Funktionsintegrierter Leichtbau mit Carbonfaser verstärkten Thermoplastwerkstoffen. Dr. Andreas Erber Werkstoff-Forum; Hannover Messe

Transcription

1 Funktionsintegrierter Leichtbau mit Carbonfaser verstärkten Thermoplastwerkstoffen Dr. Andreas Erber Werkstoff-Forum; Hannover Messe

2 Company Profile. SGL Group One of the world s largest manufacturers of carbon-based products Comprehensive portfolio ranging from carbon and graphite products to carbon fibers and composites 43 production sites worldwide Sales of ~ 1.5 bn in 2013 Head office in Wiesbaden/Germany ~ 6,300 employees worldwide Listed on German Stock Exchange Service network covering more than 100 countries Page 2

3 Organizational structure Three Business Units & Joint Ventures Joint Ventures Performance Products (PP) Graphite Materials & Systems (GMS) Carbon Fibers & Composites Materials (CF/CM) Technology & Innovation (T&I) SGL Excellence (Six Sigma) Page 3

4 Business Unit Carbon Fibers & Composite Materials Unique offering of the complete value chain Materials SGL Group Core Competencies Components Joint Venture Partnering Raw Material Carbon Fiber Composite Materials Composite Components PAN Precursor Carbon Fiber Fabrics, Preform Prepreg Automotive Parts Fisipe S.A. (100%) MSP: JV with Mitsubishi Rayon (33%) Prod. Capacity ~ 4kt in UK ~ 2kt in USA SGL ACF (51%) JV with BMW ~ 9kt in USA SGL epo (100%) SGL Kümpers (51%) SGL ACF (51%) JV with BMW Benteler SGL (50%) Brembo SGL Carbon Ceramic Brakes (50%) Page 4

5 Agenda Status-Quo Carbon Composites in Automotive Applications Current Challenges of Materials and Processes Thermoplastic Composites Material System Design Approach & Process Technologies for Thermoplastic Composites Page 5

6 Today Lot Size History of CFRP Materials Vision 2030 Serial Production Small Series Super Sports Car Formula 1 Monocoque Manual Labor Monocoque Manual Labor Class A Carbon Semiautomatic Life Cell Automated Hybrid Design Automated for High Volume Page 6 Source: RedBull F1, Daimler AG, Audi AG, BMW AG

7 RTM Process Chain and its Challenges Materials Preforms Stacks RTM Finish 25 % 50 % 20 % 5 % Production of semi-finished materials cause material costs Infusion and polymerization time dominates RTM process Page 7

8 RTM Process Chain and its Challenges Materials Preforms Stacks RTM Finish 25 % 50 % 20 % 5 % Scrap rate of preforming is too high Complex process chain to build the preform Process robustness is too low Page 8

9 Lightweight Solutions Key for achieving global CO 2 emissions targets National and global regulations for selected segments Automotive - EU fleet targets Aerospace - CleanSky Actual: Target: ~ 130g CO 2 /km ~ 95g CO 2 /km Actual: ~ 622Mt CO 2 Target: ~ 310Mt CO 2 ~ 27% Railway - Deutsche Bahn Targets 2020 ~ 50% Maritime - Int. Maritime Organization Actual: ~ 7Mt CO 2 Target: ~ 6Mt CO 2 ~ 14% Actual: ~ 865Mt CO 2 Target: ~ 714Mt CO 2 ~ 17% Sources: AllianzProSchiene, DB AG, Reinf. Plastics Mag. 07/08-12; CleanSky, GBI Research; EU CAFE; IMO Page 9

10 Multi-material design concepts CFRP potential analysis Load path Design room Location of the component Challenges for multi-material design concepts Joining concepts Thermal expansion Assembly line integration Painting (KTL) Multi-material body Analysis of the body in order to identify components with high CFRP potential Source: Audi AG B-pillar: CFRP Insert for increased impact stability Page 10

11 Thermoplastic Materials can be the Enabler for High Volume Production Short Cycle Times Recycling Repair Concepts Hybrid Materials Hybrid Design - Injection Casting - Thermo Forming Welding Page 11 Transport at Room Temperature Unidirectional Tapes Organic Sheets Source: BMBF Project SpriForm, SGL

