Funktionsintegrierter Leichtbau mit Carbonfaser...
Transcript of Funktionsintegrierter Leichtbau mit Carbonfaser...
Funktionsintegrierter Leichtbau
mit Carbonfaser verstärkten
Thermoplastwerkstoffen
Dr. Andreas Erber | Werkstoff-Forum; Hannover Messe | 2015-04-15
Page 2 Dr. A. Erber - Werkstoff-Forum - 2015-04-15 - Hannover
Company Profile. SGL Group
One of the world’s largest manufacturers
of carbon-based products
Comprehensive portfolio ranging from
carbon and graphite products to carbon
fibers and composites
43 production sites worldwide
Service network covering more than
100 countries
Sales of ~€ 1.5 bn in 2013
Head office in Wiesbaden/Germany
~ 6,300 employees worldwide
Listed on German Stock Exchange
Page 3 Dr. A. Erber - Werkstoff-Forum - 2015-04-15 - Hannover
Organizational structure
Three Business Units & Joint Ventures
SGL Excellence (Six Sigma)
Technology & Innovation (T&I)
Performance
Products
(PP)
Graphite Materials &
Systems
(GMS)
Carbon Fibers &
Composites Materials
(CF/CM)
Joint Ventures
Page 4 Dr. A. Erber - Werkstoff-Forum - 2015-04-15 - Hannover
Business Unit Carbon Fibers & Composite Materials
Unique offering of the complete value chain
Materials SGL Group – Core Competencies
Components Joint Venture Partnering
PAN
Precursor
Carbon
Fiber
Fabrics, Preform
Prepreg
Carbon
Fiber
Composite
Materials
Raw
Material
Composite
Components
Fisipe S.A. (100%)
MSP: JV with
Mitsubishi Rayon
(33%)
Prod. Capacity
~ 4kt in UK
~ 2kt in USA
SGL ACF (51%)
JV with BMW
~ 9kt in USA
SGL epo (100%)
SGL Kümpers (51%)
SGL ACF (51%)
JV with BMW
Benteler SGL (50%)
Brembo SGL Carbon Ceramic Brakes (50%)
Automotive Parts
Page 5 Dr. A. Erber - Werkstoff-Forum - 2015-04-15 - Hannover
Agenda
Status-Quo Carbon Composites in Automotive Applications
Current Challenges of Materials and Processes
Thermoplastic Composites Material System
Design Approach & Process Technologies for Thermoplastic Composites
Page 6 Dr. A. Erber - Werkstoff-Forum - 2015-04-15 - Hannover
History of CFRP Materials
Source: RedBull F1, Daimler AG, Audi AG, BMW AG
Formula 1
Super Sports Car
Small Series
Serial Production
Vision 2030
Monocoque
Manual Labor
Monocoque
Manual Labor
“Class A” Carbon
Semiautomatic
Life Cell
Automated
Hybrid Design
Automated for
High Volume
To
day
Lo
t S
ize
2003 1981 2008 2014 2025
Page 7 Dr. A. Erber - Werkstoff-Forum - 2015-04-15 - Hannover
RTM Process Chain and its Challenges
Materials Preforms Stacks RTM Finish
25 % 50 % 20 % 5 %
• Production of semi-finished
materials cause material costs
• Infusion and polymerization
time dominates RTM process
Page 8 Dr. A. Erber - Werkstoff-Forum - 2015-04-15 - Hannover
RTM Process Chain and its Challenges
Materials Preforms Stacks RTM Finish
25 % 50 % 20 % 5 %
• Scrap rate of preforming is too high
• Complex process chain to build the preform
• Process robustness is too low
Page 9 Dr. A. Erber - Werkstoff-Forum - 2015-04-15 - Hannover
Lightweight Solutions
Key for achieving global CO2 emissions targets
National and global regulations for selected segments
Sources: AllianzProSchiene, DB AG, Reinf. Plastics Mag. 07/08-12; CleanSky, GBI Research; EU CAFE; IMO
Targets
2020
Automotive - EU fleet targets
Actual: ~ 130g CO2/km
Target: ~ 95g CO2/km
Aerospace - CleanSky
Actual: ~ 622Mt CO2
Target: ~ 310Mt CO2
Railway - Deutsche Bahn
Actual: ~ 7Mt CO2
Target: ~ 6Mt CO2
Maritime - Int. Maritime Organization
Actual: ~ 865Mt CO2
Target: ~ 714Mt CO2
~ 27%
~ 14%
~ 50%
~ 17%
Page 10 Dr. A. Erber - Werkstoff-Forum - 2015-04-15 - Hannover
Multi-material design concepts
CFRP potential analysis
• Load path
• Design room
• Location of the component
Challenges for multi-material design concepts
• Joining concepts
• Thermal expansion
• Assembly line
integration
• Painting (KTL)
Analysis of the body in order to identify
components with high CFRP potential Source: Audi AG
B-pillar: CFRP Insert for
increased impact stability
Multi-material body
Page 11 Dr. A. Erber - Werkstoff-Forum - 2015-04-15 - Hannover
Thermoplastic Materials can be the Enabler
for High Volume Production
Source: BMBF Project SpriForm, SGL
Transport at
Room Temperature Organic Sheets Unidirectional Tapes
Hybrid Design
- Injection Casting
- Thermo Forming
Welding
Hybrid Materials
Repair Concepts
Recycling
Short Cycle Times
Page 12 Dr. A. Erber - Werkstoff-Forum - 2015-04-15 - Hannover
From Carbon Fiber to Thermoplastic Composites
Carbon Fiber with
customized Sizing
