Shaping the Future

Innovations in CompositeMaterials Processing

Neil Reynolds

Automotive Composites ResearchCentre, WMG

Polymer Innovation Network21st October 2015

2

Agenda

Background

Introduction to WMG ACRC research

Key capabilities

3

Background

Aims:– Development and application of suitable materials,

processing and simulation technologies for high-volumestructural application of composites in automotive industry

Considerations:– Cost (raw materials & utilisation)

– Cost (investment in processing technologies)

– Cost (cycle time)

– Also – LCA/recyclability, integration (joining)

Approach:– Industry-led collaborative R&D using a combination of

traditional and industrially-relevant research tools Fundamental analytical techniques through to industrial process

demonstration

4

Structural Composites at WMG ACRC

Processing:– Pre-preg compression moulding (PCM)– CF-SMC– Rapid stamp-forming of aligned fibre thermoplastics– HP-RTM & compression RTM, in-situ polymerisation– Formability/drape– Automation

Joining:– Volume-ready joining techniques– Pre-treatments– Automation

Performance:– Stiffness/strength & crash energy management– Durability/fatigue– Provision of key data for performance simulations, enabling

component design

5

WMG ACRC Processing Capabilities

Engel v-Duo 1700– Multi-functional 1,700t press– 2.2 x 1.8m usable platen area– Fully instrumented (pressure, temp, cure)– Sliding lower table

Heating/transfer station on order

Hennecke Streamline HP-RTM– 3+1 (Resin/Polyol)/Hardener/Isocyanate + release

agent– 60 litre day tank capacity (x3)

Zund CNC Cutting Table 2-D Ply Assembly

– Picking, assembling, joining– Up to 8 different layers/plies can be stored– 4-axis robot used to pick and place individual

layers/plies

6

WMG Test/Analysis Capabilities

ACRC:– ±250kN static Instron, temperature chamber, video

extensometry

– Mettler-Toledo HP-DSC

– Zeiss auto stage optical microscope

WMG:– 12kJ instrumented drop tower

– VHS Instron (up to 25m/s)

– 3x fatigue frames (up to ±250kN)

– ±100kN static Instron

– SEM, DMTA, CT scanning

7

Thanks for Listening

Neil Reynolds

Senior Research Fellow

Automotive Composites Research Centre, WMG

www.wmg.warwick.ac.uk

neil.reynolds@warwick.ac.uk

02476 524787