High Volume Manufacturing of Composites June 2014 Tobias Potyra Fraunhofer Project Centre @ Western [email protected] Motivation Motivation for Light-weight design Weight + 100 Alternative drive [kg] train concepts: 1400 fuel cells, hybrid and E-propulsion 1200 1000 to 300 kg + 400 kg +50 % 800 1980198519901995 2000 2005 2010 • Weight increase of typical medium-class vehicle since 1970. • Implementation of CAFE regulation. • Reduction of consumption and emissions through lighter structures. • Improvement of passive and active safety and product attractiveness through functional design. • For commercial vehicles: increased payload. • Lightweight design requires quality controlled, high-volume manufacturing processes for composites. Lightweight Potential of Composites Characteristics of Composite Materials Advantages of Composites Disadvantages of composites • Low density • High weight-specific strength and stiffness • Good damping • Very good failure behavior • Anisotropic properties • Mostly lower temperature resistant than metals • Particular knowledge required for proper design • Higher effort for quality assurance • Oftentimes high material cost • Very low thermal expansion parallel to fibers • More difficult to realize automation • Dependent on application: • Not yet established industrial processes – Low thermal conductivity – Low electric conductivity • Very good corrosion resistance Overcoming the shortcomings by Transferring a holistic approach to mass production requires competences across the entire value chain Architecture Design Material technology Light-weight strategy Component manufacture Integration of functions Bonding, joining technology Modelling Simulation Testing Verification Manufacturing Processes Reliability Use Overcoming the shortcomings by Holistic consideration of materials, production processes and methods leads to new construction methods in multi-material design Methods Multi material design Production Materials Manufacturing Technologies METHODS – PRODUCTION – MATERIALS Long-fiber reinforced thermosets (SMC + PUR) High Performance Composites RTM/ HP RTM Long-fiber reinforced thermoplastics (LFT) CAx methods for light weight multi-material design Composite technologies Automated, high-volume production chains House of Production Successful Part Production Economics Internal / External Knowledge Design Selection of the Manufacturing Process Material Selection Part Requirements / Specification / VOC House of Production with incomplete pillar Fraunhofer Project Centre for Composites Research at Western University FPC @ Western A joint venture between: Western University, London, Ontario, Canada And Fraunhofer Gesellschaft, Munich, Germany & Institute for Chemical Technology (ICT), Pfinztal, Germany Contact: tobi[email protected] www.eng.uwo.ca/fraunhofer Twin Regions Joint Expertise for Local Demands Both entities, being situated in the heart of automotive areas will jointly work on composite technologies adapted to the local demands of each region’s industry. The activities of both research entities will utilize and increase the expertise to accelerate composite innovations as lightweight solutions. Transatlantic Cooperation Applied Research with Industry Bridging the gap in the knowledge chain. Realization of industrial processes Application of developed innovative processes Optimization of existing processes and materials collaboration with industry Realization of industrial processes Application of developed innovative processes Optimization of existing processes and materials collaboration with [email protected] Basic research on fiber matrix phenomena Simulation and Design Investigation of fundamental interests collaboration With universities Benefits of collaborating with FPC Research and Development goals are addressed in a holistic way so that solutions take the whole value chain into account from the first idea over material development to manufacturing issues up to the final part and the application of the part Material Process Methods Part Applied Research in Industrial Scale Technological Highlights at FPC • Full industrial scale shop floor capable for carbon fiber composites • Globally first LFT-D line for processing of carbon fibers • Globally first HP RTM line for processing of unsaturated polyester resins, epoxy resins and polyurethane resins • Globally first injection moulding machine for direct heating and comoulding of local reinforcements with foamed polymers • North America‘s first Direct SMC line Thank you very much for your attention!