Spreaded
Fibers
Impregnation
Process
Hybrid Yarn RTM
Preform
LFT
• Powderprepreg
• Pultrusion
• Solvent-Impregnation
• Dispersion-Impregnation
• Melt-Coated Prepreg
Bumper Beam
Integrated Thermoplastic
Composite Part
Combination of different materials
Press
Preform In-Situ Polymerization
Tapes & Sheets
Sources: Dieffenbacher, FhG ICT, Concordia Fibers
Page 13 Dr. A. Erber - Werkstoff-Forum - 2015-04-15 - Hannover
Customized Sizing Solutions
EPY HTT01-2 HTT07 100% 176%
187%
HTT08 210%
Base-Line Type 1 Type 2
Type 3
Values in boxes: Flexural Strength 90°
Improvement of Fiber/Matrix Interphase
• Advanced fiber/matrix interphase by customized sizing
solutions
• Improved mechanical performance
• as received
• hot/wet conditioned
• Textile process ability compared to base-line systems
Page 14 Dr. A. Erber - Werkstoff-Forum - 2015-04-15 - Hannover
Industrialization of Thermoplastic Carbon Fibers
Laboratory Line
Pro
du
ctio
n
Sizing Formulation Pilot Line
Development and Industrialization Project
Sizing Composition
Processing and Spreading Trials
Upscaling , Mechanical Characterization and Customer Sampling
Page 15 Dr. A. Erber - Werkstoff-Forum - 2015-04-15 - Hannover
C-Fiber with Thermoplastic compatible Sizing
Customized Sizing
for Thermoplastics
Standard
Sizing
150
100
50
90
° B
en
din
g S
tren
gth
*
[MP
a]
Improved Mechanical Performance
* Values based
on PA6
Page 16 Dr. A. Erber - Werkstoff-Forum - 2015-04-15 - Hannover
Impregnation Technologies for Tapes and Sheets
• Film Stacking
• Melt Impregnation
• Powder Impregnation
• Impregnation via Solvents
• …
Creel Film-
supply
Creel Melting/Impregnation Slitting Consolidation
Influence
• Process Costs
• Mechanical Properties
• Processability
• Fatigue Behavior
Film Stacking
Source: LCC, TU Munich
Page 17 Dr. A. Erber - Werkstoff-Forum - 2015-04-15 - Hannover
Manufacturing Technologies for UD-Tapes
Incoming tape
Consolidation roller
Energy
Heating area
Consolidated tape
Crotch area
Tool
Consolidation pressure
Direction of travel
Tool heating
Tape heating
(optional)
Laminate
• Automated Tape Laying
• Automated Fiber Placement
• FiberForge Technology
Heat Sources
• Open flame
• Hot gas torch
• Laser
• Infrared
• Hot Shoe
• …
Sources: Coriolis, LCC (TU Munich)
Page 18 Dr. A. Erber - Werkstoff-Forum - 2015-04-15 - Hannover
Materials customized for Manufacturing
¼” Slit Tapes
50 mm Tapes
180 mm Tapes
Width of Sample Materials
Customized Width
Available
Page 19 Dr. A. Erber - Werkstoff-Forum - 2015-04-15 - Hannover
Organic Sheets and Molding Processes
Hydraulic needle for
preform fixation
Pre-forming spring die
LFT material feed
Blank holder
Demonstrator Part
Sources: KraussMaffei, Rucks
Thermoforming of Organic Sheets
Back injection Molding to generate
geometrical stiffness
Thermoforming
Page 20 Dr. A. Erber - Werkstoff-Forum - 2015-04-15 - Hannover
Braiding of UD-Tapes
• Set-up
– UD-slit tape with 5 mm width
– Conventional radial braider with 32 carrier
• Results
– Flexible braiding speed
– Variation in mandrel size
– Wide range of braiding angles
– Modify bobbins to improve quality
Detail of tape
braided sleeve 1
0 c
m
Radial braider
Radial braider with
32 tape bobbins
Braiding bobbin
with tape
Braiding point
2.5
cm
Consolidated
braided sleeve
Page 21 Dr. A. Erber - Werkstoff-Forum - 2015-04-15 - Hannover
Polyamide 6 UD-Tape Plain Woven Fabric
Plain Woven
Fabric
Consolidated
Organic-Sheet
(5 layers/~2mm)
Consolidated
Single layer
(~0,4mm)
• PA6 UD-Tapes
slitted to a width
of 18 mm
• Production on
industrial type
weaving machine
(Dornier)
• High mechanical
properties
• Improved
Drapeability
Page 22 Dr. A. Erber - Werkstoff-Forum - 2015-04-15 - Hannover
Tension Reinforcement by UD-Tapes
Processing of UD-tape and Injection Molding
Injection molded part
Top view & Cross section of reinforced part
• Exemplary design of UD-reinforced part
– Two metal inserts
– Circumferential UD-reinforcement
– Two-step injection molding of PA6 matrix
• Mechanical characterization
– UD-tape
– Matrix
– Single side structure
– Whole part
• Results
– Improved stiffness
– Improved tensile strength
Page 23 Dr. A. Erber - Werkstoff-Forum - 2015-04-15 - Hannover
Conclusion
• Carbon fiber reinforced thermoplastics are
the enabler for mass production
• Thermoplastic composites as a material system
• Materials and automation systems have
to be harmonized
• Multi-material design to approach
cost-efficient applications