Title: AUTOMATED PROCESS BASED ON FUNCTIONALIZED PREFORM AND NET-SHAPE HP-RTM FOR HIGH VOLUME STRUCTURAL APPLICATIONS

Authors: Alexandre HAMLYN, Sophie JOB

DOI: 10.33599/nasampe/s.23.0235

Abstract: In this paper Coriolis Composites highlights a new process the company has taken towards mass production of composite structural parts for the automotive and high-volume aerospace markets.
This process follows different steps: • Simulation of the process to optimize the design of the 3D part and its corresponding 2D blank, • High speed Automated Fiber Placement (AFP) of 2D tailored dry preform blanks made from direct fiber, online fiber spreading and binder application, • Preform functionalization to improve its formability and permeability, but also to make handling and trimming easier, • Forming of the 2D functionalized preform to 3D shape and net shape trimming, • Net shape preform impregnation with High-Pressure-Resin-Transfer-Molding (HP-RTM), thanks to excellent through thickness (z direction) permeability, and preform stability.
To assess the process performance and resulting parts, 3D parts and 2D coupons were manufactured using the new developed preforms and Non-Crimp-Fabric (NCF), having in both cases the same fiber and matrix. The performances were evaluated all along the process steps and the results show improvements in several key process parameters, equivalent mechanical performances and increase surface quality, hence resulting in less effort for surface preparation.

References: [1] Mason, H. “BMW rolls out multi-material Carbon Cage with 2022 iX vehicle line”. Composites World. 12/22/2021. BMW rolls out multi-material Carbon Cage with 2022 iX vehicle line | CompositesWorld [2] “Materials & Processes: Fabrication methods”. Composites World. 03/23/2016, updated 06/28/2022. Materials & Processes: Fabrication methods | CompositesWorld [3] Roquette, David. Dr. Meyer, Florian. Dr. Herbeck, Lars. “High Volume Manufacturing of Carbon Fiber Reinforced Plastics for Body in White.” Materialien des Karosseriebaus. Bad Nauheim, May 16, 2017. [4] Dr. Mazumdar, Sanjay. “Opportunity and Challenges in Automotive Composites Industry.” Lucintel Webinar. December 12, 2013. [5]Gardiner, G. “The rise of HP-RTM”. Composites World. 05/01/2015. The rise of HP-RTM | CompositesWorld [6]Vallons, K. “The behavior of Carbon fibre – Epoxy NCF Composites under various mechanical loading conditions”. Research Gate. January 2009. 8: Examples of stitching patterns for non crimp fabrics: chain stitched... | Download Scientific Diagram (researchgate.net) [7]”EasyPerm, the first 3D permeability bench”. Easyperm, the first 3D permeability bench (isgroupe.com) [8]Drapier, S., Pagot, A., Vautrin, A., Henrat, P. « Influence of the stitching density on the transverse permeability of Non-Crimped New Concept (NC2) multiaxial reinforcements: measurements and predictions”.

Conference: SAMPE 2023

Publication Date: 2023/04/17

SKU: TP23-0000000235

Pages: 15

Price: $30.00