IACMI: A Disruptive Moment

in Automotive History

Craig Blue

Chief Executive Officer

2IACMI Overview

January 9, 2015: President Obama

Announces New Composite Institute

“…and today, we’re proud to announce our

latest manufacturing hub, and it is right

here in Tennessee. Led by the University

of Tennessee–Knoxville, the hub will be

home to 122 public and private partners

who are teaming up to develop materials

that are lighter and stronger than steel. ”

3IACMI Overview

• Operated by an independent not-for-profit

• Governed by a board of directors

• A wholly owned subsidiary of the University of Tennessee Research Foundation

• Incorporated in the State of Tennessee

• Headquartered in Knoxville, Tennessee

4IACMI Overview

IACMI Is a Goal-Focused Institute

Five Year Technical Goals

• 25% lower carbon fiber–reinforced polymer (CFRP) cost

• 50% reduction in CFRP embodied energy

• 80% composite recyclability into useful products

Impact Goals

• Enhanced energy productivity

• Reduced life cycle energy consumption

• Increased domestic production capacity

• Job growth and economic development

5IACMI Overview

Technical Focus on

Advanced Composites and Structures

6IACMI Overview

Shared RD&D Facilities Will

Support Industry

7IACMI Overview

Core Partners are Capable and Strategically

Located

>70% of automotive production occurs in IACMI states

Colorado has more blade facilities (factories plus technical centers) than any other state

>60% of manufacturers of compressed gas–fueled vehicles with in half-day drive from IACMI focus areas

>70% of US auto R&D in Michigan alone

8IACMI Overview

Solutionspinning

line Carbon Fiber Technology

Facility Pre-preg

productionpilot/full

scale

Pilot-scalePCM

1,000 ton press

Full ScalePCM

4,000 ton press

Scale-up Across IACMI State Partners

9IACMI Overview

IACMI Organizational Structure

Senior Leadership Team

Technology Areas

Technical Advisory Board

DOE Board of Directors

Michigan

Vehicles

Lawrence Drzal | Director

Colorado

Wind Turbines

Derek Berry | Director

Ohio

CompressedGas Storage

Brian Rice | Director

Indiana

Design, Modeling,& Simulation

R. Byron Pipes | Director

Tennessee

CompositeMaterials & Process

Technology

Cliff Eberle | Director

Craig BlueChief Executive Officer

Dale BrosiusChief Commercialization

Officer

TBDWorkforce Development

& Consortium Director

R. Renae SpeckChief Operating

Officer

Uday VaidyaChief Technical

Officer

Government Advisory Board

10IACMI Overview

IACMI has >190 Supporters and Growing

11IACMI Overview

IACMI Is Supported by Multiple Sources

Federal Cash, 26%

State and Core Partner Cash,

28%

Project Cash & In-Kind Cost

Share, 25%

In-Kind Resources,

21%

Consortium Fees, 0.5%

12IACMI Overview

Economic Development Council

A Platform for State Economic Collaboration

Each state deploys

hundreds of millions of dollars annually to create jobs and investment through

• Business services/ incentives

• Venture funds

• Workforce training

• Innovation incubation

Collaboration of state

development leaders seeding economies

worth $2 trillion

13IACMI Overview

Leveraging Core State Partnerships

for STEM and Workforce Development

UniversitiesWorkforceRetraining

K–12Community

Colleges

Internships

14IACMI Overview

An Integrated Approach Is Required

Vehicles Technology Area

Professor Lawrence T. Drzal, Director

Ray Boeman, Associate Director

16IACMI Overview

August 28, 2012

17IACMI Overview

Vehicle Response to 54.5mpg Challenge

• Lightweighting is an important end-use energy efficiency strategy in transportation. For example a 10% reduction in vehicle weight can improve fuel efficiency by 6%–8% for conventional internal combustion engines or increase the range of a battery-electric vehicle by up to 10%.

• Composites can offer a range of mass reductions over steel ranging from 25 to 30% (glass fiber systems) up to 60 to 70% (carbon fiber systems).

Specific stiffness and specific strength for various materials:

carbon fiber reinforced polymer (CFRP) composites and

glass fiber reinforced polymer (GFRP) composites.

University of Cambridge, http://wwwmaterials.eng.cam.ac.uk/mpsite/interactive_charts/spec‐spec/basic.html

18IACMI Overview

Why Lightweighting?

“Excess weight kills any self-propelled vehicle. There are a lot of fool ideas about weight . . . Whenever anyone suggests to me that I might increase weight or add a part, I look into decreasing weight and eliminating a part!” – Henry Ford, 1922

Every automotive manufacturer is pursuing lightweightingas a key strategy to reduce fuel consumption—irrespective

of the powertrain technology pathway.

