Title: Short Fiber TuFF Technology for Automotive Part Production via Wet Compression

Authors: Chris Blackwell, Roger Crane, John Tierney, Joseph Deitzel, Tekin Ozdemir, Dirk Heider

DOI: 10.33599/nasampe/s.22.0872

Abstract: The paper focuses on a wet compression manufacturing approach to produce carbon fiber composites (CFC) that meet part performance and production rate requirements in the automotive market using the Tailorable Universal Feedstock for Forming (TuFF) material technology. Many of the primary applications of interest for this technology are in the automotive industry that metals currently dominate. The high degree of alignment and metal-like forming capability of the TuFF material allows parts with complex geometries and high fiber volume fractions to be manufactured at the production rates required in this market.

Good mechanical performance from low-cost, discontinuous CFs from virgin, waste, and recycled sources has been demonstrated, and manufacturing cycle times of less than one minute with the use of snap-cure thermoset resin can be achieved. The fibers are aligned in the TuFF machine and processed into dry preforms. The preforms are covered with a resin film with a prescribed amount of resin based on the desired fiber volume fraction. The wet preforms are then transferred into a heated press system, with both stamp forming and bladder molding capabilities. The part is formed in the press, rapidly infusing and curing the resin before the part is removed from the mold. The mold then remains heated and ready to accept another wet preform, allowing high throughput. The overall process has the potential to significantly reduce waste associated with composite parts and to meet the required cost, part performance, and production rate targets. The results demonstrate that the TuFF material technology combined with the snap-cure wet compression approach give a viable and competitive option for composite parts in the automotive market.

References: [1] Such et al., Aligned discontinuous fiber composites: a short history. J. of Multifunctional Composites, 2014 [2] Pimenta S. et al., “Recycling carbon fibre reinforced polymers for structural applications: Technology review and market outlook.” Waste Management 31, 378-392. 2001 [3] Pickering S., “Recycling technologies for thermoset composite materials -current status”, Composites Part A 37, 1206-1215, 2006.

Conference: SAMPE 2022

Publication Date: 2022/05/23

SKU: TP22-0000000872

Pages: 8

Price: $16.00