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GATE Center of Excellence at UAB forLightweight Materials andManufacturing for Automotive, Truckand Mass TransitUday Vaidya (GATE PI), J. Barry Andrews (PD)University of Alabama at Birmingham (UAB)Birmingham, AlabamaMay 2013Project ID# LM081Project No: DE-EE-0005580Program Manager: Adrienne RiggiThis presentation does not contain any proprietary orconfidential information
Project SummaryTimelineProject Start - Oct 2011Project End – Sep 201635% completeBudgetTotal project: 750,000DOE portion: 600,000University Cost Share: 150,000 314, 526 DOE 215,050 Expended35% completeBarriers Limited information onadvanced materialsdatabase Lack of high temperaturepropertiesPartners MIT-RCF Laurel Biocomposites e-Spin CIC, Canada Toray Carbon Fibers
DOE GATE Relevance and Goals(Consistent with VTP Goals) Development and validation of advanced materials andmanufacturing technologies to significantly reduce automotivevehicle body and chassis weight without compromising otherattributes such as safety, performance, recyclability, and cost. Train and produce graduates in lightweight automotive materialstechnologies Structure the engineering curricula to produce specialists in theautomotive area Expose minority students to advanced technologies early in theircareer Develop innovative virtual classroom capabilities tied to realmanufacturing operations3
Materials Processing and Applications Development(MPAD) at UAB – The research focus is onapplications development with rapid transition toindustry 20,000 sq.ft of industry scalefacilities Rapid technology transition toindustry – defense,transportation, infrastructure,aerospace and marine Strong industry partnershipswith materials suppliers,integrators and end users; morethan 20 active NDA’s Partnerships with federal &state agencies, and nationallabs (NSF,DOE, DOD etc)
Automotive Industry Impact in theState of Alabama – UAB DOE Graduate AutomotiveTechnology Education (GATE)LAUDERDALE LIMEMADISTONE -SON JACKSONLACOLBERTWFRANKLIN RE MORGAN H -KEEBLOUNTLA- FAY WALKERCALST.MAR -ETTEHOUN CLECLAIRBERNETALLJEFFERSON-ADPICKRANDTUSCASHELBY - EGACLAY -OLPH-ENS-LOOSATABIBBCHAMGRCOOSALL-BERSEE HALEAPCHILTONNEPERRYLEEELMORE OSUMTAUTAGAOSERADALLASMONT- MACON RUSSMARE-ELLCH-NGOLOWNDES GOM BULLOCKOC-ERYWILCOXTACRBARBOURCLWEN PIKEBUTLERMONROEARSHHEKEAWASHNRW COF DALECONECUHINYCOVIN- bama has a rapidly growingautomotive industry. Since 1993 theautomotive sector has created more than45,000 new jobs and 8 billion in capitalinvestment in Alabama. Training students in advanced lightweightmaterials and manufacturing technologies. Design and manufacturing of future generationtransportation, including automobiles, masstransit and light, medium and heavy trucks.High speedcomputational facilityModeling of crash & protective paddingAutomotivecastingsProcessmodeling
Weight reduction – Automotive, MassTransit and Truck Performance Increased ‘customer value’ while staying within CorporateAverage Fuel Economy (CAFÉ) limits Long term increase in fuel prices 6-8% (with mass compounding) increase in fuel economyfor every 10% reduction in weight, everything else beingthe sameDOE, Carpenter, 2008