19IACMI Overview

Lightweighting Vehicles

Global Comparison of Light-Duty Vehicle

Fuel Economy/GHG Emissions Standards, International

Council on Clean Transportation, August, 2011

Carbon fiber reinforced polymer (CFRP) composites have the greatest weight reduction potential if cost and

manufacturing issues can be solved.

20IACMI Overview

IACMI Goals: Fiber Reinforced Polymer

Composites for Vehicle Applications

Technical Goals

• 25% lower CFRP cost

• 50% reduction in CFRP embodied energy

• 80% ability to recycle composite into useful products

Specific Approach

• Adoption of carbon fiber composites in mass-produced platforms (≥100,000 units/year) by the end of Year 5

• Advance multiple technologies incorporating continuous fiber reinforcement to achieve cycle times under 3 minutes within 5 years, with one or more technologies under 90 seconds

• Drive down the fabricated cost of continuous carbon fiber structural parts by 50% or more within 5 years, including reduction in material and process costs

• Develop robust simulation and modeling tools that accurately and reliably predict the performance and costs of each major process and its resulting composite structures

21IACMI Overview

How Will IACMI Vehicle Technology Area

(VTA) Achieve Its Goals?

• Knowledgeable and dedicated professional staff

• State-of-the art automotive composite process facilities at manufacturing scale

• Integration of participant teams in the vehicle supply chain

– OEM, Tier 1, material suppliers, SMEs

• Identification and support for leading-edge projects

• Access to facilities for proprietary projects

• Workforce development opportunities

22IACMI Overview

>70% of automotive production occurs in IACMI states

>70% of US auto R&D in Michigan alone

Michigan Is Strategically Located and the

Leader in US Auto Production and R&D

23IACMI Overview

State of Michigan Support

• Michigan Economic Development Corporation —MEDC

– Develop automotive strategic plan

• Demographics and vehicle market

• Vehicle design

• Connected vehicles

• Powertrain and propulsion technologies

• Manufacturing and supply chain

• Material and joining technologies

– Establish collaboration center across supply chain

• OEM-tiers-suppliers-tooling-fabricators-design-testing

– Leverage expertise to attract federal and industry investment

– Develop talent in materials engineering, modeling, simulation, systems engineering and skilled trades

• Michigan State, Michigan, Michigan Tech, Wayne State

• Community Colleges: Lansing CC, Macomb CC, Alpena CC

– $15M investment in IACMI-VTA 5 years

Automotive Strategic Plan

24IACMI Overview

Vehicles Technology Area: Resources

Automation processes,

in situ thermoplastic infusion

Models for preforming,

infusion, cure kinetics, performance

High strain rate testing, NDE,

mesoscale molding,

netshape preforming,

ICME processing and performance

Low-cost carbon fiber (LCCF),

lab-scale intermediates and composites fabrication,

NDE,

recycling

• Michigan State University Resources (lab scale)

• Composite Materials and Structures Center

• Composite Vehicles Research Center

• 22,500 ft2 facility for analysis, characterization, processing and testing

• Faculty, research staff, Postdocs, graduate students

• Scale-up facility (MSU operated)

• Located in 40,000 ft2 proximate to

ALMMI/LIFT to foster IMI collaboration

and multi-material solutions

• Centrally located in Detroit

• MI State-(MEDC) funded full-scale

equipment and facilities

25IACMI Overview

MI-Vehicles Technology Area:

MSU Resources and Expertise

• Composite Materials and Structures Center

• Composite Vehicles Research Center

• MSU—Applied Research Laboratory, ITAR/EAR Compliant

– Research, characterization, testing, development facilities

• Polymer composite processing and modeling

• Process development, modeling and manufacturing-liquid systems

• Additive manufacturing of thermoplastic composites

• Multifunctional composites (nanoparticles)

• Joining—adhesive bonding, mechanical fastening, bolt design

• Surface treatments and sizing of reinforcing fibers and adherends

• Biobased structural composites

• Modeling and structural analysis (static, crash, impact, fire, fatigue)

• Dynamic characterization and design

• NDI, NDE in-situ, and remote sensing

26IACMI Overview

MSU—Composite Materials

and Structures Center

7,500 ft2 Composite Characterization Laboratoryand processing laboratory with over $5M in equipment for polymer and composites fabrication and testing

Full-time staff

– Three professionals and two technicians

Education and training of engineers and scientists 15+ Faculty and 25+ student researchers

http://www.egr.msu.edu/CMSC/

Outreach to industry and government

– Fabrication, testing and characterization capability

– Research staff for short-term contract and applied research

– Faculty and students for long-term research

27IACMI Overview

MSU—Composite Vehicle

Research Center

Center of Excellence for the research, design, and implementation of composites for lightweight, durable, cost-effective, efficient, and safe vehicles

