“NANOFORCE”

Next generation nano-engineered

Polymer-Steel/CNT Hybrids

SIM Nanoforce introduction Industrial Testimony

Peter Persoone

SIM User Forum 21 October 2013

Stuurboord Antwerpen

SIM-SIBO NANOFORCE

Outline

- Objectives of the Nanoforce program

- Consortium Partners

- Nanoforce Projects

- Industrial Testimony

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SIM-SIBO NANOFORCE

Nanoforce “Science & Technology” Objectives

- Explore breakthrough and novel strong and lightweight

Polymer-Steel/CNT Hybrids

- Explore Multi-level Modeling to support the first objective, and

to enable predictable “application Specific Design”

- Use of Multi-level modeling for optimal material life-cycle

performance (durability) and improved recyclability

- Explore new combinations of technology and materials,

combining steel, polymers and nanoparticles / aCNTb

breakthroughs and insights

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Nanoforce consortium partners

Academic Partners Departments

1. Katholieke Universiteit Leuven MTM, COK, CIT, Chemistry, ESAT

2. Universiteit Gent DMSE, DIPC

3. Vrije Universiteit Brussel MEMC, FYSC

4. Universiteit Antwerpen EMAT, Physics

5. VITO NV Materials Department

Industrial Partners

1. LMS International NV

2. NV Bekaert SA

3. Recticel NV

4. OCAS NV

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Nanoforce projects

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SBO-1: Nano-Engineered Polymer-Steel Hybrids (NaPoS)

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- Goal: to develop a scientific base to optimize the interaction between steel (fibers and

sheets) and polymers, in order to better exploit

• the unique toughness potential of (stiff) steel fibers ( brittle glass and carbon fibers), to create

tough and durable steel fiber reinforced polymer composites.

• the unique multi-functionalities of steel-polymer laminates/sandwich materials: the stiffness,

toughness and formability of steel with the lightness, damping capacity, insulation … of polymers

- Innovations and breakthroughs on different levels:

• Modifications of the steel surface to improve the adhesion to (mostly thermoplastic) polymers

• Nano-engineered modifications to the polymer in order to decrease the stiffness mismatch

between steel and polymers, but also to enhance specific non-structural characteristics

• Modifications of the interphase area by creating gradient structures and properties.

• adding nano-engineered sizings to the steel surface

• creating gradient properties in the polymer close to the steel surface.

• A lower life cycle impact and improved recyclability of steel-polymer hybrids seems to be an

affordable option.

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Nanoforce projects

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SBO-2: Multilevel modeling of nano-engineered hybrids (MLM)

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Range of levels/scales in hybrids: from application [meters] down to individual constituting phases [few micrometers tens of nanometers]

Challenges:

Extension of ongoing micro-meso modeling to hybrids with tough phases

Extension of models towards gradient/non-gradient structured nano-reinforcements

Adequate transition between nano-micro/micro-meso/meso-macro steps

Integration of all scale steps (nano-micro/micro-meso/meso-macro)

Need for efficient numerical tools, allowing simulation of actual structural components

(computational efforts, treatment of delamination,…)

Aim: develop integrated multi-level/multi-scale numerical modeling tool(s), to gain understanding of

basic load transfer mechanisms, and to predict macroscopic behavior and life-cycle performance

(durability)

nano meso micro

macro

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Nanoforce projects

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SBO-3: Light Steel Fibers (aligned CNT bundles, aCNTb)

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CNT: high stiffness, high strength, low density

CNT bundles: inferior properties

Challenges:

Alignment higher stiffness

Length higher toughness

Novel growth process

avoid presence of catalyst particles

State of the art characterization techniques

Aim: aligned CNT bundles with ultra-high stiffness and toughness

A. Windle @ Cambridge

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Nanoforce projects

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Scientific & Technical Goals

- Create validated tools for accurate fatigue prediction using local

material behavior • Interfacing to manufacturing process and material modeling software

• Model micro-mechanical behavior of steel fiber reinforced composites

• Include pre-damage into micro-mechanical model

• Fatigue behavior determined based on micro-level (Only material testing

needed)

• Fatigue simulation on component level under realistic loading conditions

- Understand the link between the microstructure and the EM

properties • Establish validated tools for efficiently predicting critical EM parameters

(conductivity, permittivity) based on fiber topology and distribution

The developed methods will be valid for all the family of RFRC material

and processes (SMC, BMC, GMT and LFT, ...) as long as the RFRC

material of interest has randomly oriented fibers.

