High Volume Composite Production Challenges and Technological Solutions. Dr. A. Erber 15. LIGHTer International Conference Gothenburg;

Transcription

1 High Volume Composite Production Challenges and Technological Solutions Dr. A. Erber 15. LIGHTer International Conference Gothenburg;

2 Company profile. SGL Group One of the world s largest manufacturers Sales of ~ 1.3 bn in 2014 of carbon-based products Head office in Wiesbaden/Germany Comprehensive portfolio ranging from carbon and graphite products to carbon ~ 6,300 employees worldwide fibers and composites Listed on SDAX 42 production sites worldwide Service network covering more than 100 countries Page 2 Dr. A. Erber LIGHTer International Conference

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 Dr. A. Erber LIGHTer International Conference

4 High Volume Composite Production Agenda Motivation and State-of-the-Art Design concepts and global supply chain Comprehensive Material Systems for Automation Network Approach to address R&D challenges Page 4 Dr. A. Erber LIGHTer International Conference

5 Lightweight Solutions Key for achieving global CO 2 emissions targets National and global regulations for selected segments Automotive - EU fleet targets Aerospace - CleanSky Actual: ~ 130g CO 2 /km Target: ~ 95g CO 2 /km Actual: ~ 622Mt CO 2 Target: ~ 310Mt CO 2 Railway - Deutsche Bahn ~ 27% ~ 50% Targets 2020 Maritime - Int. Maritime Organization Actual: ~ 7Mt CO 2 Target: ~ 6Mt CO 2 Actual: ~ 865Mt CO 2 Target: ~ 714Mt CO 2 ~ 14% ~ 17% Page 5 Dr. A. Erber LIGHTer International Conference Sources: AllianzProSchiene, DB AG, Reinf. Plastics Mag. 07/08-12; CleanSky, GBI Research; EU CAFE; IMO

6 Carbon Fiber Reinforced Polymers (CFRP) Material Systems with superior propertiesp Main characteristics of CFRP Applications for various Industries Low weight High strength and break resistance Good rigidity Automotive Energy Aviation Corrosion resistance Vibration resistance Low thermal expansion Freedom of design Sports Robotics & Automation Civil & Mechanical Engineering Medical Technology Page 6 Dr. A. Erber LIGHTer International Conference

7 Aerospace History of Lightweight g Design & CFRP Materials Share of CFRP in Primary Structure [in %] Airbus A350 Boeing 787 Airbus A320 Boeing 737 Boeing 767 Airbus A330/340 Boeing 777 Airbus A380 Composite intensive A350 >50% of the primary structure weight in CFRP Process characteristics Long cycle times Small serial Higher quality standard Page 7 Dr. A. Erber LIGHTer International Conference Sources: BofA Merrill Lynch, Airbus

8 Automotive History of Lightweight g Design Empty weight development of vehicles [in kg] Models / Vehicles Golf (I-VII) Kadett / Astra Escort / Focus Page 8 Dr. A. Erber LIGHTer International Conference Sources: VW, Opel, Ford

9 Current status of Lightweight Design by CFRP Aerospace & Automotive Aerospace Serial Production 100 units / p.a Material and automation concepts in aerospace address small lot-sizes with high performance Textile & infusion based manufacturing technologies have an upper lot-size limit Automotive Serial Production units / p.a Low material utilization of carbon fabrics High process costs due to thermoset materials Infusion and polymerization time Autoclave curing of epoxy prepregs Manufacturing equipment efficiency i too low Page 9 Dr. A. Erber LIGHTer International Conference

10 Current challenges for CFRP materials Multi-material Design Concepts Requirements CFRP Potential Analysis Challenges Multi-material Design Concepts Load path Design room Location of the component 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 B-pillar: CFRP Insert for increased impact stability Source: Audi AG Page 10 Dr. A. Erber LIGHTer International Conference

