3D Fabrics for Composites

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1 3D Fabrics for Composites Thomas Gries Institut für Textiltechnik der RWTH Aachen University, Aachen, Germany Benedikt Wendland, Timm Holtermann, Thomas Gries

2 Contents Characteristics and types of 3D-textiles Braids Warp Knits Woven Fabrics Spacer warp-knit fabric Invitation for partnership Summary 3D-braid

3 Characteristics and applications of 3D textiles Specific characteristics of 3D textiles Near net-shape High material efficiency Very good mechanical properties Delamination and impact resistance Tensile strain-to-failure values etc. Complex manufacturing techniques Higher production costs Properties Material efficiency Production cost

4 Characteristics and applications of 3D-textiles Enabler to further enhance manufacturing of 3D textiles Design tools Automation Quality management and control Fabric designing using TexGen Automated preforming

5 Contents Characteristics and types of 3D-textiles Braids Warp Knits Woven Fabrics Invitation for partnership Summary 3D braiding machine

3D braiding biomimetic structures Natural paragon Deep

Hierarchical fibrious structure with 7 levels

structure with 5 levels Advantage Material efficient

6 3D braiding biomimetic structures Natural paragon Deep sea sponge Euplectella aspergillum Calcified sceleton Hierarchical fibrious structure with 7 levels Technological imitation 3D rotary braid Hierarchical structure with 5 levels Advantage Material efficient Damage tolerant ITA 5 cm Sponge Euplectella (left) und 3D braid (right)

7 3D hexagonal braiding - prototype 2nd generation

8 3D hexagonal braiding simulations Selection of simulated hexagonal braids Hexagonal Diamond Triangle Linear Source: Ko et al.

9 Contents Characteristics and types of 3D-textiles Braids Warp Knits Woven Fabrics Invitation for partnership Tailored NCF Summary

10 Warp knitting - tailored NCF Steel processing Preforming Applying steel manufacturing methods for textile preform processes Multi-step preforming: converting Tailored-NCF and Tailored Braid into near-netshape preforms in a sequence of automated process steps Tailored Blank Tailored Tube Assembly line Source: Thyssen Krupp Source: Thyssen Krupp Source: KUKA Single-step preforming (Tailored-NCF) Tailored-Braid Multi-step preforming

Warp knitting - tailored NCF State of the art NCFs: Constant

Constant drapability Rollable good Standard NCF [LIBA]

individual layers Local reinforcements Locally adjustable

11 Warp knitting - tailored NCF State of the art NCFs: Constant width, thickness and stacking Constant knitting pattern Constant drapability Rollable good Standard NCF [LIBA] Tailored NCFs provide: Tailored (individual) stacking Up to 34 individual layers Local reinforcements Locally adjustable drapability Stackable tailored sheets Adjustable knit pattern Locally reinforced NCF

12 Warp knitting - tailored NCF ITA technology for tailored NCF production Feeding module for local reinforcements and patches Adaptive pillar-thread bar for knitting of thickness steps Electromechanically driven guide bar locally adjustable drapability Cutting and stacking module Feeding module for local reinforcements Electromechanical guide bar Adaptive pillarthread bar Warp-knitting machine with multiaxial weft insertion [LIBA] Cutting and stacking module

13 Contents Characteristics and types of 3D-textiles Braids Warp Knits Woven Fabrics 3D woven omega stringer Invitation for partnership Summary FEM simulation of woven fabric

$Applications of 3D woven fabrics Fibre volume fraction Specific advantages for different applications High energy absorption Low crack propagation Good impact behavior High tensile strength Year of$

14 Applications of 3D woven fabrics Fibre volume fraction Specific advantages for different applications High energy absorption Low crack propagation Good impact behavior High tensile strength Year of first flight Development of composite share in aviation [1] 1 Wiedemann M., CFK-Status der Anwendungen und Produktionstechnik im Flugzeugbau GZVB-Gesamtzentrum für Verkehr Braunschweig, Braunschweig, 2009

3D woven fabrics for stiffener structures Current deficits Multistep preforming processes necessary for conventional skin-stiffeners High risk of delamination after impact Advantages of woven

15 3D woven fabrics for stiffener structures Current deficits Multistep preforming processes necessary for conventional skin-stiffeners High risk of delamination after impact Advantages of woven stiffener profiles Weaving of complex profiles in a single step High resistance against delamination Automated producing, also for curved stiffeners Impact damage on stiffener structure [1] Single step woven omega profile [1] Kontinuierlich_gefertigte_CFK-Hochleistungsprofile

