) 2.38 (0.35) - - 56.3 (8.2) 4.60 (0.67) - - 52.9 (7.7) 2.72 (0.39) - - Compression Strength

After Impact (CSAI)

MPa (ksi) 186.3 (27) - - - -

Bearing Strength

Strength, MPa (ksi) 903.2 (131) - - - -

GIC J/m2 266.3 - - - -

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TE C H N I C A L DA T A SH E E T A E C M - 0 0 0 4 9 RE V: 0 2 7 MA R C H 2 0 1 2 5 www.cytec.com Table 4 | Mechanical Properties of CYCOM 2040 Fabric

Properties 2040-42%-6KT800-2X2T-200 2040-42%-6KM46J-2X2T-200 RT DRY Actual 46.8% VF RT DRY Normalized 55% VF 150°C (302°F) Actual 46.8% VF 150°C (302°F) Normalized 55% VF RT DRY Actual 47.3% VF RT DRY Normalized 55% VF 150°C (302°F) Actual 47.3% VF 150°C (302°F) Normalized 55% VF 0° Tensile

874 (127) 69.7 (10.1) 1027 (149) 81.9 (11.9) 953 (138) 70.3 (10.2) 1120 (162) 82.6 (12.0) 597 (87) 108.0 (15.7) 694 (101) 125.6 (18.2) 761 (110) 102.8 (14.9) 885 (128) 119.5 (17.3) 90° Tensile

855 (124) 69.6 (10.1) 1005 (146) 81.8 (11.9) 806 (117) 69.1 (10.0) 947 (137) 81.2 (11.8) 579 (84) 102.0 (14.8) 674 (98) 118.6 (17.2) 756 (109) 104.5 (15.2) 879 (127) 121.5 (17.6) 0° Compression

671 (97) 59.9 (8.7) 789 (114) 70.4 (10.2) 528 (76) 60.4 (8.8) 621 (90) 71.0 (10.3) 419 (61) 87.2 (12.6) 487 (71) 101.4 (14.7) 433 (62) 92.5 (13.4) 504 (73) 107.6 (15.6) 90° Compression

630 (91) 59.6 (8.6) 741 (107) 70.0 (10.2) 498 (72) 60.5 (8.8) 585 (85) 71.1 (10.3) 422 (61) 85.7 (12.4) 491 (71) 99.7 (14.5) 380 (55) 90.1 (13.1) 442 (64) 104.8 (15.2) 0° Flexural

1049 (152) 67.9 (9.8) 1232 (179) 79.8 (11.6) 800 (116) 71.4 (10.4) 940 (136) 83.9 (12.2) 687 (100) 92.4 (13.4) 799 (115) 107.4 (15.6) 647 (94) 95.4 (13.8) 752 (109) 110.9 (16.1) 90° Flexural

1096 (158) 68.6 (9.9) 1288 (186) 80.6 (11.7) 818 (118) 73.5 (10.7) 961 (139) 86.4 (12.5) 663 (96) 95.1 (13.8) 771 (112) 110.6 (16.0) 642 (93) 92.7 (13.4) 747 (108) 107.8 (15.6) Poisson’s Ratio 0° 90° ±45° 0.03 0.06 0.86 - - - 0.07 0.08 0.81 - - - 0.02 0.02 0.88 - - - - - - - - - Interlaminar Shear

Strength, MPa (ksi) 74.1 (10.7) - 49.5 (7.2) - 58.4 (8.5) - 38.8 (5.6) -

In Plane Shear

118.5 (17.2) 3.58 (0.52) - - 82.8 (12.0) 2.49 (0.36) - - 83.7 (12.1) 3.1 (0.45) - - - - - - Compression Strength

After Impact (CSAI)

MPa (ksi) _{240.9 (35)} _- _- _- _{170.3 (25)} _- _- _-

Bearing Strength

Strength, MPa (ksi) 795.8 (115) - - - 580.1 (84) - - -

GIC J/m2 923.2 - - - 575.0 - - -

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Laminate Preparation

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Cut the prepreg for the laminate

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Lay up the laminate in the desired configuration onto the tool or caul plate that has been treated

with release agent or film taking care not to distort the material



As each ply of material is positioned, work out any entrapped air using light pressure with a paddle

or roller before removing the release paper or poly film from that ply

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Apply vacuum bag using standard release films, breathers and bagging materials

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Insert at least two vacuum stems through the bag, connecting one to the vacuum source and the

other, at a point on the part furthest from the source, to a calibrated vacuum gage

Figure 4 | Bagging Schematic

Bagging Material Notes

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Any industry standard breather material can be used provided it effectively removes air and can

withstand cure temperatures.

