IACMI The Composites Institute: Innovations in ... · PDF fileIACMI –A National...

IACMI – The Composites Institute:Innovations in Lightweighting for Automotive Applications

Uday VaidyaChief Technology Officer

© Material para uso exclusivo de los asistentes al 6to. Simposio y Exposición Manufactura de Autopartes, Querétaro, México, Agosto 22

a 24 de 2017. Prohibida su reproducción, venta, comercialización o difusión, total o parcial, sin autorización expresa del autor o de B2B

Portales Inc. La información y contenido gráfico incluido en esta presentación es responsabilidad de su autor.

Manufacturing USA Integration

UT Lab:

precursor, digital

fiber

Automation

Workforce collaborationWorkforce collaboration,

Colocation

Workforce collaboration,

Modeling & Simulation

Recycling initiatives

Resins & AdhesivesFacility & Equipment

Networking; Testbeds

Composite AM,

Tooling

Confidential information-Do Not Distribute 2

© Material para uso exclusivo de los asistentes al 6to. Simposio y Exposición

Manufactura de Autopartes, Querétaro, México, Agosto 22 a 24 de 2017.

Prohibida su reproducción, venta, comercialización o difusión, total o parcial, sin

autorización expresa del autor o de B2B Portales Inc. La información y contenido

gráfico incluido en esta presentación es responsabilidad de su autor.

Operated by Collaborative Composite Solutions Corp, an independent not-for-profit

Governed by a board of directors

A wholly owned subsidiary of the University of Tennessee Research Foundation

Headquartered in Knoxville, Tennessee

Over 155 member consortium, including more than 125 industrial entities across supply chain

$250M in funding with $70M from DOE and $180 from partners

What is IACMI?

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Research and Development Partner for Industry

© Material para uso exclusivo de los asistentes al

6to. Simposio y Exposición Manufactura de

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2017. Prohibida su reproducción, venta,

comercialización o difusión, total o parcial, sin

autorización expresa del autor o de B2B Portales

Inc. La información y contenido gráfico incluido en

esta presentación es responsabilidad de su autor.

IACMI – A National Institute for Advanced Composites

OhioCompressedGas Storage

IndianaInnovativeDesign,

Predictive Modeling &Simulation

TennesseeComposite Materials & Process Technology

New YorkComposite Prototyping Center

MichiganVehicles

WashingtonComposite Recycling Technology Center & Peninsula College

ColoradoWind Turbines

Technical Goals:• Lower carbon fiber–reinforced polymer (CFRP) cost• Reduce CFRP embodied energy • Improve composite recyclability into useful products

150 partners

All 50 states

IACMI- The Composites Institute has partnered with ACMA, the premiere composites industry association and Composites One for workforce training capabilities.

© Material para uso exclusivo de los asistentes al 6to.

Simposio y Exposición Manufactura de Autopartes,

Querétaro, México, Agosto 22 a 24 de 2017. Prohibida su

reproducción, venta, comercialización o difusión, total o

parcial, sin autorización expresa del autor o de B2B Portales

Inc. La información y contenido gráfico incluido en esta

presentación es responsabilidad de su autor.

IACMI-The Composites Institute Senior Leadership Team

Dale BrosiusChief Commercialization Officer

Cliff EberleMaterials and

Processing Technology Area

Director

R. Byron PipesModeling & Simulation

Technology AreaDirector

Lawrence DrzalVehicles Technology

Area Director

Derek BerryWind Turbines

Technology Area Director

Brian RiceCompressed Gas

StorageTechnology Area

Director

Uday VaidyaChief Technology OfficerRenae Speck

Chief Operations Officer

Bryan DodsChief Executive Officer








IACMI-The Composites Institute Facilities

ColoradoIndiana

Michigan

Tennessee

Ohio








IACMI Focus Areas and Metrics

+ 500M Capital Investment

Confidential information-Do Not Distribute 8

© Material para uso exclusivo de los asistentes al 6to. Simposio y Exposición Manufactura de Autopartes, Querétaro, México, Agosto 22 a 24 de 2017. Prohibida su reproducción, venta, comercialización o

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An Integrated Approach to meet the DOE and IACMI goals

Prepreg stamping

Injection over-molding

HP RTM

Additive 3D printing

Tape layup

Filament winding / Braiding

Multi-material joining

Recycling



Advanced Composite Materials Forms for Manufacturing

Continuous fiber reinforced

Discontinuous fiber reinforced

Advanced Composites

Unidirectional tape

Woven prepreg

Other forms (braided prepreg, etc)

