High Rate Response of Novel Fiberglass for Automotive Composites. Ryan Emerson, Ph.D.

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1 High Rate Response of Novel Fiberglass for Automotive Composites Ryan Emerson, Ph.D.

2 Overview Introduction Lit review Objective Materials Experiments Results Conclusions

3 Introduction: glass fiber reinforced plastics

4 Introduction: glass fiber reinforced plastics High specific strength and stiffness Low cost Global availability Body in white? Primary structure

3 Decades of crush tube studies The cylindrical Kevlar FRP tubes exhibited a different response with regard to stable collapse; for these

With tubes of high t/d ratio, the collapse tended to be unstable with one or two circumferential folds forming and progressing only to the

In all cases, there was no appreciable difference in the collapse response between the tubes of the (0/90).

5 3 Decades of crush tube studies The cylindrical Kevlar FRP tubes exhibited a different response with regard to stable collapse; for these tubes, stable, progressive buckling collapse was observed for the lower t/d ratio tubes only. With tubes of high t/d ratio, the collapse tended to be unstable with one or two circumferential folds forming and progressing only to the point that the sample would tilt, leading to unstable collapse. In all cases, there was no appreciable difference in the collapse response between the tubes of the (0/90). or the (45/45) lay-ups, except that the glass FRP tubes with the (45/45) lay-ups tended to disintegrate into larger pieces than those with the (0/90) lay-ups, for the same t/d ratio. P.H. Thornton and P.J. Edwards, Energy Absorption in Composite Tubes, Journal of Composite Materials : 521

6 Failure modes and fixturing Aaron Brighton, Mark Forrest, Mike Starbuck, Donald Erdman and Bronwyn Fox Strain Rate Effects on the Energy Absorption of Rapidly Manufactured Composite Tubes, J. Comp. Materials : 2183

7 Strain Rate Effects? Carbon fiber tubes exhibit decreasing SEA with crush speed Nathan D. Flesher et al., A dynamic crash model for energy absorption in braided composite materials, Journal of Composite Materials : 867 7

8 Hybridization effects on SEA Evidence that the best SEA is achieved by hybrid of glass and carbon composite Ma and Yan, "Quasi-static and Dynamic Experiment Investigations on the Crashworthiness Response of Composite Tubes," Polymer Composites, 34: , 2013.

9 Objective / Approach Determine the energy absorption value of novel fiber glass reinforcements A high-elongation fiber (HP) A high modulus fiber (XM) Use braided crush tubes to simulate crash loads and to achieve high strain rates

10 Materials / Samples Sample Bias Axial Wall thickness name Material Angle ( ) W B (%) Material W A (%) (mm) XM-E XM-E60 E-glass XM-glass XM-E XM-HP XM-HP60 HP-glass XM-glass XM-HP E-HP E-HP60 HP-glass E-glass E-HP E-E E-E60 E-glass E-glass E-E E-HP30-b E-HP60-b HP-glass E-glass E-HP75-b

11 Comparison 1 Sample Bias Axial Wall thickness name Material Angle ( ) W B (%) Material W A (%) (mm) XM-E XM-E60 E-glass XM-glass XM-E XM-HP XM-HP60 HP-glass XM-glass XM-HP E-HP E-HP60 HP-glass E-glass E-HP E-E E-E60 E-glass E-glass E-E E-HP30-b E-HP60-b HP-glass E-glass E-HP75-b

Comparison 2 Sample Bias Axial Wall thickness name Material Angle ( ) W B (%) Material W A (%) (mm) XM-E30 30 61.6 38.4 0.90 XM-E60 E-glass 60 58.2 XM-glass 41.8 0.89 XM-E75 75 57.3 42.7 0.

12 Comparison 2 Sample Bias Axial Wall thickness name Material Angle ( ) W B (%) Material W A (%) (mm) XM-E XM-E60 E-glass XM-glass XM-E XM-HP XM-HP60 HP-glass XM-glass XM-HP E-HP E-HP60 HP-glass E-glass E-HP E-E E-E60 E-glass E-glass E-E E-HP30-b E-HP60-b HP-glass E-glass E-HP75-b

13 Specimens / Fixturing R8.1 O-ring grooves

14 High Speed video of crush Material away from the tup is intact

15 Failure Mode, 30 samples Roll-over

16 Failure Modes, 60 and 75 samples combined & zipper

17 Results (Force-displacement)

18 Results (Energy Absorption)

19 Energy Absorption Results Sample Mode (# specimens) Average Energy Absorption Rate (J/mm) HP % Increase Over E-glass Equivalent XM % Increase Over E-glass Equivalent XM-E30 Roll-over (6) 2.61 ± XM-E60 Zipper (1) 2.60 ±NA -25 Combined (6) 3.34 ± XM-E75 Zipper (4) 2.68 ± Combined (3) 3.89 ± XM-HP30 Roll-over (7) 2.78 ± XM-HP60 Zipper (3) 3.36 ± Combined (4) 5.02 ± XM-HP75 Zipper (3) 3.10 ± Combined (3) 4.92 ± E-HP30 Roll-over (6) 3.11 ± E-HP60 Zipper (2) 3.53 ± Combined (5) 4.63 ± E-HP75 Zipper (3) 3.14 ± Combined (4) 5.12 ± E-E30 Roll-over (7) 2.12 ±0.13 E-E60 Zipper (4) 3.47 ±0.22 Combined (2) 3.78 ±0.11 E-E75 Zipper (4) 2.85 ±0.08 Combined (3) 4.04 ±0.17 E-HP30-b Roll-over (7) 2.00 ±0.14 E-HP60-b E-HP75-b NA NA NA NA

20 Rate Effects, 30-Deg Tubes

21 Rate Effects 60-Deg Tubes

22 Rate Effects 75-Deg Tubes

23 Conclusions HP-glass exhibits significant energy absorption value over E-glass, especially for combined failure mode XM-glass did not exhibit an energy absorption value in these braided samples Evidence that HP-glass is insensitive to strain rate

24 Thank you! Ryan Emerson, PhD Applications Development Group Leader PPG Fiber Glass S&T 940 Washburn Switch Rd Shelby, NC, Tel: , ext.2131 Mobile: Brandon Strohminger Materials Engineer A&P Technology

Energy absorption capability of low-cost composite materials

Energy absorption capability of low-cost composite materials Anders Sjögren SICOMP AB, P O Box 104, SE-431 22 Mölndal, Sweden Åke Nylinder Polytec Composites Sweden AB, P O Box 302, SE-341 26 Ljungby,