The document summarizes research being conducted at the Automotive Composites Research Centre (ACRC) to develop processing technologies for high-volume structural application of composites in the automotive industry. The ACRC aims to reduce costs through materials, processing, and simulation technologies while considering factors like recyclability and integration. The research utilizes both traditional analytical techniques and industrially-relevant tools like pre-preg compression molding, carbon fiber-SMC, rapid stamp-forming of aligned thermoplastics, and RTM. Key capabilities at ACRC include processing technologies, joining techniques, automation, and performance testing to provide data for simulations enabling component design.

1. Shaping the Future
Innovations in Composite
Materials Processing
Neil Reynolds
Automotive Composites Research
Centre, WMG
Polymer Innovation Network
21st October 2015

2. 2
Agenda
 Background
 Introduction to WMG ACRC research
 Key capabilities

3. 3
Background
 Aims:
– Development and application of suitable materials,
processing and simulation technologies for high-volume
structural application of composites in automotive industry
 Considerations:
– Cost (raw materials & utilisation)
– Cost (investment in processing technologies)
– Cost (cycle time)
– Also – LCA/recyclability, integration (joining)
 Approach:
– Industry-led collaborative R&D using a combination of
traditional and industrially-relevant research tools
 Fundamental analytical techniques through to industrial process
demonstration

4. 4
Structural Composites at WMG ACRC
 Processing:
– Pre-preg compression moulding (PCM)
– CF-SMC
– Rapid stamp-forming of aligned fibre thermoplastics
– HP-RTM & compression RTM, in-situ polymerisation
– Formability/drape
– Automation
 Joining:
– Volume-ready joining techniques
– Pre-treatments
– Automation
 Performance:
– Stiffness/strength & crash energy management
– Durability/fatigue
– Provision of key data for performance simulations, enabling
component design

5. 5
WMG ACRC Processing Capabilities
 Engel v-Duo 1700
– Multi-functional 1,700t press
– 2.2 x 1.8m usable platen area
– Fully instrumented (pressure, temp, cure)
– Sliding lower table
 Heating/transfer station on order
 Hennecke Streamline HP-RTM
– 3+1 (Resin/Polyol)/Hardener/Isocyanate + release
agent
– 60 litre day tank capacity (x3)
 Zund CNC Cutting Table
 2-D Ply Assembly
– Picking, assembling, joining
– Up to 8 different layers/plies can be stored
– 4-axis robot used to pick and place individual
layers/plies

6. 6
WMG Test/Analysis Capabilities
 ACRC:
– ±250kN static Instron, temperature chamber, video
extensometry
– Mettler-Toledo HP-DSC
– Zeiss auto stage optical microscope
 WMG:
– 12kJ instrumented drop tower
– VHS Instron (up to 25m/s)
– 3x fatigue frames (up to ±250kN)
– ±100kN static Instron
– SEM, DMTA, CT scanning

7. 7
Thanks for Listening
Neil Reynolds
Senior Research Fellow
Automotive Composites Research Centre, WMG
www.wmg.warwick.ac.uk
neil.reynolds@warwick.ac.uk
02476 524787