PULLING THE STATE OF THE ART FORWARD Pultrusion …€¦ · Hybride Hybrid composite constructions...

SCIENCE SECTOR

Composites

Renato Bezerra, M.Sc. Competence Day Pultrusion KraussMaffei

Munich, 28.06.2017

PULLING THE STATE OF THE ART FORWARDPultrusion at Fraunhofer IGCV

© Fraunhofer Research Institution for Casting, Composite and Processing Technology IGCV

The Fraunhofer-GesellschaftApplication-oriented research for the benefit of th e economy and society

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more than 70%contracts with industry,publicly financed research projects

almost 30%base funding byfederal and Ländergovernments

Res

earc

h vo

lum

e

2 bn

Con

trac

t res

earc

h

1.7 bnApproximately 24 000employees

68 institutes andresearch units

München

Holzkirchen

FreiburgFreising

Stuttgart

PfinztalKarlsruheSaarbrücken

Kaiserslautern

DarmstadtWürzburg

Erlangen

Nürnberg

Ilmenau

Schkopau

Teltow

Oberhausen

Duisburg

AachenSt. Augustin

Dortmund

PotsdamBerlin

Rostock

LübeckItzehoe

Braunschweig

Hannover

Bremen

Bremerhaven

Jena

Leipzig

Chemnitz

Dresden

CottbusMagdeburg

Halle

Fürth

Wachtberg

Ettlingen

Oldenburg

Kassel

GießenErfurt

Augsburg

Straubing

Bayreuth


The Fraunhofer-GesellschaftFields of Research

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Health and Environment

Communication and Knowledge

Production and Supply of Services

Mobility and Transport

Energy and Resources

Security and Protection


Possibilities for cooperationHow to cooperate with us?

� Individual project definition

� Short to medium-term contract research

� 3-year cooperation, FhGemployees work at the client on site

� Cooperation of partners from research and industry

� Medium and long-term research projects

� Complementary partners (e.g. user and supplier)

� Using the methods and competences

� Joint development of solutions in a low-competition environment

� Long-term projects

Bilateral industry projects and FhG model Joint industry projects

Publicly funded projects Industrial joint ventures

Contact us for more information about different funding possibilities/models of cooperation!

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Services Our range of services

Improving products and processesImproved performance | cost efficiency

Developing productsPrototypes | small batches | manufacturing processes

Consulting on innovationsMarket, trend and profitability analyses | feasibility studies

Introducing new technologiesFrom TRL 1 to product qualification

Providing licensesPreliminary research | transfer of inventions to licenses

Optimizing organizational formsIdentifying and realizing potentials | generating innovations

Characterizing and testingHigh-quality equipment | test reports and certificates

Qualifying for the futurePassing know-how to expert and executive staff | training

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Fraunhofer IGCVFacts and figures

� Established: July 01, 2016

� Management:

Prof. Dr.-Ing. Gunther Reinhart (executive)

Prof. Dr.-Ing. Klaus Drechsler

Prof. Dr.-Ing. Wolfram Volk

� Development objective: Advancing into an independent Fraunhofer institute

� Augsburg site – headquartersManagement, administration, fields of research: processing and composite technology

� Garching site:Field of research: casting technology

� Supported by:

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Fraunhofer IGCVWe use synergies in these fields of research and development:

Composite technology

Hybride Hybrid compositeconstructions

Online process monitoring

Materials and test engineering

CFRP manufacturing engineering

Recycling

Efficiency and balancing

Casting technology

Molding materials

Sand and gravity die casting processes

Simulation and design of mold and cast components

Processing technology

Resource efficiency in factories

Intelligent networked production

Flexible production

Networked modeling andsimulation

Additive manufacturing

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Core competenceCFRP manufacturing engineering

� Realization of near-net-shape, material-efficient and load path-optimized composite lightweight structures

� Industrialization concepts for the manufacturing of highly complex component geometries