UAB GATE Center for Lightweight Materials andManufacturing for Automotive and TransportationMaterials Science& Engineering/MPADLightweight Composites andCastings – Materials andManufacturing R&DMechanicalEngineeringHigh-fidelity modeling andsimulation; predictiveEngineering, material modelsCivil ash & injury studies,Studies for protection usinglightweight advanced materialsHighway crash barrier, roadsafety, pedestrian collisions,Transportation infrastructureACADEMIC PARTNERS Tuskegee University(Minority institution) Bevill State Comm. College Lawson State Comm. College Heritage Community CenterTECHNICAL AREAS FOR GATE SCHOLARS THESIS / DISSERTATIONSLightweight Materials & Manufacturing – Engineered Composites / Castings / Enhanced Crashworthiness(Basic science studies leading to Prototype/Application Development & Commercialization)Next Generation Carbon Fiber forAutomotive &TransportationNext Generation RenewableMaterials for Automotive &TransportationTextile grade carbon fiber; reclaimed carbon fiber; wet laid carbon fiber; intermediateforms, effects of sizing; compounded carbon/foams; LFT injection & compressionInterface treatment of biocomposites, Bioresins, Moisture uptake and prevention;Processing and blending of natural fibers with synthetic fibersAdvanced Metal CastingsMagnesium and aluminum casting; Austempered steels, Lost foam casting, In-situX-ray analysis, predictive engineering , pressure assisted castingBiomechanical studies /Crashworthiness modelingInjury biomechanics, side impacts-material/body interaction on pelvis; crashworthin-ess modeling; body collision, pedestrian and child car safety studiesINDUSTRY & Other Partnership Automotive & Mass TransitCompanies Economic DevelopmentPartnerhship Agency (EDPA) Material Suppliers & End-Users Alabama Manufacturers National Composite Center American Chemical CouncilNATIONAL / DOE LABPartnership Oak Ridge National Lab (ORNL) Pacific Northwest National Lab,(PNNL) National Transportation ResearchCenter (NTRC) US Department of Agriculture (USDA)ADVISORY BOARD Automotive & Heavy truck reps(Mercedes, Honda, others) DOE program managers Material focused industry reps Economic Development reps7
GATE students working on Industrial scalefacilities - TrainingTheresa Bayush (MS candidate) and Melike Onat Alejandra Constante (PhD candidate) and Samuel(PhD candidate) working on natural fiber extrusion Jasper (PhD candidate) working on composite beams
Accomplishments and Progress: GATE DirectlyFunded Students (2005-2011)GATE SCHOLARWHERE PLACEDGATE Thesis / Dissertation1Mohammed ShohelKBR, Houston, (CEE, PhD ‘06)Resin infusion processing of laminated composites2Carol OchoaFenner Belts, Pennsylvania (MSE, PhD’09)Finite element analysis and modeling of thermoplasticcomposites3Balaji VenkatachariCFDRC, Huntsville (ME, PhD’ 09)Simulation of flow fields in automotive bodies4Amol KantOwens Corning (CEE, PhD ’09)Sandwich construction for crashworthiness of automotiveapplications5Lakshya DekaWhirlpool (MSE, PhD ‘06)LS-DYNA modeling of of thermoplastic composites6Satya VaddiTechnical Fiber Products (MSE, MS’09)Fire behavior of thermoplastic composites7Felipe PiraAirbus (MSE, MS’07)Process Modeling of Thermoplastic Composites8Leigh HudsonToray Carbon Fibers (MSE, MS’09)Pultrusion of thermoplastic composite elements9Lina Herrera-EstradaPursuing PhD at GA Tech (MSE, MS’ 09)Banana Fiber Composites for automotive applications10Danila KaliberovPursuing PhD, UAB (MSE, MS’ 10)Threaded long fiber thermoplastic composites11Michael MagriniTyndall Air Force Base (MSE, MS’11)Impact response of long fiber and laminated thermoplasticcomposite materials12Melike Dizbay-OnatInterdisciplinary Engineering, PursuingPhD, UAB, Graduation Dec 2014Carbon footprint reduction and emission absorpbtion activatedcarbon composites13Aaron SiegelJacobs Engineering (MSE, MS’ 12)Energy absorbing compounded thermoplastic foams forenhanced crashworthiness14Peter BarfknechtMSE, Pursuing PhD (UAB, Dec 2014)Carbon fiber sizing and liquid molding of reactivethermoplastics15Nsiande MfalaPursuing PhD, Tuskegee University(MSE, BS’ 2010)Nanostructured kenaf and banana fiber thermoplasticcomposites for automotive applications16Benjamin Geiger-WillisMSE. Pursuing PhD 2015High strain rate impact of thermoplastic composites and foamsfor crashworthiness9
