Structural long-fibre thermoplastics for automotive applications

这项拟议的研究计划的目的是建立用密度低于任何结构金属的材料制造结构汽车部件的能力，使用能够满足主流汽车市场要求的周期的工艺。福克斯的材料系统是通过直接长纤维热塑性塑料(D-LFT)I压缩成型工艺制造的玻璃纤维增强聚酰胺。聚酰胺被选为具有代表性的工程聚合物，而D-LFT工艺的重点是实现更长的纤维长度、从而产生更高的韧性和更适合结构应用的能力。 这个为期三年的项目是在通用的汽车行业发展过程之后设计的，包括每年的阶段门决策过程，并从西部弗劳恩霍夫复合材料研究项目中心(FPC)的全面制造基础设施中受益匪浅。HQP培训计划旨在最大限度地让学生接触到工业发展过程，并提供全面制造过程的实践经验。 这项研究计划将实现的主要技术进步包括：i)建立和优化玻璃增强聚酰胺的D-LFT工艺参数，并表征它们对最终微观结构的影响；ii)充分详细地表征机械性能，以便能够创建能够模拟材料的机械响应随温度和应变率变化的有限元材料模型；iii)缓解D-LFT模塑材料固有的表面质量差的问题，以解决消费者对质量的担忧。 这一努力得到了整个供应链的现金和实物捐助的支持。该项目的行业领先者是加拿大通用汽车有限公司。参与的公司包括一级供应商(Eiring-Kiinger)、材料供应商(BASF和Johns-Manville)、表面处理公司(粉末涂料解决方案)和工艺设备制造商(Dieffenbacher North America)。APC基金的目标是为加拿大汽车业的发展做出根本性贡献。通过我们的大学研究人员、行业合作伙伴和弗劳恩霍夫项目中心的团队，我们已经为加拿大的成功奠定了基础。

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.