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“NANOFORCE”
Next generation nano-engineered
Polymer-Steel/CNT Hybrids
SIM Nanoforce introduction Industrial Testimony
Peter Persoone
SIM User Forum 21 October 2013
Stuurboord Antwerpen
SIM-SIBO NANOFORCE
Outline
- Objectives of the Nanoforce program
- Consortium Partners
- Nanoforce Projects
- Industrial Testimony
1
SIM-SIBO NANOFORCE
Nanoforce “Science & Technology” Objectives
- Explore breakthrough and novel strong and lightweight
Polymer-Steel/CNT Hybrids
- Explore Multi-level Modeling to support the first objective, and
to enable predictable “application Specific Design”
- Use of Multi-level modeling for optimal material life-cycle
performance (durability) and improved recyclability
- Explore new combinations of technology and materials,
combining steel, polymers and nanoparticles / aCNTb
breakthroughs and insights
2
SIM-SIBO NANOFORCE
Nanoforce consortium partners
Academic Partners Departments
1. Katholieke Universiteit Leuven MTM, COK, CIT, Chemistry, ESAT
2. Universiteit Gent DMSE, DIPC
3. Vrije Universiteit Brussel MEMC, FYSC
4. Universiteit Antwerpen EMAT, Physics
5. VITO NV Materials Department
Industrial Partners
1. LMS International NV
2. NV Bekaert SA
3. Recticel NV
4. OCAS NV
3
SIM-SIBO NANOFORCE
Nanoforce projects
4
SIM-SIBO NANOFORCE
SBO-1: Nano-Engineered Polymer-Steel Hybrids (NaPoS)
5
- Goal: to develop a scientific base to optimize the interaction between steel (fibers and
sheets) and polymers, in order to better exploit
• the unique toughness potential of (stiff) steel fibers ( brittle glass and carbon fibers), to create
tough and durable steel fiber reinforced polymer composites.
• the unique multi-functionalities of steel-polymer laminates/sandwich materials: the stiffness,
toughness and formability of steel with the lightness, damping capacity, insulation … of polymers
- Innovations and breakthroughs on different levels:
• Modifications of the steel surface to improve the adhesion to (mostly thermoplastic) polymers
• Nano-engineered modifications to the polymer in order to decrease the stiffness mismatch
between steel and polymers, but also to enhance specific non-structural characteristics
• Modifications of the interphase area by creating gradient structures and properties.
• adding nano-engineered sizings to the steel surface
• creating gradient properties in the polymer close to the steel surface.
• A lower life cycle impact and improved recyclability of steel-polymer hybrids seems to be an
affordable option.
SIM-SIBO NANOFORCE
Nanoforce projects
6
SIM-SIBO NANOFORCE
SBO-2: Multilevel modeling of nano-engineered hybrids (MLM)
7
Range of levels/scales in hybrids: from application [meters] down to individual constituting phases [few micrometers tens of nanometers]
Challenges:
Extension of ongoing micro-meso modeling to hybrids with tough phases
Extension of models towards gradient/non-gradient structured nano-reinforcements
Adequate transition between nano-micro/micro-meso/meso-macro steps
Integration of all scale steps (nano-micro/micro-meso/meso-macro)
Need for efficient numerical tools, allowing simulation of actual structural components
(computational efforts, treatment of delamination,…)
Aim: develop integrated multi-level/multi-scale numerical modeling tool(s), to gain understanding of
basic load transfer mechanisms, and to predict macroscopic behavior and life-cycle performance
(durability)
nano meso micro
macro
SIM-SIBO NANOFORCE
Nanoforce projects
8
SIM-SIBO NANOFORCE
SBO-3: Light Steel Fibers (aligned CNT bundles, aCNTb)
9
CNT: high stiffness, high strength, low density
CNT bundles: inferior properties
Challenges:
Alignment higher stiffness
Length higher toughness
Novel growth process
avoid presence of catalyst particles
State of the art characterization techniques
Aim: aligned CNT bundles with ultra-high stiffness and toughness
A. Windle @ Cambridge
SIM-SIBO NANOFORCE
Nanoforce projects
10
SIM-SIBO NANOFORCE
11
Scientific & Technical Goals
- Create validated tools for accurate fatigue prediction using local
material behavior • Interfacing to manufacturing process and material modeling software
• Model micro-mechanical behavior of steel fiber reinforced composites
• Include pre-damage into micro-mechanical model
• Fatigue behavior determined based on micro-level (Only material testing
needed)
• Fatigue simulation on component level under realistic loading conditions
- Understand the link between the microstructure and the EM
properties • Establish validated tools for efficiently predicting critical EM parameters
(conductivity, permittivity) based on fiber topology and distribution
The developed methods will be valid for all the family of RFRC material
and processes (SMC, BMC, GMT and LFT, ...) as long as the RFRC
material of interest has randomly oriented fibers.
