HexTOOL®

M61
User Guide
HexTOOL® M61 USER GUIDE

CONTENTS

1. Introduction 4

2. HexTOOL® product definition and properties 5

2.1 Product definition 5

2.2 Main properties and features 5

3. HexTOOL® processing 7

3.1 Part model (master mold) 7

3.2 M61 tool manufacturing process 8

3.2.1 Lay-up/bagging 8

3.2.2 Cure 9

3.2.3 Machining 10

3.3 Examples of tools 11

3.4 Repairing a HexTOOL® mold 11

3.5 Manufacturing a carbon part in the HexTOOL® mold 13

May 2007
Publication No. HTU278
® Hexcel Registered Trademark
© Hexcel Corporation

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HexTOOL® M61 USER GUIDE

1 - INTRODUCTION
HexTOOL® is a new composite solution for building tools used for molding aerospace grade prepreg
parts, especially carbon 180°C (350°F) curing epoxy components.

This new concept for composite molds is an alternative to conventional composite tools and metal molds,
especially INVAR molds.

HexTOOL® uses Hexcel’s HexMC® technology as:

- Composite molds do not need the high performance provided by continuous fiber tooling prepregs;
- Using thick layers of material brings cost benefits and time savings.

The key advantages of HexTOOL® are:

• Ability to make large tools with complex shapes and tight tolerances
(able to obtain metal surface profile tolerances)
• Lighter weight compared to similar CTE metal tooling for easier handling and minimizing
infrastructure
investment
• Faster heat up and cool down rates than metal tools
• Machinable tooling surfaces without distortion
• Easily repairable
• Survive’s several hundred autoclave cure cycles at 200°C (395°F) without degradation
• Coefficient of thermal expansion to match carbon epoxy parts
• Fast and simple quasi isotropic lay up – low material waste
(Single ply of HexTOOL® is much thicker than standard composite tooling material)
• Molds in the same autoclaves as subsequent parts
• Co-cure with traditional prepreg forms
• Well suited for combinations of machined and net surfaces

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2 - HexTOOL® PRODUCT DEFINITION AND PROPERTIES

2.1 - Product definition

• 2000 gsm (0.41lbs/square foot) carbon mat

• Made of 8mm x 60mm (0.312 inch x 2.34 inch)
bundles with quasi isotropic orientation
• High strength carbon fiber
• BMI resin system, resin content 38% by weight

2.2 - Main properties and features (see also data sheet)

• Cure in autoclave at 7bar (100psi) at 190°C (375°F), post cure out of autoclave at 220°C (428°F),
• Tg 275°C (525°F) after post cure
• Nominal cured ply thickness 1.3 mm (.05 inch)

Thickness = f (number of plies)

30
28
26
mini maxi calculated machined
24
22
20
Thickness (mm)

18
16
14
12
10
8
6
4
2
0
3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
Plies nu mber

• Nominal Fiber volume 60%

• Coefficient of linear thermal expansion 3.5 x 10-6/°C
• Storage life 6 months at -18°C (-0.40°F) or below
• Rockwell B hardness comparison with metallic alloys:

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HexTOOL® M61 USER GUIDE

Tensile Tensile Compression Compression Flexure Flexure Short beam

Strength Modulus Strength Modulus Strength Modulus shear
EN 2561 EN 2850 B EN 2562 EN 2563
Mpa Gpa Mpa Gpa Mpa Gpa Mpa
Dry/RT 260 41 300 32 380 38 50
Dry/180°C 210 40 270 30 na na 43

Tensile Tensile Compression Compression Flexure Flexure Short beam

Strength Modulus Strength Modulus Strength Modulus shear
EN 2561 EN 2850 B EN 2562 EN 2563
Ksi Msi Ksi Msi Ksi Msi Ksi
Dry/RT 37.7 5.95 43.5 4.64 55.1 5.51 7.3
Dry/350°F 30.5 5.80 39.1 4.35 na na 6.2

Average HRB
Products Value
HexTOOL® machined side 83
Composite HexTOOL® tool side 78
specimen Tooling prepregs 23 to 53
Tooling board 42
Treatment 0 45
Aluminium alloy Treatment T4 75
Metallic 2024 Treatment T6 78
Specimen* Annealed 70 max
Invar T M 36 1/4 hard 78 to 83
1/2 hard 84 to 88
Coll rolled 97
* Values of metallic specimen are literature values.

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3 - HexTOOL® PROCESSING

3.1 Part model (master mold)

To be made from any material that can hold 7 bar (100psi) at 190°C (375°F), e.g. tooling board, metal or
Huntsman SMP process, and carbon foam.

No need for dimensional accuracy, as final dimensions are obtained after tool machining.

