innovative production technologies for lightweight ... production technologies for lightweight...

Mario Krupka, DORNIER Composite Systems®, Lindauer DORNIER GmbH

Innovative Production Technologies

for Lightweight Automotive Composites -

Tape Production, Tape Weaving and 3D

Weaving

BMWi USA Business Trip, Troy, MI, September 26th, 2017

Headquarters Lindau, Rickenbach, Germany

BMWi USA business trip 2

Administration

Sales of weaving machines and specialty

machines

Development of weaving machines and specialty

machines

Production of weaving machines

Number of employees: 812, including 56 apprentices

(Status as per 31.12.2016)

Production plant Esseratsweiler


Production of specialty machinery

Film stretching lines

Drying plants

Technical center of DORNIER Composite

Systems®

Tape pilot production line

Tape weaving machine

Carbon fiber weaving machine

3D weaving machine

Number of employees: 155(Status as per 31.12.2016)


American DORNIER Machinery Corporation

In Charlotte, North Carolina we take care for

our American customers.

Our subsidiary is not only a sales office, but

offers also service, installation and training

for weaving machines and service for the

clamps of film stretching lines.


1922: Proof test on a Dornier Komet II,build completely from Aluminum

This airliner was build from webframes and straight planking (2200 kg flying weight)

Maiden flight on October, 9th

1922

On December, 31st this first German airliner has flown to England with 4 passengers and one pilot on board

It was the begin of the Berlin – London air traffic by German Aero Lloyd

1931: Do X on Hudson River in New York


The flying boat Do X was build from Prof. Claude

Dornier (1884 - 1969) and was the biggest

airplane in this time

The take off weight was 52 tons with a wingspread

of 48 m. A modern Airbus A310-200 has 142 tons

and 44 m

The record flight in October 1929 with 169

passengers on board started from Lake

Constance to New York. An Airbus A310 carries

today around 220 passengers


1950: Start in Lindau, Lake Constance

Foundation of

Lindauer DORNIER GmbH

and introduction of the first

weaving machine (shuttle

loom), type “DoTex”


1973: First carbon fiber woven fabrics made on DORNIER rapier weaving machines

Introduction of the first shuttle less weaving machine (with ridige rapier) in 1967

Today worldwide more than 40 DORNIER customers produce carbon fiber fabrics

Around 85 % of worldwide production of carbon fiber fabrics are made today on DORNIER rapier weaving machines

Many other technical fabrics from aramid fibers, glass fibers or other high strength man made fibers are “woven on DORNIER“

In 1989 DORNIER introduced the first airjetweaving machine


1973: First CFRP-part in aircraft (braking flaps)

Alpha Jet

Maiden flight in 1973

Production: 480 aircraft from DORNIER (Germany) und Dassault (France)

Top speed: 1,000 km/h

Use as twinjet-trainer, light fighter und fighter bomber

Development, testing and fabrication of CFRP braking flaps from woven fabric prepreg


2016: Carbon fiber weaving machine intechnology center Composite Systems

P1 rapier weaving machine with 200 cm nominal width and 130 cm reeded width

2 feeders with chromium surfaces

Duo-Mix waist preventing system left and right

Creel with 300 spooling positions equipped with 1200 tex glass fiber roving

Several weft materials can be used (e.g. carbon-, glass-, aramid- or natural fibers

Available for customer trials

Today: Composites in modern aircraft


In modern airliners like Boeing 787 or Airbus 350

XWB, engineers use up to 50% carbon composites

in structural parts of fuselage and wings. 10% are

made from steel, 15% from Titanium, 20% from

Aluminum and 5% are others. For comparison,

Boeing 777 (maiden flight June 1994) uses 12%

composites and 50% aluminum.

Today: Composites in high-end cars


In non-structural parts of sports and

luxury cars, CFRP is often used

because of its design and low

weight

Structural parts are still exotic

For serial street cars process times

are still too long and costs too high

for classical (thermoset-based)

CRFP

Wheels, as unsprung and rotating

mass on the vehicle, create

noticeable advantages for the driver

(customer)

CFRP wheel from Carbon Revolution, Australia

Audi R8 CFRP side blade

CFRP roof panel Corvette Stingray 2014

from Plasan Carbon Composites

Mercedes SL 55 AMG deck lid inner shell

from ACE, Germany Porsche 20“ CFRP wheel


In 1981 McLaren MP4/1 used the first CRFP

monocoque in Formula 1 because of high

stiffness, low weight and good impact resistance

Meanwhile many sports and race cars have

monocoques, which are made mainly from CF-

prepreg and using autoclave process

BMW started to work with dry CF-UD-structures

and RTM in their i3 and i8 electro- and hybrid

cars (SOP 2013/2014)