GATE Directly Funded Students (2011-2012)GATE – Graduate scholarsGATE ScholarDepartment and StandingGATE Thesis / Research1Melike Dizbay-OnatInterdisciplinary Engineering,Pursuing PhDCarbon footprint reduction and emission absorptionby natural fiber composites2Danila KaliberovMaterials Science & Engineering,Pursuing PhDThreaded long fiber thermoplastic composites3Alejandra ConstanteMaterials Science & Engineering, PhDNatural fiber composites for automotive applications4Khongor JaamiyanaMaterials Science & Engineering, PhDModeling of thermoplastic pultrusion for truckframes5Hicham GhosseinInterdisciplinary Engineering, PhDNanofiber sizing and carbon fiber integration6Theresa BayushMaterials Science & Engineering, PhDNatural fiber compositesGATE Team for Industry SupportAlejandra Constante, Theresa Bayush, Arabi Hassen, Samuel Jasper, Danila Kaliberov,Benjamin Willis, Qiuishi Wang, Ranae Wright, Peter Barfknecht,GATE – Undergraduate scholars pipelineGATE ScholarDepartment and StandingGATE Research1William WarrinerMaterials Science & Engineering, JuniorExtrusion-compression molding of long fiberthermoplastics2Ranae WrightMaterials Science & Engineering,Pursuing PhD, JuniorSandwich composites with high damping andenergy absorption capabilities3Raymond C. SolomonMechanical Engineering, SophomoreCarbon fiber orientation evaluation in long fiberplaques4Emily WillisCollaborating High School, Hoover HighPull-out strength of screws from thermoplasticcomposite plates10
GATE: Undergraduate Student Pipeline1Malina PandaFord (MSE, BS’ 07)Development of hot-melt impregnated materials2Daniel KaliberovPursuing PhD UAB (MSE, Dec 2014)Vibration testing of long fiber thermoplastic composites3Michael EntzPursing PhD, NC State University (BS, ME’08)Impact analysis of laminated composites5V. AmeyaEastman Chemicals (BS, CE’12)Self reinforced polypropylene studies6Hadeel AbdelmajeedBAE Systems (MSE, BS’ 09)Thermoforming processing of laminated composites7Walter MaloneHanna Steels (MSE, BS’09)Sandwich panel construction for automotive floor boards8Victor LongRaytheon (MSE, BS’09)Compression after impact of layered materials9David SextonSouthern Company (MSE, BS’08)Carbon fiber thermoplastic impregnation10Saptarshi VichareKBR Houston (BS, 08)Carbon fiber thermoplastic impregnation11Benjamin RiceCarnegie Mellon (Grad school) (MSE, BS’08)Compression after impact of E-glass/vinyl ester composites12Khongor JaamiyanaUAB MS 2013/ Intern at Owens CorningLow velocity impact response of Carbon SMC13Alex JohnsonGM (CE’12)Carbon fiber impregnation and characterization14Krishane SureshHyundai, Dec’ 12Long fiber thermoplastics processing15Amber WilliamsJefferson County BaccelaureatePultruded composites characterization16Anshul BansalAlabama School of Fine ArtsFuel cell demo and composite bipolar plates17Sueda BaldwinGE (BS’ 08)Long fiber thermoplastic fiber orientation studies18William WarnerHonda of America, Dec’12Nondestructive evaluation of defects in sandwich composites19Theresa BayushUAB Pursuing MS; Graduating Summer 13Nanonstructured banana fibers thermoplastic composites forautomotive applications20Benjamin Geiger-WillisUAB Pursuing PhD, December 2015Split Hopkinson Pressure Bar for high strain rate impact testingof materials21Daniel CreamerHannah Steel (BS, November 2012)Lost foam casting
