Composite Materials and Structures. Kaj Fredin, Volvo Cars

Transcription

1 Composite Materials and Structures Kaj Fredin, Volvo Cars

2 Industrial needs Common drivers for lightweight technologies across industrial branches Environmental issues, reduced energy consumption Legislation, reduced emissions Improved economy and competitiveness

3 Industrial needs Composites the only enabler to meet emission requirements Performance (high specific properties) New business opportunities Increased pay-load High tech profile

4 Example automotive 250 CO 2 Segments as a function of time Actual BIW (kg) ! Aluminium CFRP *4 *1 Target BIW (kg) *2 * CO År Upper allowed level of SOP ca -60kg V70 ca 300kg Never in black range under the first 3 yrs in production 60 ca -130kg * V70 ca 230kg Year *1: -60kg mål för V70 med dagens vikt på ca 360kg, för att nå 120gCo2/km *2: Bästa idag prognosen var konkurrenter (ej 100% Al). Audi A6-koncept Stål-Bas/Al-mix *3: Viktsreducering på 130kg för dagens V70 för att nå 95gCo2/km *4: State of the art hel-aluminium kaross (A8) samt det bästa vi vet om kolfiberlösningar (TECABS, LFA, BMW) *1: -60kg mål för V70 med dagens vikt på ca 360kg, för att nå 120gCo2/km *2: Bästa idag prognosen var konkurrenter (ej 100% Al). Audi A6 Stål/Al-mix *3: Viktsreducering på 130kg för dagens V70 för att nå 95gCo2/km *4: State of the art hel-aluminium kaross (A8) samt det bästa vi vet om kolfiberlösningar (TECABS, LFA, BMW

5 Industrial needs Materials development High volume production technologies Joining technologies Recycling Multi-functionality Skilled work force at all levels Interaction between industrial sectors

6 International industrial trends

7 Supporting industry: national General lack of Tier 1 and Tier 2 suppliers Lack of knowledge at all levels Technology shift towards composites is hampered but we have world-leading textile reinforcement industry (Oxeon, BiTeam)

8 Supporting industry: international Strategic alliances created (e.g. BMW/SGL/Benteler) Joint ventures (e.g. Boeing 787) Focused research centres partly funded by industry and regional governments (e.g. TUM) Multi-sector technology parks (e.g. MAI Carbon Augsburg) Industrial centres (e.g. EADS Nantes)

9 Lightweight technologies composites offer Low investments Parts integration High performance/tailoring Low life-cycle cost Design freedom Multi-functional solutions

10 Lightweight technologies: needs Joining technologies High volume production (fast processes) Low cost/environmentally friendly materials Thermoplastics Bio-based materials Automation Industrial engng. processes and virtual tools Recycling

11 Research structure: national Has its base in Aeronautics Fragmented and performed within specific projects (NFFP, FFI, SSF, VR, Vinnova, STEM, FMV, EU) Academic research worth 70 MSEK/year Broad but at relatively low TRL Strong collaboration between partners Active research groups: Swerea SICOMP, KTH, LTU, Chalmers, Compraser SAAB, VAC, VCC, Kockums, Clean Motion, Oxeon, BiTeam, ABB, RUAG,..

12 Research structure: international University structure similar to Sweden UK has created large university centres (e.g. Bristol, ICL, Sheffield) Creation of research and development centres aiming for higher TRL, e.g. CCM (Delaware, USA) MAI Carbon/DLR (Augsburg, Germany) Institute for Carbon Composites (TUM, Germany) NCC Bristol (UK) CRC-ACS (Melbourne, Australia)

13 Research structure: status and needs No national coordination Research conducted in isolated projects No specific funding devoted to composites no national programmes National coordination desired by all stakeholders Sweden competes with Europe and the rest of the world!

14 Competence level Generally low level in industry, with some exceptions Practicing engineers need to adopt to completely new methodologies Industry may need to redesign their technology organisation Design of composite structures requires multidisciplinary knowledge!

15 Educational efforts: national B.Sc./M.Sc.-level (KTH, LTU, Chalmers) Less than 50 students completes two or more courses on composites per year Approx. 25 M.Sc.-thesis projects/year Approx. 20 Ph.D.-students Courses for blue collar workers - PUCK Courses for industry on ad hoc basis (KTH, Swerea SICOMP, SAAB)

16 Competence needs Composite materials and structures programmes fulfilling industrial need should be developed Increasing number of students Development of course materiel, net based courses and intensive courses at all levels Development of course packages for practicing engineers (e.g. certificate programmes at CCM)

17 Competence needs Current efforts were enough, but not for the future! Sweden needs; Ph.D. s in the next 10 years 100 M.Sc. s per year with composites as specialisation? 200 practicing engineers in composites continuing educational programmes per year? Blue collar worker education?