Polymer Composites Research in the ALM Materials Program

13 Pages·2008·0.46 MB·English

Polymer Composites Research in the
ALM Materials Program
27 February 2008
C. David (Dave) Warren
Field Technical Manager
Transportation Composite Materials Research
Oak Ridge National Laboratory
P.O. Box 2009, M/S 8050
Oak Ridge, Tennessee 37831-8050
Phone: [phone] Fax: [phone]
Email: [email protected]
This presentation does not contain any proprietary or confidential information
ALM Historical Timeline – Composites
1990 1995 2000 2005 2010
Glass-fiber-reinforced
Fiber-Reinforced
……
Polymer-Matrix
Composites (FP1) Carbon-fiber-reinforced
Processing
Low-Cost
Carbon Fiber
Joining
Nondestructive
Testing
(FP1)
……
Crashworthi-
ness
Recycling
AACCCC KKeeyy DDeelliivveerraabblleess
Composite Underbody Low Cost Carbon Fiber Carbon Fiber SMC Hood
22000088 22001100 22001122 22001144
Polymer Encapsulated Mega-Module Composite Seat EMWG Composite Front Structure
DOE/ALM COMPOSITE MATERIALS RESEARCH
Automotive Research Program Organization
Materials
USCAR Program Coordination DOE/OFCVT
USAMP Program Management DOE/Materials
Field Technical Management ORNL
Materials Energy Management Processing Joining
Manufacturability Demonstration Projects
Car Platforms Automotive Suppliers
COMPOSITE MATERIALS RESEARCH
What Was Done --- Glass Fiber Composites
Materials
Processing Materials
P4 Preforming Durability
Slurry Modeling Deformation & Degradation
Slurry Processing Materials Screening
Focal Project II
Joining
Energy Management
Adhesive Bonding
SCAAP
Adhesive Modeling
NHTSA Modeling
NDT Rapid Testing
Energy Management
NDT Laser Shearography
FreedomCar and Beyond Test Method Analysis
Goals
Automotive Composites
Consortium
Focal Project 2: Composite Pickup Truck Box
COMPOSITE MATERIALS RESEARCH
What we were Doing --- Carbon Fiber Composites
Materials
Processing
Low Cost Carbon Fiber
P4 Carbon Fiber
Lignin Based Precursors
High Vol Process of Composites (4)
Microwave Processing
Next Generation P4
Carbon Fiber Two Splitting
Optimal CF for P4
Advanced Oxidation
Chassis Support Structures
Advanced Stabilizaton
Chassis Structures
LCCF Integration Line
Body and Door Structures
Materials
Joining
CF Comp Durability
Focal Project III
Advanced Joining
Compressive Creep
Joint Energy Absorption
Materials Dev & Screening
NDE Techniques
Recycling PMCs
Heavy Vehicle Joining
CF SMC Structures
Development of CF SMC
Other
Cost Modeling – Program
Energy Management
Composites Conference
Crash Adsorp of Bonded Structures
FreedomCar &
Crash Energy Management (7)
21st Century Truck 21Century Truck Testing Machine for Auto Crash
Automotive Lightweighting Crash of Sandwich Structures
Goals
Materials
ACC Focal Project III
Materials
Composite (Carbon) Intensive Body-In-White
Compform / Nida-Core
Vehicle package
(based on DC JA)
P4 or Compform P4 / Compression
Molding
P4 or SMC
Phase 1 Results:
67% mass savings over baseline
Bending stiffness exceeded 20%
Torsional stiffness exceeded 140%
Durability and abuse load cases satisfied
Manufacturing strategy developed
P4 / Compression Molding
SMC with
ribs
P4 / Balsa Core Materials / Mass Distribution:
Chopped carbon - 54.8 kg
Carbon fabric - 17.7 kg
Core - 3.2 kg
Adhesive - 1.6 kg
Inserts - 8.8 kg
High-Volume Molding of Composites
Materials
Test Piece Design: Multi-Purpose B-Pillar Tool
COMPOSITE MATERIALS RESEARCH (2008)
What we are Doing --- Carbon Fiber Composites
Materials
Processing
Low Cost Carbon Fiber
TPP4
Previously Briefed Lignin Based Precursors
High Vol Process of Composites
Briefed Now Lignin Purification
(- CF SMC, Press, Inj Tools, etc)
Briefed Later Advanced Oxidation
Next Generation P4
Advanced Stabilizaton
P4 Preforming
LCCF Integration Line
FSD of Textile Precursors
Higher Performance Fibers
Materials
Natural Fiber Composites
Focal Projects IV Joining
Recycling PMCs
- Underbody Bond-line Read Through
Predictive Modeling of PMCs
Bonding of TP
- Comp Seat
Composite Underbody
Energy Management
Crash Adsorp of Bonded Structures
Other
Crash Energy Management (7)
Cost Modeling – Program
FreedomCar & Testing Machine for Auto Crash
Focal Project 3
21Century Truck
Coordinated with Hydrogen Program Goals
Current