Continuous fiber-reinforced thermoplastic composites have also become established with thin-walled housings for consumer electronics and information technology. Not only do they offer high stiffness and help to reduce weight, but also enable the integration of classy appearance and functions. What is more, if the housings are produced using the hybrid molding process, costs, processing steps, and cycle times can be reduced.

The Carbon 1 Mark II smartphone from Carbon Mobile was developed in Germany. The matt-black carbon fibers lend the smartphone a classy high-tech look

16:9

Composites Reduce Weight and Simplify Production of Electronics Housings

Composite-Halbzeuge

Halbzeuge und Zwischenprodukte

Kunststoff-Halbzeuge

Glasfasern / -matten

Kunststoff Werkstoffe

Verstärkungsstoffe

Kohlenstofffasern / -matten

Kunststoff

Bauwesen

Baustoffe

Faserverbundwerkstoffe

Andere Werkstoffe

Kunststofffasern

Organobleche (gewebeverstärkte Thermoplast-Halbzeuge)

Lightweight to Fit in a Pocket

Optics play an increasingly important role in plastic components. Glossy and even surfaces are decisive for an attractive appearance. With glass fiber-reinforced polyamides (PA), these requirements can usually only be achieved with an additional coating. A PA specially developed for surface design offers an alternative approach.

For visible components, an even, glossy surface is often desired, which is often difficult to achieve with glass fiber-reinforced PA. PA Grivory G7V from EMS now solves this problem

Aliphatic High-Performance Polyamide for Plastic Surfaces

Spritzgießen

Kunststoffverarbeitung: Verfahren

Polyamide

Thermoplaste

Oberflächentechnik

Glossy Components without Painting

Susanne Schröder will become editor-in-chief of the magazines Kunststoffe and Kunststoffe international on December 1, 2020. The current editor-in-chief Dr. Karlhorst Klotz will leave the company by mutual agreement.

Susanne Schröder will become editor-in-chief of the magazines Kunststoffe and Kunststoffe international on December 1, 2020. Until now she has been editor-in-chief of the trade journal FORM+Werkzeug

Werkzeuge für Leichtbauwerkstoffe

Präzisionswerkzeuge

Tiefziehwerkzeug

Dienstleistungen

Werkzeug-, Formen- und Modellbau

Werkzeugüberwachung

Toolmanagement

Werkzeugwechselsysteme, Spritzgieß

Kunststoffverarbeitung: Maschinen und Komponenten

Werkzeuge für die Kunststoffverarbeitung

Spritzgießwerkzeuge

Werkzeug- und Formenbau

Modulare Werkzeugsysteme

Absaugungen für Werkzeugmaschinen

Betriebsausrüstung / Betriebsmittel

Absaugvorrichtungen

Fluorkunststoffe

Werkzeugverwaltungssoftware

Prüfen von Kunststoffen

Messtechnik

Biokunststoffe

Presswerkzeuge, Kunststoff

Werkzeugreinigung, Kunststoffe

Standardkunststoffe

Kunststoffverarbeitung

Lohnfertigung

Technische Kunststoffe

Füllstoffe für Kunststoffe

Kunststoffhandel

Handel

Betriebstechnik für Kunststoffverarbeitung (Peripherie)

Kunststoff-Recycling

Kunststoff-Aufbereitung

Hochleistungskunststoffe

Qualitätssicherung Kunststoff

Qualitätssicherung

Change in the Chief Editorial Office of Kunststoffe

The non fossil fuel-based portfolio offers same high quality and performance for applications in all industries.

The Bornewables portfolio is suitable for the production of the most demanding applications, including hygiene and food-contact

Gehäuse aus Kunststoff

Elektromechanik

Kühlkörper

Polyethylen

Polystyrol

Polypropylen

Kunststoff-Regenerate

Borealis Launches Portfolio of Circular Polyolefins

Bio-based plastics can lock away vast quantities of CO2 in durable, recyclable applications and make a real contribution to climate protection. All that is needed for this is the right product design and a functioning circular economy. By focusing more on this approach, the plastics sector has the chance to evolve into a key industry of a green economy.

