Structural long-fibre thermoplastics for automotive applications

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The aim of this proposed research program is to establish the ability to manufacture a structural automotive component from a material with a density less than any structural metal using a process that is capable of meeting the cycle times required by the mainstream automotive market. The material system of focus is glass fibre reinforced polyamide manufactured via the Direct Long Fibre Thermoplastic (D-LFT) I compression molding process. Polyamide is chosen as a representative engineering polymer, while the focus on the D-LFT process is based on the ability to achieve higher fibre lengths, resulting in higher toughness, and greater suitability for structural applications. This three-year project is designed after common automotive industry development processes including yearly stage-gate decision-making processes and benefits greatly from the full-scale manufacturing infrastructure available at the Fraunhofer Project Centre for Composites Research at Western (FPC). The HQP training program is designed to maximize the students' exposure to the industrial development process and provide hands-on experience with the full-scale manufacturing processes. Key technological advances to be accomplished in this research program include: i) establishing and optimizing D-LFT process parameters for glass reinforced polyamide and characterizing their impact on final microstructure; ii) characterizing mechanical properties in sufficient detail to permit the creation of a finite element material model capable of simulating the mechanical response of the material as a function of temperature and strain rate; iii) mitigating the issue of poor surface quality inherent in D-LFT molded materials to address consumer concerns of perceived quality. The endeavor is supported by cash and in-kind contributions from the entire supply chain. The industry lead on the project is General Motors of Canada Limited. Participating companies include a Tier 1 supplier (Eiring-Kiinger), material suppliers (BASF and Johns-Manville), a surface treatment company (Powder Coating Solutions) and the process equipment manufacturer (Dieffenbacher North America). The goal of APC funding is to make a fundamental contribution to the development of the Canadian automotive industry. With our team of University researchers, industrial partners and the Fraunhofer Project Centre, we have set the stage for Canadian success.