Technology Trends in Lightweight Design for the Transportation Industry

Transcription

1 Technology Trends in Lightweight Design for the Transportation Industry Peter the Great, St. Petersburg, Polytechnic University November 21 st, 2016 Fraunhofer ICT KIT FAST & IAM-WK Fraunhofer Project Centers FPC

2 Introduction Fraunhofer Gesellschaft Applied research is core of all activities pursued by the Fraunhofer-Gesellschaft. Founded in 1949, the research organization undertakes applied research that drives economic development and serves the wider benefit of society. Its services are solicited by customers and contractual partners in industry, the service sector and public administration. Page 2

3 The Fraunhofer-Gesellschaft Main locations of the Fraunhofer institutes and research institutions in Germany Founded in 1949 in Munich 66 institutes and research units in Germany More than 24,000 employees Annual budget is about 2,2 billion, partly public founded Representative offices, research units, and subsidiaries worldwide Main sites Fraunhofer ICT Pfinztal Other sites Slide 3

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5 Organization chart of the Fraunhofer ICT Institute Director Prof. Dr. P. Elsner Deputy Directors Dr. H. Krause, Prof. Dr. F. Henning Controlling C. Steuerwald Administration Dr. B. Hefer, C. Steuerwald General Management Dr. S. Tröster Energetic Materials Dr. H. Krause Dr. T. Keicher Dr. S. Löbbecke Energetic Systems W. Eckl G. Langer Dr. J. Neutz Applied Electrochemistry Dr. J. Tübke Dr. K. Pinkwart Environmental Engineering R. Schweppe S. Rühle Polymer Engineering Prof. Dr. F. Henning Dr. J. Diemert Dr. T. Huber Fraunhofer Project Center FPC UNIST (Ulsan, Korea) Prof. Dr. F. Henning, Prof. Young-Bin Park Fraunhofer Project Center FPC London (Ontario, Canada) Prof. Dr. F. Henning, V. Ugresic Project Group for New Drive Systems NAS, Karlsruhe Dr. H.-P. Kollmeier, Prof. Dr. P. Elsner, Prof. Dr. P. Gumbsch (IWM) Project Fraunhofer Group ICT-IMM, for Sustainable Mainz Mobility FH Prof. Braunschweig-Wolfenbüttel, Dr. Michael Maskos Wolfsburg Dr. J. Tübke Slide 5

6 National and International Network Extended Research Activities Europe USA & Canada Asia Access to key markets R&D network Student exchanges Graduate schools Slide 6

7 Railed vehicles: aluminum is the dominating material, however HSS shows a growth of 14 % Market for railed v ehicles s ector Market volume in bn MMC FRP Aluminium Steel (high strength) Plastics

8 Shipping sector shows small growth due to expansion of aluminum market (4 %). Market for shipping sector Market volume in bn FRP Aluminium Plastics

9 Main lightweight-materials for the aerospace sector are aluminum (1,7 % growth), titanium (13% growth) and composites (15 %). Magnesium might also become important in the future (30 %). Market for aeros pace s ector Market volume in bn MMC FRP Titan Magnesium Aluminium Plastics

10 Weight Reduction of Airplanes Source: Prof. Dr.-Ing. Klaus Drechsler Page 10

11 Weight reduction [kg] Weight Increase of vehicle mass within 50 years BMW 7er Opel Omega VW Golf Opel Corsa Reduction of CO2-Emissions [g CO2/km] 4,3 8,5 12,8 VW Lupo 150 VW 1- Literauto University Paderborn/ Tröster Year 0,15 0,3 0,45 Reduction of fuel consumption [l/100 km]

12 The transportation sector, in particular the automotive sector as driving force, is the most important market for lightweight-technologies regarding market volume. Strong growth of other markets (e.g. wind energy with ~10 % size of the volume of the transport market) is not likely to take place before Transportation market [BCC 2013] in bn Shipping railed vehicles Aerospace Automotive Buses and trucks Wind energy Wind energy (GFRP + CFRP )