Long fiber reinforced (LFT)

Short fiber filled

FORMING AND FINISHING OPERATIONS

(AUTOCLAVE, ATP, PREFORMING, INJECTION MOLDING, EXTRUSION, COMPRESSION MOLDING, DIAPHRAGM FORMING, THERMOFORMING, PAINTING, JOINING, ETC…)

END PRODUCT© Material para uso exclusivo de los asistentes al 6to. Simposio y Exposición Manufactura de

Autopartes, Querétaro, México, Agosto 22 a 24 de 2017. Prohibida su reproducción, venta,

comercialización o difusión, total o parcial, sin autorización expresa del autor o de B2B Portales Inc.

La información y contenido gráfico incluido en esta presentación es responsabilidad de su autor.

Solutionspinning

line Carbon Fiber Technology

Facility Pre-preg

productionpilot/full

scale Pilot-scale

PCM 750 ton press

Full ScalePCM

4,000 ton press

Scale-up Across IACMI Core Partners



Materials

Production

Intermediates

Processing

Composites

Manufacturing

(Sub) System

Assembly

Composites

Recycling

Pro

du

ct

Fo

rms

Pro

cess T

ech

no

log

ies

Crosscutting Technologies and Shared Services

•Commercial PAN-CF

•Low Cost PAN-CF

•Low Cost PO-CF

•Low Cost Pitch-CF

•Low Cost Lignin-CF

•Biomass PAN-CF

•Glass Fiber

•Thermoplastic Resins

•Thermoset Resins

•Additives

•Woven Fabric

•Non-woven Fabric

•Braids

•Prepregs

•Towpreg

•Molding Compounds

•Tapes

•Pultruded Forms

(rods, beams)

•3D Parts/Preforms

•Sheet Products

•Tooling (molds, dies)

•Pultruded Forms

•Pressure Vessels

•Pipes

•Shafts

•Rollers

•Tubes

•Automotive

Assemblies

Bodies, Chassis,

Chassis

Interiors

•Gas Storage

Systems

CNG

Hydrogen

•Wind Turbines

Spars (Caps,

Shear

Webs)

Blade Skins

Blades

•Offal/Trim Scrap

•Chopped Fiber

•Roll Goods

•Preforms

•Fiber Spinning

Solution Spinning

Melt Spinning

Gel Spinning

Electro Spinning

•Fiber Conversion

Thermal

Plasma

Microwave

Ultraviolet

•Fabric Weaving

•Fiber Braiding

•Prepregging

•Compounding

SMC

BMC

•Extrusion

•Stitching

•Auto Tape

Placement

•Preforming

•Thermoforming

•Compression

Molding

•Injection Molding

•Transfer Molding

HP-RTM

VA-RTM

Other Variants

•Additive

Manufacturing

•Filament Winding

•Pultrusion

•Infusion/Compressio

n

•Resin spraying

•Infusion/Cure/Set

Cooling (TP systems)

Thermal

Plasma

Microwave

Ultraviolet

Induction

Infrared

Magnetic Field

Electron Beam

•Pyrolysis

•Solvolysis

•Modeling & Simulation

Supercomputing

Process modeling

Microstructure properties

Probabilistic failure

Analysis

Multiscale modeling

Rheokinetics modeling

Crash modeling

•NDE/NDI

Thermography

Fiber optics

Spectroscopy

Flurorescence

Attenuation/Reflection

High resolution

microscopy

Scanning lasers

•Materials

Characterization

Microscopy

X-Rays

Neutrons

Mechanical

Physical

Thermal

Chemical

•Joining

Adhesives

(Reversible, Curie

Limited Curing)

Mechanical

fastening

(For Multi-

Material

Systems)

•Innovative Design Concepts

Composite Tube Super-Light-

weight auto. body structure

Composite vehicle snap fit joints

Conformable auto CGS tanks

Segmented adhesive-bonded

wind blades

Key IACMI Capabilities (300,000 sq.ft, $200 million in replacement value investment)

© Material para uso exclusivo de los asistentes al 6to. Simposio y

Exposición Manufactura de Autopartes, Querétaro, México, Agosto

22 a 24 de 2017. Prohibida su reproducción, venta, comercialización

o difusión, total o parcial, sin autorización expresa del autor o de B2B

Portales Inc. La información y contenido gráfico incluido en esta


Plasmatreat unit at MDF (Jet - RD1004 / Generator - FG5001 / Transformer - HTR1233)



Querétaro, México, Agosto 22 a 24 de 2017.

