funktionsintegrierter leichtbau mit carbonfaser...

Funktionsintegrierter Leichtbau

mit Carbonfaser verstärkten

Thermoplastwerkstoffen

Dr. Andreas Erber | Werkstoff-Forum; Hannover Messe | 2015-04-15

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


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


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


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


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

http://2.bp.blogspot.com/-E_YsYD_SBX0/Tr_wT169JVI/AAAAAAAAA14/oquuJTAgJd4/s1600/i3-front-view.jpg


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


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


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%


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


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


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

//upload.wikimedia.org/wikipedia/commons/e/e8/Presse_f%C3%BCr_Kunststoffumformung.jpg


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


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


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


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


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)


Materials customized for Manufacturing

¼” Slit Tapes

50 mm Tapes

180 mm Tapes

Width of Sample Materials

Customized Width

Available


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


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


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


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


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

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