BMW i3 life module made from

150 CFRP components Porsche 918 spider hybrid CFRP monocoque

CFRP monocoque of AUDI Le Mans

car R18 TDI (2011) CFRP monocoque of Alfa Romeo 4C (65 kg) CFRP body of Lamborghini Aventador Spyder

Today: Composites in high-end cars

Today: Composites in high-end motorcycles

Motorbikes use CFRP components since

longer time. And some times “carbon” is just for

the show…

But this summer BMW introduced their HP4

RACE motorcycle with a main structural part

made from RTM-CFRP.

BMW Motorrad is the first motorcycle

manufacturer to present a main frame made

entirely of carbon fiber composite. The frame

weighs 7.8 kilograms and is produced

industrially in small series (750 bikes are

planed)



DORNIER Composite Systems®

Machines for tape production

Tape weaving machines

3D weaving technology

Textile competency: DORNIER Open Reed Weave (ORW) Technology


Stitch fabric Multiaxial fabric: 6K-CF roving

± 45° on glass fiber-fabric 0/90°

DORNIER rapier weaving machines with

patented positively precision controlled

yarn transfer from left- to right-hand rapier

and air jet weaving machines

Thermoplastic competency: Specialty machinery - film stretching lines


Transverse stretching machine:

Final product: BOPP-film for food packing

Film inlet width: 1 m

Film exit width: 9.6 m

Production speed: 500 m/min

Production capacity: 127 metric tons/day

machine length: 140 m, including 90 m

furnace length

Introduction of first DORNIER film

stretching line in 1956 with patented

gripper system


Spreading endless fiber roving to a specific width allows to adjust a certain fineness or areal weight (g/m²)

Fixation keeps tape width constant and allows operations like weaving, winding or braiding

The reduced weight allows to weave lighter and thinner textiles

Fiber orientation in length direction increases strength and stiffness in the composite

The use of high yarn counts like 2,400 tex glass fiber or 50K (3,200 tex) carbon fiber is possible

Cheaper yarn or roving can be used to make lightweight textiles for reinforcement of composites with even better properties

Full impregnated tapes and tape woven fabrics allow quick and cost-effective production of thermoplastic composite parts

Thinner layers and higher fiber orientation increase strength, stiffness and impact resistance of composites or allows reduction of wall thickness

Tape production – Advantages (why should we do it?)


0

100

200

300

400

500

600

700

800

900

Flä

che

nge

wic

ht

[g/m

²]

1K (67 tex) 3K (200 tex) 6K (400 tex) 12K (800 tex)

24K (1,600 tex)

48K (3,200 tex)

Unidirectional

fabrics

Are

al w

eig

ht

(gsm

)

DORNIER Composite Systems®

Tape production: Targeting defined areal weights


PP, PA, PC and PET on trial

Carbon-, Glass- or Aramid- fibers

Fixation with 3 - 15 Vol.-% Matrix 40 - 60 Vol.-%

Tape production


Two technologies for manufacturing tapes:

1. Single-tow-tapes (one roving → one tape):

Spreading e.g. one 12K carbon fiber roving to a 16 mm wide tape with 50 g/m² areal weight

2. Multi-tow-tapes (x roving → y tapes):

Combining several overlapping rovings and spreading them together to one tape. The following inline-slitter can cut tapes between 8 and 25 mm width

Tape production - spreading


Creel with 6 spooling positions and electronic

controlled winding tension during take-off

Spreading

box (closed)

Tape pilot plant


Options: Fixation or full impregnation

Fixation for a later impregnation with thermoplastic or thermoset matrix

For stabilization of the spread tape

Required binder-content is 2.5 until 5 weight-%. Application is done in a dip, using waterborne suspensions with micro powders

Advantage: Free choice of the later matrix in the composite

Impregnation using extruder and die supplying thermoplastic matrix between 40 and 60 weight-%

Fiber/matrix-ratio ready for e.g. production of organo-sheets

Tape production

Possibilities for tape fixation


Dip-coating:

Beside the known hot melt spraying, DORNIER offers a fixation

system for thermoplastics and for thermosets. Water born

dispersions with micro powders are supplied to the spread fiber

tape, dried and molten in the subsequent heating zone

The fixation with a small percentage of a matrix compatible binder

until entrance of the melting die can be advantageous for the later

impregnation

This fixation also allows to weave those fixed tapes without full

impregnation on the tape weaving machine

Possibilities for full impregnation


Matrix embedding:

