Shaping the Future
Innovations in CompositeMaterials Processing
Neil Reynolds
Automotive Composites ResearchCentre, WMG
Polymer Innovation Network21st October 2015
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Agenda
Background
Introduction to WMG ACRC research
Key capabilities
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Background
Aims:– Development and application of suitable materials,
processing and simulation technologies for high-volumestructural application of composites in automotive industry
Considerations:– Cost (raw materials & utilisation)
– Cost (investment in processing technologies)
– Cost (cycle time)
– Also – LCA/recyclability, integration (joining)
Approach:– Industry-led collaborative R&D using a combination of
traditional and industrially-relevant research tools Fundamental analytical techniques through to industrial process
demonstration
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Structural Composites at WMG ACRC
Processing:– Pre-preg compression moulding (PCM)– CF-SMC– Rapid stamp-forming of aligned fibre thermoplastics– HP-RTM & compression RTM, in-situ polymerisation– Formability/drape– Automation
Joining:– Volume-ready joining techniques– Pre-treatments– Automation
Performance:– Stiffness/strength & crash energy management– Durability/fatigue– Provision of key data for performance simulations, enabling
component design
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WMG ACRC Processing Capabilities
Engel v-Duo 1700– Multi-functional 1,700t press– 2.2 x 1.8m usable platen area– Fully instrumented (pressure, temp, cure)– Sliding lower table
Heating/transfer station on order
Hennecke Streamline HP-RTM– 3+1 (Resin/Polyol)/Hardener/Isocyanate + release
agent– 60 litre day tank capacity (x3)
Zund CNC Cutting Table 2-D Ply Assembly
– Picking, assembling, joining– Up to 8 different layers/plies can be stored– 4-axis robot used to pick and place individual
layers/plies
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WMG Test/Analysis Capabilities
ACRC:– ±250kN static Instron, temperature chamber, video
extensometry
– Mettler-Toledo HP-DSC
– Zeiss auto stage optical microscope
WMG:– 12kJ instrumented drop tower
– VHS Instron (up to 25m/s)
– 3x fatigue frames (up to ±250kN)
– ±100kN static Instron
– SEM, DMTA, CT scanning
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Thanks for Listening
Neil Reynolds
Senior Research Fellow
Automotive Composites Research Centre, WMG
www.wmg.warwick.ac.uk
02476 524787