CompositesWorld
Issue link: https://cw.epubxp.com/i/866813
SEPTEMBER 2017 68 CompositesWorld PLANT TOUR restricted to long cycle times and, thus, small-series production. Reportedly, the main challenge is infiltrating the complex, foam-cored, insert-integrated parts with resin within a short processing window. e key is process control during resin injection via in-tool sensors, which BENTELER SGL has obviously mastered. ird, it's a showcase example of BENTELER SGL's ability to manage the many facets of multi-material manufac- turing. "is is the most complex part that we build right now," Ascher notes. Indeed, production of the MSS module manages four derivatives, using 242 supplied components, many made from aluminum, and requires 17 bonded joints achieved through 146 adhesive opera- tions. Part development began in 2009 and production commenced in 2013. "is part makes a difference vs. our competi- tors," says Ascher. "We know how to inte- grate aluminum into the part's structural function and how to automate complex assembly with bonded and mechanical fasteners. Both partners built extensive knowledge through this development." e CFRP parts are bonded with poly- urethane, but bonded fasteners and mechanical fastening also are used in final assembly. Bins full of fasteners can be seen, positioned across from the auto- mated assembly cells. In one of the cells, a robot is applying polyurethane adhesive. e cell's automated door opens, a worker manipulates a metal bonding jig, closing its two wings and back section onto the main composite piece. e jig will hold and locate this piece while adhesive is applied, and subsequent pieces are located and held in place during adhesive cure. e assembly is built up in subse- quent cells, with some including installa- tion of fasteners. Future materials, processes, and parts Although epoxy and polyurethane dominate production at BENTELER SGL, thermoplastics are an option. "For us, there is no preference for thermoset or thermoplastic," says Ascher. Ernst-Seibert adds, "We adjust ourselves to market needs and we can do this quickly. We're not afraid of new materials or processes, made from 42 preforms, including left and right struts, four backplane components and two components each for left and right upper B-pillars. It's used for the Lambo- rghini Huracan and Audi R8, and received a 2016 JEC Innovation Award for BENTELER SGL and teammates Audi (Ingolstadt, Germany) and Evonik (Essen, Germany). For this part alone, BENTELER SGL fabricates more than 311,000 preforms and 200,000 composite parts per year at Ort im Innkreis. Second, the manufacturing process for the MSS composite elements — named ultra-RTM — includes developments in fiber forms, fast-cure resins and low-density foam cores with integrated fasteners. According to Audi, the combination of these technologies enables exploitation of differential construction for high-volume produc- tion, achieving the lightweight and performance of a monocoque without being COMPOSITE TEST FIXTURES Wheeling, IL USA www.mttusa.net Material Testing Technology Ph (847) 215-7448 ASTM D3410 ASTM D7249 ASTM D2344 ASTM D4255 ASTM D5379 ASTM C297 ASTM D7332 ASTM D6641 ASTM D695 ASTM D7264 ASTM C393 ASTM D3039