composites for automotive lightweighting · high mass-specific part properties achievable ... more...

Composites for Automotive Lightweighting

Prof. Dr.-Ing. Frank Henning

Fraunhofer Institute for Chemical Technology ICT

Joseph-von-Fraunhofer-Str. 7

76327 Pfinztal, Germany

Phone: +49721/ 4640-420

[email protected]

1 Fraunhofer Institute for Chemical Technology (ICT), Pfinztal 2 Karlsruhe Institut of Technology (KIT) – Institut für Vehicle System Technology (FAST), Karlsruhe

mailto:[email protected]

© Fraunhofer ICT

The Fraunhofer-Gesellschaft

Research of practical utility lies at the heart of all activities pursued by the Fraunhofer-Gesellschaft.

Founded in 1949, the research organization undertakes applied research that drives economic development and serves the wider benefit of society.

Its services are solicited by customers and contractual partners in industry, the service sector and public administration.

© Fraunhofer ICT

The Fraunhofer-Gesellschaft

Research and development

Application-oriented research of direct benefit to business and society

Application-oriented basic research

Business community

Institutes work as profit centers

One-third of the budget consists of revenues from industrial projects

Spin-offs by Fraunhofer researchers are encouraged

Contracting partners/clients

Industrial and service companies

Public sector

© Fraunhofer ICT

66 institutes and independent research units

More than 22,000 staff

An annual research budget of €1.9 billion, of which €1.6 billion is generated through contract research.

The Fraunhofer-Gesellschaft Main locations of the Fraunhofer institutes and research institutions in Germany

FRAUNHOFER-INSTITUT FOR CHEMICAL TECHNOLOGY ICT

RESEARCH FOR A BETTER TOMORROW

© Fraunhofer ICT

Business areas of the Fraunhofer ICT

Energy and environment

Chemistry and process engineering

Defense, safety, security, air and space technology

Automotive and transportation industry

© Fraunhofer ICT

Polymer Engineering Core Competence

Polymer- und Additivsynthesis Chemical engineering of polymers and additives

Compounding and Extrusion Process Technologies, twin-screw extrusion, compounds

Nanotechnology Dispersion technologies, functionalization

Foaming of Polymers Particle- and extruded foams, material technology

Processing of Thermoplastics Direct processes, LFT-foaming, continuous thermoplastics

Thermoset Technologies Long fiber reinforced structural and Class-A applications

High performance composites Preform- and (high pressure-) infusion strategies/technologies

Microwave and Plasma Technologies Thermal Process Technologies, sensors, surface technologies

Online Process Monitoring Process- and material supervision, prediction models

Recycling/Sustainability Dismantling, sorting, reprocessing and reuse

© Fraunhofer ICT

Weight Reduction of Airplanes

Source: Prof. Dr.-Ing. Klaus Drechsler

© Fraunhofer ICT Prof. Dr.-Ing. Klaus Drechsler

Weight reduction for cars?

Source: Volkswagen AG / Prof. Dr.-Ing. Klaus Drechsler

EU regulations CO2 Emissionen < 120 g/km (2012) < 95 g/km (2020)

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

© Fraunhofer ICT

S U S T A I N A B L E S Y S T E M A P P R O A C H

Lightweight Design Total system optimization considering the product life cycle

Link all disciplines in the systems value chain

Determine requirements and constraints of each product life cycle phase

Connect requirements and constraints to develop a holistic composite solution

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P R O C E S S E S

M E T H O D S

M A T E R I A L S

Q U A L I T Y

T I M E

C O S T S C O M P O S I T E S O L U T I O N S

© Fraunhofer ICT

Methods - Materials - Processes Sustainable System Approach

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In order to develop high-performance lightweight solutions which can be manufactured on an industrial scale, it is essential to concentrate and connect competences in the fields of methods, materials and production

C O M P O S I T E

S O L U T I O N S

P R O C E S S E S Thermoplastic

RTM-/RIM

SMC

Fiber spraying

Tapes

Thermoset

T-RTM LFT

Preforming

Inject. molding

M E T H O D S Engineering/Design

Structure Simulation

Process Simulation

M A T E R I A L S Fiber

Matrix

Additives, Filler, (…)

© Fraunhofer ICT

Methods - Materials - Processes

Virtual Simulation Chain

Initial analysis of component manufacturability

Linkage of process simulation and structure simulation

Integration of production boundary conditions and updated material properties into structure simulation