GATE courses Composite Design and ManufacturingTechnologies for Automotive Applications Process Modeling andSimulation for Lightweight Materials Optimized Lightweight Material Designs forPrevention of Crash-Related Injuries Mechanical Characterization andPerformance Evaluation of AdvancedLightweight Materials Advanced Composite Mechanics Nano materials for Automotive Applications. Process Quality Engineering Nondestructive Testing & Evaluation Carbon Fiber Technologies forAutomotive Sustainable/Renewable Materials andProcessing Technologies forAutomotive Predictive Engineering – IntegratedProcess Modeling and Design inComposites & Castings Materials by Design for Heavy Trucksand Mass Transit Materials and Design for Fuel Celland Hybrid Vehicles Modeling and Simulation forCrashworthiness*,** A GATE scholar takes at least 6 courses of the above 14. GATEcertificate option will be make available to the industry participants aswell.12
Materials Forms for AdvancedComposites ManufacturingThermoplastic Matrix CompositesDiscontinuous fiberreinforced thermoplasticsContinuous fiberreinforced thermoplasticsUnidirectional tapeLong fiber reinforcedthermoplastics (LFT)Woven prepregOther forms (braidedprepreg, etc)Short fiberfilledthermoplasticsFORMING AND FINISHING OPERATIONS(FIBER INJECTION MOLDING, EXTRUSION, COMPRESSION MOLDING, PULTRUSION, DIAPHRAGMFORMING, THERMOFORMING, ETC )END PRODUCT
Long Fiber Thermoplastics (LFT)Superior mechanical properties in comparison to short fiber composites(higher modulus, higher impact properties, higher tensile strength);elastic properties 70-90% that of continuous fiber compositesσfLFTsRelative Property Lev1.21.00.8M odulusStrengthImpactProcessibility0.60.40.2τl l d d Cl l d d Cl l d d CCritical length todiameter ratio:0.00.11Length (mm)Source: J. Thom ason and M .A. Vlug10100σ max l 2τ d c
Long Fiber Thermoplastic (LFT)Composites ProcessingTechnology1Take Up [7]Pelletizer[6]Puller[5] Cooled Rollers[4]3. The polymer inthe LFT pelletsmelts to produce amolten fiber-filledcharge that is thencompressionmolded.Extruder [3]Impregnation Chamber [2]Let-Off [1]Chiller[8]1. Hot-Melt Impregnation: Dry fibers are impregnatedwith extruded thermoplastic polymer in a die. Therod material is chopped into long fiber pellets (of0.5” to 1” fiber lengths)342. These LFT pelletsare fed to theplasticator2Representativemolded part
Plasticator & Press
Material TransitionsChopped PelletsCharge / Shot
Compounding Micro-Sphere PelletsTwin ScrewExtruderMain ResinFeederPuller & Pelletizer
Damping enhancement possibilities byultra lightweight compounded foam0.060.05Damping of ultralightweightcompounded foam (UABtrials)Damping Ratio0.04PP25 3 10.03PP50 3 1TPX 25 2 1TPX 50 2 10.02Damping level 00012000Frequency(Hz)Significant enhancement of damping capacity by the compounded foam materials.While we are in the process of quantifying between the variants, all variantsshow multifold increase in damping, therefore promise for enhanced crashworthiness inautomotive applications
Thermoplastic Composites inAutomotive & Mass transitHeadliner of the 2007Honda Acura MDXLong glass/PP structural duct :2007 Dodge Nitro SUVSource: Ticona
Composites forMass Transit BusAC RoofCover2-passenger seatSide Bodyand FrameSegmentsBattery Access DoorFloor Segment
\Access Doors (Passengerand Military Vehicles)ChargeToolComposites Part A: Applied Science and Manufacturing, Volume 39, Issue 9, Pages 1512-1521 (2008).
