JEC COMPOSITES MAGAZINE - Issue #74 - July 2012 - 28

lightening

tics processing method for high-volume production. But there are challenges to come.

RTM for bodywork and structural components
Through the polymer applications targeted by the automotive industry for bodywork and chassis, which should make the next step change in weight reduction possible, new demands are being placed on the performance of materials as well as their processability. It was for this reason that BASF set up the cross-departmental and material Lightweight Composite Team in 2011. They are investigating the potential of the three polymer-matrix components epoxy resin, polyurethane and polyamide with respect to the mass production use of continuous reinforcements in resin injection processes. In this way, the company can make targeted use of its extensive portfolio of all three classes of material along with the associated processing know-how in partnership with representatives of various parts of the automotive value-added chain, and create synergies. One of the processing technologies behind the new materials is resin transfer moulding (RTM), which can be used to create large and complex composite components in a resin injection, press and mould process. After being placed in a temperature-controlled mould that is subsequently closed, dry multilayer fibre or textile structures are impregnated with a very-low-viscosity polymer resin. Due to their low starting viscosity, all of the new matrix systems display very good impregnation and wetting properties, even during rapid mould filling processes. Depending on the tool temperature chosen in the case of the thermosetting systems, a fast cross-linking reaction occurs whilst the thermoplastic polyamide polymerizes and crystallizes in a short period of time (Fig. 7). Alongside the mechanical performance of the finished fibre-composite part, the good flow properties of the matrix systems (even with long flow paths), the degree of impregnation and the short

Fig. 7: Resin Transfer Molding (RTM) process for polyamide

curing time of the polymer components are highly important factors for all three material types. BASF already offers solutions based on epoxy resin and polyurethane systems under the brand names Baxxodur® and Elastolit® R. Both thermosets use innovative curing mechanisms so that they cross-link within a few minutes. They can be processed on conventional high- and low-pressure equipment. The new polyamide systems, which are currently under development, are based on the very low viscosity caprolactam, a precursor of PA6, and highly advanced activator and catalyst systems. In contrast to classic PA processing, they react only once they are within the mould. These thermoplastic composite materials can then be moulded, welded and recycled. The main target of the intensive development of the three systems is to further reduce cycle times and improve processability.

Carbon and glass: continuous fibres for structural components
Carbon fibres are of particular interest, due to their very high specific stiffness and strength as a reinforcing material. In comparison, glass fibres offer a large potential as widely available, cost-effective materials. There are also new systems which show that the performance enve-

lope of this traditional reinforcing material has in no way been fully exploited yet. The possibility of combining the various matrix polymers with the various types of fibre and textile architectures provides a high level of design freedom. However, alongside the performance of the reinforcing materials, the mass production suitability and cost-effective processes based on fast matrix systems are important factors for the market success of continuous fibre reinforced (CFR) components. In contrast to injection-moulded components with local continuous fibre reinforcement, the performance of such RTM components is even better since the continuous fibre reinforcement extends over the entire part. The initially dry fibres and rovings can also be processed into tailor-made preforms and large 3D components. Amongst these are highly loaded structural vehicle components as well as mounted parts such as doors, tailgates and roof modules. Up to now, RTM technology has been used for low-volume runs in the luxuryvehicle and racing-car sectors and for trucks and agricultural or construction machinery. In these applications, roofs, cowlings and cabin parts are produced in 2K epoxy systems with glass and carbon fibres. However, at between 10 and 20

28 jec composites magazine / No74 July 2012



JEC COMPOSITES MAGAZINE - Issue #74 - July 2012

Table of Contents for the Digital Edition of JEC COMPOSITES MAGAZINE - Issue #74 - July 2012