Prohibida su reproducción, venta, comercialización o

difusión, total o parcial, sin autorización expresa del

autor o de B2B Portales Inc. La información y

contenido gráfico incluido en esta presentación es

responsabilidad de su autor.

Ways to Partner with IACMI

1. RD&D Research Project

A. Enterprise

B. Technology Collaboration

C. Topic-Specific

2. Membership

A. Charter

B. Premium

C. Resource

D. Consortium



Release of Phase 2 IACMI Roadmap



Roadmapping Strategy

Integrated R&D efforts across IACMI Technology Areas toward 5-/10-year targets

Industry-led projects draw upon resources from one or more IACMI Technology Areas

Eight cross-cutting subtopics help address full range of enabling technologies



Body panels

Thermopastic

stamping, SMC,

HP-RTM)

Liftgate(SMC, HP RTM, Class

A)

Roof (Stamping,

HP-RTM)

Bumpers

(BMC,

SMC,

LFT, Tape

overlay)

Pedestrian Protection (multiphase materials)

Instrument Panel(LFT, Injection molding)

Seats (Injection

overmolding)

Steering and

Suspension

(Injection

overmolding, Hybrid

metal-composite)

Side rails, B-Pillar

(Pultrusion, Braiding,

Compresssion)

Interior and Trim

(Stamping, Forming,

Nonwovens,

Biocomposite)

Representative Composites in Vehicles and Processes –IACMI focus

Powertrain

(extrusion-

compression) Wheels (Carbon

fiber braiding,

overwrap)Under the hood

(High temperature

polymers,

Injection molding)

• Additive Tooling• Low cost carbon fiber• Hybrid materials• Fast acting polymer• Innovative preforms

Competitive Landscape

Not a one-material solution

AHSS, HSS, UHSS,

TRIP

ALUMINUM

MAGNESIUM

CF COMPOSITES

FG COMPOSITES

CARBON STEEL

CAST IRON



+

PA thermoplastic

laminate

(textile

or UD tape)

Press Insert

Overmolded Thermoplastic Composites Allow Cost Efficient Processes

Thermoplastic Resin®

also possible:

inmold forming (thermoforming

of thermoplastic laminate in injection mold)

Astra OPC

seat pan

Composite seat part

Thermoplastic laminate insert

+ injection molding

19Courtesy: BASF© Material para uso exclusivo de los asistentes al 6to. Simposio y Exposición Manufactura de Autopartes, Querétaro, México, Agosto 22 a 24 de 2017. Prohibida su reproducción, venta, comercialización o


BMW 7-series “Carbon Core” approach

Tablets

Smartphones

16 molded components

Mainly in periphery of BIW and transmission tunnel

Combination of processes – HP RTM, SMC, wet pressing, prepreg

Incorporates recycled plant offal

Source: Composites World

Source: BMW

© Material para uso exclusivo de

los asistentes al 6to. Simposio y

Exposición Manufactura de

Autopartes, Querétaro, México,

Agosto 22 a 24 de 2017. Prohibida

su reproducción, venta,

comercialización o difusión, total o

parcial, sin autorización expresa

del autor o de B2B Portales Inc. La

información y contenido gráfico

incluido en esta presentación es


BMW i-8 CFRP components

Tablets

Smartphones

Wet Pressing - 34 parts

RTM - 21 parts

ACCE 2015, Stefan Stanglmaier, CFRP Mass Production at BMW – Today and Tomorrow, 9/10/2015



25% lower CFRP cost demands lower Carbon Fiber cost!

CFRP cost build-up for a van door inner with intrusion beam. Source: Rocky Mountain Institute

Cost breakdown for 700-bar CFRP H2 storage tank. Source: Strategic Analysis

59%8%

10%5%

18%



Oak Ridge National Laboratory Carbon Fiber Technology Facility Scalable process for producing low-cost carbon fiber

IACMI partner, ORNL, has

demonstrated a production

method estimated to reduce

the cost of carbon fiber as

much as 50% and the

energy used in production

by more than 60%

Properties exceed requirements for industrial/ automotive structural carbon fibers

Low-cost, commercially available feedstock (textile PAN)

Vehicle Lightweighting

• Carbon Fiber throughout body and chassis

Wind Energy

• Turbine components and longer blades

Gas Storage

• High-strength, lightweight pressure vessels



Big Area Additive Manufacturing for producing large scale composites – ground vehicle components, cars, bridges, wind mill blades etc..



