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BREMEN, Germany

Agency: Cordis | Branch: FP7 | Program: CP-FP | Phase: AAT-2007-4.1-05 | Award Amount: 7.91M | Year: 2008

Main aim of the project is the development of a complete, integrated process chain for the cost effective serial production of various aerospace CFRP stiffener profiles. The production is foreseen in the two steps: Preform manufacturing and infiltration / curing. The project will focus on complex profile geometries with variable cross sections, single or multiple curvature and integrated load introduction areas. Braiding will be useful for the net shaped preforming of more massive straight and curved profiles like frames and floor beams, as well as for drive shafts, rods and other pipe-like structures. The technology offers a high potential for the cost effective production of net shaped fibre preforms with respect to optimized load paths and light weight design. For the production of stringers, especially for those with double curvature, the so called Fibre Patch Placement FPP should be used to manufacture tailored non crimped multidirectional tapes . FPP works with spread and bindered rovings, which can be laid up in any desired angle and in uni- or multilayer configuration, according to the needs of the stringer design. The infiltration of the preforms is planned with RTM technology or with the so called Stacked Curing technique, an open mould infiltration technique which allows the simultaneous curing of up to 20 profiles in one shot in a tool with comparably low complexity.

Agency: Cordis | Branch: H2020 | Program: BBI-RIA | Phase: BBI.VC2.R4 | Award Amount: 2.60M | Year: 2015

The overall objectives are to demonstrate a new biobased, renewable and economically viable carbon fibre (CF) precursor lignin produced in Europe with European raw material and to develop conditions for its processing into CF and structural CF composites. The target is a cost-effective biobased CF for use in reinforced composites delivering sufficient enough strength properties for large-volume automotive applications. Reducing vehicle weight is a decisive factor for successful fulfilment of the future targets in EU regulations regarding CO2 emissions from the automotive sector. CF reinforced plastics has been introduced as a low-weight material replacing/complementing steel and aluminium. Todays CF production is based on use of a petroleum-based raw material, PAN, which is costly due to the starting precursor and the process for turning it into CF. Most PAN used in Europe is imported. The automotive sector has identified a need for a cheaper lower-grade CF to meet the demands of components in normal consumer cars. Lignin from kraft pulp mills is a green, sustainable, abundant and cost-efficient new potential CF precursor. The European pulp and paper industry has a need for additional revenues due to the global competition and the decline in printing and writing paper. Successful lignin applications like CF will create new business opportunities and new jobs also in rural areas where the pulp mills are located. The development of lignin-based CF is still in laboratory scale and material properties meeting high-quality product demands is the main challenge. Now a new technology in commercial operation makes it possible to produce lignin with new properties, higher purity and with less impact on the pulp mill operation. The idea is to tailor kraft lignin properties already in the lignin separation/upgrading and optimise the lignin for target automotive applications. The consortium has unique competence through the complete value chain to realise this new concept.

Agency: Cordis | Branch: FP7 | Program: CP-FP | Phase: FoF.NMP.2013-10 | Award Amount: 5.37M | Year: 2013

Within current composite part development and manufacturing processes a disproportional high effort is implied in order to find optimal process parameters and to meet required qualities and tolerances of high performance light weight structures. The ECOMISE project proposes a breakthrough production system to enable next generation of thermoset composite manufacturing and post-processing. Within this new approach high precision process techniques for advanced dry fibre placement (AFP), infiltration (RTI/ RTM) and curing will be developed in order to maximize process efficiency at reduced costs and production time due to less material consumption, higher reproducibility, less energy, less waste and less rework. In detail, innovative online process monitoring systems, probabilistic process simulation methods as well as a new method for in-situ structural evaluation of resulting composite properties will be developed, followed by a new knowledge-based method for in-situ process adjustment with respect to initial structural requirements. In this novel way, the required structural performance of the final composite product can be linked and assured during every manufacturing step, yet serving qualification issues at the earliest stage. Advanced characterization and testing techniques will be utilized and tailored to evaluate the process efficiency for required product quality by focussing on process robustness and throughput rate. Hereupon, the reduced carbon footprint is evaluated during manufacturing and in-service. The resulting economic benefits of the ECOMISE approach will be evaluated and demonstrated by pilot implementations for industrial use-cases, considering particularities for volume part (automotive), large part (aeronautic) and thick complex part (marine) productions. Here, a significant impact is expected for SME and industry end users and suppliers of composite structures as well as of facilitators providing measurement systems and software solutions.

Agency: Cordis | Branch: FP7 | Program: JTI-CS | Phase: JTI-CS-2009-1-GRA-01-015 | Award Amount: 44.57K | Year: 2009

The aim of this work is the complete characterisation of innovative prepreg systems based on carbon fibres and nanoparticle modified resins. After the test specimen production well known and long time approved mechanical test methods related the aircraft industry, as well as thermo-mechanical and chemical analyses will be used for the characterisation. Regarding the fibre-matrix adhesion a novel test method will be developed which is based on a tensile test for single fibres. Considering the long time experience in harmonising test methods for fibres and the experience of testing single natural, synthetic and high performance fibres a pull out test with a so called Dia-Stron equipment will be feasible resulting in a very simple and standarised test method to determine the fibre matrix adhesion.

Agency: Cordis | Branch: FP7 | Program: JTI-CS | Phase: JTI-CS-2012-1-ECO-01-052 | Award Amount: 299.29K | Year: 2012

Todays preforming technologies are largely manual, thus increasing the costs of Liquid Composite Molding (LCM) technologies such as Resin Transfer Moulding (RTM). Systems that can drape 3D profiles automatically and continuously, such as the one developed by FIBRE, have just left the development stage but are in need of further development to in-crease productivity and quality. The chemical stitching (CS) technology offers a way to reduce the lead time by replacing the time consuming binder application with localised adhesives application. For the application, needles will be used which inject either a thermoplastic (hot melt) or thermoset (microwave curing) adhesive between the layers. This will also improve permeability and thus the quality of the finished part. Furthermore is the chemical stitching technology more energy efficient because melting or curing of the adhesive is restricted to minimal areas and volumes. The aim of this proposal is to develop an efficient process chain for the continuous pro-duction of profiles such as stingers and spars for the CS EDA WP2 torsion box generator. From the singular requirements concerning the component geometry as well as the equipment foot print it becomes clear, that a new machine needs to be designed and constructed. Extensive knowledge gathered during the development of 3D preforming technology by the applicant reduces the development time of the core preforming equipment, so that the majority of the work can be focused on developing the integrated preforming/chemical stitching process. Nevertheless, the requirements for using different sorts of fabric (woven, nonwoven, NCF, UD) requires testing of the new equipment to find the correct set of process parameters for each fabric. The new equipment will be designed in modules, so as to ease later expansion of its capabilities. Thus, the equipment can be enhanced in the future with the ability to produced curved profiles or with additional CS substructures.

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