technologygy p p development for automotive composite …light-weight construction as an...

Technology Development for Automotive Compositegy p pPart Production - New Materials & Processes

10th Automotive and Composites Conference and Exhibition ACCE

15.-16. September 2010, MSU Education Center, Troy, MI, USA

Prof Dr -Ing Frank HenningProf. Dr.-Ing. Frank Henning

Fraunhofer ICTKIT

© Fraunhofer ICT

STRUCTURESTRUCTURE

Motivation

Introduction to KITe hyLITE

Technology corridors

Research and development fields

Expansion to Augsburg – Fraunhofer ICT-A

Summary

© Fraunhofer ICT

Motivation

Weight increase of typical medium-class vehicle since 1970

Implementation of EU regulationImplementation of EU regulation

Weight [k ] + 100 to 300 kg

Alternative drive train concepts:fuell cells, hybrid and

[kg] 100 to 300 kg

1400hybrid and E-propulsion

1200

+ 400 kg Reduction of consumprtion and emissions through lighter structures

1000 +50 % Improvement of passive and active safety and product attractiveness through functional design

Transfer of technologies production 800

1980 1985 1990 1995 2000 20052010

Transfer of technologies, production processes and products into ecologically-viable small and large series

© Fraunhofer ICT

Multi-material design (MMD)

Intelligent combination of different materials (MMD): “Join the best”

Material substitution no longer

Innovativesteels

high

Material substitution no longer effective → holistic approaches needed

S i bl j i i h l i eigh

t Light-weight metals

Suitable joining technologies or intelligent intrinsic hybridization needed

We

Carbon fiber

compositesMulti Material

design

highlow

low

Production costs

© Fraunhofer ICT

KITe hyLITE – Interdisciplinary, holistic approach

Holistic consideration of materials, production processes and methods leads to new construction methods in multi-material design

Methods

MM construction

Production Materials

© Fraunhofer ICT

Research network KITe hyLITE

Innovation cluster on technologies for hybrid light-weight construction

A network initiative led by the Fraunhofer-GesellschaftA network initiative led by the Fraunhofer Gesellschaft

Fraunhofer InstitutesFraunhofer ICT Pfinztal

HESSEN

RHEINLAND- Heidelberg

Ludwigshafen

DA(Darmstadt) HESSEN

RHEINLAND- Heidelberg

Ludwigshafen

DA(Darmstadt)

Fraunhofer ICT, PfinztalFraunhofer IWM, FreiburgFraunhofer LBF, Darmstadt

FRANKREICH

PFALZ

Schwäbisch-StuttgartAalen

LudwigsburgHeilbronn

BruchsalNeckarsulm

Heidelberg

KA(Karlsruhe)

BAYERN

FRANKREICH

PFALZ

Sch äbisch-StuttgartAalen

LudwigsburgHeilbronn

BruchsalNeckarsulm

Heidelberg

KA(Karlsruhe)

Institutes of the KITFAST iwk I

FRANKREICH GmündBöblingen

DußlingenOffen-burg

Haslach

Uhingen

Bötz-ingen

FRANKREICHwGmünd

Böblingen

DußlingenOffen-burg

Haslach

Uhingen

Bötz-ingen

ipek wbk

Industrial partners SCHWEIZ

Friedrichshafen

FR(Freiburg)

SCHWEIZ

Friedrichshafen

FR(Freiburg)

Industrial partnersVehicle manufacturers, supply companies, material manufacturers, die and mould producers, process manufacturers

© Fraunhofer ICT

Karlsruhe Institute of Technology –I tit t f V hi l S t T h l (FAST)Institute for Vehicle System Technology (FAST)

Vehicle system technology

Ease of useEnergy efficiency

Safety

Vehicle system technology

Costs

Private and utility vehiclesProf. Dr. rer. nat. Frank Gauterin

y

Mobile machinesProf. Dr.-Ing. Marcus Geimer

Rail vehiclesProf. Dr.-Ing. Peter Gratzfeld

Light-weight designProf. Dr.-Ing. Frank Henning

© Fraunhofer ICT

Light-weight construction as an interdisciplinary challenge

Transferring a holistic approach to mass production requires competences across the entire value chain

ArchitectureDesign

Material technology

Component manufacture

Bonding, joining

technology

TestingVerification

Use

Light-weight t t

Integration of f ti

Modelling ManufacturingReliabilitystrategy functions Simulation ProcessesReliability

