Composites Technologies at the Fraunhofer ICT Developing an automation process to reduce the labour cost of producing composites: providing a route to mass production of composite components Global Automotive Lightweight Materials 2013 April 24-25, 2013 London, UK Dr.-Ing. Jan Kuppinger Prof. Dr.-Ing. Frank Henning M.Sc. Raman Chaudhari

Contents „ Introduction to Fraunhofer Society and Fraunhofer ICT „ Composite technologies for high-volume manufacturing and trends „ Long fiber reinforced thermoplastics

„ Long fiber reinforced thermosets „ Resin transfer molding technology „ Challenges in implementing composites for light-weight applications „ Next generation technologies

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Contents „ Introduction to Fraunhofer Society and Fraunhofer ICT „ Composite technologies for high-volume manufacturing and trends „ Long fiber reinforced thermoplastics

„ Long fiber reinforced thermosets „ Resin transfer molding technology „ Challenges in implementing composites for light-weight applications „ Next generation technologies

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FRAUNHOFER-GESELLSCHAFT PARTNER FOR INNOVATION

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The Fraunhofer-Gesellschaft The Fraunhofer-Gesellschaft carries out applied research of direct utility to private and public enterprises and to society Our customers: „ Industry „ The service sector „ Public administration

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FRAUNHOFER INSTITUTE FOR CHEMICAL TECHNOLOGY ICT

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© Fraunhofer ICT

Department of Polymer Engineering „ Nanotechnology „ Compounding and extrusion „ Foam technologies

„ Processing of thermoplastic materials „ Processing of thermosets „ High-performance fiber composites „ Microwave(s) and plasma technology „ Polymer testing

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Contents „ Introduction to Fraunhofer Society and Fraunhofer ICT „ Composite technologies for high-volume manufacturing and trends „ Long fiber reinforced thermoplastics

„ Long fiber reinforced thermosets „ Resin transfer molding technology „ Challenges in implementing composites for light-weight applications „ Next generation technologies

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THERMOPLASTIC PROCESSING

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Long fiber reinforced thermoplastics (LFT) „ Process diagram of D-LFT in the compression and injection molding process

IL compounder

Polymers ƒ Polypropylen ƒ PA 6, PA 6.6 etc. ƒ PET, PPS ƒ ABS, SAN etc. ƒ PC ƒ Blends

Reinforcement fibers ƒ Glass fibers ƒ Natural fibers Hydraulic Press ƒ Carbon fibers ƒ etc. Mixing compounder LFT melt (open transfer)

LFT Material (direct injection in the cavity)

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The principle of local continuous reinforcements Tailored LFT ŋ process diagram for function-integrated parts with continuous reinforcements „ Combination of local continuous-fiber reinforcements and established high-volume process technologies.

S ource: Fiberforge

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Tailored LFT ŋ demonstrator with wound loop structures „ Minimum use of reinforcement fibers by placing them only in the areas of highest load within the part „ Significant increase in breaking force and breaking energy „ Homogenous stress distribution in the part without damage, up to the part failure

Breaking force Bruchkraft

Breaking energy Bruchenergie 300

25 20

+176%

15 10 5 0

1,5 2,2 FiberFasergewichtsprozent weight content [%]

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250 200

+590%

150 100 50 0

0

© Fraunhofer ICT

Bruchenergie [J] [J] Breaking energy

Bruchkraft Breaking force[kN] [kN]

30

0

1,5

2,2

Fiber Fasergewichtsprozent weight content [%]

Tailored LFT for increasing impact behaviour „ Comparison* of D-LFT with diffrent wall thicknesses (2,0 ŋ 3,0 mm) and semi finish structures based on UP-tapes (2,0mm)

Im pact energy [J]

Energy at m ax . force Total energy

‡

Increase of Factor Ů

Comparison of different wall thicknesses are just permitted for showing trends. A comparison of the absolute values is not allowed

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Case study ŋ Underbody shielding for off-road purposes Manufacturing and analysis of a tailored underbody shield demonstrator „ Significant improvement of the impact behavior „ Case study for the compression molding of complex structures based on UD-Tapes and D-LFT

D-LFT

Tailored tape laminate

Press cycle of 40 sec Tape fabric insert Page 15 © Fraunhofer ICT

WRROWHPS§ƒC)

Modified underbody shield

The principle of local continuous reinforcements Why use continuous fiber semi-finished structures?