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Use non-perforated FEP

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Alternative layups can be used. All layup methods should perform the following functions:

o Prevent pinching off of the laminate edge

o Allow air to easily be removed from the laminate perimeter

o Prevent resin loss during cure

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Debulking

Vacuum debulking cycles are not required to eliminate voids for flat or mildly contoured parts. Vacuum

debulking should be performed only as necessary to eliminate wrinkles and bridging of materials in highly

contoured or very thick parts.

Vacuum Requirements

Prior to cure, a vacuum hold of 4 hours at full vacuum (minimum 28 in Hg at sea level) is required. Full

vacuum should be within 2 in Hg of absolute vacuum for the given altitude.

Leak Check

A vacuum leak check should be performed prior to cure and heat-up. The test should not show more than

a 2 in Hg vacuum loss in 5 minutes.

Cure Cycle

Figure 5 | Recommended Cure Cycle

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Apply full vacuum from start

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Apply 100 psi (689 kPa) pressure

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Heat up at a rate of 2°C/minute (4°F/minute) to 180°C (356°F)

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Hold at 180°C (356°F) for 120 minutes

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Cool autoclave to below 60°C (140°F) at 3°C/minute (6°F/minute)

Post Cure Cycle

The recommended post cure cycle for CYCOM 2040 is as follows:

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Ramp temperature at 2°C/minute (4°F/minute) to 200°C (392°F)

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Hold at 200°C (392°F) for 120 minutes

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Cool oven to below 60°C (140°F) at 3°C/minute (6°F/minute)

0 20 40 60 80 100 120 140 160 180 200 0 20 40 60 80 100 120 140 160 180 200 220 Time (min) Te m pe ra ture ( °C ) 0 20 40 60 80 100 120 P re s s ure ( ps i)

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Alternate Cures

CYCOM 2040 can be cured at 135°C (275°F). An evaluation of various cure cycles has been completed,

with Tg values provided below.

Table 5 | Cure Cycle Comparison

Cure Cycle Tg (Modulus Onset)* RT ILSS (T800 UD) GIC (T800 UD) Approx % Cure

3hrs @ 135°C (275°F) 159 106 313 70 3hrs @ 135°C (275°F) + 2hrs @ 180°C (356°F) P/C 208 105 No Data 91 2hrs @ 180°C (356°F) 206 105 303 90 2hrs @ 180°C (356°F) + 2hrs @ 200°C (392°F) P/C 221 101 292 98

*

NOTE:

Tg data is not applicable for U.S. export control classification or licensing.

For export-related information please contact us.

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R OD U C T

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AN D L IN G AN D

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AF E T Y

Cytec Engineered Materials recommends wearing clean, impervious gloves when working with epoxy

resin systems to reduce skin contact and to avoid contamination of the product.

Materials Safety Data Sheets (MSDS) and product labels are available upon request and can be obtained

from any Cytec Engineered Materials Office

.

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IS P OS AL OF

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AT E R I AL

Disposal of scrap material should be in accordance with local, state, and federal regulations.

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ON T AC T

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N F OR M AT ION

GLOBAL HE ADQUARTERS Tempe, Arizona tel 480.730.2000 fax 480.730.2088 NORTH AMERICA

Olean, New York

tel 716.372.9650 fax 716.372.1594

Springfield, Massachusetts

tel 1.800.253.4078 fax 716.372.1594

Havre de Grace, Maryland

tel 410.939.1910 fax 410.939.8100 Winona, Minnesota tel 507.454.3611 fax 507.452.8195 Anaheim, California tel 714.630.9400 fax 714.666.4345 Orange, California tel 714.639.2050 fax 714.532.4096 Greenville, Texas tel 903.457.8500 fax 903.457.8598

Cytec Carbon Fibers LLC Piedmont, South Carolina

tel 864.277.5720 fax 864.299.9373

D Aircraft Products, Inc. Anaheim, California

tel 714.632.8444 fax 714.632.7164

EUROPE AND ASI A

Wrexham, United Kingdom

tel +44.1978.665200 fax +44.1978.665222 Östringen, Germany tel +49.7253.934111 fax +49.7253.934102 Shanghai, China tel +86.21.5746.8018 fax +86.21.5746.8038

DISCLAIMER: The data and information provided in this document have been obtained from carefully controlled samples and are considered to be representative of the product described. Cytec Engineered Materials (CEM) does not express or imply any guarantee or warranty of any kind including, but not limited to, the accuracy, the completeness or the relevance of the data and information set out herein. Because the properties of this product can be significantly affected by the fabrication and testing techniques employed, and since CEM does not control the conditions under which its products are tested and used, CEM cannot guarantee that the properties provided will be obtained with other processes and equipment. No guarantee or warranty is provided that the product is adapted for a specific use or purpose and CEM declines any liability with respect to the use made by any third party of the data and information contained herein. CEM has the right to change any data or information when deemed appropriate.