Furniture and furnishings with a long service life are the ideal applications for bioplastics

20:7

How Bio-Based Polymers Can Help Sequester CO2 for the Long Term

Kunststoffe, biobasiert

Recycling

Umweltmanagement

Kunststoffe, bioabbaubar

Into the Future with Biopolymers

A number of examination methods can be used to identify weaknesses caused by incorrect fiber orientation. In particular, the fiber volume content and fiber distribution permit conclusions to be drawn regarding the stiffness and tensile strength behavior. A new ultrasound method offers the flexibility to capture these parameters on the finished component.

Ultrasound coupling: a shear wave probe contacts a glass fiber-reinforced plastic test specimen via a viscous couplant

Methods for Determining the Fiber Orientation in Reinforced Plastics

Ultraschall-Sensoren

Sensoren / Messwertaufnehmer

Verbundwerkstoffe / Werkstoffverbunde

Computer-Tomografie-Systeme

Werkstoffprüfung

Optische Mess- und Prüftechnik

Ultraschallprüfgeräte

Röntgenprüfgeräte

Software für Optische Messtechnik

Groundbreaking Ultrasound  Shear Waves

Carbon fibers are due to their high price interesting for recycling. The results of the project RecyCarb enable the multiple use of carbon fibers as functional re-use. First demonstrator parts in the areas of medical technology and automotive prove the industrial feasibility.

Plant for carbon nonwovens at STFI with guillotine cutting machine (1), tearing machine (2), feeder chute (3), airlay (4), card (5), cross-lapper (6), needle loom (7) and Maliwatt unit (8)

Re-Use of Recycled Carbon Fibers in Sophisticated Composite Parts

Faserverarbeitung

Second Life for Carbon Fibers

In the iComposite 4.0 research project, it has been possible to cut the costs for a prototype component by more than 50 percent and throughput time by 40 percent.

View of the production system built for the iComposite 4.0 project at the RWTH Aachen AZL

Economic Production of Fiber-Reinforced Plastics in High Volumes

Schröder, Susanne

Pressen von Kunststoffen

Self-Regulating Production Plant

For lightweight applications e. g. in automotive engineering BASF developed carbon fiber-reinforced polyphthalamide (PPA) grades with fillings of 20, 30 und 40 %.

The carbon fiber-reinforced PPA e. g. can replace aluminum and magnesium 

PPA Now with Carbon Fiber-Reinforcement

Elektronik

Automotive

Lightweight Metal Replacement

Teknor Apex presents three halogen-free FR glass-reinforced polyamide compounds with UL94 ratings of V0.

Application example: engine cover in the automotive industry

Glass-Reinforced and Halogen-Free Flame-Retardant

The occurrence of process-specific defects in the wet filament winding process requires an oversizing of the components which leads to high additional material costs, especially for 700 bar type-IV pressure vessels. This paper presents the development of a quality control together with an image processing algorithm based on an industrial camera with which manufacturing deviations in the cylindrical area of the vessels can be determined.

An industrial camera is used to inspect a pressure vessel for manufacturing deviations during the infeed of fiber slivers.

Bildverarbeitungs-Software

Fertigungsautomation

Bildverarbeitung

Wickelmaschinen

Optische Mess- und Prüfverfahren

Use of an industrial camera for quality control in the production of the cylindrical area of type-IV pressure vessels in the wet filament winding process

Lightweight design with fiber-reinforced plastics saves energy resources in the use phase of automobiles and aircraft. However, the savings are often offset by higher consumption in production. Therefore, the focus is increasingly shifting to sustainability in manufacturing. The Research Institute Neue Materialien Bayreuth has conducted a corresponding sustainability analysis for the processing of thermoplastic UD tapes into functionally integrated components.

Fig. 4. The demonstrator component “2D-MultiMat” was manufactured with laminates of woven fabric organosheets and UD tapes (CF or GF/CF hybrid) based on PP and injection-molded functional integration (PP-GF) with the FORCE process chain.

Evaluate the Environmental Impact of the Production of FRP Components

Fasern

UD-Tapes

Nachhaltigkeit

Schnüre, Bänder, Tapes

How Sustainable Is  Lightweight Design Really?