• Emphasis on composite vehicle systems, subsystems, and components

• Intersection of composites and vehicle technologies

• ITAR-compliant off-campus facility

• “Design validated by experiment”

• Integration of analytical, numerical, and experimental approaches

Focal Areas:

• Impact and crash resistance

• Design and manufacturing – liquid molding

• Multifunctional composites

• Composites joining – bonded and bolted

• Multi-scale damage modeling

• Wireless health monitoring

• Structural optimization

28IACMI Overview

Vehicle Scale-up Facility (Detroit Area)

• OEMs and Tier 1 Industries met over a 24 month period to identify what was necessary to achieve large-scale production of polymer composites for automotive applications

• Shared facility located in epicenter of automotive R&D

– Easy and flexible access

• Production-scale equipment to demonstrate production rates >100,000 parts/year

• Automated preprocessing of composite constituents and post-processing of composites parts at scale

• Integrated in-situ recycling of offal

29IACMI Overview

IACMI-VTA Process Capabilities

• Preforming

– Automated cutting

– Thermoplastic tape layup

– Preforming press

– Thermoplastic consolidation

• Finishing

– Waterjet

– Multiaxis trim router

• Large Composite Part Fabrication

– Insert/Overmold Injection Molding (IOIM). Structural injection molding of long fiber reinforced thermoplastics into a cavity with continuous fiber preforms, composites, etc.) has been placed in performance-critical locations.

– High Pressure Resin Transfer Molding (HP-RTM) Structural dry fiber preform is placed into a mold cavity, and a liquefied, reactive resin, such as epoxy or polyurethane, is injected through the preform and cured. Both thermoset and reactive thermoplastics.

– Compression Molding of Continuous Fiber Prepreg (Thermoset, Thermoplastic) SMC processes will be modified to accommodate continuous fiber prepregsthat have been robotically cut, stacked and debulked to reduce waste and increase properties along specific load paths.

• Material formulation

– Hot-melt prepreg line

– Thermoplastic recycling regrind/recompound

30IACMI Overview

Example Project: Compression Molding of

Continuous Fiber Prepreg

Project Elements Addressed by IACMI

• Development of large parts employing CARBON and/or GLASS fiber and unidirectional preform molding of prepregs targeted at 3 min part cycle for parts the size of a roof

• Draping simulation, rheological characterization, property determination to form the basis for process modeling and simulation

• Enhanced robotics for cutting, kitting, and stacking for complex parts at less than 3 min cycle times

• Optimized cutting paths and part design and high-speed tape laying to minimize waste

• Combination of continuous and discontinuous fiber prepreg materials in a single molding process

• Hands-on training of technicians/engineers

• Opportunity for proprietary material and/or process development

Source, Schuler

Source, Composites World

31IACMI Overview

Composite Joint Design and Multi-material Attachment Technology

Project: Develop process-specific joint and interface design incorporating

both adhesive bonding and mechanical fastening for FRP/metal joints

Example Cross-Cutting Project

Adhesive Bonding • Potential reduction in weight & cost

• Preferred over mechanical fastening

• Eliminates stress concentrations due to holes

Types of Adhesive Jointsa) Lap-Joint

b) Double Lap-Joint

c) Butt Joint

d) Scarf Joint

e) Corner/L-joint

f) T-/Pi- Joint

Objectives • Quantify the performance of tailorable, multifunctional,

adhesively bonded structural composite joints. Includes

Pi-, lap-, and dissimilar materials

• Model mechanical response under static and dynamic

conditions

• Develop high speed surface prep and fabrication methods

Mechanical Fastening• Required for repair, reassembly

• FRP composites require special hole design &

fasteners to avoid hole-initiated damage

32IACMI Overview

IACMI-Vehicle Technology Area Personnel

We welcome the opportunity to answer your questions, provide operational, facility and technical information!

Ron Averill — Design Optimization: structures, manufacturing, crash design, optimization

Jay Jayaraman — Polymer composite molding, extrusion of thermoplastics, nanocomposites

and thermoplastic elastomers; solid state forming; polymer foams and foamed composite

Mahmood Haq — Computational Design: tailorable materials / multiscale materials,

adhesively bonded and bolted hybrid composite joints, NDE

Al Loos — Manufacture of composites by RTM, VARTM, and RFI. Expertise in resin infusion

process simulation models, mechanics of composite materials.

Sharon Xiao — Composite damage – crashworthiness simulation, progressive composite

fatigue model, residual properties of damaged composites

Michael Rich — CMSC and CVRC facility operation, research, testing, fabrication

Lawrence T. Drzal, PhD

Director, IACMI Vehicle Technology

Tel. 517-353-5466

Email: drzal@egr.msu.edu

Raymond G. Boeman, PhD

Associate Director, IACMI Vehicle Technology

Tel. (865) 274-1025

Email: boemanrg@ornl.gov

Compressed Gas Storage

Technology Area and Intermediate

Scale Manufacturing

Brian Rice, Director, CGS

34IACMI Overview

Why Ohio?

