Advanced Thermoplastic Composites (ATC) At DSM …
Transcript of Advanced Thermoplastic Composites (ATC) At DSM …
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CONFIDENTIAL
Advanced Thermoplastic Composites (ATC)At DSM Engineering Plastics
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What Are Advanced ThermoplasticComposites (ATC)?
v Thermoplastics reinforced with:• Continuous fibers (UD Tapes)• UD Tapes woven into sheets/fabrics
v Why ATC?• Step change in mechanical properties
over regular compounds• Tensile Strength increased from nominal
300 MPa to > 2100 MPa• Tensile Modulus increased from nominal
35 GPa up to 125 GPa
Structuralmetals
SFT(Short fibercompounds)
CostPe
rfor
man
ce
ATC
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Why ATC: Weight loss is the most effective technology forlowered emissions
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What changed: the significance of light-weight
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UDT Physical Characteristics
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DSM UD Tape: Complete Data Package available
§ Material models and CAE Input Decks (LS Dyna)§ Thermo-forming and draping simulation§ Overmolding and insert-molding simulation (Filling and Temperature
end of filling)§ In Situ Consolidation Winding & Tape placement processing guidelines§ Hot-pressing, Autoclave and laminating processing guidelines
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DSM UD Tape: Technology and Support
q Design and CAE• Thermo-forming and simulation• Over-molding and Mold-Flow• Winding• Structural analysis
q In-House macro & micro structural analysis of UD Tape• Off-Line Quality Control• Material modeling• Micro-mechanics
q Circularity• ≥ 90% retain of performances
q Adhesion - Bonding• Plastic to Plastic• Plastic to Metal• With and without adhesives
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Examples of applications and achieved weightreductions
Weight targets for each module met
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Examples of applications
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Motivation Results Database Further steps
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omcFRTP for Application in Automobile Structural Parts
© Institute for Composite Materials | 12/6/2018 | 11
cFRTP branche Automobile branche
Support forstructural parts
Aluminumbranche
Steelbranche
Stro
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t• Focused Standardization of cFRTPàrobustness, efficiency, transparency
• Improvement of data quality andavailability for simulation
• Robust and efficient quality control Stro
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Working groupestab. 2015
The „opponent“ is not the cFRTPcompetitor but the metal branche
The only chancefor cFRTP is towork together
OEM steering committee, links to …
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Manufacturing with ATC
The UD tapes are used in a variety ofapplications:
q UDT can be woven and/or stacked intoplates (0.2 mm to 5 mm thick) andrepeatedly shaped by thermoforming(heating & pressing), analogous to hot,sheet-metal stamping
q The UD Tapes can be used as inserts ininjection molding
q The UD Tape can be wound (filament-winding) into pipes of varying cross-section profiles
UD Tape
UDT WindingUDT Insert MoldingUDT Thermoforming(Tailored Blanks)
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CONFIDENTIAL ConfidentialDSM Approachü The ambition is to create:
“DSM Automotive Weight-Loss Center”
a product development process that can drive the metal-composite conversionwith a high degree of acceptance & success
ü The strategy consists of creating key nodes in the value chain:
1. Manufacturing & supply of UD Tapes with DSM engineering polymers
2. Manufacturing Demonstration Facility that captures manufacturingtechnologies for UD Tape Winding, Tape-placement & Thermoforming andCAE simulations of UD Tape based composites behavior in customerapplications
3. Key OEM/TIERs collaboration for PTO opportunities
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DSM Approach: Fill gaps in the composites sectorwhich lacks intermediate-goods suppliers
Polymer
Fiber
UDTape
Slitting
Winding
TapePlacement
Thermo-Forming
OverMolding
MetalJoining
Tier 1
OEM
CAE CAE CAE
PartDesign
CFD
+
Intermediate Goods
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Visual Presentation of Gaps In Supply Chain
UD Tape Tape Lay Up Consolidation Thermoforming
Gaps: Fragmented/Opportunistic
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Circularity - Recycle ‘Close-the-loop’
Following Injection Molding:
q Grinded material sieved over 3 mm mesh.q Not so much issue with feeding material to the feed-throatq Some low variation in shot weight
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Circularity - Comparison against commercial gradeRegrind Q-HG10* Retention (%)
Modulus (GPa) 15 15 100Tensile strength (MPa) 200.2 215 93Elongation at break (%) 2.4 2.9 83
* Average value calculated from >15 production batches
Pretty consistentand reproducibletensile result
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Contact persons
Raj Mathur Tel.: +31652590614. Email: [email protected] Perfetti Tel.: +31683649747. Email: [email protected]