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High Volume Manufacturing of Composites
June 2014
Tobias PotyraFraunhofer Project Centre @ [email protected]
MotivationMotivation for Light-weight design
Alternative drive train concepts:fuel cells, hybrid and E-propulsion
800
19801985199019952000 2005 2010
1200
1000
Weight [kg]
+ 400 kg +50 %
+ 100 to 300 kg
1400 EU regulation
CO2 emissions
< 120g/km
EU regulation
CO2 emissions
< 120g/km
• Weight increase of typical medium-class vehicle since 1970.
• Implementation of CAFE regulation.• Reduction of consumption and emissions
through lighter structures.• Improvement of passive and active safety
and product attractiveness through functional design.
• For commercial vehicles: increased payload.• Lightweight design requires quality
controlled, high-volume manufacturing processes for composites.
Lightweight Potential of Composites
Characteristics of Composite Materials
Advantages of Composites
• Low density
• High weight-specific strength andstiffness
• Good damping
• Very good failure behavior
• Anisotropic properties
• Very low thermal expansion parallel to fibers
• Dependent on application:
– Low thermal conductivity– Low electric conductivity
• Very good corrosion resistance
Disadvantages of composites
• Mostly lower temperature resistant than metals
• Particular knowledge required for proper design
• Higher effort for quality assurance
• Oftentimes high material cost
• More difficult to realize automation
• Not yet established industrial processes
Overcoming the shortcomings by
Transferring a holistic approach to mass production requires competences across the entire value chain
IPEKInstitut für Produktentwicklung Universität Karlsruhe (TH) Prof. A. Albers
IPEKInstitut für Produktentwicklung Universität Karlsruhe (TH) Prof. A. Albers
IPEKInstitut für Produktentwicklung Universität Karlsruhe (TH) Prof. A. Albers
IPEKInstitut für Produktentwicklung Universität Karlsruhe (TH) Prof. A. Albers
Architecture
DesignMaterial
technologyComponent manufacture
Bonding, joining
technology
Testing
VerificationUse
Light-weight strategy
Integration of functions
Modelling
Simulation
Manufacturing
ProcessesReliability
Overcoming the shortcomings by
Holistic consideration of materials, production processes and methods leads to new construction methods in multi-material design
Methods
Production Materials
Multi materialdesign
Manufacturing Technologies
METHODS – PRODUCTION – MATERIALS
Automated, high-volume production chains
Composite technologies
Long-fiber reinforced thermosets (SMC + PUR)
High Performance Composites RTM/ HP RTM
Long-fiber reinforced thermoplastics (LFT)
CAx methods for light weight multi-material design
House of Production
Part Requirements / Specification / VOC
Successful Part Production
Material Selection
Selection of the M
anufacturing Process
Design
Internal / External Knowledge
Economics
House of Production with incomplete pillar
Fraunhofer Project Centre for Composites Research at Western University
FPC @ Western
A joint venture between:
Western University, London, Ontario, CanadaAndFraunhofer Gesellschaft, Munich, Germany & Institute for Chemical Technology (ICT), Pfinztal, Germany
Contact: [email protected]/fraunhofer
Twin RegionsJoint Expertise for Local Demands
Both entities, being situated in the heart of automotive areas will jointly work on composite technologies adapted to the local demands of each region’s industry. The activities of both research entities will utilize and increase the expertise to accelerate composite innovations as lightweight solutions.
Transatlantic Cooperation
Applied Research with IndustryBridging the gap in the knowledge chain.
Realization of industrial processes Application of developed innovative processes Optimization of existing processes and materials
Realization of industrial processes Application of developed innovative processes Optimization of existing processes and materials
Basic research on fiber matrix phenomena Simulation and Design Investigation of fundamental interests
collaboration withindustry
collaboration withFPC@Western
collaboration Withuniversities
Benefits of collaborating with FPC
Research and Development goals are addressed in a holistic way so that solutions take the whole value chain into account from the first idea over material development to manufacturing issues up to the final part and the application of the part
Material Process
Methods Part
• Full industrial scale shop floor capable for carbon fiber composites
• Globally first LFT-D line for processing of carbon fibers
• Globally first HP RTM line for processing of unsaturated polyester resins, epoxy resins and polyurethane resins
• Globally first injection moulding machine for direct heating and co-moulding of local reinforcements with foamed polymers
• North America‘s first Direct SMC line
Applied Research in Industrial ScaleTechnological Highlights at FPC
Thank you very much for your attention!
