Research Area Technology - T1:Polymer Processing

CoDiCoFRTS process and material advancement

Advisors: Henning (FAST), Hrymak (UWO)

Based on the results of the first generation, further research is needed to improve the impact properties. In a first step, a resin formulation based on urethane chemistry will be developed and adapted to the SMC process. Polyurethane-based composites have a high potential for good impact properties and excellent interfacial strength between fibers and matrix. However, possible blister formation (as a possible defect to be studied in T3) and the resulting reduction of mechanical properties have to be considered during material development. Adjusting the resin viscosity to the requirements of the SMC process chain will be one focus. To further improve the impact properties, the usage of additional filler materials may also be considered. For the fixation of the CoFRTS material during co-molding, the application of mechanical fixation concepts will be evaluated and supported with simulations of D1. Finally, the anisotropic viscosity behavior at sharp edges and the limits in design of structural DiCoFRTS parts will be investigated, with a special focus on rib filling, material flow length and part thickness, among others. An advanced rheology tool will be used, which was developed in the first generation and includes additional pressure sensors and dielectric thermal analysis. The development of simulation models in D1 will be supported with characterization and validation employing the rheological tool as well as the rheological characterization by Wilhelm. Material characterization tests will be performed for the identification of forming behaviour and parametrization of the according forming simulation approaches. All process characteristics are transferred to the optimization loops in D2 and taken into account in new design guidelines (D3).