Requirements for Multi-Material-Design

V I R T U A L S I M U L A T I O N C H A I N

F L O W O F I N F O R M A T I O N

O P T I M I Z A T I O N

Geometry Forming Curing / cooling

Part Assembly

integral construction

differential construction

Vehicle concept

Vehicle

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© Fraunhofer ICT


Material modification

Chemical (molecular structure, cross-linking, cristallinity, …)

Physical (reinforcements, additives, fillers, …)

Tailored materials

Material analysis

Mechanical testing

Thermal analysis

Chemical analysis

Morphological characterization

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© Fraunhofer ICT


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Thermoset processing

Sheet molding compound

Fiber spraying

Resin Transfer Molding

Prepreg

Preforming

Thermoplastic processing

Extrusion

Injection molding

Compression molding

Thermoforming

Resin transfer molding

Preforming

© Fraunhofer ICT

Technology teams Realization of the Methods - Materials - Processes approach

Tasks of the Technology teams:

Material focused strategic research

Regular internal colloquia for cross-team technical exchange

Analysis of potentials and limitations of materials

Think-tanks and quality gate management

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Fraunhofer

ICT

P R O C E S S E S

M E T H O D S

M A T E R I A L S

Sustainable System Approach

© Fraunhofer ICT

Access to automotive key markets

R&D network

Student exchanges

Graduate schools

18

Karlsruhe

Stuttgart

Pfinztal

München Freiburg

Augsburg

Darmstadt

Leichtbauzentrum

Baden-Württemberg e.V.

S O U T H E R N G E R M A N Y

G L O B A L

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K A R L S R U H E

Fraunhofer

ICT

P R O C E S S E S

M E T H O D S

M A T E R I A L S

Regional, national and international network Extended research activities

© Fraunhofer ICT 19 18.03.2014


System Engineering

POLYMER R

EIN

FO

RC

EM

EN

T THERMOSET THERMOPLASTIC

Unreinforced Thermoplastics

Short & Long-fiber Reinforced Thermoplastics

Continuous-fiber Reinforced Thermoplastics

Unreinforced Thermosets

Short & Long-fiber Reinforced Thermosets

Continuous-fiber Reinforced Thermosets

Hyb

rid

Co

mp

osi

tes



System Engineering

POLYMER R

EIN

FO

RC

EM

EN

T THERMOPLASTIC



Short & Long-fiber thermoplastic Principle of direct compounding of LFT in compression molding

LFT plastificate (open transfer)

Mixing extruder

IL compounder

Compression molding

Reinforcing fibers : Carbon Glass Natural …

Matrix res ins: Polypropylene PA 6, PA 6.6 etc. Blends …

Further developments in LFT-D-CM

Processing of carbon fibers

Use of technical thermoplastics as matrix material (e.g. PPS, PEEK…)

Combination with continuous fiber reinforcements


Short & Long-fiber thermoplastic Principle of direct compounding of LFT in injection molding

Injection molding

Reinforcing fibers : Carbon Glass Natural …

Matrix resins: Polypropylene PA 6, PA 6.6 etc. Blends …

LFT plastificate (direct injection

in the cavity )

twin screw extruder (TSE)

Further developments in LFT-D-IM

Processing of carbon fibers

Combination with continuous fiber reinforcements

FIM – Foam injection molding (LFT-D Foam)


Instrument panel

crossbeam Door

module

Bumper beam carrier

Battery tray

Frontend carrier

Instrument panel carrier

Engine and gear box bracket

Tailgate module

Automotive Applications

Short & Long-fiber thermoplastic Typical applications of LFT

Source: SMP / A2mac

© Fraunhofer ICT

Weight and material savings

Increased dimensional stability due to

less residual stress / warpage

Fewer sink marks

Injection from thin to thick

Lower viscosity due to flow promoter effect

Longer flow path / lower injection pressure

Reduced melt temperature

Lower cavity pressure and clamping force

Improved design freedom

Shorter cooling times (cycle times)

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Short & Long-fiber thermoplastic Foam injection molding (FIM) - Advantages

Foamed PP-LGF30 PP foam

© Fraunhofer ICT

Integral foam structure Sandwich everywhere in the whole part

High bending stiffness at a low surface weight

No / less embrittlement during foaming

LFT foaming processes at ICT: MuCell®, LFT-D-Foam, chemical blowing agents (CBA)

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Short & Long-fiber thermoplastic Foam injection molding (FIM) – LFT-Foams

compact skin layers

foamed core

SEM pictures of LFT foams

LFT-D-Foam PP-LGF30

© Fraunhofer ICT

Short & Long-fiber thermoplastic Methods

Process simulation

Simulation of compression molding process

Transfer of the resulting fiber orientations into structural simulation

Process optimization: Prediction of resulting flow and joint lines

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Component design and structural simulation