Cover
Edito
Point of view: Closer to the shop floor
Contents
Agenda of Events
COMPANY & BUSINESS
- In Brief
- Glass fibre
APPLICATIONS
- Pipes & tanks
- Building
MARKET
- Human resources
- Glass fibre
- Turkey
FEATURE AUTOMOTIVE
- Braiding
- Lightening
- D-LFT
- Sustainability
- RTM
- RIM
RESEARCH & DEVELOPMENT
- Design
- Fatigue behaviour
TECHNOLOGY & INNOVATIONS
- Wind
- Reinforcement
Index
In the world
JEC COMPOSITES MAGAZINE - Issue #74 - July 2012 - Cover
JEC COMPOSITES MAGAZINE - Issue #74 - July 2012 - 2
JEC COMPOSITES MAGAZINE - Issue #74 - July 2012 - Edito
JEC COMPOSITES MAGAZINE - Issue #74 - July 2012 - Point of view: Closer to the shop floor
JEC COMPOSITES MAGAZINE - Issue #74 - July 2012 - 5
JEC COMPOSITES MAGAZINE - Issue #74 - July 2012 - Contents
JEC COMPOSITES MAGAZINE - Issue #74 - July 2012 - 7
JEC COMPOSITES MAGAZINE - Issue #74 - July 2012 - Agenda of Events
JEC COMPOSITES MAGAZINE - Issue #74 - July 2012 - - In Brief
JEC COMPOSITES MAGAZINE - Issue #74 - July 2012 - - Glass fibre
JEC COMPOSITES MAGAZINE - Issue #74 - July 2012 - 11
JEC COMPOSITES MAGAZINE - Issue #74 - July 2012 - 12
JEC COMPOSITES MAGAZINE - Issue #74 - July 2012 - - Pipes & tanks
JEC COMPOSITES MAGAZINE - Issue #74 - July 2012 - - Building
JEC COMPOSITES MAGAZINE - Issue #74 - July 2012 - 15
JEC COMPOSITES MAGAZINE - Issue #74 - July 2012 - 16
JEC COMPOSITES MAGAZINE - Issue #74 - July 2012 - 17
JEC COMPOSITES MAGAZINE - Issue #74 - July 2012 - - Human resources
JEC COMPOSITES MAGAZINE - Issue #74 - July 2012 - - Glass fibre
JEC COMPOSITES MAGAZINE - Issue #74 - July 2012 - 20
JEC COMPOSITES MAGAZINE - Issue #74 - July 2012 - 21
JEC COMPOSITES MAGAZINE - Issue #74 - July 2012 - - Turkey
JEC COMPOSITES MAGAZINE - Issue #74 - July 2012 - 23
JEC COMPOSITES MAGAZINE - Issue #74 - July 2012 - - Braiding
JEC COMPOSITES MAGAZINE - Issue #74 - July 2012 - 25
JEC COMPOSITES MAGAZINE - Issue #74 - July 2012 - - Lightening
JEC COMPOSITES MAGAZINE - Issue #74 - July 2012 - 27
JEC COMPOSITES MAGAZINE - Issue #74 - July 2012 - 28
JEC COMPOSITES MAGAZINE - Issue #74 - July 2012 - 29
JEC COMPOSITES MAGAZINE - Issue #74 - July 2012 - - D-LFT
JEC COMPOSITES MAGAZINE - Issue #74 - July 2012 - 31
JEC COMPOSITES MAGAZINE - Issue #74 - July 2012 - 32
JEC COMPOSITES MAGAZINE - Issue #74 - July 2012 - 33
JEC COMPOSITES MAGAZINE - Issue #74 - July 2012 - - Sustainability
JEC COMPOSITES MAGAZINE - Issue #74 - July 2012 - 35
JEC COMPOSITES MAGAZINE - Issue #74 - July 2012 - 36
JEC COMPOSITES MAGAZINE - Issue #74 - July 2012 - - RTM
JEC COMPOSITES MAGAZINE - Issue #74 - July 2012 - 38
JEC COMPOSITES MAGAZINE - Issue #74 - July 2012 - 39
JEC COMPOSITES MAGAZINE - Issue #74 - July 2012 - - RIM
JEC COMPOSITES MAGAZINE - Issue #74 - July 2012 - - Design
JEC COMPOSITES MAGAZINE - Issue #74 - July 2012 - 42
JEC COMPOSITES MAGAZINE - Issue #74 - July 2012 - 43
JEC COMPOSITES MAGAZINE - Issue #74 - July 2012 - 44
JEC COMPOSITES MAGAZINE - Issue #74 - July 2012 - 45
JEC COMPOSITES MAGAZINE - Issue #74 - July 2012 - - Fatigue behaviour
JEC COMPOSITES MAGAZINE - Issue #74 - July 2012 - 47
JEC COMPOSITES MAGAZINE - Issue #74 - July 2012 - 48
JEC COMPOSITES MAGAZINE - Issue #74 - July 2012 - 49
JEC COMPOSITES MAGAZINE - Issue #74 - July 2012 - 50
JEC COMPOSITES MAGAZINE - Issue #74 - July 2012 - - Wind
JEC COMPOSITES MAGAZINE - Issue #74 - July 2012 - 52
JEC COMPOSITES MAGAZINE - Issue #74 - July 2012 - 53
JEC COMPOSITES MAGAZINE - Issue #74 - July 2012 - - Reinforcement
JEC COMPOSITES MAGAZINE - Issue #74 - July 2012 - 55
JEC COMPOSITES MAGAZINE - Issue #74 - July 2012 - 56
JEC COMPOSITES MAGAZINE - Issue #74 - July 2012 - Index
JEC COMPOSITES MAGAZINE - Issue #74 - July 2012 - In the world
JEC COMPOSITES MAGAZINE - Issue #74 - July 2012 - 59
JEC COMPOSITES MAGAZINE - Issue #74 - July 2012 - 60
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