� Multi-material usage

� Combination of different placement and process technologies

� Dry fiber placement and textile preforming processes

� AFP and automated tape placement (ATL – FiberForgeRELAY®) with thermoplast prepregs

� Pull braiding; pultrusion with injection process

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Core competenceCFRP manufacturing engineering – Pultrusion Technology

Facility portfolio – pultrusion

� Profile width up to 500 mm x 230 mm

� Max. drawing speed: 4 m/min

� Max. pull-off force: 10 t

� Caterpillar and alternating pullers

� Tool and process development for resin injection pultrusion with thermoset resins

� In-line braiding pultrusion and pullwinding (up to 4 layers)

� Complex geometries by combining downstream forming processes

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Pultrusion technologyProject BMBF PulForm

� Manufacturing of Complex Shape Composite Parts through the Combination of Pull-Braiding and Blow Moulding

� Feasibility demonstration of process chain and limits for part postforming


Pultrusion technologyProject ZIM SchwingPul

…Impregnation

� Enhanced impregnation using closed impregnation

� Improved impregnation especially of carbon fibers

…Fiber Package

� Homogeneous fiber/matrix distribution

� Reduction of inherent stresses

BA

� Using vibration in pultrusion processing to improve…


Pultrusion technologyMaterials characterization and processing simulation

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Resin rheology and reaction kinetics

Fiber reinforcement characterization

Analysis of processing conditions

0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 320

2

4

6

8

10

Thi

ckne

ss [m

m]

Width position [mm]

0 200 400 600 800 1000 1200 1400 16000.00

0.05

0.10

0.15

0.20

0.25

0.30 α profile surface α profile center

Deg

ree

of c

ure

x-position from die inlet [mm]

20

30

40

50

60

70

80

90

100

110

120 Profile surface TC Profile center TC Die control TC Die monitoring TC Profile surface simulation Profile center simulation Die temperature simulation

Tem

pera

ture

[°C

]

102

103

104

105

Viscosity

Vis

cosi

ty [m

Pa.

s]

0 20 40 60 80 100 120 140 160 180

10-1

100

101

102

103

104

105

106

107

No. 1 ZW 015864 100% wt.

No. 2 ZW 015864 88% wt. ZW 8117 12% wt.

No. 3 ZW 015864 76% wt. ZW 8117 24% wt.

No. 4 ZW 015864 64% wt. ZW 8117 36% wt.

Temperature

Time [min]

Mod

ulus

of v

isco

sity

[Pa.

s]

0

50

100

150

200

250

300

350

400

450

500

Tem

pera

ture

[°C

]


Pultrusion technologyContract research

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Materials selection• Resin formulation for processing • Resin system characterization• Fiber reinforcement

characterizationComposite design• Definition of fiber volume content• Definition of stacking sequence

Processing trials• Mold proving• Testing of different materials• Studies of processing conditions• Small batches

Tooling design• Conception of tools with closed

injection and impregnation• Retrofitting of existing tools

Testing and characterization• Testing of profiles• „Real-time“ characterization of

processing conditions

Industrialization• Concept for series production• Technology transfer to partner for

industrialization (e.g. KraussMaffei)


Pultrusion technologyWhat we can…

We can quick n‘ dirty

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We have „Fingerspitzengefühl“

We have man-power

… and accumulated expertise!


Thank you for your attention!

How to reach us

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ContactFraunhofer Research Institution for Casting, Composite and Processing Technology IGCVAm Technologiezentrum 2, 86159 Augsburg Phone +49 821 90678-247sebastian.strauss@igcv.fraunhofer.dewww.igcv.fraunhofer.de

The pultrusion team @ IGCVSebastian Strauß (Technology coordinator)Frederik WilhelmSimon SchwabHerbert Engelen (@ FhG-ICT)Renato Bezerra

PULLING THE STATE OF THE ART FORWARD Pultrusion …€¦ · Hybride Hybrid composite constructions...

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