SCIENCE SECTOR
Composites
Renato Bezerra, M.Sc. Competence Day Pultrusion KraussMaffei
Munich, 28.06.2017
PULLING THE STATE OF THE ART FORWARDPultrusion at Fraunhofer IGCV
© Fraunhofer Research Institution for Casting, Composite and Processing Technology IGCV
The Fraunhofer-GesellschaftApplication-oriented research for the benefit of th e economy and society
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more than 70%contracts with industry,publicly financed research projects
almost 30%base funding byfederal and Ländergovernments
Res
earc
h vo
lum
e
2 bn
Con
trac
t res
earc
h
1.7 bnApproximately 24 000employees
68 institutes andresearch units
München
Holzkirchen
FreiburgFreising
Stuttgart
PfinztalKarlsruheSaarbrücken
Kaiserslautern
DarmstadtWürzburg
Erlangen
Nürnberg
Ilmenau
Schkopau
Teltow
Oberhausen
Duisburg
AachenSt. Augustin
Dortmund
PotsdamBerlin
Rostock
LübeckItzehoe
Braunschweig
Hannover
Bremen
Bremerhaven
Jena
Leipzig
Chemnitz
Dresden
CottbusMagdeburg
Halle
Fürth
Wachtberg
Ettlingen
Oldenburg
Kassel
GießenErfurt
Augsburg
Straubing
Bayreuth
© Fraunhofer Research Institution for Casting, Composite and Processing Technology IGCV
The Fraunhofer-GesellschaftFields of Research
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Health and Environment
Communication and Knowledge
Production and Supply of Services
Mobility and Transport
Energy and Resources
Security and Protection
© Fraunhofer Research Institution for Casting, Composite and Processing Technology IGCV
Possibilities for cooperationHow to cooperate with us?
� Individual project definition
� Short to medium-term contract research
� 3-year cooperation, FhGemployees work at the client on site
� Cooperation of partners from research and industry
� Medium and long-term research projects
� Complementary partners (e.g. user and supplier)
� Using the methods and competences
� Joint development of solutions in a low-competition environment
� Long-term projects
Bilateral industry projects and FhG model Joint industry projects
Publicly funded projects Industrial joint ventures
Contact us for more information about different funding possibilities/models of cooperation!
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© Fraunhofer Research Institution for Casting, Composite and Processing Technology IGCV
Services Our range of services
Improving products and processesImproved performance | cost efficiency
Developing productsPrototypes | small batches | manufacturing processes
Consulting on innovationsMarket, trend and profitability analyses | feasibility studies
Introducing new technologiesFrom TRL 1 to product qualification
Providing licensesPreliminary research | transfer of inventions to licenses
Optimizing organizational formsIdentifying and realizing potentials | generating innovations
Characterizing and testingHigh-quality equipment | test reports and certificates
Qualifying for the futurePassing know-how to expert and executive staff | training
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© Fraunhofer Research Institution for Casting, Composite and Processing Technology IGCV
Fraunhofer IGCVFacts and figures
� Established: July 01, 2016
� Management:
Prof. Dr.-Ing. Gunther Reinhart (executive)
Prof. Dr.-Ing. Klaus Drechsler
Prof. Dr.-Ing. Wolfram Volk
� Development objective: Advancing into an independent Fraunhofer institute
� Augsburg site – headquartersManagement, administration, fields of research: processing and composite technology
� Garching site:Field of research: casting technology
� Supported by:
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© Fraunhofer Research Institution for Casting, Composite and Processing Technology IGCV
Fraunhofer IGCVWe use synergies in these fields of research and development:
Composite technology
Hybride Hybrid compositeconstructions
Online process monitoring
Materials and test engineering
CFRP manufacturing engineering
Recycling
Efficiency and balancing
Casting technology
Molding materials
Sand and gravity die casting processes
Simulation and design of mold and cast components
Processing technology
Resource efficiency in factories
Intelligent networked production
Flexible production
Networked modeling andsimulation
Additive manufacturing
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© Fraunhofer Research Institution for Casting, Composite and Processing Technology IGCV
Core competenceCFRP manufacturing engineering
� Realization of near-net-shape, material-efficient and load path-optimized composite lightweight structures