13 The dimension of the entire global lightweight market will be in the order of the dimension of the market for automotive applications. Studies are assuming a growth of about 7-8%. Lightweight market automotive - comparison of different studies (in bn ) BCC 2013: Automotive (without buses and trucks) BCC 2013: Automotive (total) MacKinsey 2012: Automotive (total) Frost & Sullivan 2011: Automotive (passenger vehicle)

14 Forel Study - Accepted Costs for Lightweight Design automotive sector with conventional engine automotive sector with electric drive up to 7 up to 18 up to 500 aerospace up to 3000 aerospace outer space Source: Forel Studie

15 Conclusion Market Trends Analysis Lightweight design is mainly established in the transportation sector. Automotive industry is most important; Utility vehicles (buses and trucks) show strong growth Other markets, e.g. wind energy, nowadays of lower importance but with a strongly increasing tendency emerging markets Lightweight design based on metals is and will be the main market in automotive until approx High-strength-steel shows highest growth rate in automotive; Magnesium shows growth rate as well but based on a much lower market size emerging market Plastics show constant but intermediate growth rate Composites show very high growth rate and will most likely be of increased importance in the long term (2020 and later) cost as main challenge In the long term increasing trend towards hybrid lightweight design

16 MMP Approach New materials Steel/metal design Opportunities & New Challenges Source: Audi, Porsche FRP Further development of methods, materials and processes to access opportunities for automotive industry

17 MMP Approach Component performance MMP-Approach Economics A R E A S OF I N T E R A C T I O N METHODS TIME MATERIALS S Y S T E M E F F I C I E N T L I G H T W E I G H T D E S I G N COSTS PROCESSES QUALITY Slide 17

18 Methods - Materials - Processes Virtual Simulation Chain Initial analysis of component manufacturability Linkage of process simulation and structure simulation Integration of production boundary conditions and updated material properties into structure simulation Requirements for Multi-Material-Des ign integral construction differential construction V I R T U A L S I M U L A T I O N C H A I N Vehicle concept Geometry Forming Curing / cooling Part Assembly Vehicle F L O W OF I N F O R M A T I O N O P T I M I Z A T I O N Slide 18

19 KIT Institute of Vehicle System Technology Lightweight technology FAST Process simulation Optimization of cycle times for manufacturing of composite components Evaluation and improvement of process control and machinery Dissemination of relevant material and process information on structural simulation (within the context of CAE-chain, e.g. fiber orientation, fiber volume content, porosity) Structural simulation Simulation of deformation and failure behavior of composite structures Investigation of the influence of manufacturing effects on the component behavior Consideration of production factors to increase the prediction accuracy (integration in the CAE-chain) Further development of models and methods for hybridization Slide 19

20 Methods - Materials - Processes Material modification Chemical (molecular structure, cross-linking, cristallinity ) Physical (reinforcements, additives, fillers, ) Tailored materials Material analysis Mechanical testing Thermal analysis Chemical analysis Morphological characterization Slide 20

21 1 mm in throughthickness direction C KIT Institute of Applied Materials Materials Science and Engineering IAM-WK Polymer Technology Design of polymer materials Polymer processing Hybrid and Lightweight Materials Mechanical Characterization of polymer and metal based composites under near-service loads Microstructural analysis of composites using X-ray computed tomography Development of in-situ-test methods for the analysis of damage in composites Visualization of in-plane orientation 1200 x 750 x 400 Voxel B A Insert Slide 21 CFRP 3.5 m m

22 Methods - Materials - Processes Thermoplastic processing Tape placement Handling technologies LFT injection molding LFT compression molding Thermoset processing Sheet Molding Compounds (SMC) D-SMC High-perform ance com pos ites PU-fiber spraying Preforming technologies Injection technologies (EP, PU, Cast-PA) Process and structural simulation Manufacturing in industrial scale (3600t, 640t) Slide 22