Master mold Materials - some examples:

Type Light Concrete

Tooling Board Tooling Paste Carbon Foam Wood
Boards

Supplier General EBALTA RAMPF Huntsman * Massive or MDF XELLA

Plastics

Las-a-foam
Grade Ebablock HT3 SMP XB4633 * Ytong
FR-10100

Availability
in Europe no yes soon 2007 yes yes yes yes

Cost Low very high high Moderate low low

0.5 (combined
Density 0.2 to 0.4 1.9 na 0.35 0.9 to 1.2 0.35 to 0.6
with HRH-10)

Machining ok, Model Cheap, well known Cheap, available

Processing, High thermal
Pros standard model Processing accuracy/surface techno, many high thermal
properties vs cost resistance, stiff
maker techno aspect/re-usable subcontractors resistance, stiff
no EU distributor, Low temp
Heavy, expensive, High tech process, 5 axis machining
Cons high temp Expensive Expensive, fragile resistance, vapors,
high CTE high CTE not proven
stiffness to check distortion

* Contact your Hexcel representative

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HexTOOL® M61 USER GUIDE

Part Model features

– Surface offset final machined mold thickness :

– Return flange
– Blade stiffeners
– Boss attachment points
– Tool reference system

3.2 HexTOOL® M61 Tool manufacturing process

3.2.1 Lay-up / bagging

Remove product from freezer and leave to reach room

temperature (minimum 6 hours for a 30 kg (60 lb) roll).

Apply release agent to the part model (e.g. Frekote 700 or Cirex
043).

Cut material plies preferably with steel rule die or razor blade knife, or pneumatic cutter or electrical
rotating cutter.

Best options tested so far :

• TMI – Ultrasonic Branson trim knife,

• Hoog’s electrical cutter – Well adapted – Allows slitting speed of 1m/mn, :
• Eastman Buzzair model – Rotary shear,
• Die + cut-out – convenient for “simple” performs and important series.

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a/ Lay up

Lay down master model on a heated table at 50°C (120°F) during the whole HexTOOL® lay up
process in order to ease the operation (improve tack and drapability). Lay up the HexTOOL® plies
directly on the part model.

Trim off and dart overlaps and radii to minimize bulk up and folds.

Debulk of multiple plies is only required in very thick sections.

Edges and drops can be filled with individual strips as needed.

b/ Build the vacuum bag

- Sealant tape for 200°C (395°F) autoclave molding

- Perforated film (eg Halar P2 film)
- Bleeder cloth (eg 1 ply 120 glass fabric)
- Vacuum bag film
- Breather material (eg 300gsm (60 lbs sq. foot) glass
fabric or bidim)
- Nylon vacuum bag (e.g. Airtech DTP1000, 50µm 120µm)

3.2.2 Cure

a/ Typical Autoclave Cure

• Apply vacuum -0.85 bar (12.5psi)

• Ramp to 150°C (300°F) at 1°C(1.8°F)/min
• Hold 30 minutes
• Apply 7 bars (100psi) at 1 bar (15psi)/min
• Ramp autoclave 190°C (375°F) at 1°C(2°F)/min
• Hold for 240 minutes
• Cool down at 3°C(5°F)/min
• Release pressure and vacuum

b/ Post Cure Cycles (Free Standing)

• Heat up from RT to 150°C (300°F) at 2°C(4°F)/min

• Heat up from RT to 220°C (425°F) at 0.25°C(0.5°F)/min
• Hold 16 hours at 220°C (425°F)
• Cool down to RT at 3°C(5.4°F)/min
(Do not release pressure until 65°C (150°F) has been reached)

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HexTOOL® M61 USER GUIDE

3.2.3 Machining

The “as cured” tool can be easily machined to final desired shape, accurate dimensions, and
required surface roughness, using typical carbon composites machining equipment.
Best results are obtained by using diamond cutting tools
No liquid cooling when machining.

Machining procedure :

• 1st step: rough machining to get shape and dimensions to +0.1/+0.5 mm (+0.004/+0.02 inch):
Cut depth 5mm max (0.20 inch); tool cutting speed 100/200 m/min (321.8/656.2 ft/min).

• 2nd step : finishing to get final surface aspect at +/- 50 µm tolerance. Cut depth 0.1/0.2 mm
(0.004/0.008 inch), tool cutting speed 500/1500 m/min (1640/4900 ft/min).

All kinds of shapes and part details can be machined. Holes or threaded holes, to hold the tool to
its support structure, can be machined as well. Inserts can be put into machined holes where
screws are needed.

Machined surface and details Machining on the bag side

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3.3 Examples of tools

3.4 Repairing a HexTOOL® mold

HexTOOL® molds can be repaired by molding HexTOOL® material on the damaged area after suitable
surface preparation. This procedure can be used as well to modify the shape in some areas for
engineering design change purposes.