Particularly two industries have shown considerable interest in FPP technology: aerospace industry in automating the lay-up processes of multi-material lightweight components with sandwich cores, as well as manufacturers of CFRP pressure vessels for hydrogen-powered vehicles (FCEVs), who can thus achieve savings in the double-digit percentage range. In both areas, FPP is the first technology to automate critical fiber lay-up processes in order to industrialize the production.

Laminate reinforcement of filament-wound pressure tanks. The shape of the patches and the gripper is adapted to the size and complexity  of the component.

New Applications for the Automated Production of Fiber Composite Components

Greifer

Automatisierungstechnik

Handling, Handhabungstechnik

Inspektionssysteme

Industrieroboter

Montagetechnik

Reinforcement on Approach

Two new inorganic yellow pigments based on iron oxide and zinc oxide respectively are designed for coloration in a temperature range of between 220 and 260 °C.

The yellow pigments are used for all common polymer materials as well as for engineering thermoplastics even at the highest production temperatures

Pigmente, bunt

Additive

Farbstoffe und Pigmente

Farbstoffe

Yellow for High Temperatures

Polymaker will offer the Polymaker PC-r 3D printing filament made from recycled polycarbonate (PC). The PC for the filaments comes from materials supplier Covestro and consists of a combination of recycled plastic waste and virgin material.

The combination of recyclates and virgin material reduces the carbon footprint of the polycarbonate and still allows it to be extruded into filaments

Filamente für additive Verfahren

Werkstoffe für additive Verfahren

Additive Fertigung

Polycarbonat

Kunststoff-Rezyklat

Water Bottles Become Filaments

Process for Repairing CFRP Components without Machining

CFRP components are often in continuous use under harsh environmental conditions, for example in aircraft and motor vehicles. If any damage occurs, the CFRP structures are simply replaced by new components in most cases. This is mainly due to the high cost of established repair methods. With a newly developed process, defective CFRP structures can now be repaired locally much more easily.

The use of fiber-reinforced plastics (FRP) based on continuous fiber reinforcements is growing steadily [1]. This is mainly due to the desire for reduced pollutant and greenhouse gas emissions and increased energy efficiency combined with very good mechanical performance and increased cost-effectiveness, which has led to the a rising demand of lightweight solutions. With the widespread usage of carbon fiber-reinforced plastics (CFRP), including in the automotive and aerospace industries, the need for high-performance and on-demand repair concepts for FRP components is also increasing [2]. Damage to CFRP structures in need of repair has a variety of causes. The most common types of damage during the service life are material fatigue, excessive operating loads, impact or crash loads, damage during maintenance, contact corrosion and special load cases.

Repairing such damage without oversizing or changing wall thicknesses can be done by completely replacing the damaged CFRP components. However, this is not very sustainable and is associated with high costs due to the new parts required [3]. For this reason, various repair methods have been developed for special groups of components and individual cases, but these are often associated with considerable manual effort and thus insufficient reproducibility. These methods are predominantly based on a machining removal of the damaged area and the subsequent gluing or riveting of a new CFRP patch [4–7].

Three Process Steps to the Repaired CFRP Component

A different principle underlies a process for repairing CFRP components developed at the Institute of Textile Machinery and High Performance Material Technology (ITM) at the TU Dresden, Germany. In this process, the use of inorganic semiconductor oxides (SCO) and targeted irradiation with ultraviolet (UV) light oxidatively degrades the matrix material in the damaged area and completely exposes the carbon fiber structure. The aim of the completed research project was to develop a flexibly applicable repair method for defective, multi-axially loaded, thin-walled CFRP components. It is based on three process steps (Fig. 1). First, a load-adapted textile patch is designed with simulation support. This is followed by local matrix removal in the area of the defect by means of targeted UV irradiation. The textile repair patch is then applied to the damaged area to replenish it, and finally reinfiltrated with a resin system.

For the load-compatible structural repair, a simulation model was created to design the textile repair patches. For this purpose, the composite structure was modeled from scrims. A meso model with shell elements was used to simulate the reinforcing fibers, with material modeling based on a three-layer laminate approach. For curved components, a drape model was created for this purpose. The composite was generated by applying the Domain Superposition Technique (DST) from coupling the textile model with a matrix model.