11 History of CFRP Materials Vision 2030 Lo ot Size Small Series Serial Production Super Sports Car Formula 1 Monocoque Manual Labor Monocoque Manual Labor Class A Carbon Semiautomatic Life Cell Automated Today Hybrid Design Automated for High Volume Page 11 Dr. A. Erber LIGHTer International Conference Source: RedBull F1, Daimler AG, Audi AG, BMW AG

12 Lightweight Design for E-Mobility BMW i3/i8 A benchmark for CFRP in Automotive Overall concepts dedicated to electro mobility Structural design aligned with composite requirements BMW i3. Large scale production of Carbon fibers and Composites BMW i8. Page 12 Dr. A. Erber LIGHTer International Conference

13 Carbon Core for BMW 7 series The next level of CFRP in Automotive Hybrid Design realized in BMW 7 series Metal/CFRP hybrid in Carbon Core design High Volume production of Carbon fibers and Composites Picture source: BMW AG Page 13 Dr. A. Erber LIGHTer International Conference

14 SGL Automotive Carbon Fibers Global supply chain Carbon Fiber Textiles and Composite Precursor Production Recycling Components BMW i3/ i8 Production - Japan - - USA - - Germany - - Germany - - Germany - 2 Moses Lake 1 Otake 5 Leipzig Mitsubishi Rayon-SGL Precursor SGL Automotive Carbon Fibers BMW Group 3 Wackersdorf 4 Landshut Page 14 Dr. A. Erber LIGHTer International Conference

15 SGL Automotive Carbon Fibers Production Sites Subtitle Moses Lake / USA Wackersdorf / Germany Selection Criteria 100 % Green Energy: Hydro-electric power station nearby Low Energy Costs: Sustainable and competitive Key facts Production: 6000 t/p.a. of carbon fiber fabrics Recycling: Recycling of cutting trims Sustainability: Site runs on renewable energy Location: Close to Munich, Landshut and Leipzig Page 15 Dr. A. Erber LIGHTer International Conference

16 High Volume Composite Production Agenda Motivation and State-of-the-Art Design concepts and global supply chain Comprehensive Material Systems for Automation Network Approach to address R&D challenges Page 16 Dr. A. Erber LIGHTer International Conference

17 Thermoset Prepregs Reactive Resins Toughness Viscosity Functional Properties (Tack, FST, conductivity, etc.) Mechanical Properties Resin & Curing Agent Resin class Basic frame work Cross linking density Thermal mech. stability Processing Resin formulation Additives Accelerator Reactivity (Curing time) Shelf-/out life (RT & -18 C) Processing conditions (curing cycle) Page 17 Dr. A. Erber LIGHTer International Conference

18 Towpreg material based on 24k Carbonfiber Advantages Ease of processing (low tack) Fast curing cycles Health and safety Excellent mechanical performance Typical property Unit Value Roving weight g / 1000 m 1600 TowPreg weight g / 1000 m 2280 Width mm 5 Resin content m % 30 Youngs modulus 0 * Gpa 170 Tensile strength 0 * MPa 2570 Possible applications Automotive Pressurized containers Marine masts & riggings Leaf springs Sports articles Page 18 Dr. A. Erber LIGHTer International Conference *Experimental values based on filament winding

19 MAI ReCar: Resource efficient and robust Carbon-component production Project in the framework of Page 19 Dr. A. Erber LIGHTer International Conference

20 MAI ReCar: Resource efficient and robust Carbon-component production Page 20 Dr. A. Erber LIGHTer International Conference

21 MAI ReCar: Resource efficient and robust Carbon-component production Automation System 16 lane Fiber Placement Machine ¼ material width Integrated AC 2D deposition MAI ReCar Goals Processing of SGL Towpreg 50K, 300 g/m² fast curing Towpreg Improvement of OEE > 75% Machine adaption for Thermoplastics 2 ½ D deposition Page 21 Dr. A. Erber LIGHTer International Conference