For the impregnation of the spread and pre-fixed fiber tapes with a

thermoplastic matrix of a polymer with suitable viscosity

Inside the die the tapes are treated with the molten polymer from both

sides

The hinged melting die has a width of 69 mm and the die gap can be

adjusted for different tape thicknesses and coatings. Working

temperature is up to 320°C. A small lab extruder (25 mm) with 3 kg/h

output is available. For easy access (maintenance and cleaning) the

die can be swing opened

Tape pilot plant


Cutting station

(inline slitting)

for tape widths

of 2 - 25 mm

Friction winder for

3” pancake spools

up to 450 mm OD


Creel: 6 tension controlled spooling positions

Working width: Up to 70 mm wide tapes (die slot 69 mm width)

Production speed: Up to 30 m/min

Working temperature: Max. 320°C in extruder and melting die

Fibers: Endless-roving from glass, aramid-, carbon-, PE-, PA- or natural fibers

Weights per meter: 12K - 100K for carbon fiber rovings and 300 - 2,400 tex for glass fiber rovings

Fixation: Dip with suspensions of EP, PP, Co-PA or Co-PET

Impregnation: By extruder and die with PP, PA, PC and PET

Cutting: Inline slitter for 8 - 25 mm wide tapes

Presentation: Wound up on pancake spools with 3“ ID and up to 400 mm OD

Tape pilot plant general information

Tape production (single-tow)

Spreading of 2 single 12K carbon fiber rovings


Entrance width of roving: 7 mm Exit width of tape: 14 mm

Spreading of a single aramid fiber roving (1500 tex)


Entrance width

of roving: 5 mm

Exit width of tape:

30 mm


Spreading of a single 280 tex glass fiber roving


Entrance width of roving: 2 mm Exit width of tape: 8 mm


Tape production (multi-tow)

Spreading of multiple roving


Exit: Tape of 70 mm width

Entrance: 7x 24K carbon fiber roving

Tape production


Cross section of a carbon fiber tape with Co-Polyamide fixation and around

5 - 6 filament layers

Filament diameter: 7 µm

Tape thickness: 40 µm


Cross section of a full

impregnated carbon fiber tape

(5x 12K roving) with

Polypropylene matrix

(around 33 weight-%).

Filament diameter: 7 µm

Tape thickness: 130 µm

Tape production

Tape production line general information


Creel: Up to 60 spooling positions

Working and tape width: 200, 400 and 600 mm

Production speed: Up to 50 m/min

Working temperature: Max. 330°C in extruder and melting die

Fibers: Endless-rovings from glass, aramid-, carbon-,

PE-, PA- or natural fibers

Weights per meter: Rovings with 12K (800 tex) - 100K for carbon fibers and

300 - 2,400 tex for glass fibers

Fixation: Dip with suspensions of EP, PP, Co-PA or Co-PET

Impregnation: By extruder and die with PP, PA, PC and PET.

Other thermoplastics on request

Cutting: Inline slitter with number of cutting and winding stations on

request

Presentation: Wound up on pancake spools with 3“ ID


Pre-fixed carbon fiber

Examples for tape woven fabrics:

Full impregnated carbon

fiber/PA6Pre-fixed glass fiber

Weaving of prefixed or full impregnated tapes:

Prefixing with minimum binder content keeps tape in shape. The fabrics can be used for

thermoplastic- or thermosets-applications

Full impregnated tapes with thermoplastics for organo-sheets

Full impregnated glass

fiber/PP

Tape weaving

Spread and taped fibers in the fabric are less undulated, which leads to higher strengths and stiffness of composites and better impact resistance

Fibers are perfectly aligned and orientated in the tape and can transfer their properties better into the product

Tape fabrics are thin and light and can be easily draped

They have a smooth and closed surface, which is ideal e.g. for coating


Advantages of tape fabrics


Nominal width: 2,100 mm

Fabric widths: Between 950 and 1,800 mm adjustable

Single rapier right hand: With special tape rapier head

Tape width: 8 - 25 mm for weft tapes and 8 - 40 mm for warp tapes

Colors: 2 different weft tapes can be inserted via zero-twist-

feeders without distortion

Fabric weave: Plain 1/1, twill 2/2 or 1/3

Production speed: Up to 50 picks/min

Selvedge fixation: Thermal fixation with thermoplastic bonding yarns

Creel: Up to 216 adjustable spooling positions for warp tapes,

for 3“ (76.2 mm) inner diameter of spools



Careful tape handling because of:

Individual creel configuration with adjustable positions and tension control for warp tapes

Distortion free weft insertion with 2 zero-twist-feeders for 2 colors and constant weft tape

tension by moving guide rollers with adjustable vacuum support

Long shed opening times

Pneumatic down holder moving parallel with cloth table, fixing and protecting the weft tape

during shed opening

Reed is only guiding the rapier and does not touch the weft tape

Special rapier head designed for tapes up to 25 mm width



Comparison of 2 carbon fiber fabrics each with 200 g/m² areal weight

1. Woven with 3K carbon fiber roving (200 tex)

2. Woven with 100 g/m²-tape made from 50k roving (3,600 tex)

Price advantage 50K compared to 3K roving is around 40%

Tape-process: Spreading 50K roving to 36 mm width and using dip-fixation. Cutting into 2 tapes of 18 mm individual width. Costs for tape production at 20 m/min line speed are below price difference 3K to 50K carbon fiber roving

Tape weaving: With 50 picks/min the productivity is 0.9 linear meters of tape fabric per minute. Weaving 3K roving with 5 threads/cm and 280 picks/min, 0.56 linear meters of roving fabric per minute are generated

The thicker the roving (high number of filaments and weight per meter) and the wider the spread tape, the better the economy of tape technology!

Economy of tape technology


Example 1:

2 layers of tape fabric, full impregnated glass

fiber/polypropylene tape, 800 g/m² areal weight,

shaped by thermoforming

DORNIER/CrossLink

Example 2:

One layer of tape fabric, full impregnated

carbon fiber/polypropylene tape, 100 g/m² areal

weight, shaped by thermoforming

DORNIER/CrossLink

Drapability


Suit case made from tape woven fabric

Material: Full impregnated glass fiber/polypropylene tape, 800 g/m² areal weight (fabric).

Woven by company on a DORNIER tape weaving machine and shaped by thermoforming.

Drapability


Production technology Jacquard

2014: Jacquard woven picture from Matsukawa Ltd. „woven on DORNIER“

Digital production technology

Invented in the 19th century

Great flexibility regarding weaving pattern

High reproducibility

Technical applications

1 mm

10 mm

3D fabrics


First digital production machine worldwide.

Based on binary programming system (punched cards)

First description of a mechanical computer by Charles Babbage

in 19th century based on modified Jacquard-loom

Digital work process: The finished picture, tablecloth etc. woven

in one work step in reproducible large scale production

Joseph-Marie Jacquard‘s weaving loom from 1814


Textile structures with pre-defined properties can be manufactured by 3D weaving in a

reproducible way

3D woven structures offer possibilities for more complex preform shapes and enable

thick structures with good resin infusion and shorter manufacturing times

CFRP structure by 3D fabric,

produced on a DORNIER Jacquard

weaving machine.

(Sigmatex/DORNIER/Stäubli/2011)

Riveted aluminum profile-knot

of airplane DORNIER Do X

from 1928.

I-beam profile made from 3D woven glass fiber

fabric and epoxy matrix material by vacuum

infusion technology.

(DORNIER 2016)



3D textile composite structure „woven on DORNIER“

3D textile modelling:

TexGen software

Glass fiber textile (2,400 tex):

DORNIER 3D weaving machine

Epoxy resin matrix material:

Vacuum infusion technology



Digital programming of weaving pattern

Flexible shed geometry for fabrics up to 25 mm

thickness

“Free-flight” rapier movement without race board

Reinforcement fibers in X-, Y- and Z-direction

DORNIER 3D technology platform:

Creel with 1,512 bobbins

(e.g. 2,400 tex glass fiber)

200 picks/min

UNIVAL 100 Jacquard machine with 2,112

individual “hooks”

DORNIER 3D weaving machine at DORNIER Composite Systems

technology center – available for customer trials



DORNIER provides innovative solutions for composite applications

Flexible industrial production of high quality tapes

Cost-efficient production of drapable tape fabrics

Vision: High performance 3D woven fabrics

Single-layer tape fabric made of

full impregnated thermoplastic

carbon fiber tape, reshaped

during hot pressing

CFRP structure by 3D fabric,

produced on a DORNIER

Jacquard weaving machine

[DORNIER/CrossLink Faserverbundtechnik]

[Sigmatex/DORNIER/Stäubli]

Summary

Thank you very much for your attention!


innovative production technologies for lightweight ... production technologies for lightweight...

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