23 Fraunhofer ICT - Department Polymer Engineering Compounding and extrusion Materials and cutting-edge processing technology Nanocomposites Functional composites and their characterization Foam technologies Processes and materials for particle and extrusion foams Thermoplastic processing Injection and compression molding, thermoplastic composites Thermoset processing Process and material development, tailored SMC High-performance composites RTM processing chain, injection, preforming, prepregs Microwaves and plasmas Microwave technology, surface modifications Plastics testing Mechanical and rheological analysis, microscopy, DoE Slide 23

24 Overview of process technologies Braiding* 1 Braiding* 1 * 1 Continuous-fiber preform Slide 24

25 Thermoplastic composites - Discontinuous fiber reinforcement Slide 25

26 Overview of Process Technologies Thermoplastic processing Unreinforced thermoplastics Thermoplastic foam injection molding Processing of functionalized polymers (e.g. electricallyconductive compounds) Advanced processing technologies for injection molding Discontinuous-fiber reinforced thermoplastics Direct processing of long-fiber reinforced thermoplastics (LFT-D) in compression and injection molding (CM / IM) Foaming technologies for fiber reinforced thermoplastics Continuous-fiber reinforced thermoplastics (CFRTP) Automated thermoplastic tape-laying Local reinforcement of discontinuous-fiber reinforced thermoplastics to create function-integrated designs Page 26

27 Discontinuous-fiber reinforced thermoplastics Typical applications of LFT Thermoplastic composites with discontinuous-fiber reinforcement are already a well-established engineering material for semi-structural applications with constant growing market share Oil tray Actros; PA6.6/GF35 Source: Lanxess/Daimler Frontend-module Golf VII; PA6/LGF Source: BASF/VW Instrument panel Ford Escape/Kuga; PP/LGF Source: Faurecia/Sabic Under body shield; PP/GF Source: Polytec/VW Seat structure BMW I3; PA6/LGF Source: BASF/BMW Gear carrier BMW 5er GT; PA6/GF Source: ContiTech/BASF Slide 27

28 Discontinuous-fiber reinforced thermoplastics CAE-Chain Design and Concept CAE-Chain for long fiber reinforced polymers (LFRPs) Integrate design, process simulation and structure simulation Allow systematic and efficient communication in between different software Main goal is to create a more efficient product development method V I R T U A L S I M U L A T I O N C H A I N Geometry Process Mapping Part Assembly F L O W OF I N F O R M A T I O N O P T I M I Z A T I O N Topology/Topography Slide 28

29 Discontinuous-fiber reinforced thermoplastics Processing technologies Compression Molding (CM) Processing of glass-mat reinforced thermoplastics (GMT) Direct processing of long-fiber reinforced thermoplastics (LFT-D-CM) Injection Molding (IM) Processing of short or long-fiber reinforced thermoplastics (SFT / LFT-IM) Direct processing of long-fiber reinforced thermoplastics (LFT-D-IM) Foaming technologies for fiber reinforced thermoplastics (e.g. MuCell, LFT-D foam, CBA -Chemical blowing agents) Slide 29

30 Discontinuous-fiber reinforced thermoplastics Principle of direct compounding of LFT in compression molding (LFT-D-CM) Polymer + Additives Inline Compounder Reinforcing fibers : Carbon Glass Natural Matrix resins: Commodity Thermoplastics Engineering Thermoplastics Blends Mixing Extruder with die LFT plastificate (open trans fer) Compression molding Further developments in LFT-D-CM Use of technical thermoplastics as matrix material (e.g. PPS, PEEK ) Combination with continuous-fiber reinforcements Slide 30

