Composite Materials and Structures Kaj Fredin, Volvo Cars
Industrial needs Common drivers for lightweight technologies across industrial branches Environmental issues, reduced energy consumption Legislation, reduced emissions Improved economy and competitiveness
Industrial needs Composites the only enabler to meet emission requirements Performance (high specific properties) New business opportunities Increased pay-load High tech profile
Example automotive 250 CO 2 Segments as a function of time Actual BIW (kg) 340 330 320 310 300 290 280 270 260 250 1970 1980 1990 2000 2010 2020! Aluminium CFRP *4 *1 Target BIW (kg) *2 *3 340 330 320 310 300 290 280 270 260 250 240 230 220 210 200 CO 2 200 150 100 50 År 220 200 180 160 140 120 100 180 160 145 130 110 100 80 Upper allowed level of Positioning @ SOP ca -60kg V70 ca 300kg Never in black range under the first 3 yrs in production 60 ca -130kg * V70 ca 230kg 0 2006 2008 2010 2012 2014 2016 2018 2020 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) 130 120 105 95 80 70 *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
Industrial needs Materials development High volume production technologies Joining technologies Recycling Multi-functionality Skilled work force at all levels Interaction between industrial sectors
International industrial trends
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)
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)
Lightweight technologies composites offer Low investments Parts integration High performance/tailoring Low life-cycle cost Design freedom Multi-functional solutions
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
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,..
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)
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!
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!
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)
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)
Competence needs Current efforts were enough, but not for the future! Sweden needs; 60-80 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?