„ Higher fiber volume content of 50 ŋ 60 %

„ Possibility for load-related part design „ Increase of the heat distortion temperature

Bildquelle: Fiberforge

„ Parts with good weight-related mechanical properties

„ Stable mechanical properties at higher temperatures „ Reduction of creep by load introduction into the continuous fiber reinforcements

Continuous-fiber-reinforced semi-finished structures allow the use of thermoplastic materials in structural parts Page 16 © Fraunhofer ICT

Contents „ Introduction to Fraunhofer Society and Fraunhofer ICT „ Composite technologies for high-volume manufacturing and trends „ Long fiber reinforced thermoplastics

„ Long fiber reinforced thermosets „ Resin transfer molding technology „ Challenges in implementing composites for light-weight applications „ Next generation technologies

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Long fiber reinforced thermosets (SMC)

SMC-manufacturing

Mixture of fillers and resin

Raw materials

Automated handling Maturing

SMC-coil

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Time, Temperature Compression molding

Long fiber reinforced thermosets (D-SMC)

Glass rovings

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Long fiber reinforced thermosets - trends Class A formulations „ Launch of the Direct SMC Process in 2010 „ R&D focus primarily on Class A material formulations „ Filler material: exclusively based on calcium carbonate density: 2,7 g/cm³

20 ŷm

Scanning electron microscopy of calcium carbonate

Density reduction of the SMC material „ Incorporation of light weight fillers: hollow glass microspheres density: 0,4 g/cm³

20 ŷm

Scanning electron microscopy of hollow glass microspheres Page 20 © Fraunhofer ICT

Long fiber reinforced thermosets - trends Low density Class A formulations Class A finish

Class A A Finish Finish Class small, heavy particles

surface defects defects surface

large, light particles

„ Blending of small, hard particles with light, hollow particles „ Meeting demands of density reduction and Class A surface properties

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20 ŷm

Long fiber reinforced thermosets - trends „ Incident light microscopy of the resin-filler paste before molding (Set up A) damaged hollow glass microspheres: light reflection of nonspherical contour Undamaged hollow glass microspheres calcium carbonate, UP resin „ High share of damaged microspheres visible by light reflection

„ Incident light microscopy of the resin-filler paste before molding (Set up B) „ No damaged microspheres visible by light reflection (spherical contours) „ Qualitatively good dispersion and impregnation of all filler types

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Sheet Molding Compound (SMC) S MC proces s ing „ S MC „ Material development „ Low density SMC „ Natural fibers „ Recycling

„ D-S MC „ New matrix systems and applications „ Short process chain „ Flexibility

Com pres s ion m oulding „ Clas s -A parts „ Exterieur parts for automotive

Des ign „ Des ign for m anufacture „ Safety parts „ Panel constructions Page 23 © Fraunhofer ICT

„ S tructural parts „ Endless fiber reinforcement „ Local reinforcement by inlays

Deflectom etry „ Validation of Clas s -A „ Long waviness „ Short waviness

Contents „ Introduction to Fraunhofer Society and Fraunhofer ICT „ Composite technologies for high-volume manufacturing and trends „ Long fiber reinforced thermoplastics

„ Long fiber reinforced thermosets „ Resin transfer molding technology „ Challenges in implementing composites for light-weight applications „ Next generation technologies

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Resin transfer molding technology Applications of Resin Transfer Molding (RTM) in the automotive industry Body  structure  

Side  frame  

Source: AUDI AG

Audi  R8  Spyder   Source: maschinenmarkt.vogel.de

Bumper  

Source: maschinenmarkt.vogel.de

Roof  

BMW  M6  

Source: BMW AG Source: maschinenmarkt.vogel.de

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BMW  Project  I  CityCar  

Source: BMW AG

RTM process cycle

3D Preform

Preform production and fixing

Handling semi-finished product

Preform handling

Mold technology Resin

Infiltration and curing

Fixing 2D-semifinished fabric product

Semi-finished fabric cuts 2D Textile product Start of cycle

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Component demolding and post-processing