Ohio ranks #2 in the US in automotive-related employment

60% of compressed gas−fueled vehicle manufacturers within half-day drive from IACMI centers

35IACMI Overview

• >40 years’ experiencein applied, advancedcomposites RD&D

• 200,000 ft2, fully equippedand industrially focusedUS composites manufacturingresearch center andbusiness incubator

− 1,000 ton, 10 x 8 ft press

− 3-station robotic preformer

− Long-fiber thermoplastics

molder

− Sheet mold compounder

− Thermoplastic tow

infusion line

− 440 ton co-injection molder

− 10 x 5 ft, 800 F, 200 psi autoclave

Filament Winder

Automation processes

• In situ thermoplastic infusion

Models for

• Preforming

− Infusion

• Cure kinetics

• Performance

Develop automated manufacturing cell

High-Pressure Resin Transfer Modeling (HP-RTM)

• Preforming

− Joining

Low costcarbon fiber

• Lab-scale intermediates and composites fabrication −Nondestructive

evaluation

• Recycling

Site DirectorBrian P. Rice

UDRI─Division Head937-229-2519

brian.rice@udri.udayton.edu

Ohio Technology Area

36IACMI Overview

DOE Compressed Gas Storage (CGS) Tank

Targets

Reduce the cost of a type IV hydrogen storage tank by 30% (2018) and 50% (2024) with a capacity of 500,000 units/year

Type IV: An all-composite construction featuring a polymer (typically high-density polyethylene, or HDPE) liner with carbon fiber or hybrid carbon/glass fiber composite. The composite materials carry all of the structural loads.

Fabrication method: Filament winding, a mature industry, 40+ years

The markets: Pressure vessels (2015)*

High-pressure gas storage vessels represent one of the biggest and fastest-growing markets for advanced composites, as transportation markets demand alternative fuels (Compressed natural gas [CNG] and hydrogen) for motive power systems.

*Composites World January 12, 2015

37IACMI Overview

http://www.calstart.org/Libraries/CalHEAT_Documents/Heavy-Duty_NGV_Roadmap_2014.sflb.ashx

KCF = 1000 cubic feet

Reduced Cost of CGS Tanks Enables

Greater Use of Domestic Fuels Such

As Natural Gas

38IACMI Overview

*Composites World January 12, 2015

CNG Market Projections

Payback period for CNG fuel system is 3−5 years. 70% of cost is carbon fiber composites.

IACMI seeks to reduce cost by 25% to drive faster growth.

39IACMI Overview

(1) http://www.afdc.energy.gov/vehicles/natural_gas.html(2) overview_of_ngv_cylinder_safety_standards.pdf (Mark Trudgeon, July 2005)

Natural Gas Vehicle Cylinder Safety

Standards

There are approximately 15 million road vehicles, worldwide, using CNG for fuel. That number is increasing every year (but only 150,000 in the US) (1).

In 1992, the US developed ANSI/AGA NGV,2 “American National Standard for Basic Requirements for Compressed Natural Gas Vehicle (NGV) Fuel Containers.” (NGV2-2000) (NGV2-2007) (2)

Cylinder designs that meet the requirements of these standards:

will have a fatigue life that exceeds the specified service life

when pressure-cycled to failure, will leak but not rupture

when subject to hydrostatic burst tests, will have stress ratio factors that exceed the valuesspecified for the cylinder type and the materials used

must meet damage tolerance criteria for drop impact, bonfire, penetration, and environment

Service pressure of 245 bar (3600 psi), safety factor of 2.35 for carbon fiber

IACMI to foster improved safety as well as cost reduction

40IACMI Overview

*Courtesy of Xperion

CGS Manufacture SOA

41IACMI Overview

CGS Tank Manufacturing Innovation

42IACMI Overview

Braid Offers Potential for Enhanced Safety

and Reduced Mass

43IACMI Overview

Safety is Critical

44IACMI Overview

UDRI Overview

• Established in 1956 in Dayton, OH

• Performs basic and applied research, engineering services, and testing

• Fully supported by external sponsors

• Third in the US in funded materials research

• More than 450 professional research staff

• 218,000 ft2 of facilities

• Average annual revenues (last 3 years): $90 million

• Currently under contract for more than $550 million of research

45IACMI Overview

1000 ton press for HP-RTM and prepreg compression molding

Ohio IACMI Automotive Work Cell

46IACMI Overview

Injection Molding Specifications

• Cincinnati Milacron NT440 S Powerline model

• Horizontal injection shot capacity: 40 oz (1135 g)

• Vertical injection shot capacity: 10 oz (284 g)

• Maximum injection rate (horizontal): 20.8 oz/s (590 g/sec)

• Peak injection pressure: 30,000 psi (206 MPa)

Mold and Clamp Unit

• Daylight: 56.1 in. (1425 mm)

• Minimum mold height: 9.8 in. (250 mm)

• Maximum mold height: 29.5 in. (750 mm)

“One of a kind” all-electric Cincinnati

Milacron injection molding machine.

