thermoset composite structures for automotive...
TRANSCRIPT
Thermoset Composite Structures for Automotive Lightweighting
Prof. Dr.-Ing. Frank Henning
Peter the Great, St. Petersburg, Polytechnic University
November 21st, 2016
© Fraunhofer ICT
Contents
Introduction
Motivation for lightweighting
The high pressure RTM process chain
Preforming - cutting, stacking and draping of fabrics
Reinforcement Draping simulation The challenges of processing
HP-RTM - infiltration and consolidation
Resins Mold filling simulation Curing characterization and modelling The challenges of processing
Future research and development goals
Summary
Page 2
© Fraunhofer ICT © Fraunhofer ICT
Page 3
Fraunhofer Institute for
Chemical Technology ICT
© Fraunhofer ICT
IntroductionKarlsruhe Institute of Technology KIT
Page 4
We are a group of scientists developing methods for manufacturing and structural simulation of composite materials
Institute: Vehicle System Engineering
Department: Lightweight Technology
© Fraunhofer ICT
Collaboration between Fraunhofer ICT, KIT Institutes and Fraunhofer Project Center
Fraunhofer ICT - Polymer Engineering
KIT – FAST
KIT – IAM-WK
FPC Canada
FPC Korea
Technology Corridors
FPC@
FPC@
IntroductionCollaboration between the Institutions
Page 5
© Fraunhofer ICT
Contents
Page 6
Introduction
Motivation for lightweighting
The high pressure RTM process chain
Preforming - cutting, stacking and draping of fabrics
Reinforcement Simulation The challenges of processing
HP-RTM - infiltration and consolidation
Resins Mold filling simulation Curing characterization and modelling The challenges of processing
Future research and development goals
Summary
© Fraunhofer ICT
Motivation for lightweightingUse of FRP in Lightweight applications
Page 7
High weight related performance
Highly integrated and “ tailored” design is feasible
» High geometrical design freedom
» Targeted use of the anisotropy
High weight related energy absorption potential
Excellent fatigue propertiesPicture: BMW-Group www.lightweight-design.de
Fixing and mounting elements
Targeted surface modifications
Structural Health Monitoring
Picture: Airbus
Fraunhofer ICT Fraunhofer ICT
Source: Roland Berger, VDMA
Source: Roland Berger, VDMA
© Fraunhofer ICT
Motivation for lightweightingUse of FRP in Lightweight applications
• Methods• Materials• Processes
technological advances
?
Page 8
© Fraunhofer ICT
Motivation for lightweightingMethods - Materials – Processes (MMP) approach
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, (…)
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
Page 9
© Fraunhofer ICT
Contents
Page 10
Introduction
Motivation for lightweighting
The high pressure RTM process chain
Preforming - cutting, stacking and draping of fabrics
Reinforcement Simulation The challenges of processing
HP-RTM - infiltration and consolidation
Resins Mold filling simulation Curing characterization and modelling The challenges of processing
Future research and development goals
Summary
© Fraunhofer ICT
The High Pressure RTM Process ChainAutomotive applications
Side frames
Exterieurs
Body in white (BMW i3)
Back seat structure
BMW i3 Source: http://bmw-wiki3.de/
BMW i8 Source: http://bmw-wiki8.de/
Audi R8 Spyder Source: AUDI AG
Page 11
Source:
http://evworld.com/press/bmw_i3_lifepod600x400.jpg
Source: BMW AG
Source: BMW AG
Leaf spring
Source: BMW AG
Source: Benteler SGL / Henkel
© Fraunhofer ICT
Motivation for the s imulation of the RTM process
Initial verification of the manufacturability of the part geometry
Virtual design and optimization of the process
Detailed knowledge of manufacturing effects and their influence on structural performance
Reduction of development time and costs
Page 12
Requirements for Multi-Material-Design
V I R T U A L P R O C E S S 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
Molding Curing /
cooling
Part Assembly
integral constructiondifferential
construction
Geometry Forming
The High Pressure RTM Process ChainVirtual process chain
© Fraunhofer ICT
The High Pressure RTM Process ChainProcess chain for HP-RTM
Page 13
© Fraunhofer ICT
Continuous-fiber reinforced thermosetsResin Transfer Molding (RTM) process chain