31 Discontinuous-fiber reinforced thermoplastics Principle of direct compounding of LFT in injection molding (LFT-D-IM) Polymer + Additives Reinforcing fibers : Carbon Glass Natural Melt buffer Twin screw extruder Injection unit Matrix resins: Commodity, engineering and high temperature thermoplastics Clamping unit Further developments in LFT-D-IM Combination with continuous-fiber reinforcements FIM Foam injection molding (LFT-D Foam) Slide 31

32 Discontinuous-fiber reinforced thermoplastics Functional principle: integral foam structure compact Kompakte skin Außenhaut Schaumkern foamed core 300 µm sandwich-like integral foam structure with a foamed core and a compact skin PP-LGF30 Kompakte compact skin Außenhaut 1 cm 1 mm profile of a human humerus (left) [source: cross section of a PP-LGF30 injection molded integral foam component (right) Slide 32

33 position in cross-section Discontinuous-fiber reinforced thermoplastics Foam injection molding (FIM) Fiber-reinforced integral foams PP integral foam PP-LGF30 integral foam local density / stiffness I-beam / sandwich Slide µm µm 100 µm 100 µm PP-LGF30 integral foam fiber-reinforced cell walls fine-celled foam

34 relative bending stiffness [ ] Discontinuous-fiber reinforced thermoplastics LFT-Foams Lightweight potential of the Breathing mold 3,0 CBA MuCell LFT-D-Foam 2,0 1,0 PP-LGF30 CBA mold delay breathing time increasing wall thickness density reduction bending stiffness PP-LGF30 MuCell PP-LGF30 LFT-D 0,0 3,5 4,0 4,5 5,0 5,5 6,0 wall thickness [mm] S B = E B I y = E B b h3 12 slightly decreasing strongly increasing Slide 34

35 Thermoplastic composites - Continuous fiber reinforcement Slide 35

36 Continuous-fiber reinforced thermoplastics Types of continuous-fiber reinforcement UD-Strands UD-Tapes Wound Structures Fabrics Profiles source: Zoltek source: Fiberforge source: Bond Laminates source: Xperion Benefits of continuous-fiber reinforcement Semi-finished products containing fiber volume contents of up to % High mass-specific part properties achievable Part designs can be optimized for specific load cases More stable mechanical performance at elevated temperatures Increased dimensional stability Reduced creep tendency (if loads are transferred into continuous fibers) Application of thermoplastics in structural applications Slide 36

37 Tailored Fiber Placement - TFP UD Fiber Tape Tailored Blank Consolidated Blank Thermoformed Part FIBERFORGE TFP System Slide 37

38 Continuous-fiber reinforced thermoplastics Thermoplastic tape-laying based on RELAY technology Advantages Any fiber orientation possible Varying thickness within a part possible Minimized scrap Recyclable material Hybrid layup configurations possible Automated process with short cycle times Combination with other thermoplastic processing and joining technologies Technical challenge Limited drapeability and flowability Economic challenge The cost targets are often difficult to achieve in large series ultrasonic welding Slide 38

39 Continuous-fiber reinforced thermoplastics Differences between tape-laying and semi-finished woven fabrics Reduced cutting scrap No limitation on the fiber orientation 0 / 90. No fiber ondulation (max. performance) Source: Script of Paolo Ermanni (woven fabric) and (tape layup) Gradual thickness changes possible Slide 39

40 Continuous-fiber reinforced thermoplastics CAE-Chain Design and Concept Main focus: Virtual Representation of the Continuous Virtual Process Chain virtually combine design, manufacturing and structural validation Requirements for Multi-Material-Des ign integral cons truction differential construction V I R T U A L P R O C E S S C H A I N Geom etry Form ing Molding Cooling Part As s em bly F L O W OF I N F O R M A T I O N O P T I M I Z A T I O N Slide 40

41 Continuous-fiber reinforced thermoplastics Processing technologies Automated thermoplastic tape-laying of tailored blanks Thermoforming of fabrics and laminates Alternative heating and consolidation methods Investigation of process-controlled drapeability Prediction and evaluation of process-induced shape deformations (spring-in & warpage) Hybrid thermoplastic composites with embedded continuous-fiber reinforcements in CM and IM Function-integrated solutions for structural components Local continuous-fiber reinforcements using wound structures or tailored blanks Sandwich structures Slide 41