Ability to use 440 tons of clamping

force and two barrels, our machine is

ideal to conduct developmental work

and short production runs for

automotive insert/overmolding

applications.

Dry insert; reinforcing fabric

Thermoplastic Injection Overmolding

47IACMI Overview

Custom Polymer Compounding

Devolatilizing Twin Screw Extruder

• Model: Coperion ZSK 26

• Drive: 30 HP Allen Bradley AC induction motor, 1800 RPM base speed, oil-lubricated reduction and distribution gear assembly with torque limiting coupling

• Screw: co-rotating shafts, 12–1200 RPM screw speed, 82 N-m available torque per shaft, configurable screw designs

• Barrel: 25mm diameter barrels, 1300 mm length, nitrided steel, 7 independent controlled heating zones, 15.6 kW total heating power, 400°C maximum temperature, pressure transducer at barrel exit

• Venting: 3 vent ports for devolatilization, each with vacuum/pressure gauge, sight glass, throttling nitrogen valve, and insert block (when venting is not used). All vents connect to vacuum manifold pipe system

48IACMI Overview

Fatigue testing

of composite

spring

Truck spring fatigue

Structures and Material Evaluation

• Proficient with a large variety of standardized tests(e.g., ASTM, SAE)

− ISO-9000 certification

• Wide variety of materials:

− Metals (e.g., aluminum, titanium, steel, nickel- based, magnesium)

− Composite systems

• polymeric (PMCs)

• metallic (MMCs)

• ceramic (CMCs)

− Elastomers

− Polymers

− Components

− Structures/substructures

49IACMI Overview

Jared Stonecash937-229-4361

jared.stonecash@udri.udayton.edu

Brian Rice937-229-2519

brian.rice@udri.udayton.edu

UDRI Contact Information

Contact UDRI personnel to network and discuss potential IACMI projects:

Materials and Processing

Technology Area

Cliff Eberle

Director, Materials and Processing Technology Area

51IACMI Overview

• Carbon fibers

• Lab-scale intermediates and composites prototyping

• Recycling

• Nondestructive evaluation (NDE)

• Materials characterization

Materials and Process

Technology Area Snapshot

Wide area flaw detection

Carbon Fiber Technology Facility

Polymer AM Cell

Robotic preformer

Nonwovens Research

Lab

ORNL: US leading neutron characterization and

computing power

-Thermo-plastic-glass-carbon

recycling -Factory floor NDE-Full-scale molding

with LCCF -Pultruded spar caps

-Product lifecycle modeling-Process modeling

for lab-scale validation

-Largest open access

solution spinning lab in US

-Closed loop recycling

-Factory floor NDE -Full-scale preforming-Molding

processes with LCCF

-Factory floor NDE -Full-scale

preforming and winding processes

with LCCF

52IACMI Overview

IACMI Goals as stated in the Funding

Opportunity Announcement

Focus Areas

• Vehicles• Wind Turbine Blades• Compressed Gas Storage (CNG, Hydrogen)

Five Year Technical Goals

• 25% lower CFRP cost• 50% reduction in CFRP embodied energy • 80% composite recyclability into useful products

Impact Goals

• Enhanced energy productivity• Reduced life cycle energy consumption• Increased domestic production capacity

• Job growth and economic development

TRL 4 - 7

These goals depend on materials and processing technology developments

53IACMI Overview

25% lower CFRP cost demands lower

CF cost!

CFRP cost build-up for a van door inner with intrusion beam. Source: Rocky Mountain Institute

Cost breakdown for 700-bar CFRP H2 storage tank. Source: Strategic Analysis

59%

8%

10%

5%

18%

54IACMI Overview

50% reduction in CFRP embodied

energy requires attention to CF

0

200

400

600

800

1000

1200

Baseline, 30%scrap rate

Baseline, 5%scrap rate

50% Less CFEnergy

75% Less CFEnergy

Co

mp

osi

te E

mb

od

ied

En

erg

y, M

J/kg

Energy Embodied in HP-RTM Composite with 61 wt% CF

Intermediate & Composite Fab

Resin

Carbon Fiber Scrap

Net Carbon Fiber

Source: ORNL

55IACMI Overview

IACMI has unique precursor and carbon

fiber processing capabilities

Melt spinning

World’s largest university-based

solution spinning lab

Bench and pilot

scale heat treatment

equipment

World’s most flexible carbon fiber

semi-production facility

56IACMI Overview

Highlighted M&P Composites Fabrication

• Lab scale

– Compounding

– Weaving

– Prepregging

– Injection molding

– Compression molding

– Thermoforming

• Full scale

– Robotic preforming

– 3D printing

– Filament winding

– Pultrusion

Robotic preforming

Big area additive manufacturing cell

57IACMI Overview

Current ROM estimated recycling rates (all “downcycling”):