Pre-cut partTextiles Final machining Preform RTM
Source: SGL Carbon Source: KIT wbkSource: BMW Source: Fraunhofer ICTSource: Dieffenbacher
Main cost driver:
Lack of automation during preforming High cutting rate during preform manufacturing High scrap rates due to lack in process understanding
Research areas at Fraunhofer ICT
Cost overview
25% 50% 20% 5%
© Fraunhofer ICT
Continuous-fiber reinforced thermosetsResin Transfer Molding (RTM) process chain
© Fraunhofer ICT
The High Pressure RTM Process ChainCase Study – Automotive Trunk Lid Component
Demonstration part:
Preform made of three Sub-preforms
Minimizing of the geometrical com-plexity in the areas of the light pots
„light pod left“
„light pod right“
„inner part“
Page 16
© Fraunhofer ICT
Contents
Page 17
Introduction
Motivation for lightweighting
The high pressure RTM process chain
Preforming - cutting, stacking and draping of fabrics
Reinforcements Simulation The challenges of processing
HP-RTM - infiltration and consolidation
Resins Mold filling simulation Curing characterization and modelling The challenges of processing
Future research and development goals
Summary
© Fraunhofer ICT
Preforming - ReinforcementFibers
Page 18
Fiber Structure Features
Carbon fiber 2D covalent bonds
Para crystallin (100%)
High orientation
Glas fiber 3D crosslinking leads to isotropic properties
Amorphous
Covalent bonds between silicon and oxygen
Aramid fiber 1D covalent bonds
Hydrogen bonds and Van der Waals bonds
Para crystallin (100%)
Very high degree of orientation
Carbon fiber: High strength and modulus, low density, electrical conductive, small diameter
Glass fiber: Low price, good strength, chemical resistance, electric insulator, medium diameter
Aramid fiber: High strength, lowest density, high impact strength, low pressure resistance
© Fraunhofer ICT
Preforming - ReinforcementSemi-Finished Products
Page 19
Continuous fiber
1D semi-finished
products
2D semi-finished
products
3D semi-finished
products
Non stich-forming Stich-forming Mats and Fleeces
Non-woven fabrics
Woven fabrics
Braided fabrics
Mesh ware
Knitted fabrics
Non-crimp fabrics
Continuous Mats
Long fiber Mats
Fleece
Roving
Yarns
Plied Yarns
3D-braided fabrics
3D-knitted fabrics
Preform
Bild
Source: sgl.de Source: toray.comSource: saertex.com
Source: sglacf.com Source: sgl-kuempers.com
© Fraunhofer ICT
Preforming - ReinforcementFabrics for HP-RTM process chain
Page 20
Linen Köper Atlas
Most relevant weaving styles for FRP‘s:
Standard non-crimp fabric (NCF), stitched with trickot-style
Multi-axial non-crimp fabric
Examples for different braiding styles
Litze
„Round“
Tri-axial
Upper sideBottom side
© Fraunhofer ICT
Contents
Page 21
Introduction
Motivation for lightweighting
The high pressure RTM process chain
Preforming - cutting, stacking and draping of fabrics
Reinforcement Draping s imulation The challenges of processing
HP-RTM - infiltration and consolidation
Resins Mold filling simulation Curing characterization and modelling The challenges of processing
Future research and development goals
Summary
Virtu
al P
roce
ssC
hain
Geometry
Curing / cooling
Requirements for Multi-Material-Design
V I R T U A L P R O C E S S 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
Molding Curing /
cooling
Part Assembly
integral constructiondifferential
construction
Geometry Forming
Molding
Requirements for Multi-Material-Design
V I R T U A L P R O C E S S 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
Molding Curing /
cooling
Part Assembly
integral constructiondifferential
construction
Geometry Forming
Forming
Requirements for Multi-Material-Design
V I R T U A L P R O C E S S 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
Molding Curing /
cooling
Part Assembly
integral constructiondifferential
construction
Geometry Forming
© Fraunhofer ICT
Preforming: Separate textile forming process to transform the 2D engineering textiles in a complex double-curved 3D geometry
Goal: Processing, that transforms the 2D textile in an 3D geometry without manufacturing defects like winkling in consideration of the textiles specific forming behavior:
Low shear and bending stiffness
High stiffness the direction of the fibers