42 Fiberforge 4.0 Machine Architecture Tape Tensioning Tape Toogle 24 US-Welders Lay-up beam Spool Unwinding Cutter X- Axis Motion Table Rotation Axis 42

43 Fiberforge Improvements Productivity Fiberforge 4.0 is 3.5 times faster than Fiberforge Relay 2000 Continuous tape supply to lay-up system no downtime due to reloading of spools Cycle time of less than 1s per tape at maximum tape length of 2000mm; including spot welding Two shorter tapes (e.g. 300mm + 500mm) can be placed in a row with same cycle time of less than 1s Performance example Glass fiber tapes (PP/GF60), with 0,25mm thickness + 165mm width + average tape length of 1500mm results in a production capacity of 368 kg/h Carbon fiber tapes (PA/CF55), with 0,16mm thickness + 165mm width + average tape length of 1500mm results in a production capacity of 208 kg/h 43

44 Fiberforge Improvements Flexibility Can work with all different formulations of thermoplastic tape Range of tape width: max. 165mm; min. 50mm Range of tape length: max. 2000mm; min. 30mm Range of thickness: max. 0.4mm, min. 0.1mm Up to 4 different tapes can be used within a production run Tape source can be switched from one tape to the next With the capability to lay-up more than one tape in a row at one cycle, more than one individual part at a cycle can be produced, with a significant cycle time advantage LH part Motion Table RH part 44

45 Fiberforge Improvements Efficiency New angle cutting system does minimize the waste of material Angle cutting without any cycle time reduction Loss of material w/o angle cut = 5% minimized with angle cut = 2,5% Gap between the tapes can be set from -2 to +5mm (overlap) Lay-up with small gap; e.g. 0,4mm Lay-up with overlap; e.g. 3mm 45 Low level of complexity due to 2D lay-up small effort to generate machine program

46 Fiberforge 4.0 Improvements / Applications Precision High accuracy and repeatability Constant gap between the tapes within a layup Machine repeatability: C = 0.01 ; Y = 0.25 mm; U = 2.0 mm (U is the tape feed axis) Machine resolution: C = ; X, Y = 0.03 mm; U = 0.1 mm Applications - Seat structures - Load Compartment - Battery compartment - Floor pan - Door inner - Hood, roof and tail-gate structural reinforcement - Bumper beam - Fire wall - Local reinforced front end carrier and underbody shielding 46

47 Continuous-fiber reinforced thermoplastics Development of consolidation process technologies UD Tape Tailored-blank Tailored-blank (Consolidated) Composite Part Cons olidation Proces s - based on hydraulic presses (HTP) - based on vacuum technology (fast out-of-autoclave process) Slide 47

48 Continuous-fiber reinforced thermoplastics Heating-Transfer-Pressing (HTP) consolidation process Metal caul sheets Layup made from UD-tapes Unconsolidated tape layup Contact heating to processing temperature and pre-consolidation Solidification - Cooling with applied press force Monolithic laminate Slide 48

49 Continuous-fiber reinforced thermoplastics Radiation-induced vacuum consolidation Process characteristics Low invest No consumables Closed-loop process Exclusion of oxygen (minimization of thermal degradation) Pressure > 1 bar out of autoclave achievable Area of vacuum (A1) > Area of tape layup (A2) Short cycle times (< 60 sec) High surface quality Low fiber distortion Sealing Tape layup A1 Vacuum sewer IR-transparent tool wall A2 Slide 49

50 Poor Quality Good Quality Continuous-fiber reinforced thermoplastics Analysis of consolidation quality Mechanical analysis Definition Execution Analysis Optical analysis SEM C-Scan CT Slide 50

