Radiation Curing of Composites for Vehicle Component and ......Xray cured carbon fiber composites...
Transcript of Radiation Curing of Composites for Vehicle Component and ......Xray cured carbon fiber composites...
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Radiation Curing of Composites for Vehicle Component and Vehicle Manufacture
Marshall R. Cleland a , Richard A. Galloway a , Daniel Montoney b ,
Dan Dispenza c , Anthony J. Berejka d
a IBA Industrial, Inc., Edgewood, NY b Strathmore Products, Syracuse, NY
c Nordan Composite Technologies, Patchogue, NY d Ionicorp + , Huntington, NY
IAEA/ANS AccApp ’09 Vienna, Austria 48 May 2009
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Presentation Outline
Advantages of Composites in Vehicles
Radiation Processing in Automobiles
Use of Composite Materials in Automobiles
Advantages of Xray Curing Versus Thermal Curing for Composites
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Advantages of Composites in Vehicles
Reduced Vehicle Weight
Increased Fuel Efficiency
Reduced Use of Fossil Fuels
Reduced Environmental Pollution
Reduced Corrosion of Body Parts
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Radiation Processing in Automobiles
Weight reduction:
In tire manufacture In use of closed cell foams
Safety benefit:
Crosslinked underhood wiring
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EB Processing in Tire Manufacture
Controlled Partial Cure to Improve Quality
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EB Processing in Tire Manufacture
Benefits of Radiation Processing:
Stabilize tire cords during molding
Reduce weight of innerliners and other tire components
Costeffective processing
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EB Processing in Foam Manufacture
Interior side panels and header
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EB Processing in Foam Manufacture
Benefits of Radiation Processing:
Crosslinking of the polymer is separate from the foam blowing process
Controlled size of closed cells
Controlled stiffness and cushioning
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EB Crosslinking of Electrical Wire
Flame retardant underhood wiring
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EB Crosslinking of Electrical Wire
Benefits of EB Crosslinking:
Prevents insulation melting and dripping
Tolerates high temperature environment
Flame retardancy inhibits underhood fires
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Composite Materials in Automobiles
GM Corvette: 1953 – outer body 1984 – leaf springs
Automotive Composites Consortium (ACC): 1996 – crash test of front end section
Light weight components used in highperformance autos
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Composite Materials in Automobiles
Weight reduction:
GM Corvette
Current high performance autos
Safety benefit:
Crash testing by ACC
High speed racing cars
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Composite Materials in Automobiles
1953 Corvette
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Composite Materials in Automobiles
Porsche Carrera GT subframe
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Composite Materials in Automobiles
Tesla Motors electric car body
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Composite Materials in Automobiles
1996 Ford composite crash testing
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Composite Materials in Automobiles
Race car safety
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Xray Curing versus Thermal Curing
Advantages of Xray vs Thermal Curing:
Greater penetration
Complex product shapes
Shelfstable materials
Shorter cure cycles
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Xray Sources and Properties
Sources: Highenergy, highcurrent industrial electron beam (EB) accelerators.
Xrays are generated by electrons hitting watercooled tantalum targets.
Xrays can provide penetrating, nonthermal energy transfer processes.
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Forward Peaked Xray Penetration
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DepthDose Distributions – EB and Xray
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Xray Sources and Properties
Dynamitron ® 5.0 MeV, 300 kW electron accelerator
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Xray Sources and Properties
Dynamitron 5.0 MeV, 300 kW electron accelerator
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Xray Sources and Properties
Rhodotron ® 7.0 MeV, 700 kW electron accelerator
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Xray Sources and Properties
Rhodotron ® 7.0 MeV, 700 kW electron accelerator
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5.0 MeV and 7.0 MeV Xray targets
Industrial Xray Processing Facilities
2m
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Dedicated Xray Processing Facilities
Xray Facility for a 7.0 MeV, 700 kW Rhodotron ®
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Dedicated Xray Processing Facilities
Xray Facility for a 7.0 MeV, 700 kW Rhodotron ®
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Xray Cured Fiber Reinforced Composites
+ Cure within inexpensive, simple molds
+ Use common shelfstable materials
+ Cure faster than thermal processes curing times only 2 to 3 minutes
+ Encase metallic pieces for fasteners
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Xray Cured Fiber Reinforced Composites
Carbon fiber cups in a simulated mold
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Xray Cured Fiber Reinforced Composites
Xray cured carbonfiber cup
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Xray Cured Carbon Fiber Motorcycle Fender
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Xray Cured Carbon Fiber Motorcycle Fender
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Xray Cured Carbon Fiber Sports Car Fender
Class A gloss finish
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Comparative Toughness Testing
Falling tup test apparatus 123 cm
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Comparative Toughness Testing Four ply carbon fiber composite and
aluminum panel of comparable thickness
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Comparative Autobody Weights
Material Density Body weight g/cm 3 kg
Steel 7.8 ~750
Aluminum 2.7 ~260
Carbon fiber 1.6 ~155 composite
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Comparative Mechanical Properties
Material Young’s modulus GPa
Steel ~190210
Aluminum ~70
Carbon fiber ~125150 composite
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Advantages of Radiation Curing
Room temperature curing Makes stressfree joints No thermal distortion
Saves energy Eliminates need for autoclaves
Avoids air pollution No volatile organic compounds
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Conclusions
Xrays penetrate through inexpensive molds made of aluminum, plastics or composites.
Composite parts can be cured with Xrays in a few minutes while still in the mold.
Common radiation curable materials can be used in formulating matrix systems.
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Conclusions
Xray cured carbon fiber composites can be used for all auto structures, including the vehicle chassis and body frame.
An 80% weight savings from carbon fiber composites versus steel could lead to more than double the fuel efficiency.
Composites completely eliminate operations such as coating for corrosion protection.
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Conclusions
Cost analyses should include the added value to the consumer and societal benefits from greater fuel efficiency and less environmental emissions leaving a lower carbon footprint.