Shear and bending are the main forming mechanisms
Wrinkling occurs due to low bending stiffness
Page 22
shearing bending
Preforming - SimulationGoal of process simulation
© Fraunhofer ICT
Simulation of the sequential preforming process
Page 23
High shear strains in the double curved area
Preforming - SimulationCase Study - Lamp Pot Draping Simulation
© Fraunhofer ICT
Contents
Page 24
Introduction
Motivation for lightweighting
The high pressure RTM process chain
Preforming - cutting, stacking and draping of fabrics
Reinforcement Draping simulation The challenges of process ing
HP-RTM - infiltration and consolidation
Resins Mold filling simulation Curing characterization and modelling The challenges of processing
Future research and development goals
Summary
© Fraunhofer ICT
Preforming - The Challenges of ProcessingSequential Draping Process
Page 25
Stack supply over
heated draping-belt
Input:
2D-LayupStack handover
to Draping mold
Stack fixation in Draping-
mold with Draping-stamp
Mold completely closed,
Curing of the binder
Output:
3D-Preform Initial state of the mold,
Demolding of the
Preform
Partly/sequential closed
draping mold while
continues stack handover
© Fraunhofer ICT
Preforming - The Challenges of ProcessingDraping (d)effects
Page 26
Manufacturing (D)effects
Various fabric deformation modes
Multi-scale deformation
(D)effects:
In-plane fiber waviness gaps between fiber bundles Out-of-plane fiber waviness large-scale wrinkling In-plane fiber waviness out-of-plane fiber wavinessgapping
Complex 3D-preform Large-scale wrinkling
Complex 3D-Preform with arising manufacturing effects
© Fraunhofer ICT
Contents
Page 27
Introduction
Motivation for lightweighting
The high pressure RTM process chain
Preforming - cutting, stacking and draping of fabrics
Reinforcement Simulation The challenges of processing
HP-RTM - infiltration and consolidation
Resins Mold filling simulation Curing characterization and modelling The challenges of processing
Future research and development goals
Summary
© Fraunhofer ICT
HP-RTM – ResinsResin System Requirements
Page 28
Resin System Requirements
Component specific
Temperature behavior
Mechanical properties
Structural integrity
Resistance to diff. medium
Environmental requirements
Long-term behavior
Legal requirements
Viscosity
Shrinkage
Curing behavior
Car body specific
Ref.: Derks, Martin (BMW AG )- 2007
Process specific
Compatibility to other components:
Elongation metal-composite, adhesives, sealing compounds, vibration absorbing materials, etc.
Compatibility to coating processes (assembly):
Heat and form resistance, good mechanical properties, etc.
Future requirements:
Reduced curing time, high Tg , no need for post curing
© Fraunhofer ICT
HP-RTM – ResinsIndustry Overview
Page 29
Epoxy Resin Systems
Polyurethane SystemsProtective Coatings
11%
Automotive8%
Powder
Coating
16%
Construction18%
ElectricalApplications
24%
Aviation and Aerospace11%
Others4%
Ships 8%
© Fraunhofer ICT
Automotive
Wind energy
Sports
Molding + Compound
Pressure Tanks
Construction
Marine
Others
Aerospace & Defense
Global Demand [%] 2014 (Application based)
http://composites-germany.org
HP-RTM – ResinsComposites Market
Page 30
Global demand for Carbon fibers [kT] 2009 – 2014 and outlook
http://composites-germany.org
(*Estimation)
http://composites-germany.org
Breakdown of Manufacturing Processes for Composites [%]
© Fraunhofer ICT
HP-RTM – ResinsPolyurethanes - Chemistry
Page 31
Polyaddition of Polyol and Isocyanate („gel reaction“) Thermoset resin
A second reaction („foam reaction“) leads to foaming of resin system
Well adjustable material properties for HP-RTM
For HP-RTM application a mixture of different Polyols and MDI (Methylendiphenyldiisocyanate) is used
Polyol (based on polyether or polyester)
Reactive OH-groups Material properties
Isocyanate
TDI or MDI
Reactivity
Additives
Accelerator Catalyst Propellant Release agent
Urethane-groupIsocyanate-group
© Fraunhofer ICT
HP-RTM - ResinsEpoxy Resin Systems – Resin Chemistry
Page 32
Resin component is a product of Epichlorhydrine and Bisphenol A or F
~90% of epoxy resins are based Bisphenol-A (~ double viscosity compared to Bisphenol-F)
High energetic epoxy ring
Bisphenol A ….or….
