Innovative Production Technologies for Lightweight Automotive Composites - Tape Production, Tape Weaving and 3D Weaving

Transcription

1 Innovative Production Technologies for Lightweight Automotive Composites - Tape Production, Tape Weaving and 3D Weaving BMWi USA Business Trip, Greenville, SC, September 28 th, 2017 Mario Krupka, DORNIER Composite Systems, Lindauer DORNIER GmbH

2 Headquarters Lindau, Rickenbach, Germany 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 ) BMWi USA business trip 2

3 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 ) BMWi USA business trip 3

4 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. BMWi USA business trip 4

5 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, 9 th 1922 On December, 31 st 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 BMWi USA business trip 5

6 1931: Do X on Hudson River in New York The flying boat Do X was build from Prof. Claude Dornier ( ) and was the biggest airplane in this time The take off weight was 52 tons with a wingspread of 48 m. A modern Airbus A 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 BMWi USA business trip 6

7 1950: Start in Lindau, Lake Constance Foundation of Lindauer DORNIER GmbH and introduction of the first weaving machine (shuttle loom), type DoTex BMWi USA business trip 7

8 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 airjet weaving machine BMWi USA business trip 8

9 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 BMWi USA business trip 9

10 2016: Carbon fiber weaving machine in technology 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 BMWi USA business trip 10

11 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. BMWi USA business trip 11

12 Today: Composites in high-end cars Mercedes SL 55 AMG deck lid inner shell from ACE, Germany CFRP roof panel Corvette Stingray 2014 from Plasan Carbon Composites Audi R8 CFRP side blade Porsche 20 CFRP wheel CFRP wheel from Carbon Revolution, Australia 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) BMWi USA business trip 12

13 Today: Composites in high-end cars Porsche 918 spider hybrid CFRP monocoque BMW i3 life module made from 150 CFRP components 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 CFprepreg 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) CFRP monocoque of AUDI Le Mans car R18 TDI (2011) CFRP monocoque of Alfa Romeo 4C (65 kg) CFRP body of Lamborghini Aventador Spyder BMWi USA business trip 13

14 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) BMWi USA business trip 14

15 DORNIER Composite Systems Machines for tape production Tape weaving machines 3D weaving technology BMWi USA business trip 15

16 Textile competency: DORNIER Open Reed Weave (ORW) Technology DORNIER rapier weaving machines with patented positively precision controlled yarn transfer from left- to right-hand rapier and air jet weaving machines Stitch fabric Multiaxial fabric: 6K-CF roving ± 45 on glass fiber-fabric 0/90 BMWi USA business trip 16

17 Thermoplastic competency: Specialty machinery - film stretching lines Introduction of first DORNIER film stretching line in 1956 with patented gripper system 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 BMWi USA business trip 17

18 Tape production Advantages (why should we do it?) 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 BMWi USA business trip 18

19 Tape production: Targeting defined areal weights Areal weight (gsm) Flächengewicht [g/m²] K (1,600 tex) 1K (67 tex) 3K (200 tex) 6K (400 tex) 12K (800 tex) 48K (3,200 tex) Unidirectional fabrics DORNIER Composite Systems BMWi USA business trip 19

20 Tape production Carbon, Glass or Aramid fibers PP, PA, PC and PET on trial Fixation with 3 15 Vol. % Matrix Vol. % BMWi USA business trip 20

21 Tape production - spreading 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 BMWi USA business trip 21

22 Tape pilot plant Creel with 6 spooling positions and electronic controlled winding tension during take-off Spreading box (closed) BMWi USA business trip 22

23 Tape production 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 BMWi USA business trip 23

24 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 BMWi USA business trip 24

25 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 BMWi USA business trip 25

26 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 BMWi USA business trip 26

27 Tape pilot plant general information Creel: Working width: Production speed: Working temperature: Fibers: Weights per meter: Fixation: Impregnation: Cutting: Presentation: 6 tension controlled spooling positions Up to 70 mm wide tapes (die slot 69 mm width) Up to 30 m/min Max. 320 C in extruder and melting die Endless-roving from glass, aramid-, carbon-, PE-, PA- or natural fibers 12K - 100K for carbon fiber rovings and 300-2,400 tex for glass fiber rovings Dip with suspensions of EP, PP, Co-PA or Co-PET By extruder and die with PP, PA, PC and PET Inline slitter for 8-25 mm wide tapes Wound up on pancake spools with 3 ID and up to 400 mm OD BMWi USA business trip 27