© Fraunhofer ICT

Composite technologies

METHODS – PRODUCTION – MATERIALS

Long-fiber-reinforced thermoplastics

Thermosetting sheet molding compound

UD-fiber structures Metal inlays

zatio

npi

c le

vel)

Thermoplastic & thermo-setting RTM processes

Fiber-reinforced polyurethanes

Composite technologiesTextile reinforcements Foams

ybrid

izac

rosc

op local functionalization

Hy

(m

Automated, high-volume production chains

© Fraunhofer ICT

Press system facilities and equipmentM ld i d t h lMold carriers and press technology

Kannegiesser mold carrier Dieffenbacher Dieffenbacher COMPRESS PLUS

Clamping force 600 kNPress table 1200 x 1200 mmMaximum component size

Clamping force 3.600 kNPress table 1200 x 1500 mmMaximum component size

Clamping force 36.000 kNPress table 2900 x 2100 mmMaximum component sizeMaximum component size

RTM approx. 700 x 600 mmpivotale mold carrier

Maximum component sizeRTM approx. 1000 x 1400 mmHandling system

Maximum component sizeRTM approx. 2.800 x 2.000 mmHandling system

© Fraunhofer ICT



Thermoset sheet molding compound

Thermoplastic & thermosetting RTM process

Fiber-reinforced polyurethane

Long-fiber-reinforced thermoplastic

A t t d hi h l d ti h i



© Fraunhofer ICT

Long-fiber-reinforced thermoplastics (LFT)P d i d t i l d l tProcess design and material development

Reinforcing fibers:Glass fibersNatural fibers (hemp flax etc )IL compounder Natural fibers (hemp, flax etc.)Carbon fibersMan-made polymer fibers, e.g. rayon, polyester etc.

Mixing extruder

g y p y

Matrix resins:PolypropylenePA 6 PA 6 6 etc

Press

LFT plastificate

PA 6, PA 6.6 etc.PET, PPSABS, SAN etc.PC p

Compression moldingBlends

© Fraunhofer ICT

Tailored LFTP d iProcess design

Load-bearing structure d f ti LFT made of continuous

fiber roving

F b i

PressLFTplastificate

Filament

Fabric reinforcement

LFT for functional integration

Filament wound structures Automation unit

Textile reinforcement Reinforcement with UD fibers

Filament wound reinforcement

© Fraunhofer ICT

Continuous-fiber impregnation

Manufacturing of impregnated and calibrated continuous thermoplastic fiber structures

I ti it M f t d iP fil lib tiImpregnation unit Manufactured specimensProfile calibration

10µm

Simulation of the temperature during the calibration processp g p

The surface quality is mainly affected by

th t t filthe temperature profile

the surface of the calibration die

© Fraunhofer ICT

Structural and process simulation

Form filling analysisAcquisition of process data

Part designSupport in design of composite parts

P ti fAcquisition of rheological material parametersMold filling analysis

Validation of part geometry using FE methodsConsulting services in mold design

Properties ofsolid parts

Optimization of press cycle parameters

Mold filling simulationsimulation

Parameter of composite meltcomposite melt

Material modelling Properties of

solid parts

© Fraunhofer ICT

Sheet molding compoundP biliti t th F h f ICTProcess capabilities at the Fraunhofer ICT

Weighing of resin, fillers and additivesPaste mixingSMC processing fillers and additives

filler

gSMC processing

Automated

Press

Automated handling

Maturation

SMC coilTime, temperature

© Fraunhofer ICT

SMC – Direct molding technologyP d iProcess design

Gravimetric dosing of liquid components Extruder

Press

Compounder

Fiber glass

Sidefeeder for fillers

Automated handlingComponent

© Fraunhofer ICT

Research and development – future strategies f hi h l PU S i t h l ifor high-volume PU Spraying technologies

MaterialsPolyols based on natural resourcesFire and flame retardantsIn-mold coating and paintable surfacesIn mold coating and paintable surfacesTailoring of materials

ProductionP t t il i i ti fibPart tailoring using continuous fibersSandwich technologiesFiller convertingProcess combination with fiber spraying and pultrusion

MethodsMaterial characterizationMaterial characterizationSandwich simulation and testingPart design suitable for series production

© Fraunhofer ICT

Polyurethane fibre sprayingP d iProcess design

Press

Cutting unit

Simultaneous deposition of PU and fibers

Spraying depositionFibers for reinforcement(rovings) Open cavity(rovings) p y

Robot

© Fraunhofer ICT

Sandwich structures

Manufacturing and evaluation of sandwich structures with different core materials and outer layers with improvised fire- and flame-retardancy