• ~ 100k tpy CFRP production; > 10k tpy scrap & < 1k tpy recycled; negligible EOL

• ~ 9M tpy GFRP production; ~ 500k tpy scrap; ~1M tpy EOL, 10 - 80% recycled

Near-term focus on recycling waste from CFRP production scrap

Mid-term we will add end-of-life composite structures

Achieving 80% composites recyclability

Key challenges:1. Strong value proposition for GFRP recycling

2. Collection, sorting, classification, separation

End of life materials often lack a known pedigree and include

metals, electronics, etc.

3. Fiber reclamation

Current technologies at TRL 5 – 8 based on: mechanical

recycling, chemical recycling, solvolysis, and pyrolysis

4. Delivering many life cycles of high value intermediates and

components in high volume manufacturing

Scientific Research

Technology

Development

Recyclers and

end users;

Regulations

and policies

IACMI

58IACMI Overview

IACMI recycling capabilities

Adherent Technologies wet chemical composite recycling pilot reactor

MIT-RCF’s slurry preforming (top) and roll goods (bottom) production in its commercial carbon fiber recycling facility

Photos courtesy of Adherent Technologies and MIT-RCF

59IACMI Overview

Title: Three Dimensional Microstructure of Polymeric Composite Materials Used

in Sandwich Structures Using Dual Modality from Combined High Resolution

X-ray and Neutron TomographyDr. Dayakar Penumadu, University of Tennessee, Knoxville, USA

18th International conference on Composite Materials (ICCM 18), Jeju, S. Korea

Navy Relevance: Understanding the failure mechanism at multi-length scales non-destructively of the wet and dry CFRP specimen will benefit

with safer application of CFRP use in Navy vessels.

Current Research: X-ray and neutron tomography techniques provide non-destructive method to visualize the interior of the CFRP facings for

failure mechanism investigation. The technique revealed the non-uniform density distribution of resin in the sample. The wet sample failed with

the delamination of the outer layer concentrating in the failure zone while the entire dry sample took part in the failure process during cyclic

loading.

Objective: Overview of X-ray and neutron tomography performed on the CFRP facing used for sandwich structures is given. The capabilities and limitations of the techniques are presented. Three-dimensional Image registration of X-ray and neutron tomography data is performed, and the contrasts of X-ray and neutron images are compared. The imaging technique will be applied to study the failure mechanism of wet and dry CFRP under loading.

X-ray Tomography SetupNeutron Tomography Setup

Peak Energy: 7.30x10-6 keV

Parallel Beam

Resolution: 29.8 m/voxel

FOV: 61 x 61 mm2

Peak Energy: 100 keV

Cone Beam

Resolution: 13.2 m/voxel

FOV: 30.5 x 30.5 mm2

Neutron Tomography Slice X-ray Tomography Slice

Dry Wet

Failure

ZoneAway Failure

ZoneAway

Failure Mechanism Comparison of Wet and

Dry CFRP after Cyclic Loading

1.70

cm-1

0.98

0.27

Resin

Fiber Bundle

Non-Uniform Resin

Density Distribution

NDE Overview

• We apply NDE data to help meet IACMI metrics for speed and yield by closing the loop around process design and control.

• We deploy our NDE capabilities where and when needed across the supply chain and product lifecycle.

Process Quality ControlProperty Quality AssuranceProduct Lifecycle Support

Flaw imaging

Precursors

Fibers

Composites

Components

Assemblies

Rapid inspection

Process monitoring

of material state

Products

Health

monitoring

Microstructure

imaging

60IACMI Overview

IACMI

Characterization

• Mechanical and physical properties, stress-life testing, fatigue behavior, durability, environmental conditioning

• Multi-Scale and high resolution microscopy, spectroscopy, diffraction/scattering, residual stress and imaging

• Premier polymer characterization facilities for molecular weight and distribution, conformation, size, and thermal properties

