Carbon Fiber SMC Technology for Lightweight Structures

Carbon Fiber SMC Technology for Lightweight Structures Matt Kaczmarczyk Senior Design Engineer Quantum Composites- AS9100C:2009 / ISO9001:2008 1310 South Valley Center Drive Bay City, Michigan 48706-9798 USA Phone: 989-922-3863 ext. 116 Fax: 989-922-3915 mkaczmarczyk@quantumcomposites.com Tim Langschwager Lead Development Chemist Quantum Composites- AS9100C:2009 / ISO9001:2008 1310 South Valley Center Drive Bay City, Michigan 48706-9798 USA Phone: 989-922-3863 ext. 120 Fax: 989-922-3915 tlangschwager@quantumcomposites.com The Composites Group 1

Outline of Presentation What is Forged Composite? Differences Between CF-SMC and Traditional SMC High Flow vs. Low Flow Molding Typical Mechanical Properties of CF-SMC Important Characteristics of CF-SMC CF-SMC Applications Processes Comparisons The Composites Group 2

What is Forged Composite? Forged Composites: Term for compression molded CF-SMC Manufactured by Quantum Composites Headquartered in Bay City, Michigan The Composites Group 3

CF-SMC First Branded as Forged Composites October 2010 Paris Auto Show March 2012 Geneva (Aventador J) April 2012 Beijing (Urus) Courtesy: Dr. Paolo Feraboli Automobili Lamborghini Advanced Composites Structures Laboratory The Composites Group 4

Carbon Fiber Sheet Molding Compound Glass fiber SMC has been around since the 1960 s In 1987 Quantum developed epoxy 3k carbon fiber molding compound CF-SMC have been in use since early 1990 s What is unique about CF-SMC? Quasi-Isotropic properties Excellent for fastener-intensive and stiffness dominated parts Carbon fiber reinforcement High fiber content: V f 40%+ / W f 50%+ The Composites Group 5

Carbon Fiber Sheet Molding Compound Traditional SMC: Sheet Molding Compounds (SMC) have traditionally been a low-performance process: Glass fiber Low fiber content: V f 18%+ / W f 25%+ Low mold coverage/ high flow Typically polyester resin Higher specific gravity CF-SMC: Feedstock material is chopped carbon fiber with resin They are similar to prepreg in principle, but not in practice We define Advanced Compression Molding to differentiate it from the traditional Compression Molding if: Carbon fiber High fiber content: V f 40%+ / W f 50%+ Typically vinyl ester or epoxy resin but also BMI and phenolic Lower specific gravity The Composites Group 6

Advanced Compression Molding Ability to use the CF-SMC in a repeatable and predictable way to form unique applications Minimum molded thickness as low as 0.035 in. (1 mm) Reduced variability in strength Co-mold with selective UD reinforcement Understanding the requirements is the key to material selection Excellent for fastener-intensive and stiffness-dominated parts The Composites Group 7

Advanced Compression Molding Example Fabricated (Welded) Steel Tubing Compression Molded CF-SMC 21 lbs 8 lbs Structural features such as ribs and gussets can easily be molded for acceptable and even matched performance. The Composites Group 8

Advanced Compression Molding Matched-mold process Figure 1. Mold is closing Figure 2. Mold is opening after cure The Composites Group 9

High Flow Molding Similar to traditional SMC - fiber orientation is not controlled Cut the material Weigh the charge Prepared Charge Load the Charge Courtesy: Premix The Composites Group 10

Low Flow Molding Similar to traditional lay-up - fiber orientation is more controlled Material is precisely cut and placed into mold The Composites Group 11

High Flow vs. Low Flow Molding Material flow and charge pattern can effect mechanical properties. Creating a uniform direction of fibers does not necessarily translate into improved strength. Flow fronts and fiber bunching creating weak areas in the coupons/parts. Tensile Strength Tensile Modulus 45000 8 40000 7 (psi) 35000 30000 25000 20000 15000 10000 (Msi) 6 5 4 3 2 5000 1 0 0 High Flow Low Flow High Flow Low Flow The Composites Group 12

High Flow vs. Low Flow Molding High Flow Low Flow The Composites Group 13

High Flow vs. Low Flow Molding High flow specimen showing fiber bunching at fracture area (Edge Effect at end of flow) Low flow specimen showing a more uniform fiber displacement resulting in elevated strength properties. The Composites Group 14

Comparison of Material Performance Tensile Strength vs. Tensile Modulus 100.00 90.00 80.00 70.00 60.00 Quasi-Iso Tape (15.2,174.0) Ti-6-4 Tensile Streng gth (ksi) 50.00 40.00 30.00 20.00 Glass SMC AL6061-T6 10.00 0.00 0 2 4 6 8 10 12 14 16 18 20 Tensile Modulus (Msi) Reference Materials Discontinous Carbon Fiber Molding Compound The Composites Group 15