Bisphenol F + 2 NaOH
Epichlorhydrine
+ +
Diluent for
- Reduced viscosity,- Changed reactivity and Tg
and physical strength- Mainly for Bisphenol A resins
© Fraunhofer ICT
Aminecuring agents
aliphatic cycloaliphatic,
aromatic:
Anhydridecuring agents
- Monoanhydrides- Dianhydrides
Examples for HP-RTM hardeners(based on aliphatic amines):
Triethylentetramine (TETA) 70-95%Triethylendiamine (TEDA) 2-20%Polyethylenpolyamine (PEPA) 1-8%2-Piperazin-1-ylethylamin 0.1-1.4%
(UV , Tg )
(Tg , UV , reactivity , health )
Not common for HP-RTM, accelerated with catalysts
Amine curing agents (aliphatic) are used in different formulations (know-how of resin suppliers)
Anhydrides often used in Pultrusion (insulation of power lines)
HP-RTM - ResinsEpoxy Resin Systems - Hardener Chemistry
Page 33
© Fraunhofer ICT
Page 34
Resin
HardenerB- Component Diamine
Poly-addition
Epoxy resin
A- Component Epoxy
Cure reaction of an epoxy resin with a diamine hardener
Degree of cure as function of time:
High curing temperature decreases curing time In HP-RTM: 100-120°C
Resin/hardener formulation is the key for processing & curing behavior + material properties
Fast demolding and postcuring possible (shouldbe avoided)
HP-RTM - Raw MaterialsEpoxy Resin Systems – Curing
© Fraunhofer ICT
Contents
Page 35
Introduction
Motivation for Lightweighting
The High Pressure RTM Process Chain
Preforming - Cutting, Stacking and Draping of fabrics
Raw materials Simulation The Challenges of Processing
HP-RTM - Infiltration and Consolidation
Raw materials Mold Filling Simulation Curing Characterization and Modelling The Challenges of Processing
Future Research and Development Goals
Summary
Virtu
al P
roce
ssC
hain
Geometry
Curing / cooling
Requirements for Multi-Material-Design
V I R T U A L P R O C E S S 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
Molding Curing /
cooling
Part Assembly
integral constructiondifferential
construction
Geometry Forming
Molding
Requirements for Multi-Material-Design
V I R T U A L P R O C E S S 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
Molding Curing /
cooling
Part Assembly
integral constructiondifferential
construction
Geometry Forming
Forming
Requirements for Multi-Material-Design
V I R T U A L P R O C E S S 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
Molding Curing /
cooling
Part Assembly
integral constructiondifferential
construction
Geometry Forming
© Fraunhofer ICT
The mold filling process during RTM manufacturing is often modelled as
incompressible flow through porous media
A first approach to calculate the flow was formulated by Henry Darcy in 1856:
Darcy's law describes the average volume-flow velocity 𝒗 as function of:
permeability K, viscosity 𝜂 und pressure gradient 𝛻𝑝
The weight force (𝜌𝒈) is often neglected because of its small impact compared to
the pressure gradient
HP-RTM - SimulationMold Filling Simulation, Fluid Mechanics
Page 36
𝒗 = −𝑲
𝜂(𝛻𝐩 − ด𝜌𝒈
≪𝛻𝐩
)
© Fraunhofer ICT
HP-RTM - SimulationMold Filling Simulation, Fluid Mechanics
Page 37
When Darcy´s law is combined with equation of continuity:
𝛻 𝒗 = 0
A second order partial differential equation is obtained:
0 = 𝛻𝑲
𝜂𝛻𝐩
This equation can be solved by using numerical methods like finite difference, finite element, finite volume or spectral methods.