• Advance fiber characterization using FTIR, NMR, XPS

Multi-Scale, Multi-ModalProcess-Property

Relationship & Durability

Automotive Crashworthiness

Precursors

Carbon Fibers

Composites

Components

Assemblies

Products

Structural

monitoring

Multi-axial static &

fatigue behaviorSingle Carbon Fiber

Nano-Tensile Testing

Interface/interphase

shear with resin

Material Joining

Characterization

61IACMI Overview

Materials and Processing POC’s

Doug Adams (NDE)

douglas.adams@vanderbilt.edu

615-322.-2697

Cliff Eberle (M&P)

eberlecc@ornl.gov

865-574-0302

Soydan Ozcan (Recycling)

ozcans@ornl.gov

865-241-2158

Dayakar Penumadu

Materials characterization

dpenumad@utk.edu

865-974-2503

Matt Weisenberger

Solution Spinning

matt.weisenberger@uky.edu

859-257-0322

Innovative Modeling and

Simulation Technology Area

R. Byron PipesExecutive Director

Innovative Modeling and Simulation Technical Area

63IACMI Overview

The State of Composites

Manufacturing Simulation

• Unlike design simulation software, the manufacturing of polymer composite materials and structures involves multi-physics phenomena.

• Phenomena span the disciplines of polymer science, rheology, reaction kinetics, fluid mechanics of non-Newtonian liquids, heat and mass transfer, mathematical topology, anisotropic thermoelasticity, and viscoelasticity.

• Curing reactions of thermoset polymers, melting and solidification of thermoplastic polymers, flow and impregnation of viscous polymers in fibrous preforms and tows, consolidation of fiber preforms, conduction and convective heat transfer, geometric conformation of fiber preforms to curvilinear surfaces, residual deformations due to anisotropy in thermal expansion.

64IACMI Overview

Human Talent and Tools

• Education and training of a new generation of engineers who can transform a metals-based industry to a composites-based industry is needed.

• Simulation tools that capture the multiplephenomena in composites manufacturing to achieve near-optimum manufacturing and designs are essential.

• These tools can revolutionize high performance products for energy efficiency and value in use.

65IACMI Overview

• Purdue’s cdmHUB and cvfHUB will put browser-based simulation in the hands of subject matter expertsand Tier III suppliers− cvfHUB: Deliver a comprehensive suite of commercial simulation

tools for center of excellence project teams in MI, OH, CO, TN

Innovative Design, Predictive Modeling

and Simulation Technology Area: Portal IN

Integration of many major commercial simulation tools

Vehicle teams

Wind teams

CGS teams

Tool training

Tool evaluator (TML)

New tool development

Commercial tools

Browser-based

Secure data

• Automated tape laying and fiber placement

• RTM• Nondestructive

evaluation• Curing simulation

• Molecular material studies

• Material and discovery studio

• Preforming draping • Simulation cure kinetic

modeling

• HP-RTM• Preforming• Joining• Braiding• Design and modeling

simulation• Draping simulation• Curing

• Molecular material studies

• Material and discovery studio

66IACMI Overview

Preform

Stacking

Consolidation/

Compaction in

Mold

Consolidated Preform Assembly: Fiber Orientation

Cure Kinetics in

the Mold

Heat Transfer

and Exotherm

in the Press

Resin Infusion

Effective Anisotropic Heat Transfer Properties

Preform Assembly: Fiber Orientation

Residual Stress

State

Preform

Shaping

Effective

Mechanical

Properties

Post-mold

Deformation

CATIA

DIGIMATPAM-RTMDIGIMAT

CATIA DIGIMATCATIA

RAVEN

CATIA/COMPAC

DIGIMAT COMPRO MARC/ ABAQUS

COMPRO

Model Composites Manufacturing

Process—High Pressure RTM

67IACMI Overview

Simulation

across IACMI

Partners and Scales

SolutionSpinningLine Carbon Fiber

Technology Facility (CFTF)

Pilot Scale

PCM1,000 ton press

PrepregProductionPilot / Full Scale

Full Scale

PCM4,000 ton press

68IACMI Overview

Simulation Tool Validation

• Simulation tools validated at the lab scale at Purdue

• Lab-scale manufacturing process facilities established for all IACMI processes

• Simulation tools validated for all manufacturing processes within IACMI

• Simulation tool input data developed for all IACMI materials systems and processes

• Simulation tool validated at subscale and full scale at other IACMI sites

69IACMI Overview

Indiana Manufacturing Institute

70IACMI Overview

Indiana Manufacturing Institute (IMI)

• WEST LAFAYETTE, Ind.—Purdue Research Foundation board of directors on February 18, 2015 approved construction of the $50 million, 62,000 ft2 IMI, where Purdue University researchers will expand research in composite materials manufacturing.

• IACMI will occupy approximately 30,000 ft2 of the IMI.

• Validation at the lab scale for all IACMI manufacturing processes will be located adjacent to simulation studios of the cvfHUB.

• Cooperating industries are invited to co-locate in the IMI.

