Composites–Co-molding of local reinforcements foroptimized force transmission and locallyincreased mechanical performance–Local reinforcement with fabrics, non-wovens and component specific pre-forms–Optimization of crash worthiness of LFTparts and injection molded parts by theintegration of high strength fiber structures–Utilization of glass, aramid and carbonfibers etc. for efficient light weight design ICT TrägerTailored LFTdemonstrationpartTailored Structures for Efficient Lightweight ConstructionComposites at a GlanceMaterial and Process Development for:–Long fiber reinforced thermoplastics,e.g. LFT direct process (LFT-D/ILC)–Advanced LFT – use of engineeringthermoplastics as matrix polymerin the LFT-D/ILC process–Tailored LFT – co-molding of LFT withlocal continuous fiber reinforcement(Tailored Fiber Placement)–Processing of thermoset composites andprocess development for thermoset materialse.g. SMC–Development of natural fiber reinforcedcomposites in combination with biopolymers–Plastic-metal-hybrid – compression moldedlong fiber reinforced parts with metal insertsfor joining of metal and polymer components–Component and process simulation forLFT-parts and structures–Cast-Polyamide – in-situ-polymerizationfor the production of fiber reinforced highperformance partsStructural compositedoor-moduleSchematic layout of the LFT-D process with In-Line-Com-pounding (LFT-D/ILC)Twin screw mixing extruder with fiber direct incorporationDirect Process forLong Fiber Reinforced Thermoplastics (LFT)LFT Direct Process (LFT-D)Production of glass fiber reinforced thermoplastic parts with fiber direct incorporation: Direct incorporation of reinforcement fibers into the polymer resin melt and succeeding molding of the component parts–Development of component-specific material compositions and properties –Adjustable fiber content and free choice of reinforcement typeAdvantages–Reduced production costs by the elimination of semi-finished products and logistical effort –Increased production flexibility –LFT-strand with variable thickness for optimized mold fillLFT-D with In-Line Compounding (LFT-D/ILC)–Versatility regarding material composition –Just-in-time production–In-line compounding of polymers and additives–Use of engineering polymers –significant increase of propertiesThis process and material development was awarded with theJEC Award 2002Our partner Dieffenbacher GmbH & Co. KG was awarded for the development of processing equipment with theAVK-TV Innovationspreis 2001Tailored LFT – Co-Molding of LFT and Continuous Fiber ReinforcementsMaterial–Long fiber reinforced and continuous fiber reinforced thermoplastics (Tailored LFT)–In-Line-Compounding of LFT material in the LFT-D/ILC process–Local reinforcement of LFT-parts with fabrics and pultruded profilesFront-end carrier BMW E46 made of Tailored LFTResearch Topics–Mold fill analysis for compression molding of LFT and SMC–Investigation of rheological material data for LFT-D and SMC materials–Structural analysis with finite element simulation of co-molded LFT parts and SMC structures–Available Software: Catia V5, Ansys,Express, Moldflow, Marc, Coda and othersProcess Simulation ofLong Fiber Reinforced MaterialsTailored LFT Process–Co-molding of woven fabric and LFT in one single compression molding step–Completely automated production process:Transfer and positioning of LFT andreinforcements are automated with cycle times of 35 seconds per componentPrototype Part–Front-end carrier of BMW E46(3 series) made of Tailored LFT–Weight reduction of 30 % compared to original steel construction, approximately 10 % weight reduction compared to a plastic-metal-hybrid solutionThis project was funded by the german federal ministry of research and education and supervised by PTJ Jülich (Project number: 03N3069)Our Offer–Material and process development –Technology and equipment development –CAD, FEM–CharacterizationEquipment –Schmidt & Heinzmann SMC equipment –BMC Z-blade compounder–Fjellman and Dieffenbacher press –Reaktometer and Plastometer –Diffractometer–Process data acquisition–Wide range of characterization methodsMain Research –Class-A SMC–CF and Tailored SMC–Low density and foaming of SMC –Optimization of reproducibility,quality and emissions–Natural fibers and polymers –Recycling technologies –In-line data acquisition–Structural and process simulation –Nano technologyLong Fiber Reinforced Thermosetting Composites (SMC/BMC)Schmidt &Heintzmann SMC lineFjellmann SMC pressPart manufactured in low density SMCThermoplastic-RTM-Process (T-RTM)Development Topics–Thermoplastic composites with continuous fibre reinforcement–Tailored Fiber Placement technology (TFP),as positioning and stitch bonding of rovings and textile layers–Reduction of cycle time and costs –Process development for large scale productionProcess–Activated anionic polymerization to cast polyamide 6 with different textile fiber structures–T-RTM-process (Thermoplast-Resin Transfer