Component design and optimization for use in FRPs

Material models for fiber-reinforced materials

Simulation of hybrid components

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System Engineering

POLYMER R

EIN

FO

RC

EM

EN

T THERMOPLASTIC



Continuous-fiber thermoplastic Types of reinforcement

UD-Tapes Coiled Structures Fabrics UD-Strands Non-woven Fabrics

Benefits of continuous fiber reinforcements

Semi-finished products containing fiber volume contents of up to 60 -70 %

High mass-specific part properties achievable

Part designs are optimized for specific load cases

More stable mechanical performance at elevated temperatures

Increased dimensional stability

Reduced creep tendency (if loads are transferred into continuous fibers)

Application of thermoplastics in structural applications

source: Bond Laminates source: Zoltek source: Zoltek


Continuous-fiber thermoplastic Thermoplastic tape-laying based on RELAY® technology

Advantages

Fiber orientations arbitrarily adjustable

Varying thickness within a part possible

Minimized scrap

Recyclable material

Hybrid layup configurations possible

Automated process with short cycle times

Combination with other thermoplastic processing and joining technologies possible

Technical challenge

Limited drapeability and flowability

Economic challenge

The cost targets are often difficult to achieve in large series

ultrasonic welding

© Fraunhofer ICT

No fiber ondulation (max. performance)

No unnecessary cutting scrap

No limitation on the fiber orientation 0 ° / 90 °

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Continuous-fiber thermoplastic Differences between tape-laying and semi-finished woven fabrics

Source: Script of Paolo Ermanni (woven fabric) and www.hedag-recycling.de (tape layup)

© Fraunhofer ICT

Case Study - Continuous-fiber thermoplastic Structural Reinforcement of a Truck Storage Compartment

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From UD-tapes to a structural part

Laminate optimization

Tape laying

Preconsolidation

Thermoforming

Trimming

© Fraunhofer ICT

Transfer system

Gripper Tape layup

1. Fixing of tape layup in the transfer system

2. Heating to processing temperature

IR-heaters

3. Forming

Tool

IR heaters

Press

F


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© Fraunhofer ICT

Further project content

Temperature analysis over the whole process

Mechanical properties

Analysis of consolidation

Study on draping of the material

02468

10121416182022

Young's-Modulus [GPa]*


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© Fraunhofer ICT

Case Study - Continuous-fiber thermoplastic Structure frame for a truck service cover

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© Fraunhofer ICT

Continuous-fiber thermoplastic Methods Research goals Understanding and modelling the complex

material behavior of continuous-fiber-reinforced thermoplastics

Identifying the potential and limitations of these materials with regard to structural applications

Mechanical characterization Characterization of deformation behavior

Quasi static

Long-term (creep)

Multiscale simulation Investigation and evaluation of the time-

dependent deformation behavior based on micro-, meso- and macro-FE models

Hybridization Evaluation of the time-dependent

deformation behavior of load application points

Evaluation of concepts to expand the application range of these materials, using hybridization methods

Micro Meso Macro

Elongation [%]

Ten

sio

n [

MPa]

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System Engineering

POLYMER R

EIN

FO

RC

EM

EN

T THERMOSET THERMOPLASTIC

Unreinforced Thermoplastics



Hyb

rid

Co

mp

osi

tes

© Fraunhofer ICT

Compression (LFT-D-CM) and injection molding

(LFT-D-IM, LFT-G)

Local reinforcement with continuous fibers

Final composite parts

Hybrid thermoplastic composites Approach for realizing function-integrated parts

Combination of local continuous fiber reinforcements and established high-volume process technologies

© Fraunhofer ICT

Technology demonstrator with wound fiber structure (Injection molding)

Minimal fiber content with restriction on highly loaded areas

Significant increases in breaking force and breaking energy

Homogeneous stress distribution in the demonstrator without damages until collapse

0

50

100

150

200

250

300

0 1,5 2,2

Bre

akin

g e

ne

rgy [

J]

Glass Fiber-content wt.-%

Breaking energy

+590%

0

5

10

15

20

25

30

0 1,5 2,2

Bre

akin

g f

orc

e [

kN

]

Glass Fiber-content wt.-%

Breaking force

+176%

Case Study - Hybrid thermoplastic composites Advantages of Local Continuous Fiber Structures

© Fraunhofer ICT

39

woven UD-Tape

non-woven UD-Tape

LFT-D

Compression molding

Modificated engine capsule


Technology demonstrator „engine capsule“ with UD-Tape reinforcement (Compression molding)

