Advanced Materials Enabling High-Volume Road Transport Applications of Lightweight Structural Composite Parts

Current applications of carbon fibre reinforced plastics (CFRP) can be found mostly in sectors where their use is not principally cost-driven and which have limited production volumes, such as aerospace and sports cars. In order to achieve a step-change in the application of high-performance composites in larger-volume applications, new materials systems are needed that combine very short production cycle times with performance that meets automotive requirements. The EU-FP 7-project HIVOCOMP is developing two material systems that show unique promise for cost effective, higher-volume production of high performance carbon fibre reinforced parts. These materials systems are: Advanced polyurethane (PU) thermoset matrix materials offering a combination of improved mechanical performance and reduced cycle times in comparison with conventional matrix systems, Thermoplastic PP- and PA6-based self-reinforced polymer composites incorporating continuous carbon fibre reinforcements offering increased toughness and reduced cycle times in comparison to current thermoplastic and thermoset solutions. In this introduction, the global concept of the HIVOCOMP-project is presented, and an overview is given of the achievements during the first three project years. Emphasis is then put on the demonstrators (see figures) and how they show the advantages of both innovative material concepts, both in processing (reduced cycle times) and in properties (increased toughness). Finally, the environmental impact of these new material concepts is evaluated by reporting on the results of the LCA (life cycle assessment) and LCC (life cycle costing) studies.

Assessing the life cycle costs and environmental performance of lightweight materials in automobile applications

Christian Ludwig, Jan-Anders Månson, Véronique Michaud, Jérôme Payet, Robert Andrew Witik

Life cycle assessment (LCA) and manufacturing focused life cycle costing are used to evaluate the potential advantages of composites in automotive applications. The life cycle costs and environmental performance of several suitable lightweight polymer composites are quantified and compared against magnesium and steel for a representative component. The results indicate that weight reduction will not always lead to improved environmental performance. Materials offering high weight savings such as carbon fibres and magnesium have been shown to give limited or negative environmental benefits over their life cycles due to increased environmental burdens associated with their production. Lower performance materials such as sheet moulding compounds were found to perform better from a life cycle perspective despite not being recycled. Lighter weight vehicle components were found to be always more costly; however their use did lead to reduced costs for the consumer through lower fuel consumption. (C) 2011 Elsevier Ltd. All rights reserved.

2011

Processing of Sustainable Cellular Biocomposites

Carole Boissard

Petroleum-based polymers and composites are commonly used in a wide variety of application fields. However ecological concerns, increasing oil prices and dwindling natural resources explain why nowadays industrial and public interest is more than ever focused on new bio-based – “greener”- products. In order to find viable substitutes for petroleum-based materials, major efforts are devoted to the development of sustainable solutions combining fully compostable matrices and fibres from renewable resources. Polylactide (or polylactic acid) (PLA) is currently one of the most versatile biodegradable polymers derived from renewable resources such as non-food crops of corn or sugar cane. Its transformation into foamed cellular structures would decrease its density and at the same time may improve its specific mechanical properties. This could provide cost-effective and sustainable products for packaging and construction. In the context of developing “green” foams, the focus in the present work has been on a solvent-free process based on physical foaming with supercritical carbon dioxide (ScCO2) as a foaming agent. This foaming process includes thermally driven but kinetically controlled phenomenon. Solubility and diffusion of the gas in the molten polymer, cell nucleation and growth, as well as stabilization of the final foam structures were studied for neat and composite materials. At low processing temperatures and low depressurization rates, homogeneous structures were obtained thanks to a balance between cell growth mechanisms and cell stabilization, thus limiting uncontrolled cell coalescence. The density of the resulting polylactide foams ranged from 0.12 to 0.3 g/cm3 with corresponding compression moduli of 6 to 73 MPa respectively. The processing windows were strongly dependent on the rheological melt properties of the PLAs. PLA is generally considered to be a high strength, high modulus thermoplastic but its brittleness has limited its industrial use. PLA was therefore combined with wood fibres (WF) and microfibrillated cellulose (MFC) in order to improve its mechanical performance without compromising its environmental impact. Two compounding methods, a wet mixing papermaking-like process and a solvent casting process were investigated for the production of WF/PLA and MFC/PLA biocomposites. Degradation of PLA occured during wet-mixing, due to the water used as a dispersant, and to several heating steps applied during compounding. Improvement of the drying and processing conditions and/or the replacement of water by isopropanol limited this degradation. The presence of cellulose fibres considerably modified foaming mechanisms; gas solubility was decreased and the coefficient of diffusion increased, leading to lower quantities of CO2 available for foaming. In addition, stiffness of the fibre network impeded full expansion of the polymer matrix. Thus smaller cells were created. Densities from 0.15 (neat PLA) to 0.37 and 0.55 g/cm3 and moduli ranging from 35 (neat PLA) to 125.5 and 373 MPa were obtained by the addition of 5wt% WF and MFC respectively. Addition of a chain extender enabled viscosity of the matrix to be increased causing increased orientation of the fibre network during flow and hence fibre alignment in the cell walls. Density was thus decreased by 95 % to 0.017 g/cm3 and compression modulus decreased to 0.32 MPa for 5wt% WF composite. Cell wall shrinkage was observed in the neat PLA foams obtained with the chain extender. This was reduced by adding wood fibres while maintaining similar density and modulus. Cellulose fibres act as an extra scaffold in the cellular structures. Industries are currently considering the use of these materials for applications in packaging e.g. as cushioning materials, or in architecture as display panels, or as sandwich core materials for the replacement of expanded polystyrene, polyvinyl chloride or polyurethane foams.

EPFL2012

Processing of Sustainable Cellular Biocomposites

Carole Boissard

EPFL2012