Large Scale Additive Manufacturing

Extrusion-DepositionLarge scale BAAM

Willys Jeep

Aircraft trim tool Ground vehicle

LVAD Truck

Energy exchange: House & Jeep

© Material para uso exclusivo de los asistentes al 6to. Simposio y

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difusión, total o parcial, sin autorización expresa del autor o de B2B

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Leverage Computing Power to Enhance Design Confidence

Create Composites Virtual Factory HUB (cvfHUB)

Develop platform for hosting and integration of commercial software tools for composites

Provide end-to-end simulation for composites

Correlate at multiple scales prediction and reality

Make tools and knowledge available to entire value chain to enhance confidence and reduce cost

Implementation is underway, rollout commences mid-2017



Modeling and Simulation

© Material para uso exclusivo de los

asistentes al 6to. Simposio y

Exposición Manufactura de

Autopartes, Querétaro, México,

Agosto 22 a 24 de 2017. Prohibida su

reproducción, venta, comercialización

o difusión, total o parcial, sin

autorización expresa del autor o de

B2B Portales Inc. La información y

contenido gráfico incluido en esta

presentación es responsabilidad de

su autor.

Shared Joiningand Pretreatment

Area

Shared Joiningand Pretreatment

Area

4000 TSchuler Comp. Press

Installed 2Q 2017

Facility Refurb and Construction Started August 8, 2016

IACMI/LIFT VTA-SUF Facility Layout

Carbon Fiber Containment Area

Pre-Preg, Lay-upEtc.

Sample PrepWet Lab and Analysis

Area

3000 TMilacron Inj PressInstalled 4Q 2016

Confidential information-Do Not Distribute



National Capabilities-MichiganVehicle Scale Up Facility in Corktown, Detroit

• Co-located with LIFT, 9300 m2 total• Capitalization underway >$15M• Construction complete Q3/Q4 2017• Equipment coming online

Confidential information-Do Not Distribute



• Facility is shared by IACMI-The Composites Institute and LIFT Innovation Institute

IACMI-The Composites Institute Facilities, Vehicle Scale Up Facility in Corktown Area of Detroit, Michigan

• Co-located with LIFT, 9300 m2 total

• Capitalization underway >$15M

Compression Press

Schuler Press: 4000T, 3.7m x 2.4m platen

Thermosets & Thermoplastic

Infusion, compression

Injection Molding Cell

Milacron Press: 3000T, 3m x 2.4m platen

1-10kg shot size, 3 – 275kg dryers

Robotic handling© Material para uso exclusivo de los asistentes al 6to. Simposio y Exposición Manufactura de Autopartes, Querétaro, México, Agosto 22 a 24 de 2017. Prohibida su reproducción, venta, comercialización o


Workforce Training

STEM Events

Hands-On Events

Intern Program

Online Training (CCT)



Industry, Academia and Government Stakeholders

Building on Strong Partnerships

A partnership of world-class companies including: Top universities including:A partnership of outstanding

small and medium sized organizations including:



$70M - DOE

$189M - Other

123 - Member Consortium

6 Core Partner States

Strong Leadership

5 Technology Areas

Production capacity

Jobs

- 75%CFRP embodied energy savings

- 50%CFRPproduction cost

Greenhouse gas avoidance

- 25%

- 50%

- 50%- 75%

95%FRP recycled

and/or reused

80%

Federal Investment Will Catalyze a Composites Ecosystem in the Heart of US Manufacturing



8/28/2017 Confidential information statement (go to INSERT>>HEADER & FOOTER) 34

Contact info:

Uday Vaidya

Chief Technology Officer

IACMI-The Composites Institute, managed by Collaborative Composite

Solutions Corporation

Email: [email protected]

© Material para uso exclusivo de los asistentes al 6to. Simposio y Exposición Manufactura de

Autopartes, Querétaro, México, Agosto 22 a 24 de 2017. Prohibida su reproducción, venta,

comercialización o difusión, total o parcial, sin autorización expresa del autor o de B2B

Portales Inc. La información y contenido gráfico incluido en esta presentación es


mailto:[email protected]

IACMI The Composites Institute: Innovations in ... · PDF fileIACMI –A National...

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