IBO: Micro-mechanical & Fatigue modeling of short steel fiber

reinforced composites (ModelSteelComp)

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Nanoforce presentations in the parallel session

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Nanoforce related posters on display

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Project Title Author

SBO1 Effect of silane coupling agent based surface treatment of stainless

steel on adhesion strength

Amit Kumar Ghosh

(VUB)

SBO1 Optimizing Silane Deposition Conditions: Tensiometry and Mechanical

Testing

Ellen Bertels

(KULeuven)

SBO1 Role of atmospheric pressure plasma for adhesion improvement

between steel and epoxy

Gabriella Da Ponte

(VITO)

SBO1 Energy absorption in 316L steel fibre reinforced epoxy laminate under

low velocity impact

Klaas Allaer

(UGent)

SBO1 Improving steel fibre composites through modification of the fibre/matrix

interphase

Michaël Callens

(KULeuven)

SBO2 Steel fibre reinforced epoxy on meso scale: numerical modeling and

experimental validation

Jana Faes

(UGent)

SBO3 Carbon nanotubes for next generation light "steel" fibers Luis González Urbina

(KULeuven)

IBO A mean-field based approach for micro-mechanical modelling of short

wavy fiber reinforced composites

Yasmine Abdin

(KULeuven)

IBO Micro-mechanical and fatigue damage modelling of short wavy steel

fiber reinforced composites

Yasmine Abdin

(KUleuven)

Master SN curve method - A hybrid multiscale approach to generate

SN-curves for short random fiber composites

Atul Jain

(LMS)

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Why is Bekaert interested in Nanoforce ?

- Cooperation BASF, Bekaert & Voestalpine Plastics Solution • Energy Absorption Safety Integrity (EASI) material development

• Generation 1 product

• High strength steel cords

• Polypropylene matrix

• Compression molding

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Serial application

Mercedes SLS AMG series

(Magna Steyr Fahrzeugtechnik)

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EASI2, a next generation with even more possibilities

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Steel cords and Ultramid® are ultimately joined

together to build an unbreakable connection

Plastic hybrids with a totally new performance level

Injection molded parts behave as ductile as metal parts

Excellent conduction of loads in static and dynamic load

situations

Post failure behavior without structural failure and thus

continued energy absorption

E-coating compatibility allows utilization in body-in-white

structural parts

Excellent suitability for adhesive bonding and riveting

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The EASI material in action

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EASI – developed example

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Possible reinforcements BIW (up to > 30k/p.a.)

• E.g. A-Pillar Reinforcement

• Current Situation

• Welded steel tubes

• EASI Solution

• Fabric over-molded

• Weight reduction min 30-40%

• Investments: cheaper than series metal solution

Conclusion:

• Complex reinforcements are possible with EASI

• Simulation capabilities are a must

A- Pillar

Reinforcement

EASI Fabric UNI

+ PA6 GF30

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Bekaert stainless steel fibers

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No stainless steel fibers in composites yet:

New markets and Business Opportunities

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Potential of metal fibers as multifunctional reinforcement

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High elongation of ANNEALED fibers

High energy absorption (ANNEALED)

Knot strength: fibers don’t damage

each other

processing advantage

+ drapable fabrics

In combination with properties as:

Shielding

Electrical conductivity

Thermal conductivity

Performance curve

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Metal fiber introduces plastic deformation in the composite

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Plastic deformation of the steel fibers is clearly

shown during tensile test of the composite

offers solution to brittle fracture of carbon, glass

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Elongation

carbon

glass

steel 30µm

steel 14µm

On composite level

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Exploration of reinforcement with steel fibers

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High elongation of annealed fibers

higher strain to failure of composite

high energy absorption, even specifically

High stiffness

In combination with properties as:

Shielding,

Electrical conductivity,

Thermal conductivity, ...

Fine fiber (like carbon & glass fibers)

in fine textile structures

Opportunities for high

performance composites!

CO

NC

LU

SIO

NS

Potential for making light, stiff, tough & durable composites

Potential for making light steel sandwich plates

Additional properties can be added to both composites and sandwich plates Electrical and thermal conductivity (Anti-static, EM Shielding, ….)

Sound & vibration absorption ….

SIM-SIBO NANOFORCE

Thank You !