� Industrialization concepts for the manufacturing of highly complex component geometries
� Multi-material usage
� Combination of different placement and process technologies
� Dry fiber placement and textile preforming processes
� AFP and automated tape placement (ATL – FiberForgeRELAY®) with thermoplast prepregs
� Pull braiding; pultrusion with injection process
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© Fraunhofer Research Institution for Casting, Composite and Processing Technology IGCV
Core competenceCFRP manufacturing engineering – Pultrusion Technology
Facility portfolio – pultrusion
� Profile width up to 500 mm x 230 mm
� Max. drawing speed: 4 m/min
� Max. pull-off force: 10 t
� Caterpillar and alternating pullers
� Tool and process development for resin injection pultrusion with thermoset resins
� In-line braiding pultrusion and pullwinding (up to 4 layers)
� Complex geometries by combining downstream forming processes
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© Fraunhofer Research Institution for Casting, Composite and Processing Technology IGCV
Pultrusion technologyProject BMBF PulForm
� Manufacturing of Complex Shape Composite Parts through the Combination of Pull-Braiding and Blow Moulding
� Feasibility demonstration of process chain and limits for part postforming
© Fraunhofer Research Institution for Casting, Composite and Processing Technology IGCV
Pultrusion technologyProject ZIM SchwingPul
…Impregnation
� Enhanced impregnation using closed impregnation
� Improved impregnation especially of carbon fibers
…Fiber Package
� Homogeneous fiber/matrix distribution
� Reduction of inherent stresses
BA
� Using vibration in pultrusion processing to improve…
© Fraunhofer Research Institution for Casting, Composite and Processing Technology IGCV
Pultrusion technologyMaterials characterization and processing simulation
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Resin rheology and reaction kinetics
Fiber reinforcement characterization
Analysis of processing conditions
0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 320
2
4
6
8
10
Thi
ckne
ss [m
m]
Width position [mm]
0 200 400 600 800 1000 1200 1400 16000.00
0.05
0.10
0.15
0.20
0.25
0.30 α profile surface α profile center
Deg
ree
of c
ure
x-position from die inlet [mm]
20
30
40
50
60
70
80
90
100
110
120 Profile surface TC Profile center TC Die control TC Die monitoring TC Profile surface simulation Profile center simulation Die temperature simulation
Tem
pera
ture
[°C
]
102
103
104
105
Viscosity
Vis
cosi
ty [m
Pa.
s]
0 20 40 60 80 100 120 140 160 180
10-1
100
101
102
103
104
105
106
107
No. 1 ZW 015864 100% wt.
No. 2 ZW 015864 88% wt. ZW 8117 12% wt.
No. 3 ZW 015864 76% wt. ZW 8117 24% wt.
No. 4 ZW 015864 64% wt. ZW 8117 36% wt.
Temperature
Time [min]
Mod
ulus
of v
isco
sity
[Pa.
s]
0
50
100
150
200
250
300
350
400
450
500
Tem
pera
ture
[°C
]
© Fraunhofer Research Institution for Casting, Composite and Processing Technology IGCV
Pultrusion technologyContract research
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Materials selection• Resin formulation for processing • Resin system characterization• Fiber reinforcement
characterizationComposite design• Definition of fiber volume content• Definition of stacking sequence
Processing trials• Mold proving• Testing of different materials• Studies of processing conditions• Small batches
Tooling design• Conception of tools with closed
injection and impregnation• Retrofitting of existing tools
Testing and characterization• Testing of profiles• „Real-time“ characterization of
processing conditions
Industrialization• Concept for series production• Technology transfer to partner for
industrialization (e.g. KraussMaffei)
© Fraunhofer Research Institution for Casting, Composite and Processing Technology IGCV
Pultrusion technologyWhat we can…
We can quick n‘ dirty
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We have „Fingerspitzengefühl“
We have man-power
… and accumulated expertise!
© Fraunhofer Research Institution for Casting, Composite and Processing Technology IGCV
Thank you for your attention!
How to reach us
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ContactFraunhofer Research Institution for Casting, Composite and Processing Technology IGCVAm Technologiezentrum 2, 86159 Augsburg Phone +49 821 90678-247sebastian.strauss@igcv.fraunhofer.dewww.igcv.fraunhofer.de
The pultrusion team @ IGCVSebastian Strauß (Technology coordinator)Frederik WilhelmSimon SchwabHerbert Engelen (@ FhG-ICT)Renato Bezerra
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