40% lighter Roof Door for Vehicle;Weight reduction - 450 lbs0.160.140.12Damping ratio Thermoplastic composite technology demonstrated ona large scale part; Innovative utilization of synergisticmaterials Form-fit function; including existing hardware 39% weight reduction & 77% less free standingdeformation Order of magnitude improved vibration dampingLowering of Center of Gravity. The BRT bus has 8 roofdoors per segment –potential weight savings 450 lbs Cost effective manufacturing – reduced assembly steps Generic to military, light rail, trucks and other vehicles0.10.080.06Enhanced vibrationdamping and terials & Design, Volume 30, Issue4, Pages 983-991 (2009).AC roof cover door23
CompositeDoorfor TruckLFT Extrusion-compression molded part–Material selection – Weight & performance optimizationDesign VariableAluminum design(baseline)PanelRib (mm)(mm)324243324243MaxMaterial --Composite Design40 wt%glassNylon6640 wt%glassNylon66 8% Maximum stress: 8.7 MPaMax deflection: 0.47 mmMass: 1.84 kgWeight saving: 26.4%
GATE Collaboration with MIT-RCFMIT-LLC Project Planning and Execution Document (PPED) for GATE Program at UAB Project Name: RCF-LFT: effects of fiber length, resin viscosity, and mixing Project Partner: Materials Innovation Technologies LLC, Fletcher, NC Project Monitor: Dr. Mark Janney Brief Project Description: Define the roles played by fiber length, resin viscosity, andmethods of mixing in determining the mechanical properties of compression molded longfiber thermoplastic (LFT) composites made from recycled carbon fiber. Properties can bedirectly compared with RCF-PET Co-DEP properties form MIT-LLC DOE III project.(30%wt)(40%wt)(40%wt)(50%wt)
Thermoplastic Composite Shelland Baseplate used forElectronic Modules234112Composite BaseplateComposite AeroshellPatent No: 8,277,933 - USPTO
Complex shapes in carbon thermoplasticin 1 minute cycle times –Manufacturability trials with MIT-RCF
FineIntegratedEMI ShieldingVeilCoarse
LFT Co-molded with ContinuousThermoplastic Tapes Co-molding LFT with pre-consolidated /continuous reinforced tape Local reinforcements Replace traditional rib structures Local tailored strength & stiffness Functional integration Parameters influencing final properties Processing Bonding interface Stiffness of the materials Thickness ratioE - rcementPolymer Composites, In-print, Jan 2013
MacDon – Duct Screen Cleaner Develop compounding and processing parameters for achieving maximum fiberaspect ratio of hemp fiber. Investigate fiber treatments and coupling agents for enhanced fiber matrixinterface Evaluate PP/hemp fiber composite for manufacture of duct screen cleaner forMacDon tractor application; mechanical testing, thermal characterization, UVstability, hydrothermal aging. Redesign duct screen cleaner for extrusion-compression molding (ECM). Design tooling for proto-typing of part / Prototype and test. Volume 650 parts per year.
Representative Material FormsIntimate wet-outSimple blends, hot-melt pelletsTapes, Woven FabricsWet-laid or roll bonded
Future Work Leverage GATE and expand industrypartnerships Carbon fiber thermoplastic impregnationstudies for PP, nylon and PPS Further processing, test data and designparameters for recycled carbon fibers Compounded recycled carbon fibers forinjection and compression molding Interaction with Oak Ridge on specific projects
Summary Selective insertion of cost-effective, lighter, highperforming, mass produced composite parts forautomotive and transportation. Next generation work-force development Materials and process innovations Applications developed ready for commercialization. The applications developed are generic for marine,aerospace, medium/heavy vehicles and energysector.
Thermoforming processing of laminated composites . 7 . Walter Malone . Hanna Steels (MSE, BS'09) Sandwich panel construction for automotive floor boards . 8 . Victor Long . Raytheon (MSE, BS'09) Compression after impact of layered materials . 9 . David Sexton . Southern Company (MSE, BS'08) Carbon fiber thermoplastic impregnation . 10 .