There is an important modification of Darcy´s law, where instead
of volume-averaged velocity 𝒗 the seepage velocity 𝒗 is calculated:
𝒗 = −𝑲
𝜙𝜂𝛻𝐩
𝒗𝒗 =
𝒗
𝛟
𝒗
𝛟: Porosity
© Fraunhofer ICT
Page 38
The local changes in fiber structure (fiber orientation and fiber volume fraction), that result from preforming process, should be considered in the model for the mold filling simulation
HP-RTM - SimulationMold Filling Simulation: Import of Local Fiber Structure
© Fraunhofer ICT
HP-RTM - SimulationMold Filling Simulation: Material Parameters
Page 39
The permeability K of the textile (here: unidirectional fabric) depends on fiber orientation and fiber volume fraction
© Fraunhofer ICT
Page 40
Because of the higher fiber volume fraction at the tip of the saddle, there is a delay at the beginning of the mold filling
HP-RTM - SimulationMold Filling Simulation: Influence of Local Fiber Structure
with draping simulation
without draping simulation
Legend█ = Air█ = Resin
© Fraunhofer ICT
Contents
Page 41
Introduction
Motivation for Lightweighting
The High Pressure RTM Process Chain
Preforming - Cutting, Stacking and Draping of fabrics
Raw materials Simulation The Challenges of Processing
HP-RTM - Infiltration and Consolidation
Raw materials Mold Filling Simulation Curing Characterization and Modelling The Challenges of Processing
Future Research and Development Goals
Summary
Virtu
al P
roce
ssC
hain
Geometry
Curing / cooling
Requirements for Multi-Material-Design
V I R T U A L P R O C E S S 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
Molding Curing /
cooling
Part Assembly
integral constructiondifferential
construction
Geometry Forming
Molding
Requirements for Multi-Material-Design
V I R T U A L P R O C E S S 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
Molding Curing /
cooling
Part Assembly
integral constructiondifferential
construction
Geometry Forming
Forming
Requirements for Multi-Material-Design
V I R T U A L P R O C E S S 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
Molding Curing /
cooling
Part Assembly
integral constructiondifferential
construction
Geometry Forming
© Fraunhofer ICT
Monitoring of cross-linking reactions with Differential Scanning Calorimetry (DSC):
Measuring heat flow of curing reaction
Various temperatures / heating rates
Evaluation of data (integrating heat flow over time)
𝛼 𝑡 =0𝑡 ሶ𝑄 𝑡 − 𝐵 𝑡 𝑑𝑡
Δ𝑄
HP-RTM - SimulationCuring Characterization and Modelling
𝛼 = degree of cure; ሶ𝑄 = heat flow; Δ𝑄 = heat of reaction of fully cured resin; 𝐵 = baseline (if no exothermal reaction would occur)
© Fraunhofer ICT
HP-RTM - SimulationCuring Characterization and Modelling
Page 43
Example: DSC of epoxy resin at different heating rates
Temperature dependency: Faster heating leads to higher curing rates
Kinetic model is needed for process simulation
-0,5
0
0,5
1
1,5
2
0 50 100 150 200
Temperature T [°C]
Hea
tfl
ow
ሶ𝑄
[W/g
]
higherheatingrate
Heating rate
Enthalpy
5 K/min 512 J/g
10 K/min 465 J/g
20 K/min 433 J/g
© Fraunhofer ICT
Modelling of cross-linking using the Kamal-Malkin kinetic model:
𝑑𝛼
𝑑𝑡= 𝐾1 + 𝐾2 ⋅ 𝛼
𝑚 ⋅ 1 − 𝛼 𝑛 with 𝐾1|2 = 𝐴1|2 ⋅ exp −𝐸1|2
𝑅⋅𝑇
Model parameters (𝐴1|2, 𝐸1|2, 𝑚, 𝑛) are identified by curve-fitting against DSC data
using genetic algorithms
HP-RTM - SimulationModeling of reaction kinetics
Page 44
© Fraunhofer ICT
Viscosity is measured using rheometry for different temperatures:
Viscosity is influenced by temperature and curing
Behavior is modeled using a Williams-Landel-Ferry (WLF) approach
HP-RTM - SimulationModeling of viscosity
Page 45
© Fraunhofer ICT
Contents
Page 46
Introduction
Motivation for light-weighting