28 Tape production (single-tow) Spreading of 2 single 12K carbon fiber rovings Entrance width of roving: 7 mm Exit width of tape: 14 mm BMWi USA business trip 28

29 Tape production (single-tow) Spreading of a single aramid fiber roving (1500 tex) Entrance width of roving: 5 mm Exit width of tape: 30 mm BMWi USA business trip 29

30 Tape production (single-tow) Spreading of a single 280 tex glass fiber roving Entrance width of roving: 2 mm Exit width of tape: 8 mm BMWi USA business trip 30

31 Tape production (multi-tow) Spreading of multiple roving Entrance: 7x 24K carbon fiber roving Exit: Tape of 70 mm width BMWi USA business trip 31

32 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 BMWi USA business trip 32

33 Tape production 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 BMWi USA business trip 33

34 Tape production line general information Creel: Working and tape width: Production speed: Working temperature: Fibers: Weights per meter: Fixation: Impregnation: Cutting: Presentation: Up to 60 spooling positions 200, 400 and 600 mm Up to 50 m/min Max. 330 C in extruder and melting die Endless-rovings from glass, aramid-, carbon-, PE-, PA- or natural fibers Rovings with 12K (800 tex) - 100K for carbon fibers and 300-2,400 tex for glass fibers Dip with suspensions of EP, PP, Co-PA or Co-PET By extruder and die with PP, PA, PC and PET. Other thermoplastics on request Inline slitter with number of cutting and winding stations on request Wound up on pancake spools with 3 ID BMWi USA business trip 34

35 Tape weaving 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 Examples for tape woven fabrics: Pre-fixed glass fiber Pre-fixed carbon fiber Full impregnated glass fiber/pp Full impregnated carbon fiber/pa6 BMWi USA business trip 35

36 Advantages of tape fabrics 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 BMWi USA business trip 36

37 Tape weaving machine Nominal width: Fabric widths: Single rapier right hand: 2,100 mm Between 950 and 1,800 mm adjustable 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-twistfeeders without distortion Fabric weave: Plain 1/1, twill 2/2 or 1/3 Production speed: Selvedge fixation: Creel: Up to 50 picks/min Thermal fixation with thermoplastic bonding yarns Up to 216 adjustable spooling positions for warp tapes, for 3 (76.2 mm) inner diameter of spools BMWi USA business trip 37

38 Tape weaving machine 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 BMWi USA business trip 38

39 Economy of tape technology 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! BMWi USA business trip 39

40 Drapability 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 BMWi USA business trip 40

41 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. BMWi USA business trip 41

42 3D fabrics Production technology Jacquard 1 mm Digital production technology Invented in the 19 th century Great flexibility regarding weaving pattern High reproducibility Technical applications 10 mm 2014: Jacquard woven picture from Matsukawa Ltd. woven on DORNIER BMWi USA business trip 42

43 Joseph-Marie Jacquard s weaving loom from 1814 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 BMWi USA business trip 43

44 3D weaving technology 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 Riveted aluminum profile-knot of airplane DORNIER Do X from CFRP structure by 3D fabric, produced on a DORNIER Jacquard weaving machine. (Sigmatex/DORNIER/Stäubli/2011) I-beam profile made from 3D woven glass fiber fabric and epoxy matrix material by vacuum infusion technology. (DORNIER 2016) BMWi USA business trip 44

45 3D weaving technology 3D textile modelling: TexGen software Glass fiber textile (2,400 tex): DORNIER 3D weaving machine Epoxy resin matrix material: Vacuum infusion technology 3D textile composite structure woven on DORNIER BMWi USA business trip 45

46 3D weaving 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 BMWi USA business trip 46

47 Summary DORNIER provides innovative solutions for composite applications [DORNIER/CrossLink Faserverbundtechnik] 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 [Sigmatex/DORNIER/Stäubli] CFRP structure by 3D fabric, produced on a DORNIER Jacquard weaving machine BMWi USA business trip 47

48 Thank you very much for your attention! BMWi USA business trip 48