Source: DLR Source: ICT

Source: ICT

Source: DLRSource: ICT

© Fraunhofer ICT

Continuous fibers in the PU fiber spraying process

Manufacture of load-optimized PUR components using continuous fibers in a PUR fiber spraying process

Source: wbk, ICT

Results of the continuous-fiber placement

Source: wbk, ICT

Source: wbk, ICTSource: wbk, ICT Source: Bombardier

© Fraunhofer ICT

Thermoset RTMDevelopment focus

Development of new RTM process variants e.g. Compression p p g pRTM / Advanced RTM, Core expansion RTMAlternative curing technology development for thermosetresins e.g. microwave assisted curing (Curing on Demand)Materials formulation development and testingMaterials formulation development for accelerated curing using microwaves

d d ff ld dPrototype component production using different moulds and testing

RTM equipment with heating cabin

Prototype mouldFunctions integrated seat post developed in core expansion RTM

© Fraunhofer ICT

Development of Compression RTM process

Process schematic

RTM Presse

Harz Härter

Advantages of the process:Strong reduction of the impregnation time in the RTM process by applying high

i h i i j d f fcompressive pressure on the resin injected on preform surface

High surface quality

High mechanical properties (through high fibre volume content)g p p g g

Selection of the high reactive resins with curing time less than 5 min

© Fraunhofer ICT

Development of Two-step RTM-Process

Process schematic

RTM Presse

Harz Härter

Advantages of the process

Separation of impregnation and curing steps in the RTM process for high volume production

Serial impregnation and preheating of the preforms as well as the precuring of Serial impregnation and preheating of the preforms as well as the precuring of the resin

Final curing of the RTM parts in the mould for a short time

© Fraunhofer ICT

Two-step RTM process

Application of microwave technology (300 MHz to 300 GHz) for homogeneous heating and accelerated 300 GHz) for homogeneous heating and accelerated curing reaction for RTM resins

Modification of resin systems for optimized absorption of microwaves for accelerated curing g

Development of microwave process for its adaption to serial production

Microwave antenna

© Fraunhofer ICT

Schematic of High Pressure Injection RTM Process

RTM Presse

Advantages of the processg p

Injection of the resin under high pressure (60-100 bar) to reduce the impregnation time significantly

R d ti f id t t i th RTM t d t hi h i j tiReduction of void content in the RTM parts due to high pressure injection

Robust, highly automated and high volume production capable process chain

© Fraunhofer ICT

Research Areas

Mould technology

Development of mould concept allowing high pressure injection of resin without di l t f i f i fibdisplacement of reinforcing fibres

Cascade injection technique

Evaluation of multiple point injection technique (cascade injection technology) to offer quick impregnation and optimized impregnation time

Process-property relationship

Determination of effect of injection pressure on the void content in the RTM parts surface quality and mechanical propertiesparts, surface quality and mechanical properties

Simulation

Simulation of the impregnation process in the High Pressure RTM

© Fraunhofer ICT

RTM Process cycle

Preform production and fixing Preform handlingand fixing

Mold technologyHandling semi-finished product

Product infiltration and curing

Harz Härter

Fixing 2D-semifinished fabric product

product

Component demolding and end processing

fabric product

Textile product

Semi-finished fabric cuts 2-D and end processing

RTM componentMold cleaningp

Start of cycle End of cycle

g

© Fraunhofer ICT

Handling technologies for the RTM process

Ice gripper

Needle gripper

g pp

© Fraunhofer ICT

Preform manufacturing technologies for the RTM process

Present competences Future strategy

Manual preform production

Spray binder

Automated preforming station

Development of the „chemical stitching“ process for preforming and handling of textile

Binder flies

process for preforming and handling of textile structures

In cooperation with the

© Fraunhofer ICT

T-RTM – Potential of cast polyamideAd tAdvantages

In situ polymerisation of ε Caprolactame to In-situ polymerisation of ε-Caprolactame to PA6 in the presence of textile fiber reinforcements

RTM-parts made of PA 6 matrixwith excellent impact behaviour

Low cycle times of approx. 3 minutesy pp

Very low melt viscosity(5mPas at 110°C and 150°C)

i h iff d hHigh stiffness and strength

Low wall thickness and at the same time high fiber content possibleg p

Matrix resin max. 2,- €/kg (plus reinforcing textile structures)