The high pressure RTM process chain
Preforming - cutting, stacking and draping of fabrics
Reinforcement Simulation The Challenges of processing
HP-RTM - Infiltration and Consolidation
Resins Mold filling simulation Curing characterization and modelling The challenges of process ing
Future research and development goals
Summary
© Fraunhofer ICT
Page 47
HP-RTM - The Challenges of ProcessingHP-RTM Equipment
HP-RTM machine (KraussMaffei) Mixing head principle
Maintenance-free mixing head
Hydraulic press with press force (max. of 3200kN)
Equipment necessary for HP-RTM process:
Precise press with parallel holding feature
HP-RTM equipment with mixing head connected to mold cavity
Mold with vacuum function, injection gate and fiber clamping
feature
© Fraunhofer ICT
Page 48
HP-IRTM
HP-CRTM
HP-RTM - The Challenges of ProcessingHP-RTM process variants
© Fraunhofer ICT
25 30 35 400
10
20
30
40
50
60
0.5
Time [s]
Near injection port
Middle of flow length End of
flow length
0
1
0
500
1000
90 95 100 105
0
10
20
30
40
50
60
Middle of flow length
End of
flow length
Time [s]
Near injection port
1
0.5
0
0
500
1000
Page 49
HP-IRTM:
Constant press force
Mold gap increase
Mold gap [mm]
Press force[kN]
Ref.
: R
ose
nb
erg
, P., C
hau
dh
ari
, R
., A
lbre
cht,
P., K
arc
her,
M., H
en
nin
g,
F.,
“Eff
ect
s o
f p
roce
ss p
ara
mete
rs o
n c
avi
ty p
ress
ure
an
d c
om
po
nen
t p
erf
orm
an
ce i
n H
igh
-Pre
ssu
re R
TM
pro
cess
vari
an
ts”
HP-RTM - The Challenges of ProcessingCharacterization of the process variants
HP-CRTM:
Constant injection gap
Press force increase
Cavity pressure[bar]
© Fraunhofer ICT
Page 50
Viscos ities at process temperature
ResinTemper-
ature [°C]Dynamic
viscosity [mPas]
EP - Mixture* 69.3 74.5PU - Mixture* 59 67.3EP - Mixture* 120 10.3PU - Mixture* 90 19.1
*Viscosity of the mixture calculated by mixture law of Arrhenius
Rheological characterization of highly reactive resin systems by measuring of single components
Calculation of mixing viscosity using mixture law of Arrhenius
Viscosity of PU is 85% higher at mold temperature than Epoxy viscosity
Viscosity in mixing head
Viscosity at mold temperature
Viscosity at mold temperature
HP-RTM - The Challenges of ProcessingEpoxy and Polyurethane - Processing Viscosities
© Fraunhofer ICT
Page 51
Pressure increase rate [bar/s]:
Epoxy 5.1
PU 8.1 (+59%)
Higher PU resin system viscosity leads to higher pressure increase rate
Increasing the flow rate further, the high pressure increase can cause fiber distortions
HP-RTM - The Challenges of ProcessingEpoxy and Polyurethane Behavior During Injection
84 86 88 90 92 94 96 98 100 102
10
20
30
40
50
Injection
start
Cavity p
ressure
[b
ar]
Time [s]
Injection
end
0 0
100
200
300
400
500
600
700
800
Epoxy
Polyurethane
Pre
ss fo
rce [
kN
]Press force
© Fraunhofer ICT
Epoxy resin system
Polyurethan resin system
0µm 10µm 20µm
HP-RTM - The Challenges of ProcessingEpoxy and Polyurethane - Fiber Push-Out Test
Single fiber filaments were pushed-out of a 50 µm thick sample and analyzed in SEM
Upper side Lower side
brittle resinbehavior
ductileresinbehavior
© Fraunhofer ICT
Page 53
Fiber volume content analysis (biaxial carbon fiber reinforced test samples):
Epoxy resin system: 52.9 ± 1.2%
PU resin system: 51.5 ± 1.2% Material properties can be compared directly
50 52 54 56 58 60 62 64 66 68 70 72 74 76 78 80
700
750
800
850
900
950
1000
1050
1100
1150
1200
+ 2%
EP-CF 969 38 MPa / 66.9 3 GPa
PU-CF 950 14 MPa / 63.9 4 GPa
+ 4.7%
Bendin
g s
trength
[M
Pa]
Bending modulus [GPa]
50 52 54 56 58 60 62 64 66 68 70 72 74 76 78 80
500
550
600
650
700
750
800
850
900
950
1000
+ 5.1%