51 Continuous-fiber reinforced thermoplastics Laminate forming in context of the MMP approach P R O C E S S E S Process realization Process characterization Process monitoring Part validation M A T E R I A L S Customized testing set ups Mechanical & morphological characterization - data interpretation - link to M & P M E T H O D S Model development Process Simulation CAE chain approach Slide 51

52 Continuous-fiber reinforced thermoplastics Draping behavior of tape laminates Process analysis and evaluation during non-isothermal stamp forming Temperature profile characterization Evaluation of wrinkling formation Deformation state analysis Characterization of material properties relevant for forming simulations Friction (ply-ply & tool-ply) In-plane shear Single-ply bending Slide 52

53 Continuous-fiber reinforced thermoplastics Temperature profile during non-isothermal stamp forming PPS/CF laminate with 12 layers (~ 1.8 mm) Slide 53 Forming ends well before recrystallization of the material

54 Continuous-fiber reinforced thermoplastics Quantification of wrinkles during stamp forming Evolution of wrinkles during forming (experimental results for PPS/CF) Source: T. Joppich, D. Dörr, et. al. Layup and Process Dependent Behavior of PPS/CF UD Tape-Laminates during Non-Isothermal Press Forming Into a Complex Component, proceedings from ESAFORM Conference, Nantes, 2016 Slide 54

55 Curvature (rad/mm) Continuous-fiber reinforced thermoplastics Draping simulation Prediction of deformation behavior using advanced simulation methods Model development using Abaqus Validation via curvature and pointwise comparison of distances experiment simulation comparison Source: D. Dörr, T. Joppich, et. al. A method for validation of Finite Element forming simulation on basis of a pointwise comparison of distance and curvature, proceedings from ESAFORM Conference, Nantes, 2016 Slide 55

56 Continuous-fiber reinforced thermoplastics Methodology to predict and evaluate shape deformations * Variation of design and process parameters Process- and material characterization * Scan data CAD Deformation measurement Comparison Prediction of deformations Comparison of scan data with ideal geometry and simulation * Part design realized within BMBF SMiLE project Slide 56 56

57 Continuous-fiber reinforced thermoplastics Methodology to predict and evaluate shape deformations Variation of design and process parameters Processing parts with different layups Manufacturing of various part geometries Application of different press forces and tool temperatures Hybridization by combining long-fiber reinforced thermoplastics with unidirectional tape * * Part design realized within BMBF SMiLE project Slide 57

58 Continuous-fiber reinforced thermoplastics Methodology to predict and evaluate shape deformations Process and material characterization Conducting studies with varying process parameter sets Investigating the influence of processing routes Mechanical and thermo-analytical material characterization Holistic evaluation of process chains Recorded temperature profiles of a laminate s process cycle DSC measurements of CF/PPS UD-tape Slide 58 58

59 Continuous-fiber reinforced thermoplastics Methodology to predict and evaluate shape deformations Deformation measurement Designing and manufacturing of measurement-jigs Validation of the measuring procedure Generating measurements with tactile and non-contact measurement systems (coordinate measuring equipment, 3D laser scanning) Postprocessing of generated data Manufactured part Alignment in jig 3D-Scanning of surface Digitalized part Slide 59 59

60 Continuous-fiber reinforced thermoplastics Methodology to predict and evaluate shape deformations Prediction of shape deformations Simulation of a component s cooling behavior Modelling the crystallization kinetics of semi-crystalline thermoplastics Modelling of thermo-mechanical effects Structural analysis to determine thermal stresses Crystallization kinetics of a CF/PPS composite Prediction of shape deformations due to a local patch reinforcement Slide 60 60

61 Continuous-fiber reinforced thermoplastics Methodology to predict and evaluate shape deformations Comparison of scan data with ideal geometry and simulation Automated processes for alignment and analysis Variance analysis of nominal geometry and component s warpage Developing interpretation routines and deriving characteristic parameters Slide 61

