Structural long-fibre thermoplastics for automotive applications

这项研究计划的目的是建立一种能够使用密度小于任何结构金属的材料制造结构汽车部件的能力，该材料使用的工艺能够满足主流汽车市场所需的周期时间。重点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。聚酰胺被选为代表性的工程聚合物，而对D-LFT工艺的关注是基于实现更高纤维长度的能力，从而获得更高的韧性和更大的结构应用适用性。 这个为期三年的项目是在常见的汽车行业开发过程（包括年度阶段-门决策过程）之后设计的，并从弗劳恩霍夫复合材料研究项目中心（FPC）的全方位制造基础设施中受益匪浅。HQP培训计划旨在最大限度地提高学生对工业发展过程的接触，并提供全面制造过程的实践经验。 本研究计划中要实现的关键技术进步包括：i）建立和优化玻璃增强聚酰胺的D-LFT工艺参数，并表征其对最终微观结构的影响; ii）充分详细地表征机械性能，以允许创建能够模拟材料作为温度和应变率函数的机械响应的有限元材料模型; iii）减轻D-LFT模制材料中固有的不良表面质量的问题，以解决消费者对感知质量的担忧。 这一奋进得到了整个供应链的现金和实物捐助的支持。该项目的行业领导者是加拿大通用汽车有限公司。参与公司包括一家一级供应商（Eiring-Kiinger）、材料供应商（BASF和Johns-Manville）、一家表面处理公司（粉末涂料解决方案）和工艺设备制造商（Dieffenbacher North America）。APC资助的目标是为加拿大汽车工业的发展做出根本性的贡献。与我们的大学研究人员，工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.