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HexTOOL® M61 USER GUIDE

1- Preparation of the area to be repaired 2- Surface preparation (grinding) to allow good

by machining a cavity bonding

3- Plies preparation 4- Lay up of the plies over the cavity

5- Bagging and autoclave cure 6- After cure and post cure

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 7- Surface machining

3.5 Manufacturing a carbon epoxy part in the HexTOOL® mold

1- HexTOOL® mold surface preparation: 2- Lay up of the carbon epoxy prepreg plies
Frekote B15 sealer + Frekote 700 release agent

3- Bagging on the HexTOOL® mold 4- Autoclave cure 190°C (375°F) 7bars

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HexTOOL® M61 USER GUIDE

5- Easy demolding after cure 6- Prepreg part and reusable HexTOOL® mold

Important
Hexcel Corporation believes, in good faith, that the technical data and other information provided herein is materially accurate as of the date this
document is prepared. Hexcel reserves the right to modify such information at any time. The performance values in this data sheet are
considered representative but do not and should not constitute specification minima. The only obligations of Hexcel, including warranties, if any,
will be set forth in a contract signed by Hexcel or in Hexcel's then current standard Terms and Conditions of Sale as set forth on the back of
Hexcel's Order Acknowledgement.

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Tool maker/machinists already familiar with HexTOOL® :

FRANCE USA
• CARL • Nova-tech Engineering, Inc
26-28 Rue Charles Gide, 61000 Alençon, France, 20818 44th Avenue W, Suite 201 Lynnwood,
Contact Mr Lottin WA 98036, USA
Tel number : 33 (0)2 33 29 10 17 Contact Larry Carver
E-mail : c.lottin@carl.fr Tel number : 1 425 245 7000 x 213
Fax number : 1 425 245 7099
• Loire Modelage Web : www.novatechengineering.com
Zac de la Verdière, 44470 Mauves sur Loire, France
Contact Frank Bourcier • Touchstone Research Laboratory
Tel number : 33 (0)2 40 25 50 62 The Millennium Centre, Triadelphia, WV 26059, USA
E-mail : fbourcier.mplast@loiremodelage.fr Tel number : 1 304 547 5800
Fax number : 1 304 547 5802
• MMD E-mail : info@trl.com
15 rue de la Paix, 38130 Echirolles, France, Web : www.trl.com
Tel number : 33 (0)4 76 09 08 54
Fax number : 33 (0)4 76 09 86 23 • Visioneering
E-mail : mmd@mmd.fr 17501 Masonic, PO Box 127, Fraser, Michigan
Web : www.mmd.fr 48026, USA,
Contact Tony Robinson – Tel number : 586-293-1000
• Savoies Composites ext 229, Fax number : 586-293-7454
818 Route d’Aix les Bains, 74540 St Felix, France E-mail : trobinson@vistool.com,
Contact Mr Beluffi Web : www.vistool.com
Tel number : 33 (0)4 50 60 96 38
E-mail : contact@savoie-composites.com

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For further information, please contact your nearest sales office, or visit our website at www.hexcel.com
Australia China Japan USA
Suite 2, 86 Grimshaw Street D2101, Shanghai Everbright 4F Yokohama YS Nishiguchi Bldg 900 Main Street South
Greensborough, Victoria 3088 Conference & Exhibition 2-25-1 Tsuruya-cho Building 1, Suite 104
Tel: 61 3 9432 7100 Center Kanagawa-ku Yokohama 221-0835 Southbury, CT 06488
Fax: 61 3 9432 7200 80 Cao Bao Road Tel 81 45 290 0866 Tel: 1 203 267 1414
Shanghai 200235 Fax 81 45 314 0852 Fax: 1 203 267 1561
Tel: 86 21 64836741
Fax: 86 21 6483674

Austria France Spain USA

Industriestrasse 1 Z1 La Plaine, B.P.27 Dagneux Bruselas, 10 - 16 2350 Airport Freeway, Suit 550
A-4061, Pasching 01121 Montluel CEDEX Polig. Ind, "Ciudad de Parla" Bedford, TX 76022-6027
Tel: 43 (0)7229 7720 Tel :33 (0)4 72 25 26 27 28980 Parla, Madrid Tel: 1 817 315 3939
Fax: 43 (0)7229 772299 Fax: 33 (0)4 72 25 27 30 Tel: 34 91 664 4900 Fax: 1 817 571 8629
Fax: 34 91 698 4914

Belgium Germany United Kingdom

Rue Trois Bourdons, 54 Postfach 1560 Ickleton Road, Duxford, Cambridge
B-4840 Welkenraedt 21655 Stade CB22 4QD
Tel: 32 87 307 411 Tel: 49 4141 7879-00 Tel: 44 (0)1223 833141
Fax: 32 87 882 895 Fax: 49 4141 7879-01 Fax: 44 (0)1223 838808

Brazil Italy USA

Av. J. Guilhermino, 474/72 Via San Cristoforo, 44 11711 Dublin Blvd.
S.J.Campos, SP 12210-130 21047 Saronno (VA) Dublin, CA 94586-2832
Tel: 55 12 3941 2242 Tel: 39 02 96709082 Tel: 1 925 551 4900
Fax: 55 12 3923 1186 Fax: 39 02 960080 Fax: 1 925 828 9202