62 Continuous-fiber reinforced thermoplastics Hybrid thermoplastic composites Combination of local continuous-fiber reinforcements and established high-volume process technologies Local reinforcement with continuous fibers Compression (LFT-D-CM) and injection molding (LFT-D-IM, LFT-G) Final composite parts Component was realized within the MAI Carbon cluster Slide 62

63 Continuous-fiber reinforced thermoplastics Wound fiber structures Local continuous-fiber reinforcement with fiber skeletons Optimal fiber usage in thermoplastic components Reduced content of the required fiber reinforcement saves weight and costs No fiber damage by subsequently drilled holes Load transfer and connection points allow an integral design Linkage between component requirements, structural and topological optimization and bionic local reinforcements Slide 63

64 Continuous-fiber reinforced thermoplastics Development of fiber skeletons to realize increased part complexity 1D Basic experiments for design guidelines 2D Injection molding technology demonstrator 3D Case study on complexity and processing guideline Slide 64

65 Continuous-fiber reinforced thermoplastics Development route for locally reinforced components From design space to optimized lightweight structure 1. Definition of cons traints 2. Identification of load paths 3. Verification of structure 4. Manufacturing feas ibility s tudy 5. Production F 1 F 2 Design space Loads Boundary conditions Use of force cone and primary point method Use of FEM simulation Collision detection Division into subloops Winding of fiber skeleton Overmolding of reinforcement structure Slide 65

66 Continuous-fiber reinforced thermoplastics Case study: In-mold-forming an co-molding of a passenger vehicle seat structure From UD-tapes / fabrics to a passenger vehicle seat structure Laminate optimization* Tape-laying* Pre-consolidation* Trimming In-mold-forming and injection molding *Process steps are necessary, if UD-tapes are used. Slide 66

67 Continuous-fiber reinforced thermoplastics Case study: In-mold-forming an co-molding of a passenger vehicle seat structure Gripper Linear robot Injection molding machine Pneumatic drawer IR heaters Clamping frame Laminate or fabric F Slide Heating to processing temperature 2. Transfer of clamping frame with a linear robot 3. Forming and injection molding

68 Continuous-fiber reinforced thermoplastics Case Study Locally reinforced vehicle floor section Holistic approach to realize a highly-tailored structural thermoplastic component Initial design based on list of requirements and CAE methods Derive final design: LFT-D combined with local UD-Tape reinforcem ents Component testing with multiple load cases LFT-D UD-tape Slide 68

69 Economical Benefits of Tailored Thermoplastic Composites Strength and Stiffness can reach close to the level of Epoxy based CFRP components Complete flexibility in tailoring the part. Fiber orientation in any angle. Local reinforcements possible Local use of UD tapes for structural optimization High degree of functional integration does minimize the costs Integration of inserts, rips, bossing etc. possible Short cycle times of < 30s possible very high productivity approx. 1 million parts a year in single part mode Near net shape tape placement does minimize the waste Large saving compared to textile based processes Easy process with low level of down grade Any waste can be directly recycled by feeding it back to LFT-D Slide 69

70 Overview of process technologies RTM * 1 Continuous-fiber preform Slide 70

71 Contact details Prof. Dr.-Ing. Frank Henning Deputy Director Fraunhofer Institute for Chemical Technology ICT Director Department Polymer Engineering Joseph-von-Fraunhofer Strasse Pfinztal, Germany Phone: Mail: frank.henning@ict.fraunhofer.de Internet: Dr.-Ing. Timo Huber Deputy Director Department Polymer Engineering Joseph-von-Fraunhofer Strasse Pfinztal, Germany Phone: Mail: timo.huber@ict.fraunhofer.de Internet: Director Institute of Vehicle System Technology - Lightweight technology Rintheimer Querallee 2, Building Karlsruhe, Germany Phone: Mail: frank.henning@kit.edu Internet: Slide 71