Significant improvement of impact properties

Feasibility for compression molding of complex UD-Tape structures with LFT-D was detected

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© Fraunhofer ICT

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System Engineering

POLYMER R

EIN

FO

RC

EM

EN

T THERMOSET

Unreinforced Thermosets

Short & Long-fiber Reinforced Thermosets

© Fraunhofer ICT

Long-fiber thermoset Sheet molding compound (SMC) process

filler

Resin-filler

production

Manufacturing of

semi-finished

products

Production of parts

Ma

tura

tio

n p

roc

es

s

Tra

nsp

ort

if

nec

es

sa

ry

SM

C p

roc

es

s

SMC

Material development

Low-density SMC

CF-SMC

Bio-fibers and

bio-resins

Class-A applications

Exterior parts for

automobiles and

commercial vehicles

Direct-SMC

New matrix systems

and applications

Short process chain

Flexibility

D-SMC equipment

Structural parts

Continuous-fiber rein-

forcements using winding

technology and

UD prepregs

Metallic inlays

Ecoshell

Cu

rre

nt

res

ea

rch

an

d

de

ve

lop

me

nt

top

ics

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© Fraunhofer ICT

Simulation of compression molding process

Prediction of fiber orientations and joint lines

Measurement of material properties by using a compression molding rheometer

Structural simulation and construction

Development of a phenomenological material model for SMC components

Characterization and modeling of damage behavior

Consideration of fiber orientations from the simulation

Simulation and design of SMC components

Potential and limitations in the application of hybrid SMC components

Manufacturing and characterization of mechanical properties and simulation of hybrid specimens

Long-fiber thermoset Methods

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System Engineering

POLYMER R

EIN

FO

RC

EM

EN

T THERMOSET

Continuous-fiber Reinforced Thermosets

© Fraunhofer ICT

Preform

2D-

layer

High-pressure RTM mold

Preform center at ICT (from 2014) Ref.: Dieffenbacher GmbH

3600 t p

ress

High-pressure RTM equipment Semi-finished textile Head profile

Hollow structure with undercut

RT

M p

roc

es

s c

ha

in

Continuous-fiber thermosets Processes

Achievement of a consistent, fully-automated process chain

Process characterization and analysis, process optimization for manufacturing of structural components

Development of new process technologies for serial production

Material characterization as a function of different process parameters

Cu

rre

nt

top

ics

Preforming process High-pressure RTM Alternative infiltration processes

(continuous RTM, inline-prepreg, etc.)

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© Fraunhofer ICT

Continuous-fiber thermoset Applications of Resin Transfer Molding in the automotive industry

Side frame

Roof

Body in white

Bumper

Audi R8 Spyder

BMW M6

BMW Project I

Source: BMW AG

Source: AUDI AG

Source: maschinenmarkt.vogel.de

Source: BMW AG Source: maschinenmarkt.vogel.de

Source: maschinenmarkt.vogel.de

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© Fraunhofer ICT

Continuous-fiber thermoset RTM Process - cycle

Textile product

Semi-finished fabric cuts 2D

Preform production and fixing

Start of cycle

Fixing 2D-semifinished fabric product

Handling semi-finished product

3D Preform Preform handling

Mold technology

Infiltration and curing

Component demolding and post-processing

End of cycle

RTM component Mold cleaning

Res in Hardener

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© Fraunhofer ICT

Continuous-fiber thermoset RTM Process - facilities

Dieffenbacher PreformCenter

Hydraulic presses (clamping force of 600 t and 3600 t)

High pressure RTM Equipment, max. injectionpressure of 220 bar

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© Fraunhofer ICT

Continuous-fiber thermoset PreformCenter Installation planned by Q1 - 2014

Source: Dieffenbacher GmbH

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© Fraunhofer ICT

Continuous-fiber thermoset RTM Process - cycle

Textile product

Semi-finished fabric cuts 2D

Preform production and fixing

Start of cycle

Fixing 2D-semifinished fabric product

Handling semi-finished product

3D Preform Preform handling

Mold technology

Infiltration and curing

Component demolding and post-processing

End of cycle

RTM component Mold cleaning

Res in Hardener

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© Fraunhofer ICT

Continuous-fiber thermoset Ongoing research activities in the field of HP-RTM

55

High-pressure injection RTM HP-IRTM

Impregnation of preform in x- and y-direction

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

High-pressure compression RTM HP-CRTM

90

0 m

m

550 mm

90

0 m

m

550 mm

HP-IRTM Injection time – appr. 10s HP-CRTM Injection time – appr. 10s

High-pressure RTM equipment at the ICT

3600 t Press at the ICT

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© Fraunhofer ICT

Mold filling and curing simulation

Consistent modeling and simulation of injection and curing process

Evaluation of mold filling behavior and

optimization of injection and evacuation strategy

Prediction of process-induced residual stresses and of the expected component distortion