© Fraunhofer ICT

Process development InSitu Inject

Construction of a prototype unit for the reactive processing of cast polyamide in an injection molding unit

Process design Development of components Prototype development

Specimen validation

Transfer to series production

© Fraunhofer ICT

Development & synergies in the CFRP-research and -technology

DLR-ZLP Augsburg FhG FIL AugsburgDLRStuttgart

AerospaceAutomotive and

Mechanical engineeringFhG ICTPfinztal

H b id t ti ( t l CFRP)CFRP-DesignCFRP-Manufact.Joining Techn.Crash – ImpactQA Testing

Cooperating robot systemsNew robot configurationsRobotic-based CFRP-Production methodsMechatronical handling systemsProduction integrated test techniques

Hybrid construction (metal – CFRP)Pultrusion and Fiber PlacementCuring methodsInjection- / Consolidation processesProcess monitoringRecycling

CFRP-ProcessesMicrowaveMetal - CFRPNanotechnologyPolymers

DLROb.pfaffen- IWB / FHG

QA - Testing Recycling PolymersFoams

phofen Augsburg

RoboticMechatronics Automation

Mechatronics

TU München LCCUni Stuttgart

IFBITCF

Denkendorf

Fiber developmentPrecursorFiber manufacturingprocesses

Process simulationsMaterialsModeling of materialsDesign to Process

Preforming (textile engineering)Material characterizationMoulding

Preform processesSimulationSandwichDesign

© Fraunhofer ICT

Partners and axis of technologies for composites„CFRP-South“

Focusing of competences and innovation cluster

Karlsruher Institut für

Universität Stuttgart

Karlsruher Institut fürTechnologie KIT-

FAST

Universität StuttgartIFB, IKT; DLR-IBK

ITCF

Audi

FiberforgeFhG-ICT

SGL CarbonEurocopter

BMW

Universität Augsburg, AMUDLR-ZLP

CCeVCoriolis

Diehl AircabinGE Global Research

GKN Aerospace

TU MünchenLCC, IWB

FhG-FIL / RMVFH Augsburg

KUKAmanroland

MT AerospacePremium AEROTEC

Diehl Aircabin

EADSEurocopterQuickstep

p

Industrie

Forschung Karte: Google Maps

© Fraunhofer ICT

p

Project Group „Functional Lightweight Design“

Planned research topics

„Funktionsintegrierter Leichtbau“:Realisierung durch den Aufbau & Vernetzung verschiedener

Themenschwerpunkte

„Functional Lightweight Design“:Realization through establishment & networking

of different main topicsp

TS 1Bauweisen für Hochleistungs-

faserverbundwerkstoffe

TS 2Werkstoff- und Bauteil-

eigenschaften

of different main topics

TS1

Design for highperformance

TS2

Material and componentpropertieseigenschaftenperformance

composites properties

TS 3Modulare Fibre

Placement-Technologien

TS 4Alternative, schnelle

und energie-effiziente

Härteverfahren

TS 5On-line Injektions-

undKonsolidierungs-

verfahren

TS 6Intelligente Misch-

bauweisen(CFK-Metallhybrid-

strukturen)

TS 7On-line

Prozessmonitoring

TS 8Recycling

TS 3

Modular FiberPlacement

Technologies

TS 4

Alternative, fastand energy-efficient

curing methods

TS 5

On-line Injectionand Consolidation

Processes

TS 6

Intelligent HybridConstructions(CFRP – metal)

TS 7

On-lineProcess monitoring

TS 8

Recycling

Härteverfahren verfahren strukturen)

© Fraunhofer ICT

Project Group “Functional Lightweight Design”O tOur partners

Carbon Composites e.V.&

IHK Schwaben

Regional and nationalmachinery industry

Raw and intermediate

Project Groupl h hFraunhofer ICT

Automotive industry material producers

Industrial Partners

U i ität St tt t“ Functional Lightweight Design“Fraunhofer ICT

KIT-Karlsruhe Research partners

Universität Stuttgart

DLR St tt t

Technical University

Institute of Technology Research partners DLR Stuttgart

ZLP AugsburgUniversity of Augsburg

yMunich (TUM)

