Polymer Composites Research in the ALM Materials Program 27 February 2008 C. David (Dave) Warren Field Technical Manager Transportation Composite Materials Research Oak Ridge National Laboratory P.O. Box 2009, M/S 8050 Oak Ridge, Tennessee 37831-8050 Phone: 865-574-9693 Fax: 865-574-0740 Email: [email protected] This presentation does not contain any proprietary or confidential information ALM Historical Timeline – Composites 1990 1995 2000 2005 2010 Glass-fiber-reinforced Fiber-Reinforced …… Polymer-Matrix Composites (FP1) Carbon-fiber-reinforced Processing Low-Cost Carbon Fiber Joining Nondestructive Testing (FP1) …… Crashworthi- ness Recycling AACCCC KKeeyy DDeelliivveerraabblleess Composite Underbody Low Cost Carbon Fiber Carbon Fiber SMC Hood 22000088 22001100 22001122 22001144 Polymer Encapsulated Mega-Module Composite Seat EMWG Composite Front Structure DOE/ALM COMPOSITE MATERIALS RESEARCH Automotive Research Program Organization Materials USCAR Program Coordination DOE/OFCVT USAMP Program Management DOE/Materials Field Technical Management ORNL Materials Energy Management Processing Joining Manufacturability Demonstration Projects Car Platforms Automotive Suppliers COMPOSITE MATERIALS RESEARCH What Was Done --- Glass Fiber Composites Materials Processing Materials P4 Preforming Durability Slurry Modeling Deformation & Degradation Slurry Processing Materials Screening Focal Project II Joining Energy Management Adhesive Bonding SCAAP Adhesive Modeling NHTSA Modeling NDT Rapid Testing Energy Management NDT Laser Shearography FreedomCar and Beyond Test Method Analysis Goals Automotive Composites Consortium Focal Project 2: Composite Pickup Truck Box COMPOSITE MATERIALS RESEARCH What we were Doing --- Carbon Fiber Composites Materials Processing Low Cost Carbon Fiber P4 Carbon Fiber Lignin Based Precursors High Vol Process of Composites (4) Microwave Processing Next Generation P4 Carbon Fiber Two Splitting Optimal CF for P4 Advanced Oxidation Chassis Support Structures Advanced Stabilizaton Chassis Structures LCCF Integration Line Body and Door Structures Materials Joining CF Comp Durability Focal Project III Advanced Joining Compressive Creep Joint Energy Absorption Materials Dev & Screening NDE Techniques Recycling PMCs Heavy Vehicle Joining CF SMC Structures Development of CF SMC Other Cost Modeling – Program Energy Management Composites Conference Crash Adsorp of Bonded Structures FreedomCar & Crash Energy Management (7) 21st Century Truck 21Century Truck Testing Machine for Auto Crash Automotive Lightweighting Crash of Sandwich Structures Goals Materials ACC Focal Project III Materials Composite (Carbon) Intensive Body-In-White Compform / Nida-Core Vehicle package (based on DC JA) P4 or Compform P4 / Compression Molding P4 or SMC Phase 1 Results: 67% mass savings over baseline Bending stiffness exceeded 20% Torsional stiffness exceeded 140% Durability and abuse load cases satisfied Manufacturing strategy developed P4 / Compression Molding SMC with ribs P4 / Balsa Core Materials / Mass Distribution: Chopped carbon - 54.8 kg Carbon fabric - 17.7 kg Core - 3.2 kg Adhesive - 1.6 kg Inserts - 8.8 kg High-Volume Molding of Composites Materials Test Piece Design: Multi-Purpose B-Pillar Tool COMPOSITE MATERIALS RESEARCH (2008) What we are Doing --- Carbon Fiber Composites Materials Processing Low Cost Carbon Fiber TPP4 Previously Briefed Lignin Based Precursors High Vol Process of Composites Briefed Now Lignin Purification (- CF SMC, Press, Inj Tools, etc) Briefed Later Advanced Oxidation Next Generation P4 Advanced Stabilizaton P4 Preforming LCCF Integration Line FSD of Textile Precursors Higher Performance Fibers Materials Natural Fiber Composites Focal Projects IV Joining Recycling PMCs - Underbody Bond-line Read Through Predictive Modeling of PMCs Bonding of TP - Comp Seat Composite Underbody Energy Management Crash Adsorp of Bonded Structures Other Crash Energy Management (7) Cost Modeling – Program FreedomCar & Testing Machine for Auto Crash Focal Project 3 21Century Truck Coordinated with Hydrogen Program Goals Current