16 Economic assessment Assumptions: Always the same stringer dimensions, length of 2 m Same weight of carbon fibre material for all techniques 5000 curved stringers are to be produced in one lot Salary of 34 /h, interest rate 3,67 % All other information is gathered from machine producers and manufactures Significant values in the economical comparison are Production rate [kg/h] Capital consumption over usage time [ /year] Cut-off [%] Deficient products/scrap [%] Consumable material [ /kg] Labour costs [person hours/machine/h]

Economic assessment production cost (without material) for one m stringer [ /m] 80,00 70,00 5,60 1,13 0,82 0,00 60,00 50,00 40,00 46,65 4,60 0,69 0,27 0,00 0,27 0,00 30,09 0,14 30,00 20,00 1,37 30,09

17 Economic assessment production cost (without material) for one m stringer [ /m] 80,00 70,00 5,60 1,13 0,82 0,00 60,00 50,00 40,00 46,65 4,60 0,69 0,27 0,00 0,27 0,00 30,09 0,14 30,00 20,00 1,37 30,09 28,84 15,05 0,41 1,34 36,65 10,00 17,78 0,45 8,04 15,99 21,32 0,00 Prepreg- Layup with foamcore Braiding and RTM core 3D woven preform with RTM impregnation 3D woven preform with pultrusion impregnation 3D woven preform with compression moulding Capital consumption [ /m] Deficient products [ /m] Costs of labour [ /m] Cut off [ /m] Consumable material [ /m]

the loom is modified at ITA to weave 12k rovings in 4 directions ORW technology Focus for

18 Open Reed Weaving Current work With the new and worldwide unique Dornier Open Reed Weaving loom multiaxial woven fabrics can be produced by adding an additional yarn system Right now the loom is modified at ITA to weave 12k rovings in 4 directions ORW technology Focus for future projects lies on local reinforcements and reinforcements of holes Partial reinforced ORW fabric

19 Partial reinforcements Basefabric Partial Reiforcement

20 Contents Characteristics and types of 3D-textiles Braids Warp Knits Woven Fabrics Spacer warp-knit fabric Invitation for partnership Summary 3D-braid

Reasons for companies to cooperate with us Reasons to cooperate with us or to join our team at RWTH Aachen University: Top international position in polymer, production and automotive research Ranked

21 Reasons for companies to cooperate with us Reasons to cooperate with us or to join our team at RWTH Aachen University: Top international position in polymer, production and automotive research Ranked No. 1 university for technology in Germany Several sources of research funding ITA All relevant textile production chains present in competencies and facilities Role model of ITA process upscaling and product development close-to-market Technology campus Aachen [rha reicher haase + associates]

Reasons for exchanging people with RWTH Aachen

Machinery from lab to industrial scale All relevant

DFG, Humboldt, Research language is English,

22 Reasons for exchanging people with RWTH Aachen Infrastructure Analytics Computational Engineering Machinery from lab to industrial scale All relevant textile processes Several funding possiblities DAAD, DFG, Humboldt, Research language is English, Language courses in German provided Assistance in accomodation, etc.

23 Contents Characteristics and types of 3D-textiles Braids Warp Knits Woven Fabrics Spacer warp-knit fabric Invitation for partnership Summary 3D-braid

24 Summary Summary 3D textiles offer unique properties such as high material efficiency Depending on the application there are specific requirements for 3D textiles Because of their properties 3D textiles are most suitable for composite applications What we provide in the field of 3D textiles Devolvement of machines, processes and process chains Design of 3D fabrics for different applications Cooperation within our RWTH Aachen University network 25

25 Thank you very much for your attention! You are invited to visit us in Aachen! Univ.-Prof. Dr.-Ing. Dipl.-Wirt. Ing. Thomas Gries Institut für Textiltechnik der RWTH Aachen University Otto-Blumenthal-Str Aachen, Germany Tel.: Fax:

Composites in Automotive

Composites in Automotive 1.11.2013 Prof. Dr.-Ing. Dipl.-Wirt. Ing Thomas Gries Contents Carbon Fibre Textile Manufacturing Resin Impregnation Simulation / Quality Assurance Recycling Textile solutions