Advanced Thermoplastic Composites (ATC) At DSM …
19
CONFIDENTIAL Advanced Thermoplastic Composites (ATC) At DSM Engineering Plastics
Transcript of Advanced Thermoplastic Composites (ATC) At DSM …
CONFIDENTIAL
Advanced Thermoplastic Composites (ATC)At DSM Engineering Plastics
CONFIDENTIAL Confidential
1
CONFIDENTIAL Confidential
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
CONFIDENTIAL Confidential
Why ATC: Weight loss is the most effective technology forlowered emissions
CONFIDENTIAL Confidential
What changed: the significance of light-weight
CONFIDENTIAL Confidential
CONFIDENTIAL Confidential
UDT Physical Characteristics
CONFIDENTIAL Confidential
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
CONFIDENTIAL Confidential
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
CONFIDENTIAL Confidential
Examples of applications and achieved weightreductions
Weight targets for each module met
CONFIDENTIAL Confidential
Examples of applications
CONFIDENTIAL Confidential
Motivation Results Database Further steps
ww
w.th
efut
urei
scom
posi
te.c
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
ngsu
ppor
t• Focused Standardization of cFRTPàrobustness, efficiency, transparency
• Improvement of data quality andavailability for simulation
• Robust and efficient quality control Stro
ngsu
ppor
t
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 …
CONFIDENTIAL Confidential
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)
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
CONFIDENTIAL Confidential
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
CONFIDENTIAL Confidential
Visual Presentation of Gaps In Supply Chain
UD Tape Tape Lay Up Consolidation Thermoforming
Gaps: Fragmented/Opportunistic
CONFIDENTIAL Confidential
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
CONFIDENTIAL Confidential
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
Contact persons
Raj Mathur Tel.: +31652590614. Email: [email protected] Perfetti Tel.: +31683649747. Email: [email protected]
