Thermoplastic composites: Tomorrow is only a day away

Transcription

1 Thermoplastic composites: Tomorrow is only a day away Sirris/SLC-Lab Linde De Vriese, Project engineer

2 Thermoplastic composites: tomorrow or today? Impact Bumper (Audi AG, Krauss Maffei) Samsonite Bond Laminates Fokker Aerostructures Aerotec Inxide 19/06/2017 2

3 Thermoplastic composites Fast processing possible Typically tough, good impact resistance Recyclable, low VOC s Fatigue performance Post-forming, Welding Good fire/smoke/toxicity (FST) properties Infinite shelf life 19/06/2017 3

4 A hub for composite innovations Engineering, prototyping and testing lab Open initiative by KU Leuven, UGent and Sirris Create composite innovations for Material producers Composite part convertors Designers & OEMs

5 Influence on material properties Polymer material Interface, Fiber material Material properties Fiber volume fraction Fiber length Textile architecture 19/06/2017 5

6 Influence on material properties Polymer material Material properties Textile architecture Fiber material Fiber length Ultra Polymers High-Performance Polymers Engineering Polymers Commodity Polymers 19/06/2017 6

7 Influence on material properties Polymer material Material properties Fiber material Fiber length Textile architecture 19/06/2017 7

8 Influence on material properties Polymer material Material properties Fiber material Fiber length Textile architecture Source: J.L. Thomason & M.A. Vlug 19/06/2017 8

9 Influence on material properties Polymer material Drapability Fiber material Material properties Fiber length Textile architecture Mechanical performance 19/06/2017 9

10 Material properties Polymer material Material Volume Fraction Tensile Modulus [GPa] Tensile Strength [MPa] Material properties Textile architecture Fiber material Fiber length Long fiber LFT PP-GF 20 9,0 130 Nonwoven GMT - 3,3-8, Glass Fabric Glass/PET Glass UD Glass/PP tape Carbon Fabric Carbon/PA Carbon UD Carbon/PEEK tape /06/

11 Processing and porosity Porosity How to avoid porosity? a. Decrease viscosity: High processing temperature (>Tm) b. Decrease flow length 19/06/

12 High viscosity results generally in 2-step process Consolidation: decrease flow length Forming process 19/06/

13 Preconsolidated materials Pellets Organoblech * Tapes * Also known as organosheet, thermopreg, thermoplastic prepreg, 19/06/

14 Consolidation process for organoblech Continuous double belt press Static multiple daylight press 19/06/

15 High viscosity results generally in 2-step process Consolidation: decrease flow length Forming process 19/06/

16 Forming processes Press Forming Continuous Fibers Tape laying Pultrusion 19/06/

17 Forming processes Press Forming Continuous Fibers Tape laying Pultrusion 19/06/

18 Press forming See 19/06/

19 Today: Aerospace clips Trend in aerospace: out-of-autoclave production Small parts are commercial: Boeing 787: 10,000-15,000 clips Current developments: cost-effective larger parts Source: DTC composites 19/06/

20 Today: Samsonite suitcase See 19/06/

21 Process simulation of lamp shade Source: SLC-Lab / Aniform 19/06/

22 Forming processes Press Forming Continuous Fibers Tape laying Pultrusion 19/06/

23 Tape laying and pultrusion Reactive thermoplastic pultrusion Fokker industries CQFD Composites 19/06/

24 Today: tape laying of tubular structures Innovative spoolable pipes in the oil&gas industry - Airborne Pressure vessels Automated Dynamics 19/06/

25 Forming processes Hybrid Processes: Overmoulding Press Forming Continuous Fibers Tape laying Pultrusion 19/06/

26 Overmoulding technologies Consolidation Overmoulding Impregnation of glass tows Overmoulding Tape laying Overmoulding 19/06/

27 Today: Automotive seat shell Overmoulded glass-pa seat shell Opel Astra OPC Sportcoupe 45% weight saving from glass-filled PP 19/06/

28 Tomorrow: Process alternatives Vacuum consolidation in-situ polymerisation Source: JD C SLC-Lab Source: Engel 19/06/

29 Tomorrow: automated hybrid process See 19/06/

30 To conclude Today Proven production technology Fast production High toughness Function-integration Examples from consumer products to aerospace Tomorrow Automated hybrid processes Contact us! 19/06/

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