EP-CF 741 51 MPa / 66.9 4 GPa
PU-CF 783 37 MPa / 63.6 3 GPa
Ten
sile
str
en
gth
[M
Pa
]
Tensile modulus [GPa]
+ 5.6%
Mechanical properties on equal level:
Tensile: EP: 741 MPa PU: 783 MPa Bending: EP: 969 MPa PU: 959 MPa
HP-RTM - The Challenges of ProcessingEpoxy and Polyurethane - Quasi-Static Properties (Test Plate)
Fiber dominated – quasi-static test
© Fraunhofer ICT
Page 54
HP-RTM - The Challenges of ProcessingEpoxy and Polyurethane - Impact Tests
Impact testing following the compression after Impact test standard Results show the force measured during impact on sample
Raise of impact energy causes more delamination
Epoxy samples had significant drop at lower energy (37J) compared to PU laminates (45J)
24J 37J 45J
© Fraunhofer ICT
Contents
Page 55
Introduction
Motivation for light-weighting
The high pressure RTM process chain
Preforming - cutting, stacking and draping of fabrics
Reinforcement Simulation The challenges of processing
HP-RTM - infiltration and consolidation
Resins Mold filling simulation Curing characterization and modelling The challenges of processing
Future research and development goals
Summary
© Fraunhofer ICT
Future Research and Development GoalsPreforming Process
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Automated Preforming Process for complex structural parts
Current situation: Sub-Preforming Approach
Assembly of different sub-preforms before resin infiltration (usually in manual process)
Single-lap joint design vs. stepped-lap joint design
Stepped-lap joint designs contribute to higher mechanical performance
Performance can be optimized to maximize light-weighting potential
tc
2x tc
Single-lap joint
Stepped-lap joint designs
Ref.
: N
iu,
Mic
heal
C.Y
.: C
om
po
site
Air
fraim
eSt
ruct
ure
s. T
hir
d E
dit
ion
, 2010.
© Fraunhofer ICT
Future research and development goalsHP-RTM - Infiltration and Consolidation
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Current situation :
High injection pressure & limitation of maximum flow rate
Fiber distortion effectsInjection and curing
Future requirements:
High speed infiltration (high flow rate) & precise control of cavity pressure
Low cavity pressure process profiles for pressure sensitive foam cores
HP-IRTM
Risk of fiber washout (gap injection leads to low clamping force) during injection
High cavity pressure after injection HP-CRTM
Injection and curing
New process variants
Processing of “1min cure” resin systems Complex and functions integration Maximized light-weighting
Hollow sections/Foam cores Use of recycled fibers
© Fraunhofer ICT
Contents
Page 58
Introduction
Motivation for light-weighting
The high pressure RTM process chain
Preforming - cutting, stacking and draping of fabrics
Reinforcement Simulation The challenges of processing
HP-RTM - Infiltration and Consolidation
Resins Mold filling simulation Curing characterization and modelling The challenges of processing
Future research and development goals
Summary
© Fraunhofer ICT
Summary
Structural performance Economic efficiency
I N T E R AC T I O N S W I T H I N L I G H T W E I G H T D E S I G N AP P R O AC H E S
QUALITY
TIME
COSTS
PROCESSES
METHODS
MATERIALSE F F I C I E N T L I G H T W E I G H T
D E S I G N O N S Y S T E M L E V E L
MMP-approach
Page 59
© Fraunhofer ICT
Thank you very much for your attention
Fraunhofer Institute for Chemical Technology
Prof. Dr.-Ing. Frank HenningJoseph-von-Fraunhofer-Straße 7
76327 Pfinztal - Germany
Phone: +49 (721) 4640-711
Fax: +49 (721) 4640-730
Email: [email protected]
Internet: http://www.ict.fraunhofer.de/
Page 60
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/