22 MAI ReCar: Resource efficient and robust Carbon-component production Page 22 Dr. A. Erber LIGHTer International Conference

23 MAI ReCar: Resource efficient and robust Carbon-component production Demonstration of CAD/CAM process chain Scrap rate: 1% Undercarriage Cover Deposition time: ~ 7 min. Towpreg material SGL Carbon fiber SGL resin system (E420) Page 23 Dr. A. Erber LIGHTer International Conference

24 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 Transport at Room Temperature Page 24 Dr. A. Erber LIGHTer International Conference Unidirectional Tapes Organic Sheets Source: BMBF Project SpriForm, SGL

25 Customized Sizing Solutions Ad Advanced d fib fiber/matrix / t i interphase i t h b customized by t i d sizing i i solutions Improved mechanical performance as received hot/wet conditioned Textile process ability compared to base-line systems HTT08 T Type 3 210% HTT07 Type 2 187% Improvement p of Fiber/Matrix Interphase p EPY Base-Line 100% Values in boxes: Flexural Strength 90 Page 25 Dr. A. Erber LIGHTer International Conference HTT01-2 Type 1 176%

26 Carbon Fiber with thermoplastic compatible sizing Page 26 Dr. A. Erber LIGHTer International Conference

27 Customized UD-Tapes Width of sample materials ¼ Slit Tapes 50 mm Tapes 180 mm Tapes Customized width available Page 27 Dr. A. Erber LIGHTer International Conference

28 Customized Organic Sheets Examples Thickness and layup tailored to applicable load case Carbon fiber or glass fiber reinforcement Standard size 600 x 400 mm 350 x 200 mm Layup UD 0 /90 Woven Nonwoven Example materials Performance plastics combined with carbon fibers Performance plastics combined with carbon fibers Thermoplastic polyurethane with woven fabrics (CF/GF) Polyamide or polypropylene with carbon fiber nonwoven Page 28 Dr. A. Erber LIGHTer International Conference

29 Customized Long Fiber Thermoplastics (LFT) Application Examples LFT-Pellets are typically used in injection molding or pressing processes Reinforcement with carbon fiber and glass fiber Polyamide compatible carbon fiber available for compounding of direct LFT Typical property Unit Value Density g/cm ,36 Fiber Content by Weight % 30 Diameter mm ~2 Length mm 7-23 Krauss Maffei injection molding part with CF-LFT by SGL Group Page 29 Dr. A. Erber LIGHTer International Conference

30 Example: Automotive Frontend Materials used for the Demonstrator: Long glass fiber-reinforced thermoplastics (GF-PA6 LFT 30%) Unidirectional carbon fiber organic sheet (CF-PA6) Woven fabric carbon fiber organic sheet (CF-PA6) Tape woven fabric organic sheet (CF-PA6) Injection Molding Compounder Automotive Frontend Page 30 Dr. A. Erber LIGHTer International Conference

31 Network Approach in R&D Topics How to cope with the Death Valley of Innovations? Pilot Plants Prototyping Pilot plants are required to bridge the gap for innovations into products. Networks along the entire value chain enable a sustainable product development. A balanced portfolio between public funded and company funded projects keeps the innovation pipeline under pressure. Page 31 Dr. A. Erber - e-monday

32 Leading Edge Cluster MAI Carbon Goals 90% Process cost reduction 50% Material cost reduction 60% - 80% added value in Germany Munich Augsburg - Ingolstadt Page 32 Dr. A. Erber LIGHTer International Conference

33 Carbon Fiber Reinforced Polymers Industry Snapshot CFRP materials still represent a small niche i3/i8 production is industrial pioneering for carbon composites in automotive Transfer from manual production to serial production Multi-material mix addresses upcoming challenges Comprehensive material systems for automated processes Networks are requisite for future success Page 33 Dr. A. Erber LIGHTer International Conference

34 Thank you for your attention! Some results were achieved within: Copyright SGL CARBON SE Registered trademarks of SGL CARBON SE