Polymer Composites Research in the ALM Materials Program 27 February 2008 C. David (Dave) Warren Field Technical Manager Transportation Composite Materials Research Oak Ridge National Laboratory P.O. Box 2009, M/S 8050 Oak Ridge, Tennessee 37831-8050 Phone: 865-574-9693 Fax: 865-574-0740 Email: [email protected]This presentation does not contain any proprietary or confidential information
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Polymer Composites Research in the ALM Materials Program
27 February 2008
C. David (Dave) Warren
Field Technical Manager Transportation Composite Materials Research
Oak Ridge National LaboratoryP.O. Box 2009, M/S 8050
Oak Ridge, Tennessee 37831-8050Phone: 865-574-9693 Fax: 865-574-0740
COMPOSITE MATERIALS RESEARCHWhat we were Doing --- Carbon Fiber Composites
Materials
FreedomCar &21Century Truck
Goals
Energy ManagementCrash Adsorp of Bonded Structures
Crash Energy Management (7)Testing Machine for Auto CrashCrash of Sandwich Structures
ProcessingP4 Carbon Fiber
High Vol Process of Composites (4)Next Generation P4Optimal CF for P4
Chassis Support StructuresChassis Structures
Body and Door Structures
MaterialsCF Comp Durability
Compressive Creep Materials Dev & Screening
Recycling PMCsCF SMC Structures
Development of CF SMC
JoiningAdvanced Joining
Joint Energy AbsorptionNDE Techniques
Heavy Vehicle Joining
Focal Project III
Low Cost Carbon FiberLignin Based PrecursorsMicrowave Processing
Carbon Fiber Two SplittingAdvanced Oxidation
Advanced StabilizatonLCCF Integration Line
OtherCost Modeling – ProgramComposites Conference
21st Century TruckAutomotive Lightweighting
Materials
ACC Focal Project III
Composite (Carbon) Intensive Body-In-WhiteVehicle package (based on DC JA)
P4 / Compression Molding
P4 / CompressionMolding
SMC with ribs
Compform / Nida-Core
P4 or Compform
P4 or SMC
P4 / Balsa Core
Materials
Phase 1 Results:67% mass savings over baselineBending stiffness exceeded 20%Torsional stiffness exceeded 140%Durability and abuse load cases satisfiedManufacturing strategy developed
ACC 115 High-Volume Processing of Composites 683,000
16313 Natural Fiber Composite Retting, Preform Manufacturing and Molding
400,000
ACC 100 Crash Energy Management 750,000
B Predictive Modeling of Polymer Composites C P4 PreformD Development of Next Generation P4E Focal Project 4 – Floor Pan (Composite Underbody)E High-Volume Processing of CompositesF Natural Fiber Composite Retting, Preform Manufacturing and MoldingG Crash Energy Management