12 From Carbon Fiber to Thermoplastic Composites Spreaded Fibers Powderprepreg Pultrusion Solvent-Impregnation Dispersion-Impregnation Melt-Coated Prepreg Impregnation Process Tapes & Sheets Integrated Thermoplastic Composite Part Carbon Fiber with customized Sizing LFT Press Bumper Beam Hybrid Yarn Preform RTM Combination of different materials Preform Sources: Dieffenbacher, FhG ICT, Concordia Fibers Page 12 In-Situ Polymerization

13 Customized Sizing Solutions Advanced fiber/matrix interphase by customized sizing solutions Improved mechanical performance as received hot/wet conditioned Textile process ability compared to base-line systems HTT08 Type 3 210% Improvement of Fiber/Matrix Interphase EPY HTT01-2 HTT07 Base-Line 100% Type 1 176% Type 2 187% Values in boxes: Flexural Strength 90 Page 13

14 Industrialization of Thermoplastic Carbon Fibers Development and Industrialization Project Upscaling, Mechanical Characterization and Customer Sampling Processing and Spreading Trials Sizing Composition Production Sizing Formulation Laboratory Line Pilot Line Page 14

15 90 Bending Strength* [MPa] C-Fiber with Thermoplastic compatible Sizing Improved Mechanical Performance * Values based on PA6 Standard Sizing Customized Sizing for Thermoplastics Page 15

16 Impregnation Technologies for Tapes and Sheets Film Stacking Melt Impregnation Powder Impregnation Impregnation via Solvents Influence Process Costs Mechanical Properties Processability Fatigue Behavior Film Stacking Creel Filmsupply Melting/Impregnation Consolidation Slitting Creel Source: LCC, TU Munich Page 16

17 Manufacturing Technologies for UD-Tapes Automated Tape Laying Automated Fiber Placement FiberForge Technology Tape heating (optional) Incoming tape Consolidation roller Energy Consolidation pressure Laminate Heating area Crotch area Consolidated tape Direction of travel Tool Tool heating Heat Sources Open flame Hot gas torch Laser Infrared Hot Shoe Sources: Coriolis, LCC (TU Munich) Page 17

18 Materials customized for Manufacturing Width of Sample Materials ¼ Slit Tapes 50 mm Tapes 180 mm Tapes Customized Width Available Page 18

19 Organic Sheets and Molding Processes Blank holder LFT material feed Hydraulic needle for preform fixation Demonstrator Part Thermoforming Pre-forming spring die Thermoforming of Organic Sheets Back injection Molding to generate geometrical stiffness Sources: KraussMaffei, Rucks Page 19

20 2.5 cm 10 cm Braiding of UD-Tapes Set-up UD-slit tape with 5 mm width Conventional radial braider with 32 carrier Results Flexible braiding speed Variation in mandrel size Wide range of braiding angles Modify bobbins to improve quality Radial braider Braiding bobbin with tape Braiding point Radial braider with 32 tape bobbins Consolidated braided sleeve Detail of tape braided sleeve Page 20

21 Polyamide 6 UD-Tape Plain Woven Fabric Consolidated Organic-Sheet (5 layers/~2mm) Consolidated Single layer (~0,4mm) PA6 UD-Tapes slitted to a width of 18 mm Production on industrial type weaving machine (Dornier) Plain Woven Fabric High mechanical properties Improved Drapeability Page 21

22 Tension Reinforcement by UD-Tapes Processing of UD-tape and Injection Molding Exemplary design of UD-reinforced part Two metal inserts Circumferential UD-reinforcement Two-step injection molding of PA6 matrix Top view & Cross section of reinforced part Injection molded part Mechanical characterization UD-tape Matrix Single side structure Whole part Results Improved stiffness Improved tensile strength Page 22

23 Conclusion Carbon fiber reinforced thermoplastics are the enabler for mass production Thermoplastic composites as a material system Materials and automation systems have to be harmonized Multi-material design to approach cost-efficient applications Page 23

24 Thank you for your attention! Copyright SGL CARBON SE Registered trademarks of SGL CARBON SE