Continuous-fiber thermoset Methods

Draping simulation

Simulation of sequential preforming processes for semi-finished products with different layers

Initial validation of manufacturability

Prediction of fiber orientations and deformation faults

Transfer of fiber orientations to further simulation steps

Injection point

Vent (outlet)

Flow front

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© Fraunhofer ICT

Simulation of adhesive joints

Characterization of energy release rates (GIC, GIIC)

Simulation of coupon samples for parameterization of the models

Evaluation and development of different modeling approaches

Cohesive zone model

Cohesive elements

Continuum mechanical approaches

Continuous-fiber thermoset Methods Structural simulation and

construction

Component design and optimization of

layup

Damage models for static loads

Efficient models for three-dimensional failure prognosis

Influence of production effects on component performance

DCB trial (Ref. Fraunhofer IWM)

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Fraunhofer Project Centre for

Composites Research at Western

University

FPC @ Western

A joint venture between:

Western University, London, Ontario, Canada

And

Fraunhofer Gesellschaft, Munich, Germany & Institute for Chemical Technology (ICT),

Pfinztal, Germany

Contact: [email protected]

www.eng.uwo.ca/fraunhofer

mailto:[email protected]

Vision

• To accelerate the adoption of advanced composites

technologies and processes by North American industry

• To offer an excellent environment for the transfer of know-how

to industry, leaders, engineers and technicians.

• To accelerate the development cycle for new products by

industry.

Twin Regions

Joint 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

To reduce the consumption and the emissions within the field of transportation by implementing lightweight design.

Improvement of passive and active safety as well as product attractiveness through functional structures.

Realisation of innovative technologies, production processes and products in economically viable small, medium and large-scale volumes.

Mission

Design Process and Material Demonstrator Part

Applied Research with Industry

Bridging 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 with industry

collaboration with FPC@Western

collaboration With universities

Set of Principles

The FPC is a neutral, not-for-profit, University-linked applied research facility

The FPC is open to all potential users (no exclusive relationships)

The FPC focuses on industry-led and industrially relevant needs

The FPC takes a holistic approach to problem-solving

The FPC collaborates with academic institutions and leverages industry funding with grants from research agencies (the ICRC takes the lead at UWO for developing and managing research grants and works closely with the FPC

The FPC acts with the aim of being self sustaining

FPC’s service offerings

Clients can engage FPC personnel for: Trials in industrial scale Material and formulation development Manufacturing process investigation and development Part development Workshops for know-how transfer into industry Training of personnel and students Access to a cluster of other research facilities and services

International Composite Research Center (ICRC)

The ICRC is a cluster of connected and collaborating academic institutes of universities in Canada and the USA involved in composites and lightweighting coordinated by Western University. We aim for a contribution on project level and common research in different programs we plan to commonly apply for. The partners contribute their expertise on polymers and composite materials especially on modelling, testing and characterization as well as processing


Fundamental Research

Education of PhD students

Education of Master students

Network of Academia and

Science

Applied Research

Training of students

Training of Industry

Expertise on Composite

Technologies

Composite Materials

and Technologie

s

ICRC FPC@Western

Industrial Clients


Academic Researchers

UWO

McMaster

U of Toronto

U Windsor

RMC

Ecole Polytechnique

others

Infrastructure

Fraunhofer Project Centre

•Industrial-scale, SOTA manufacturing facility

University and College Laboratories

•Laboratory and pilot-scale facilities

•Testing and Characterization

Industry Support

OEMs

Tier Suppliers

Equipment Manufactures

Material Producers

© Fraunhofer ICT

Contact

Karlsruhe Institute for Technology (KIT)

FAST Institute for Vehicle System Technology

Rintheimer-Querallee 2

76131 Karlsruhe

Germany

Phone: +49 (721) 608-45905

Fax: +49 (721) 608-945905

http://www.fast.kit.edu/

Fraunhofer Institute for Chemical Technology

Joseph-von-Fraunhofer-Straße 7

76327 Pfinztal

Germany

Phone: +49 (721) 4640-711

Fax: +49 (721) 4640-730

http://www.ict.fraunhofer.de/

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http://www.fast.kit.edu/

http://www.ict.fraunhofer.de/

composites for automotive lightweighting · high mass-specific part properties achievable ... more...

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