The simulation of the repair was done using a damaged CFRP sample. A parameter study with varying overlap lengths of the repair patch was performed and the necessary overlap was analyzed in both experiment and simulation to realize the best possible force flow via interlaminar shear between the individual layers. The simulation results show that higher the overlap length of the repair patch that higher is the tensile strength of the repaired composite. The model was validated by experimental studies showing that with optimum frictional connection of the patch to the as-built component, an almost complete restoration of the structural mechanical properties can be achieved.

Based on the simulation results, the local matrix removal in the repair area was carried out by activating semiconductor oxides (SCO) with a UV LED emitter. This process initiates a radical decomposition of the thermoset matrix polymer. For this process section, the process parameters were determined by evaluating the surface properties and by means of optical, mechanical and thermal analysis. Subsequently, a cleaning or activation and simultaneous re-sizing of the exposed carbon fibers was realized by means of a plasma torch. In this process, the differences in the fiber surface were leveled out by a specific treatment and introduction of an adhesion promoter and these were prepared for the subsequent repair process steps (Fig. 2).

A Semray 4103 UV LED emitter from Heraeus with an emitter area of 45 mm x 154 mm and a wavelength of 395 nm was used for the project (Fig. 3). This allowed almost complete exposure of the filaments in the damaged area [8]. However, in order to successfully perform complete, localized matrix degradation in the damaged area of thin-walled CFRP components, the irradiation parameters of power and irradiation area, as well as the installation space of the emitter, must be adapted. In addition, there is still a need for research on the subsequent cleaning and re-sizing with the plasma torch. Insufficient adhesion between the exposed filaments in the component and the textile 2D repair patch results in reduced bonding properties. A possible solution is a two-step treatment with the plasma torch: in the first step, degraded matrix residues on the filaments are removed with compressed air, and in the second step, the filaments are resized with an adhesion promoter. The mediator EP 871 from Michelman was used for the investigations.

The thin-walled CFRP components (four layers of biaxially reinforced scrim [(0/90)2]s, thickness = 1.5 mm) with the repair area previously exposed and again coated with sizing (adhesion promoter) could be repaired in the third step using a textile 2D patch and reinfiltration with a resin system. The repair patches used in the project were blanks made of unidirectional layers (UD), tailored fiber placement (TFP) and multilayer knit (MLG). All of them were based on Toray T700SC 50 C 800 tex carbon fiber feedstock. They were designed load-adjusted according to the simulation results, machine-made, then characterized textile-physically (basis weight, yarn densities, thickness) and compared with the reference (removed fiber mass). After patch application, the repair site was refilled and consolidated with a repair matrix system using a vacuum-assisted resin infusion (VARI) method (Fig. 4). Different variants (RIMR 135; ER0051; ER5500) were used as resin system. After composite mechanical characterization, the original resin system from which the specimens were prepared was selected as the preferred variant due to the highest strength determined.

The investigations were successfully carried out on functional specimen of rising complexity with a component thickness of up to 2 mm. The practical suitability of the developed process was successfully tested on two thin-walled CFRP demonstrators. The flat composite panels were damaged in a defined manner by CNC milling, i. e. all fibers were cut in the direction of loading (0°), which caused a residual load-bearing capacity of 0 %. The specimens repaired with the aid of the process were characterized in tensile test according to DIN EN ISO 527–4. Irrespective of the textile manufacturing process of the repair patch, a breaking strength in the 0° direction of approx. 55 % of the undamaged CFRP reference material could be achieved (Fig. 5).

The developed approach thus represents a functioning repair procedure for simply curved, thin-walled CFRP components with a wall thickness of up to 2 mm. After repairing the previously completely damaged CFRP specimens, it was thus possible to restore a load-bearing capacity of more than 50 % while maintaining the same component thickness. Compared to the complete replacement of the CFRP component, costs are reduced by up to 80 %.

However, further research is required for the repair of complex, multi-curved and thick-walled 3D CFRP components to reach a load-bearing capacity of more than 50 % in tensile tests. For this purpose, simulation-based designed 3D textile patches with free thread ends and a sequential layer-by-layer 3D matrix degradation of the repair area with thus exposed threads for sufficient force transfer between patch and as-built component are mandatory. This is the subject of future research activities at ITM.