Mold cleaning End of cycle

RTM component

Hardener

Resin Transfer Molding (RTM) PreformCenter Installation planned by Q2 - 2013

Source: Dieffenbacher GmbH Page 27 © Fraunhofer ICT

RTM process cycle

3D Preform

Preform production and fixing

Handling semi-finished product

Preform handling

Mold technology Resin

Infiltration and curing

Fixing 2D-semifinished fabric product

Semi-finished fabric cuts 2D Textile product Start of cycle

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Component demolding and post-processing

Mold cleaning End of cycle

RTM component

Hardener

High-pressure RTM process High-pressure injection resin transfer molding HPIRTM

High-pressure compression resin transfer molding HP-CRTM

Impregnation of preforms in x- and y- direction

Impregnation of preforms in x-, y- and z- direction

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High-pressure RTM process Infiltration investigation for different process parameters at the HP-CRTM Experimental setup at the computer tomograph (CT)

specimens Focused x-ray beam (70 KV tube voltage) specimen carrier

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High Pressure RTM process Infiltration investigation: Experimental setup at the computer tomograph (CT)

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Contents „ Introduction to Fraunhofer Society and Fraunhofer ICT „ Composite technologies for high-volume manufacturing and trends „ Long fiber reinforced thermoplastics

„ Long fiber reinforced thermosets „ Resin transfer molding technology „ Challenges in implementing composites for light-weight applications „ Next generation technologies

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Challenges in implementing composites for light-weight applications Processes: Robust and efficient processes Reduction in manufacturing costs Reduction of cycle time Repeatability and overall quality control

Ľ Source: Colourbox

Quelle: Internet

Source: ECOeffekt GmbH

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Control RIņLQVHFXUHŃ3URFHVVHV(Example RTM process-chain) 2D- semifinished

Pre-cut part

textile

Handling of the

Preforming and

pre-cut parts

fixation

Zuschnitte

S S

S S

S S

S S

Data analy s is and data ev aluation / proces s control

S S

S S S S

Product

Quelle: Alcan

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Mold

S S

cleaning

Source: ASCO Kohlensäure AG

Demolding and postprocessing

S S

Infiltration &

Tool

curing

design

Challenges in implementing composites for light-weight applications Processes: Robust and efficient processes Reduction in manufacturing costs Reduction of cycle time Repeatability and overall quality control

Ľ Composite material knowledge: Durability of composites

Source: Fh Koeln

Source: Colourbox

Creep behavior Ľ

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Quelle: Internet

Source: ECOeffekt GmbH

Creep behavior (Example high-performance thermoplastic composite) Long term deformation behavior

Elongation 1/100 [%]

Break in the clam ping area Deform ation x % 03DŮ ıbreak

Tim e [s ] Page 38 © Fraunhofer ICT

7 day s

Challenges in implementing composites for light-weight applications Processes: Robust and efficient processes Reduction in manufacturing costs Reduction of cycle time Repeatability and overall quality control Ľ Composite material knowledge: Durability of composites

Source: Colourbox

Creep behavior Ľ Composite parts: Process and structural simulation

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Quelle: Internet

Source: ECOeffekt GmbH

l1 l0

Simulation of the compression molding process

Simulation of the closing gap and channel flow

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Challenges in implementing composites for light-weight applications Processes: Robust and efficient processes Reduction in manufacturing costs

Reduction of cycle time Repeatability and overall quality control Ľ Composite material knowledge: Source: Colourbox

Durability of composites Creep behavior Ľ Composite parts: Process and structural simulation Design guidelines Repair and recycling guidelines Ľ Page 41 © Fraunhofer ICT

Quelle: Internet

Source: ECOeffekt GmbH

l1 l0

Contents „ Introduction to Fraunhofer Society and Fraunhofer ICT „ Composite technologies for high-volume manufacturing and trends „ Long fiber reinforced thermoplastics

„ Long fiber reinforced thermosets „ Resin transfer molding technology „ Challenges in implementing composites for light-weight applications „ Next generation technologies

Page 42 © Fraunhofer ICT

Thank you very much

for your attention

© Fraunhofer ICT