Evaluation of a concept out-of-autoclave process for manufacturing carbon fibre reinforced polymer automotive parts
Evaluation of a concept out-of-autoclave process for manufacturing carbon fibre reinforced polymer automotive parts
复制标题
碳纤维增强聚合物汽车零部件制造概念非热压罐工艺的评估
DOI：
10.1016/j.procir.2020.01.030
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发表时间：
2019
期刊：
影响因子：
--
通讯作者：
J. Yanagimoto
中科院分区：
文献类型：
--
作者：
T. Taylor;J. Zhang;J. Yanagimoto
遵守对内燃机汽车日益严格的废气排放和燃料消耗法规；为了实现重型储能系统阻碍电动汽车的广泛部署，预计在未来几年，通过将纤维增强聚合物（尤其是碳纤维增强聚合物）应用于大规模生产的汽车架构，实现轻量化结构。然而，目前的时间、劳动力、能源和废物密集型零件制造工艺，包括高压灭菌器加工和非高压灭菌器工艺，如树脂转移成型，很难想象这一点。在本文中，一种基于预浸料压缩成型工艺的创新概念- out - autoclave工艺，将增强热固性复合材料预浸料的热成型和固化集成在一个步骤中，之前已经证明可以缩短周期时间、交货时间和财务成本；与目前的工艺相比，更大的环境可持续性，用于制造碳纤维增强聚合物汽车零部件。通过宏观观察、扫描电镜观察、弯曲试验、拉伸试验和疲劳试验，确定了零件的成形性、回弹性、几何精度和力学性能。生产的无回弹零件的机械性能约为基准高压灭菌器生产零件的80%。然后在应变率为0.02、0.20和2.00 s-1的情况下进行压缩碰撞箱试验，其破碎长度、比能量吸收和破碎力效率优于高压灭菌器生产的零件。因此，这一概念过程向实现碳纤维增强聚合物在大规模生产的汽车结构中的应用迈出了重要的一步，并应用于一系列应用，包括拉伸和弯曲强度关键的安全单元车身部件、冲击能量吸收关键的弯曲区车身部件和疲劳关键的悬架部件。
To comply with increasingly stringent exhaust-emission- and fuel-consumption-legislation imposed on internal-combustion-engine-powered vehicles; and to realise the widespread deployment of electric vehicles hindered by heavy energy storage systems, lightweight construction achieved through application of fibre reinforced polymers, most notably Carbon Fibre Reinforced Polymer, to the mass-produced automotive architecture has been predicted to increase in the coming years. However, this is difficult to envisage by the time-, labour-, energy- and waste-intensive part-manufacturing processes of present, including autoclave-processing and Out-of-Autoclave processes such as Resin Transfer Moulding. In this paper, an innovative concept Out-of-Autoclave process, based on the Prepreg Compression Moulding process, in which hot forming and curing of reinforced thermoset composite prepreg are integrated in one step, previously demonstrated to offer potential for reduced cycle-time, lead-time and financial cost; and greater environmental sustainability compared to current processes, was evaluated for manufacturing Carbon Fibre Reinforced Polymer automotive parts. Formability, springback, geometric accuracy and mechanical properties of parts were determined by macroscopic observation, scanning electron microscopy, flexural testing, tensile testing and fatigue testing. Springback-free parts exhibiting mechanical properties within approximately 80 % of benchmark autoclave-produced parts were produced. Compressive crash-box testing was then conducted across strain-rates of 0.02, 0.20 and 2.00 s-1, with crushed-length, specific energy-absorption and crush-force-efficiency superior to autoclave-produced parts. The concept process thus demonstrated a significant step towards realising the application of Carbon Fibre Reinforced Polymer to the mass-produced automotive architecture and to an array of applications including tensile and flexural strength-critical safety-cell body-parts, impact-energy-absorptive-critical crumple-zone body-parts and fatigue-critical suspension-parts.