AUG 2016


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37 NEWS CFRP Stabilizer Bar Production CW senior editor Ginger Gardiner has an engineering/ materials background and has more than 20 years in the composites industry. Prototype parts are tested in IFA's extensive test center (which houses burst, crash, noise/vibration/harshness (NVH), acoustics and service-life test systems as well as climate chambers capable of -41°C to 75°C and up to 80% relative humidity) against real road data diagrams defined by the OEM. Automated nondestructive testing equipment is available for both prototype and produc- tion parts (Step 6, p. 35). e CFRP stabilizer bars for the Volk- swagen XL1 passed all required performance tests, yet weighed only 786g for the rear axle and 1,159g for the front. ose weights are extremely low, however, because the XL1 hybrid is designed to travel 100 km on one liter of fuel. Newer stabilizer bars designed for high-perfor- mance sports cars weigh closer to 1,250g, but that is still half the mass of their metallic counterparts. Opportunities for carbon and glass IFA Composite already is using the process developed for its stabilizer bars to broaden its pursuit of production- scale CFRP suspension structures. It has since developed structural CFRP chassis components that include not only leaf springs and anti-roll bars, but torsional springs and other suspension parts — and broadened its production to other high-performance automobiles. Although the XL1 stabilizer bar uses a monolithic design, Schulz sees growth in multi-part assemblies, similar to those developed for a new sports car. "It allows even more design freedom with mix- and-match lever arms and also hollow torsional tubes," he explains. "With almost the same weight as the XL1 parts, these stabilizer bars are six times stiffer!" e big question is will this tech- nology go into high-volume produc- tion? IFA Composite's product group leader Hinrich Hampe sees that future for CFRP and GRP chassis compo- nents. "e advantages, like good failure modes and lightweight design, are valued, both for today's cars and future models," he says. "We also see options for torsional springs, which can be made more compactly than metallic compo- nents, opening up totally new layout options." Hampe adds, "Due to the high cost of carbon fiber raw material, it will be limited to sports cars and electric vehicles, but glass fiber offers an alterna- tive still underestimated today." W T F yoming est ixtures INC. • Over 40 types of fixtures in stock, ready to be shipped. • Expert consultation with Dr. Adams • Email or call today to discuss your fixture and custom design needs. Three and Four Point Short Beam Fixture ASTM D 790, D 6272, D 7264 2960 E. Millcreek Canyon Road Salt Lake City, UT 84109 Phone (801) 484.5055 Fax (801) 484.6008 email: Dr. Donald F. Adams President 50 years of Composite Testing Experience FLEXURE FIXTURES FOR EVERY SPECIMEN SIZE We provide quotes for a variety of grips, fixtures, and jigs. We carry over 40 types of fixtures in stock, available for immediate delivery. Email or call us today. We look forward to hearing from you. Three and Four Point Flexure ASTM D 790, D 6272, D 7264 Long Beam Flexure Fixture w/Alignment Rods and Bearings ASTM C 393, D 7249 Reversed Cycle Flexural Fatigue Miniature Flexure Fixture

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