Fiber Aspect Ratio Higher Fiber Aspect Ratio = Higher performance Lower COV strength values Higher notch sensitivity 3K 3,000 filaments per tow (roving) 3k=100 tows 12k=25 tows 12K 12,000 filaments per tow 50K 50,000 filaments per tow 50k=6 tows The Composites Group 16

Comparison of Carbon Fiber Tow (CF-SMC) 70,000 Tensile Strength comparison of ASTM Method 60,000 iel Strenght (psi) Tensi 50,000 40,000 30,000 20,000 3K SMC 12K SMC 50K SMC 10,000 0 ASTM D-638 ASTM D 3039 MD ASTM D 3039 CMD ASTM D 5766 MD ASTM D 6742 MD Test Method *ASTM D-638 in the graph above uses as molded net shape test specimen. ASTM D3039, D5766, and D6742 use specimen machined from molded plaques. The Composites Group 17

Comparative Properties of CF-SMC Moduli as high as prepreg quasi baseline Unnotched strengths lower than prepreg quasi baseline Compression higher than tension Open-hole strengths more appealing Higher CoV in strength and modulus Excellent for fastener-intensive and stiffness-dominated parts UNT T mod OHT UNC C mod OHC CoV CoV [ksi] [Msi] [ksi] [ksi] [Msi] [ksi] Aluminum 30 2% 10.0 0% 30 30 10.0 30 Quasi-isotropic fabric T700/977-6 108 4% 6.0 5% 60 70 4.9 45 3k CF-SMC 47 10% 5.0 10% 37 52 5.4 37 12k CF-SMC 29 18% 5.5 27% 29 42 6.0 33 50k CF-SMC 22 20% 5.5 20% The Composites Group 18

Comparative Fatigue Curves 50,000 S-N curve 45,000 40,000 35,000 30,000 UTS (psi) 25,000 20,000 15,000 3K CF-SMC 12K CF-SMC AL6061-T6 10,000 5,000 0 0 200000 400000 600000 800000 1000000 Life (Cycles) Tension Tension 3Hz The Composites Group 19

Notched Behavior Specimens containing open holes fail both in the net and gross section Typical fastener hole size ¼-inch diameter hole 3k 98.6% failed at hole 1.4% failed away from hole 12k 26.4% failed at hole 73.6% failed away from hole The Composites Group 20

Effects of Defects

Modulus Variability Modulus measurements either via strain gage or extensometer High variability encountered (approx19%) much higher than strength variability (approx 10 %) Experiments using gage lengths of 0.125, 0.25, 0.5, 1.0 and 2.0 in. Also 1.0 in. extensometer Longer gages do not yield better measurements Measurements vary along length and across width of specimens The Composites Group 22

Modulus Variability Digital image correlation (DIC) Black speckles are applied to a white background on one side of a specimen Images are taken during testing by a pair of digital cameras Post processing allows to measure full field strain Measurement shows local variations The Composites Group 23

Fiber Orientation High degree of influence on mechanical properties, stiffness Changes with high flow vs. low flow molding process and part geometry Molded specimens will give high mechanical values due to favorable fiber orientation. With cut specimens, the fibers are cut in the gage length reducing the strengths by about 25-30% from molded specimens. Fibers tend to orient in the direction of flow and along the cavities edge. Fibers are random, but cut at the parts edge ASTM D 638 MOLDED SPECIMEN ASTM D 3039 CUT FROM PANEL The Composites Group 24

Outline of Presentation What is Forged Composite? Differences Between CF-SMC and Traditional SMC High Flow vs. Low Flow Molding Typical Mechanical Properties of CF-SMC Important Characteristics of CF-SMC CF-SMC Applications Processes Comparisons The Composites Group 25

CF-SMC Applications Carbon-Fiber Sheet-Molded Composite Underbody Diffuser for Nissan GTR Challenge Lower cost, parts consolidation Solution Lower part cost vs. prepreg parts Corrosion resistance High stiffness Good impact strength Dimensional stability Ability to mold in ribs, bosses, changes in thickness (e.g., for attachment points) The Composites Group 26

CF-SMC Applications Carbon-Fiber Sheet-Molded Composite Monocoque Tube and Suspension Arm for Lamborghini Siesto Elemento Challenge Lower cost, cycle time Solution Much lower part cost vs. prepreg parts Lightweight High stiffness / strength Faster cycle time than RTM Higher volume compression molded Hybrid structures (e.g., Continuous + Discontinuous Fibers) The Composites Group 27

CF-SMC Applications The Composites Group 28

Additional CF-SMC Applications Carbon fiber hood inner structure http://www.sae.org/mags/sve/12288/ Carbon fiber fender support The Composites Group 29

Composite Fabrication Processes (thermoset) Compression Molding (CF-SMC) Transfer Molding Injection Molding RTM Autoclave / Vacuum Bag Tooling Cost Hand Lay-up Spray-up Production Volume The Composites Group 30

Thank you! The Composites Group 31