[1] Sauer, M.: Composites-Marktbericht 2020. Carbon Composites e.V. (2020)

[2] Lässig, R.; Eisenhut, M.; Mathias, A.; Schulte, R. T.; Peters, F.; Kühmann, T.; Waldmann, T.; Begemann, W.: Serienproduktion von hochfesten Faserverbundbauteilen. Roland Berger Strategy Consultants 09/2012(2012)

[3] Hofacker, A.: Leichtbau mit CFK: Prozesse müssen weiter optimiert werden. <a href="http://springerprofessional.de">springerprofessional.de</a>

[4] Harder, S.; Röper, F.; Gibhardt, D.; Koert, B.; Fiedler, B.: Strength of scarf-bonded CFRP repairs containing disc-shaped zones of weak bonding considering hot-wet conditioning. International Journal of Adhesion and Adhesives 102(2020), pp. 102643 f.

[5] Jacob, A.: Carbon fibre and cars – 2013 in review. Reinforced Plastics 58(2014)1, pp. 18ff.

[6] Pantelakis, S.; Tserpes, K.: Revolutionizing Aircraft Materials and Processes. 1. Auflage, Cham: Springer International Publishing; Imprint: Springer, 2020 – ISBN 9783030353469

[7] HOSHI, H.; NAKANO, K.; IWAHORI, Y. (HRSG.): 16th International Conference on Composite Materials, Kyoto, Japan, 3–8 July

[8] Böhnke, P. R. C.; Kruppke, I.; Hoffmann, D.; Richter, M.; Häntzsche, E.; Gereke, T.; Kruppke, B.; Cherif, C.: Matrix Decomposition of Carbon-Fiber-Reinforced Plastics via the Activation of Semiconductors. Materials (Basel, Switzerland) 13(2020)15

Technische Universität Dresden  

https://www.tu-dresden.de

Ausgabenartikel

Fig. 1. Overview of the simulation-based repair method for CFRP components: the method enables targeted repair of the damaged area

Fig. 2. In the process, the damaged area of the test specimen (1) is treated with a UV LED lamp (see Fig. 3). The fibers are then separated (3) in the repair area (2) thus exposed. The prepared repair area (4) is then cleaned, activated and prepared by an adhesion promoter for the insertion of the patch

Fig. 3. Matrix removal in the repair area is carried out with the help of an UV LED lamp. Compared to conventional processes, the manual effort is highly reduced, which ensures higher reproducibility

Fig. 4. For the repair, for example, a TFP patch is inserted into the prepared site (A – first patch part inserted, B – second patch part inserted). For the subsequent reinfiltration (C), a method based on the VARI process is used

Fig. 5. Rupture force (Fmax) and elongation at Fmax for the different patch variants: the UD and MLG patches achieve the best values

KU 7-21_TUD - Hauptartikel

<ul><li> Dipl.-Ing. David Rabe has been a research associate at the Institute of Textile Machinery and High Performance Textile Materials (ITM) at TU Dresden, Germany, since 2018; <a href="mailto:david.rabe@tu-dresden.de">david.rabe@tu-dresden.de</a></li><li>Philippa Böhnke is a research associate in the research group Textile Chemistry/Textile Finishing and Polymer and Fiber Technology at ITM.</li><li>Thi Anh My Huỳnh is a research associate in the research group Structure and Process Simulation at ITM.</li><li>Dr. Iris Kruppke heads the research group Textile Chemistry/Textile Finishing and Polymer and Fiber Technology at ITM.</li><li>Dr. Thomas Gereke heads the research group Structure and Process Simulation at ITM.</li><li>Eric Häntzsche heads the research group Textiles for Lightweight Construction at ITM.</li><li>Prof. Chokri Cherif is institute director of ITM and holder of the professorship for textile technology.</li></ul>

The IGF project 19946 BR of the Research Association Forschungskuratorium Textil e. V. was funded by the Federal Ministry for Economic Affairs and Energy via the AiF within the framework of the program for the promotion of joint industrial research (IGF) on the basis of a resolution of the German Bundestag. The author would like to thank the above-mentioned institutions for providing the financial resources and the companies of the Project Advisory Committee (PA) for their technical support and the provision of test material. The final report and further information are available at ITM.