OCT 2018


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NEWS 69 design to accommodate both standard (sedan/saloon/five-seater) and long (wagon/estate car/seven-seater) vehicle models. Aspects of the team's design are now covered by three patents. To keep tooling costs manageable, the team optimized the mold design to allow the top and bottom parts of both left and right rails, the front cross-beam, plus three pieces of bonding interface that connect to the rear GR-PP cross-beam (molded separately) to be produced in each cycle. Another cost-saving step was AARK- Shapers' use of modular blocks (which are inserted/removed to run both long and short rail versions) rather than costly tooling slides. To mold all eight GR-SMA/ABS components in a large family tool, an injection press with a clamping force of 1,500 kN was needed. Ultrasonic welding was selected to join the top and bottom rails, and a special assembly jig was designed and built. A prototyping and testing phase enabled the team to finalize rail design, anticipate production challenges and assure parts would pass Renault's validation tests, which included: • Durability testing for 10,000 lifecycles. • Tri-axis vibration testing over a temperature range of -20°C to 110°C at 95% relative humidity (RH). • Temperature cycling from 85°C to -20°C to 50°C @ 95% RH to 110°C. • Peel strength and shear strength after adhesive bonding. • Renault driving noise test for NVH. • Rollover "corkscrew" test. Cross-section of composite guide rail Final design of a composite guide rail (top) including its complex cross-section (bottom). Both top and bottom sections are injection molded in the same 15% glass-reinforced GR-SMA/ABS composite. Yellow (top) is adhesively bonded to glass; green (bottom) is ultrasonically welded to yellow top side. By injection molding each rail in two pieces for left and right sides and then ultrasonically welding each pair together, it is possible to exceed the performance and func- tional integration of the benchmark aluminum rails. The rails are 1,169 mm long for the Scenic and 1,239 mm long for the Grand Scenic models, nominal walls are 2-3 mm thick, and the bottom rail is 55 mm wide and the top rail is 50 mm wide. Source | Webasto SC New Thermoplastic Composite Design Material: 15% GR-SMA/ABS (upper and lower sections) Thermoplastic Composites PRESENTER PRESENTED BY EVENT DESCRIPTION: With the recent advent of practical atmospheric pressure plasma treatment systems, pretreatment of composite materials via plasma to improve the reliability of composite/ composite adhesive bonds has been receiving a lot of attention. Understanding the relationship between plasma/material interactions provides material engineers with knowledge that allows science-based process control in manufacturing. is knowledge can prevent unexpected deterioration of bond quality. PARTICIPANTS WILL LEARN: • Plasma treatment of composite materials and the intelligent use of this technology to engineer specific, beneficial surface chemistry through plasma treatment • Controlling strategies for obtaining and documenting desired treatment levels • The importance of knowledge and control of the surface state prior to treatment (age, contamination level, contaminant composition) as a major factor in variability of the outcome of plasma treatment processes. Strategies to Control and Optimize Plasma Treatment in Composite Manufacturing October 11, 2018 • 2:00 PM ET REGISTER TODAY FOR WEBINAR AT: SHORT.COMPOSITESWORLD.COM/BTG1011 GILES DILLINGHAM Founder & CTO

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