“Composites in Automotive”

1.11.2013

Prof. Dr.-Ing. Dipl.-Wirt. Ing Thomas Gries

Carbon Fibre

Textile Manufacturing

Resin Impregnation

Simulation / Quality Assurance

Recycling

Textile solutions for mobility

NRW / RWTH / ITA

Contents

2

From the fibre to the product

3

Global demand for carbon fibre

0

20000

40000

60000

80000

100000

120000

140000

2008 2009 2010 2011 2012 2015 2020

Year

Dem

an

d [

t]

4

Carbon Fibre

Production capabilities

Carbon fibres @ ITA

Scale

Thermal Analysis Chamber Oven Laboratory Line Pilot Line

5 – 10 cm 1 m 100 m bobbin

Equipment

Quantities

laboratory discontinious quasi-continious continious

Dec. 2012

6

Recource-efficient and highly productive production of carbon fibres

for a wide application spectrum

Objectives:

Increase of production speed

Increase of capacity of the new production plants

Lowering the power demand

MegaCarbon

Polymerisation Spinning Solution Spinning Procedure Stabilisation Carbonisation Finishing

7

Textile Manufacturing

Textile Manufacturing

TailoredBlank Tailored Tube Assembly Line

TailoredNCF TailoredBraid Preformcenter

Steel

FRP

9

Production technology for Tailored-NCF

Enhancement of multi-axial warp-knitting machinery

Warp-knitting machine Source: LIBA Maschinenfabrik

10

BMW M3 Large scale production

Resin Impregnation

≤ 70 /day ≥ 1000 /day

Minutes Seconds

11

State Of The Art - Prepreg

12

New Technologies at RWTH – Gap Impregnation IKV

Mould

Preform

Flow front

Frame

Matrix

Discharge of Matrix Spread of Matrix

13

Simulation/

Quality Assurance

Textile characterization

Friction coefficient

Geometry

Shearability

Modelling

Kinematic simulation

Level Macro (Meso, Micro)

Validation

Digital Image Correlation (DIC)

Modelling

15

Real Time Quality Assurance –

Falcon (Fibre Automatic Live Control)

16

Recycling

© CAMISMA 2012 · All rights reserved20.01.2012Slide Nr. 311ic0003_Short presentation_2012.pptx

The value chain

Goal: Cost effective concept for mass production of composites

Starting materialsUD- and non-

woven Tapes

Simulation and

Design

Thermoforming

and Function

integration

Multi-Material-

Component

Automobile

sector

18

Textile solutions for mobility

19

Quelle BMW

Lightweight construction with FRP

Textile fabrics

3D-Preforming

Braiding technologie

Prepregging

Tailored NCF 3D-Fabric

ITA-Preformcenter

Braiding of a hub

FRP convertible roof

Crashabsorber

Simulation Coating ficility

20

Smart Textiles and integration of functions

Textile bus systems

Textile integrated illumination

Sensor systems

Heated textiles

Conductive paths Conductive fabrics

LEDs on textiles

Sensor rope

Illuminated structures Source: ITCF Denkendorf

Sensor wear

Heated fabric Source: Sefar

Heated fabric Source: TITV Greiz

21

Technical fibres for innovative materials

Additives in thermoplastic fibres

High modulus fibres

Piezoelectric fibres

Hybrid fibres

Luminescent fibres High temperature fibres

Carbon fibre Source: Zoltec

PVDF- Fibres

Glass fabric

Fibre integration

Hybrid yarn Thermoplastic FRP frontend

PEEK Polyether

ether-keton

PEI Polyetherimid

PSU Polysulfon

Source: Ticona

22

Recycling of FRP

Opening of fibres

Formation of nonwovens

Yarn formation

Bonding of Nonwovens

Laboratory Card

Aerodynamic web

formation

Ring spinning

Consolidation of

nonwovens

Recycled nonwoven

Opening roller

web on screen

Laboratory Card

23

RWTH Aachen Campus

New form of cooperation

between industry and

university:

15 relevant clusters

Exchange of research results,

employees,

further resources

Biggest European technology

campus

2 Bill € investment

till 2020

Source: rha reicher haase + associierte

ITA

19

Aachen Composites Engineers - ACEs

Integrated solutions for textile composites

Objectives

Interdisciplinary innovations and enhancements of:

Products, processes, production machines

Design, simulation and measurement technique

Technology and know-how transfer between research and industry

Technologies for composite structures in automotive applications

Source: ACEs

Component

design

Textile

technology

Plastic

processing

Production technology

Automotive

applications

20

4500 scientists

2300 service personnel

36,000 students

750 Mill. € budget

40 % research projects

RWTH Aachen University and ITA

80 scientists

55 service personnel

190 graduate research assistants

50 students majoring in textile

technology per year

14,3 Mill. € budget

90 % research projects

RWTH Aachen University Institut für Textiltechnik (ITA)

21

Organisation

TF

I: I

nsti

tut

für

Bo

den

syste

me

an

der

RW

TH

Aa

ch

en

e.V

.

Man Made Fibre

Technology

Medicine /

Smart

Textiles

Fibre

Reinforced

Composites

Textile Engineering

Our Strengths:

Fibres

Textile

structures

Production

technology

Application

22