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25/08/2016
PRESENTATION TITLE - Entity
1
Process & Resin Development for BMW M4 GTS hood program
• Marco Bernsdorf
• Application Research & Engineering
Agenda
1. Introduction
2. Double Diaphragm Forming Technology
3. Development of a matching Resin System
4. Production Video
5. Process Optimization in the field
6. Summary
2
Agenda
1. Introduction
2. Double Diaphragm Forming Technology
3. Development of a matching Resin System
4. Production Video
5. Process Optimization in the field
6. Summary
3
Introduction
21.000 km race testing passed
Process
Development
Material
Development
09/2016 750th
hood made
CFRP
Design
Validation
by BMW
05/2014 CFRP concept
Weight - 40%
06/2014 Resin
Concept
05/2015 Black version
of Resin
02/2015 DDF trials
first hoods
04/2015 Prototypes
Drive tests
09/2015 MTR760®
fully validated
07/2015 Pre-series 1
Crash tests
10/2015 Pre-series 2
Quality control
CFRP hood made with SOLVAY material reduced
weight from 12.5kg down to 7.5kg
08/2015: Press Release inner structure outer body panel
03/2016 SOP
at customer
4
Project Lead & Design All Equipment & Blank supply
Contracted by BMW
Technology Centre
Design & tooling supplier for
major OEM’s
Based in Germany
324 employees
€31.2M revenue
Material Development Double Diaphragm Technology
Application Engineering
Tailored Resin System
Access to German serial OEM’s
Referral for volume applications
Based in 53 countries worldwide
30,000 employees worldwide
€12.4 Billion revenue
Stamping & Bonding Automated production cell
Logistics, Spare Parts
Robot bonding cell
Tier1 supplier of stamping
parts & assemblies to OEM’s
Based in Southern-Germany
1100 employees
€250M revenue
Alliance for development & production
5
Agenda
1. Introduction
2. Double Diaphragm Forming Technology
3. Development of a matching Resin System
4. Production Video
5. Process Optimization in the field
6. Summary
6
7
Double Diaphragm Forming (DDF) - as developed and practised at Solvay
First film layer vacuumed
onto bed and lower frame
‘Prepreg’ blank laid on film
Centre frame
Top film layer
Top frame
Frames clamped and
vacuum applied
Two films, sandwiching the materials and are held together by vacuum in a frame
Conditioned offline through the application of heat
Formed using a press or external force to create the geometry
DDF Preheating and Part Forming/Curing
25/08/2016
Double Diaphragm Forming
8
Shuttles into pre-heat station
Blank held in frame
Press tool forms DDF
film and part
Shuttles into press tool
Contact pre-heating
Part cured
DDF benefits
9
X
Provides a closed environment within existing metal supply chain No part contamination
Enables automatable & repeatable forming of challenging geometries
secures materials in place
allows controlled draping
prevents out-of plane wrinkles
Compatible with many product forms
UD, D-Form, NCF, woven fabrics
Different blank thicknesses
Different resin chemistries
Facilitates a number of processes
compression moulding of prepreg
preforming of dry (e.g. for HP-RTM) and prepreg materials
No mould release agent nor cleaning need
DDF films are specifically designed to be released from the tool & the part
no detrimental impact on the finished product
Agenda
1. Introduction
2. Double Diaphragm Forming Technology
3. Development of a matching Resin System
4. Production Video
5. Process Optimization in the field
6. Summary
10
Objective: Resin to match blank and part manufacturing properties
Low impregnation viscosity VS. Medium viscosity for handling
Tg > 120°C (248°F) & good mechanicals VS. Resin price
Toughness for dynamic loading characteristics
7 day out-life at RT VS. Rapid curing
Durable class-A surface compatibility
Resin Design
11
Solution: Behavior achieved through optimized curing chemistry
Two component epoxy system compatible with double diaphragm forming and compression-moulding processes
Initial low viscosity for impregnation which develops to enable easy handling
Rapid cure advancement at RT, imparting flexibility for handling and forming
Secondary fast curing at HT yielding high conversion and Tg
Resin Design
12
Different cure times at 140°C
Cure Optimization Different cure temperatures
140°C is the sweet spot providing fast cure & high Tg
! Higher temperature lowers the Tg
! No advantage to cure above 140°C
to accelerate the curing
13
Understand sensitivity to staging variations:
Current: staging for 24h at RT
But: varying process conditions
Result: variations of final part quality
Ideally: Final cure unaffected by staging
Investigation of staging scenarios
7,5
8
8,5
9
9,5
10
10,5
11
11,5
12
12,5
0 10 20 30 40 50 60
Lo
g(I
on
ic V
isco
sit
y)
Time (Hours)
Ion Viscosity (1Hz) during staging
RT Staging21°C
RT Staging25°C
RT Staging30°C
Explore alternative staging conditions:
Cycle time: staging complete << 1 h
Process window: low advancement
Still formable after pre-heating
Resin flow to give a good surface
-20
-10
0
10
20
30
40
50
60
0 10 20 30 40 50 60
Un
cu
red
Tg
(°C
)
Time (min)
Oven Staging
70°C
80°C
90°C
100°C
Too much
Target
Identify an optimized staging process 14
Agenda
1. Introduction
2. Double Diaphragm Forming Technology
3. Development of a matching Resin System
4. Production Video
5. Process Optimization in the field
6. Summary
15
Production Video
16
Agenda
1. Introduction
2. Double Diaphragm Forming Technology
3. Development of a matching Resin System
4. Production Video
5. Process Optimization in the field
6. Summary
17
Press Moulding Conditions – Lab versus “in the field”
DEA Cure Monitoring in the lab
DEA allows linking lab data to customer scenario
Process Step In the lab In the field
Pre-heating within the mould Pre-heat time + transfer time + radiation from mould
Curing 140°C ±0.5K Temperature tolerance over the mould +-3K
Pressure 5s ramp rate to max. pressure 15s ramp rate to max. pressure
Lo
g (
Ion
Vis
co
sit
y)
Time (min)
DEA Cure Monitoring “in the field”
Time (min)
Lo
g (
ion
vis
co
sit
y)
Pre-heating Transfer Press Cure
blank on
lower plate
mold fully
closed blank on
lower mold
18
DoE to optimize the process in the field
Factors: Pre-heat time
Pre-heat temperature
Mold temperature
Stops position
Measurements: Part thickness
Pressure in the mold
Visual appearance
Porosity level
19
bad parts
good parts
pre
ssure
time
Agenda
1. Introduction
2. Double Diaphragm Forming Technology
3. Development of a matching Resin System
4. Production Video
5. Process Optimization in the field
6. Summary
20
The team… Developed a novel bespoke resin suitable for class-A surface
Developed a new impregnation process together with C-CON
Gained interest from Automotive and Aerospace OEM's
Summary
Challenges: ! Time (6 months for resin development / 1.5 years to serial part)
! Three different companies and their approaches
! Making composite parts in a metal press shop
! Using partner facilities
What’s Next: … Improve engineering understanding
… Next generation resins
… High-volume programs
21