Molding), developed at Fraunhofer ICTReinforcements–Organic and inorganic fibers(carbon, aramide, glass and others)–Textile structures like non-woven, woven or knitted fabrics, mats or combinations of these reinforcementsProcess AdvantagesSuitable for series production:–One-step-process with short cycle time –Low energy consumption from monomer to a finished component–Large, thick-walled and stress-freecomponents, also with varied thickness and embedded metallic inserts–Excellent single fiber impregnation by a low-viscosity melt also in thick structuresTwo or three component reaction injection molding machine,maximum melttemperature 200 °CSchematic layout ofthe T-RTM-processOur Offer Press Center for Production of Prototypes and Small Batch Series–Hydraulic high speed press withclosing force of 6.300 kN and active servo-controlled parallel motion system –SMC line–Press with closing force of 3.000 kN with heatable press table (up to 400 °C)–Dieffenbacher LFT-D extrusion line with in-line compounding (LFT-D/ILC)–Single screw plasticizing unit for long fiber reinforced thermosets and thermoplastics –High temperature RTM injection equipment for thermoset and thermoplastic reactive systems–Pivotable press for molding of liquid and reactive systemsOther Processing Equipment–2K injection molding machine with closing force of 1.100 kN and injection molding machines with closing forces of 600 kN and 350 kN–Twin screw extrusion lines with 27 mm diameter and 40 mm diameter –Different comminution devices for plastics and fiber reinforced materials –IR heating system (Heating area 1500 mm x 900 mm)–Automated clamping and transfer system for production of fabric reinforced sandwich structures and thermoforming respectively –Facilities for physical and chemical foaming of thermoplasticsMaterial and Component Characterization –Incineration oven 550 x 750 x 400 mm,up to 1.200 °C–Component construction and simulation –CATIA, ANSYS and EXPRESS–Testing facilities for material characterizationSpecial Equipment–Press center for molding and formulation trials–Compounding of customer specific LFT compounds–Processing of engineering plastics with long fiber reinforcement–Product development of advanced LFT structures with specific local reinforcements–Production of thermoset composite structures–Production of structural components with high performance fibers and cast-polyamide–Testing of composites and determination of service ranges–Consulting in material optimized and process optimized design of fiber reinforced products–Process development and modification of processes for specific products –Component and process simulation for LFT parts and structures–Development of closed loop recycling concepts for composites–Recycling of fiber reinforced materialsOther Competences in Polymer Engineering at the Fraunhofer ICT –Material- and process development in the range of polymers, polymer foams and conducting polymers –Product development –Extrusion–Injection molding and special injection molding processes–Mold technologies and Rapid-Tooling –Microwave applications in polymer engineering–Plasma- and Corona treatment e.g. for surface refinement–Comminution, treatment for recycling and recycling technologies–Polymer testing and characterizationContactBy Air –Airport Frankfurt/Main (approx. 120 km)–Airport Straßburg/France (approx. 100 km)–Airport Stuttgart (approx. 80 km)–Baden Airport Karlsruhe (approx. 40 km,only regional flights)By CarApproaching from the direction of Frankfurt/Main or Basel (CH):Motorway A5, exit Karlsruhe-Durlach, follow B10towards direction of Pforzheim until Pfinztal-Berghausen,follow B293 towards direction of Bretten, after the railway underpass turn left and follow the signs to the Fraunhofer ICT.Approaching from the direction of Stuttgart/München:Motorway A8, exit Pforzheim-West, follow B10 towards direction of Karlsruhe until Pfinztal-Berghausen, follow B293 towards direction of Bretten, for further directions please see above.By TrainTrain to Karlsruhe Hauptbahnhof; there you take the »Stadtbahn« S4 tram which departs every 20 or 40minutes towards Bretten/Eppingen/Heilbronn; exit at the stop »Berghausen-Hummelberg«. Please do NOT use the »Eilzug«. Note that the tram only stops on request (i.e. please press the button on the door). Travelling time approx. 25 minutes walk up the hill for about 10 minutes.By TaxiTake a taxi from Karlsruhe Hauptbahnhof to the Fraunhofer ICT – travelling time between 15 and 30 minutes. Price: 20,– Euro.Fraunhofer-Institut fürChemische Technologie ICTJoseph-von-Fraunhofer-Straße 7D-76327 Pfinztal (Berghausen), Germany Phone: +49(0)721-4640-0Fax: +49(0)721-4640-111info@ict.fhg.de www.ict.fhg.deDirectorsProf. Dr.-Ing. Peter Eyerer Dr.-Ing. Peter ElsnerGeneral ManagementDr.-Ing. Karl-Friedrich Ziegahn Phone: +49(0)721-4640-388kfz@ict.fhg.deCompositesDr.-Ing. Frank HenningPhone: +49(0)721-4640-420E-Mail: hg@ict.fhg.de Dr. Jan DiemertPhone: +49(0)721-4640-433di@ict.fhg.de。