Perspektiven und Trends im Leichtbau mit Faserverbundwerkstoffen für das Automobil

Transcription

1 Perspektiven und Trends im Leichtbau mit Faserverbundwerkstoffen für das Automobil Aus Sicht der Forschung Professor Dr.-Ing. Volker Altstädt, Dr.-Ing. Thomas Neumeyer WT Wissenschaftstag der Europäischen Metropolregion Nürnberg Bayreuth, 22. Juli 2016 Neue Materialien Bayreuth GmbH / Professor Dr.-Ing. V. Altstädt /

2 INTRODUCTION Megatrend Growing Society Rising life expectancy (in years) Declining child mortality (in Mio.) Less hungry people (in Mio.) Better access to drinking water (in %) 1, / 2 /

3 INTRODUCTION Air Pollution is Becoming Serious Dicke Luft wenn Städte ersticken, ARTE, , 20:15 Uhr / 3 /

4 INTRODUCTION Alternatives are Possible Far-UK.com Carbon fibre frame 70% lighter compared to equivalent steel structure / 4 /

5 INTRODUCTION Kraftfahrzeugbundesamt 2016 Automotive Body-Frame Share by Material* * Existing vehicle stock in Germany 2015 / 5 /

6 MOTIVATION Profitability / 6 /

7 STATE OF THE ART BMW Group BMW i3: CFRPs enter Automotive Serial Production... / 7 /

8 STATE OF THE ART Pictures: BMW Group BMW i3: CFRPs enter Automotive Serial Production... Life-Modul CFRP Bodywork: 40% lighter than aluminum 60% lighter than steel Drive-Modul / 8 /

9 STATE OF THE ART Life-Modul: Structural Elements J. Starke (BMW Group), AVK conference, 2014 Individual parts are joined by gluing. / 9 /

10 STATE OF THE ART RTM Processing Limited Quantities Pictures: R. Chaudhari, Fraunhofer ICT, International AVK Conference, 2012 High pressure RTM: Insertion of Preform Resin injection and curing Demolding Insertion of preform Injection of resin Curing time Demolding and mold cleaning Total 0.5 min 0.5 min 2 min 0.5 min 3.5 min Cycle time limits production quantities to app to cars per year. / 10 /

11 THERMOPLASTIC COMPOSITES Reduce the Cycle Time! Pictures: BMW Group, BASF SE Thermosets Thermoplastics Cycle time: 3.5 min Cycle time: 90 s / 11 /

12 THERMOPLASTIC COMPOSITES Status Quo Acc. to: M. Schemme, FH Rosenheim Injection molding Pressing Unidirectional Mechanical properties Material cost Unfilled Short fibre Long fibre Mat Fabric Quasi Relative fibre length l/d / 12 /

13 THERMOPLASTIC COMPOSITES Acc. to: M. Schemme, FH Rosenheim Status Quo Mechanical properties Material cost Unidirectional Fabric Performance Short fibre Unfilled 0 / 13 / Mat Functional integration Long fibre Relative fibre length l/d Quasi

14 PROCESSING OF UD-TAPES Our Approach: Processing Chain for UD-Tapes Thermoplastic UD-Tape 2D Lay up Pre-consolidation and trimming Function integrated part Compression and Injection Molding From UD-tape to function-integrated part: short cycle times at industrial scale / 14 /

15 THERMOPLASTIC COMPOSITES Pictures: Lange & Ritter, BASF Not everything that looks like carbon is carbon... Impregnation For automotive applications glass fibres are predominantly impregnated with black stained polymers. / 16 /

16 SUSTAINABILITY Ref: ProBas - Umweltbundesamt CO 2 -Emissions during material production 3 CO 2 10 Kg / ton 35* 12 *CO 2 äquiv Timber Concrete ALU secondary Glas Steel PP PA % GF CFK waterpower* ALU primary CFK regular* / 17 /

17 SUSTAINABILITY Ref: ProBas - Umweltbundesamt CO 2 -Emissions during material production 12 3 CO 2 10 Kg / ton 35* 25 53* 3 CO 2 10 Kg / m 3 *CO 2 äquiv Timber Concrete ALU secondary Glas Steel PP PA % GF CFK waterpower* ALU primary CFK regular* / 18 /

18 SUSTAINABILITY OEMs start to think differently Ref.: The VERGE, April 6 th, 2016 Toyota s SETSUNA is an amazing wooden concept car designed to last generations / 19 /

19 VISIONS Individualization by Additive Manufacturing / 21 /

20 WT16 LEICHTBAU MIT FVK Thank you! Professor Dr.-Ing. Volker Altstädt Head of Department of Polymer Engineering University of Bayreuth Dr.-Ing. Thomas Neumeyer Head of Division Plastics Neue Materialien Bayreuth GmbH CEO Neue Materialien Bayreuth GmbH / 22 /