ZLP Augsburg

© Fraunhofer ICT

Project Group “Functional Lightweight Design”O tOur partners

a u ner an

n

er

enat

o B

ezer

ra

azi

hat

zig

eorg

iou

ob

ert

Gra

up

n

nd

rea

Ho

hm

a

Ach

im D

anko

Mat

thia

s H

eid

l

Re La C Ro

AnA M

Prof. Dr.-Ing. Klaus Drechsler

Prof. Dr.-Ing. Frank Henning

eira

da

eho

rsch

mit

t

ner

ing

An

a N

og

ue

Silv

a

Rei

nh

ard

Se

Stef

an S

chm

Hei

ke W

ag

Jutt

a W

eih

i

© Fraunhofer ICT

Project Group “Functional Lightweight Design”F h f b ildi k fiFraunhofer new building: key figures

Number of employees (projection 2013) approx. 50 – 55

Technical area for large machinery: approx. 750 m²

Laboratory area: approx. 600 m²

Storage area: approx. 350 m²

Office area / other: approx 860 m²Office area / other: approx. 860 m²

© Fraunhofer ICT

Project Group “Functional Lightweight Design”C t j tCurrent projects

Design for high-performance compositesIHK Innovation Project

“Functional lightweight shafts for machine manufacturing“

Alternative, fast and energy-efficient curing processesEnergy-efficient manufacturing fluid transfer heatingEnergy efficient manufacturing fluid transfer heating

On-line injection and consolidation processesO e ject o a d co so dat o p ocessesPultrusion technology – Key Investment ICT-A 2009

[Pultrusion Industry Council]

Modular fiber placement technologiesProcess chain for a flexible, intelligent tow-placement technology

© Fraunhofer ICT

Pultrusion

High continuous fiber content, production of high-performance

it ibl

1. Guiding & preforming of reinforcing materials (glass and/or carbon, mats

d f b i l ibl ) di composites possible

High productivity, low operational costs

and fabrics are also possible) according to profile shape

2. Impregnation with resin (polyester, vinyl ester epoxy polyurethane)Suitable for production of non-

complex profiles

vinyl ester, epoxy, polyurethane)

3. Pulling through heated forming die, where the matrix cures

l h f f l

Roving Rack

Mat / veil support stand

Guiding plates Pendant control

4. Cutting-to-length of profile

Pultrusion DiePulling Unit Cut-off Saw

Resin Bath

© Fraunhofer ICT

PultrusionD l t fDevelopment focus

Reaction Injection Pultrusion of thermoset (polyurethanes) and thermoplastic (ε-Caprolactame to PA6) matrices

Pultrusion of profiles with natural-fiber reinforcement

Application of microwave techniquespp q

Inline braiding

Joining with adjacent structural parts

Metering and mixingEquipment

Resin system Component B

Resin system Component A

Mixing head

Die for Resin Injection, Impregnation and curing

Pultruded profiles Reaction injection pultrusion (RIP)

© Fraunhofer ICT

Advanced ATL - Fiberforge Manufacturing Process

1. High-speed layup of thermoplastic prepreg bands by the Relay Station™ Station → 2D multilayer semi-finished part

2. Consolidation of the 2D semi-finished part

3. Warming of part and subsequent

4. Thermoforming process

5 Finishing: cutting painting etc5. Finishing: cutting, painting, etc.

→ High level of automationCycle time (steps 1 - 4): approx. 3 min

Applications

Helmets, seat shells, spare wheel housing, bicycle frames, truck cover panels

© Fraunhofer ICT

AFP – Automated fiber placement

Robot-based machine

Small-sized compact deposition Small sized, compact deposition head

Flexible capabilities

Processing of diverse materials (glass and carbon fibers)

Processing of prepregs and Processing of prepregs and powdered tows or binder yarns

Deposition on sandwich core materialsmaterials

→ Highly complex 3D geometries feasible

Above: Fiber-placement machine from Coriolis;

Below: Typical fiber-placement part

© Fraunhofer ICT

Summary

Strategy

Providing and developing advanced composite technologies with a focus on medium and large scale production suitable for the Automotive industry

MaterialsPhysical Modification of Polymers

and large scale production suitable for the Automotive industry

y yChemical Modification of PolymersCombination of suitable competitive materialsTailoring of materialsg

ProductionHighly automated composite technologiesProcess optimizationProcess optimizationIntegrated process controlling and on-line process monitoring

MethodsM t i l h t i ti d d l t f t i l d l f i l tiMaterial characterization and development of material models for simulationMaterial and production simulation CAE/CAxPart design and structure simulation

© Fraunhofer ICT

technologygy p p development for automotive composite …light-weight construction as an...

Documents