Polymer Composites Research in the ALM Materials Program

27 February 2008

C. David (Dave) Warren

Field Technical Manager Transportation Composite Materials Research

Oak Ridge National LaboratoryP.O. Box 2009, M/S 8050

Oak Ridge, Tennessee 37831-8050Phone: 865-574-9693 Fax: 865-574-0740

Email: WarrenCD@ORNL.GOV

This presentation does not contain any proprietary or confidential information

ALM Historical Timeline – Composites

Fiber-Reinforced Polymer-Matrix

Composites Processing

Low-Cost Carbon Fiber

Joining

Nondestructive Testing

Crashworthi- ness

Recycling

1990 1995 2000 2005 2010

Carbon-fiber-reinforced

Glass-fiber-reinforced……

(FP1)

(FP1) ……

20082008 20102010 20122012 20142014

EMWG Composite Front Structure

Carbon Fiber SMC HoodComposite Underbody

Composite SeatPolymer Encapsulated Mega-Module

Low Cost Carbon Fiber

ACC Key DeliverablesACC Key Deliverables

DOE/ALM COMPOSITE MATERIALS RESEARCHAutomotive Research Program Organization

USCAR Program Coordination DOE/OFCVT

USAMP Program Management DOE/Materials

Field Technical Management ORNL

Materials Energy Management Processing Joining

Manufacturability Demonstration Projects

Car Platforms Automotive Suppliers

Materials

COMPOSITE MATERIALS RESEARCHWhat Was Done --- Glass Fiber Composites

Energy Management

SCAAPNHTSA Modeling Energy Management

Processing

P4 PreformingSlurry ModelingSlurry Processing

Materials

DurabilityDeformation & DegradationMaterials Screening

Joining

Adhesive BondingAdhesive Modeling NDT Rapid TestingNDT Laser ShearographyTest Method Analysis

Focal Project II

FreedomCar and BeyondGoals

Materials

Automotive Composites Consortium

Focal Project 2: Composite Pickup Truck Box

COMPOSITE MATERIALS RESEARCHWhat we were Doing --- Carbon Fiber Composites

Materials

FreedomCar &21Century Truck

Goals

Energy ManagementCrash Adsorp of Bonded Structures

Crash Energy Management (7)Testing Machine for Auto CrashCrash of Sandwich Structures

ProcessingP4 Carbon Fiber

High Vol Process of Composites (4)Next Generation P4Optimal CF for P4

Chassis Support StructuresChassis Structures

Body and Door Structures

MaterialsCF Comp Durability

Compressive Creep Materials Dev & Screening

Recycling PMCsCF SMC Structures

Development of CF SMC

JoiningAdvanced Joining

Joint Energy AbsorptionNDE Techniques

Heavy Vehicle Joining

Focal Project III

Low Cost Carbon FiberLignin Based PrecursorsMicrowave Processing

Carbon Fiber Two SplittingAdvanced Oxidation

Advanced StabilizatonLCCF Integration Line

OtherCost Modeling – ProgramComposites Conference

21st Century TruckAutomotive Lightweighting

Materials

ACC Focal Project III

Composite (Carbon) Intensive Body-In-WhiteVehicle package (based on DC JA)

P4 / Compression Molding

P4 / CompressionMolding

SMC with ribs

Compform / Nida-Core

P4 or Compform

P4 or SMC

P4 / Balsa Core

Materials

Phase 1 Results:67% mass savings over baselineBending stiffness exceeded 20%Torsional stiffness exceeded 140%Durability and abuse load cases satisfiedManufacturing strategy developed

Materials / Mass Distribution:Chopped carbon - 54.8 kgCarbon fabric - 17.7 kgCore - 3.2 kgAdhesive - 1.6 kgInserts - 8.8 kg

High-Volume Molding of Composites

Test Piece Design: Multi-Purpose B-Pillar Tool

Materials

COMPOSITE MATERIALS RESEARCH (2008)What we are Doing --- Carbon Fiber Composites

Materials

FreedomCar &21Century Truck

Goals

Energy ManagementCrash Adsorp of Bonded Structures

Crash Energy Management (7)Testing Machine for Auto Crash

ProcessingTPP4

High Vol Process of Composites(- CF SMC, Press, Inj Tools, etc)

Next Generation P4P4 Preforming

MaterialsNatural Fiber Composites

Recycling PMCsPredictive Modeling of PMCs

JoiningBond-line Read Through

Bonding of TPComposite Underbody

Focal Projects IV- Underbody- Comp Seat

Low Cost Carbon FiberLignin Based Precursors

Lignin PurificationAdvanced Oxidation

Advanced StabilizatonLCCF Integration Line

FSD of Textile PrecursorsHigher Performance Fibers

OtherCost Modeling – Program

Focal Project 3

Coordinated with Hydrogen ProgramCurrent

Previously BriefedBriefed NowBriefed Later

Focal Project 4 – Composite Underbody

Underbody rails

Ribs above and below the floor

Underbody rails

Bonded components

enable closed

sections

Ribbed Design Concept Bonded Design Concept

Ribbed Composite:Components: ~55% reductionReinforcements: ~17% reduction

Bonded Composite:Components: ~41% reductionReinforcements: ~17% reduction

Materials

SELECTED

Focal Project 4 - Composite Seat

• Structures Level– Back Frame and Cushion

Frame only– Carry-over Headrest

Design– Mechanisms and legs not

included (except as related to attachments and joints)

– Seat Integrated Restraint to be included.

• Materials Level– Thermoplastics and

Thermosets included– Glass reinforcement with

local carbon as required– Metal reinforcements

included.

Materials

Courtesy of:

Time Agreement Technical Presentation Briefing Presenter(s)Funding ($)

Low-Cost Carbon Fiber

10:20 – 12:00 Overview of Polymer Composites A

B

C

D

E

E

F

G

David Warren

Mark Smith

Don Vesey

Dave Warren

Don Vesey

Don Vesey

Mark Smith

Don Vesey

11131-1113012559

Predictive Modeling of Polymer Composites 1,203,000

ACC 040 P4 Preform 426,000

9223 Development of Next Generation P4 690,000

ACC 007 Focal Project 4 – Floor Pan (Composite Underbody) 644,000

ACC 115 High-Volume Processing of Composites 683,000

16313 Natural Fiber Composite Retting, Preform Manufacturing and Molding

400,000

ACC 100 Crash Energy Management 750,000

B Predictive Modeling of Polymer Composites C P4 PreformD Development of Next Generation P4E Focal Project 4 – Floor Pan (Composite Underbody)E High-Volume Processing of CompositesF Natural Fiber Composite Retting, Preform Manufacturing and MoldingG Crash Energy Management

CARBON FIBER – Research Efforts Materials