71IACMI Overview

Innovative Design, Predictive Modeling

and Simulation Technology Area: Portal IN

• R. Byron Pipes, Executive Director bpipes@purdue.edu(765) 418-5447

• Ron Steuterman, Managing Director steuterm@purdue.edu(765) 426-1335

• Wenbin Yu, cvfHUB Director wenbinyu@Purdue.edu(435) 764-8877

• Johnathan Goodsell, Validation Director jgoodsel@Purdue.edu (765) 414-7858

WE WELCOME INQUIRIES

Working with IACMI

Craig Blue

Chief Executive Officer

73IACMI Overview

Ways to Partner

with IACMI

1. RD&D Research Project

A. Enterprise

B. Technology Collaboration

C. Topic-Specific

2. Membership

A. Charter

B. Premium

C. Resource

D. Consortium

74IACMI Overview

Charter Members (Available)

Required investment:

• $5 million over 5 years

• At least 50% in cash

• $100,000 cash annually toward IACMI overhead expenses

Benefits:

• Cash contribution eligible for match subject to available funds

• Leverage significant intellectual and resources capabilities

• Influence in creation and direction of IACMI

• Participation in governance

– All Charters have a Seat on the Board

– Elect one rep for the Technical Advisory Board

• Rapid access to shared RD&D facilities

75IACMI Overview

Premium Members (Available)

Required investment:

• $1 million over 5 years

• At least 50% in cash

• $20,000 annually toward IACMI overhead expenses

Benefits:

• Cash contribution eligible for match subject to available funds

• Participation in governance

– Elect one rep for the Board

– Elect one rep for the Technical Advisory Board

• Leverage significant intellectual and resources capabilities

• Enterprise-wide proprietary projects

76IACMI Overview

Resource Members (Available)

Required investment:

• Provide resources (e.g. equipment, materials, or software) as cost share

• Donated resources must be of value to IACMI

• Must execute a Consortium Level Membership Agreement

Benefits:

• Right to use unique modifications to their technology

• Exposure to potential customers

• Participate in projects to improve their products

77IACMI Overview

Consortium Members (Available)

Required investment:

• $5,000 annually for industry with ≤500 employees and educational institutions

• $10,000 annually for industry with >500 employees

Benefits:

• Opportunities to engage

• Opportunities to build key relationships

• Opportunities to participate in governance

– Elect one SME rep for the Board

– Elect one SME and one Large Co. rep for the Technical Advisory Board

• Opportunities to fuel your company’s growth within the composites ecosystem

78IACMI Overview

Project Types

Project Type

Project

Total

Budget

Cost Share

RequirementDuration Other Requirements Intent

Enterprise >$600K

Minimum 1:1

with 50%

being cash

Up to 5

years

• A small number of

value-chain members

can jointly submit

• Must involve team

collaboration and

potential large

economic and

commercial impact

Bigger projects

with multiple

partners that

significantly

contributes to

achieving

IACMI goals.

Technical

Collaborations

$20K-

$600K

Minimum 1:1

(large

entities: 50%

being cash)

Up to 2

years

Awarded in 2 phases:

• Phase 1 is <6 months

and $150K total costs

• Optional Phase 2 is

<18 months and

$450K total costs

Smaller

investigatory

efforts that can

be started up

quickly.

Topic Specific >$20K Minimum 1:1Up to 1

year

Only accept white

papers that address

specific IACMI-issued

topics

Address topics

of interest to

our Members

79IACMI Overview

IP Summary

Enterprise and

Technology

Collaboration

Projects

Topic Specific

Projects

Company(ies)

Generated IP

Company(ies) owns* 1st: Charter Members would get a

6 months from notification option to

co-exclusive commercial license* then;

2nd: Premium Members would get a

6 months from notification option to

co-exclusive commercial license* then;

3rd: Resource Members would get a

6 months from notification option to

co-exclusive commercial license*.

Academic & DOE

National Lab

Generated IP

Company(ies) would get

6 months option to a

field-limited exclusive

license for an additional

fee*

Jointly-Created IP Same as above*

*Government agencies may have certain statutory or contractual IP rights, e.g. license for government use,

requirements, and substantial US Manufacturing

80IACMI Overview

Project

Proposal

and Review

Process

RFP will include

evaluation criteria,

including statement

of industrial need that

aligns with IACMI

goals

Responsive to

roadmap needs

Evaluators include

Directors, TAB, TAB-

assigned, BOD,

and/or DOE

White Papers

accepted on a rolling

basis

81IACMI Overview

$70M - DOE

$189M - Other

123 - Member Consortium

6 Core Partner States

Strong Leadership

5 Technology Areas

Production capacity

Jobs

- 75%CFRP embodied energy savings

- 50%CFRPproduction cost

Greenhouse gas avoidance

- 25%

- 50%

- 50%- 75%

95%FRP recycled and/or reused

80%

Federal Investment Will Catalyze

a Composites Ecosystem in the

Heart of US Manufacturing

82IACMI Overview

Questions?

• Visit IACMI.orgto learn more.