IBO: Micro-mechanical & Fatigue modeling of short steel fiber
reinforced composites (ModelSteelComp)
SIM-SIBO NANOFORCE
Nanoforce presentations in the parallel session
12
SIM-SIBO NANOFORCE
Nanoforce related posters on display
13
Project Title Author
SBO1 Effect of silane coupling agent based surface treatment of stainless
steel on adhesion strength
Amit Kumar Ghosh
(VUB)
SBO1 Optimizing Silane Deposition Conditions: Tensiometry and Mechanical
Testing
Ellen Bertels
(KULeuven)
SBO1 Role of atmospheric pressure plasma for adhesion improvement
between steel and epoxy
Gabriella Da Ponte
(VITO)
SBO1 Energy absorption in 316L steel fibre reinforced epoxy laminate under
low velocity impact
Klaas Allaer
(UGent)
SBO1 Improving steel fibre composites through modification of the fibre/matrix
interphase
Michaël Callens
(KULeuven)
SBO2 Steel fibre reinforced epoxy on meso scale: numerical modeling and
experimental validation
Jana Faes
(UGent)
SBO3 Carbon nanotubes for next generation light "steel" fibers Luis González Urbina
(KULeuven)
IBO A mean-field based approach for micro-mechanical modelling of short
wavy fiber reinforced composites
Yasmine Abdin
(KULeuven)
IBO Micro-mechanical and fatigue damage modelling of short wavy steel
fiber reinforced composites
Yasmine Abdin
(KUleuven)
Master SN curve method - A hybrid multiscale approach to generate
SN-curves for short random fiber composites
Atul Jain
(LMS)
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SIM-SIBO NANOFORCE
Why is Bekaert interested in Nanoforce ?
- Cooperation BASF, Bekaert & Voestalpine Plastics Solution • Energy Absorption Safety Integrity (EASI) material development
• Generation 1 product
• High strength steel cords
• Polypropylene matrix
• Compression molding
14
Serial application
Mercedes SLS AMG series
(Magna Steyr Fahrzeugtechnik)
SIM-SIBO NANOFORCE
EASI2, a next generation with even more possibilities
15
Steel cords and Ultramid® are ultimately joined
together to build an unbreakable connection
Plastic hybrids with a totally new performance level
Injection molded parts behave as ductile as metal parts
Excellent conduction of loads in static and dynamic load
situations
Post failure behavior without structural failure and thus
continued energy absorption
E-coating compatibility allows utilization in body-in-white
structural parts
Excellent suitability for adhesive bonding and riveting
SIM-SIBO NANOFORCE
The EASI material in action
16
SIM-SIBO NANOFORCE
EASI – developed example
17
Possible reinforcements BIW (up to > 30k/p.a.)
• E.g. A-Pillar Reinforcement
• Current Situation
• Welded steel tubes
• EASI Solution
• Fabric over-molded
• Weight reduction min 30-40%
• Investments: cheaper than series metal solution
Conclusion:
• Complex reinforcements are possible with EASI
• Simulation capabilities are a must
A- Pillar
Reinforcement
EASI Fabric UNI
+ PA6 GF30
SIM-SIBO NANOFORCE
Bekaert stainless steel fibers
18
No stainless steel fibers in composites yet:
New markets and Business Opportunities
SIM-SIBO NANOFORCE
Potential of metal fibers as multifunctional reinforcement
19
High elongation of ANNEALED fibers
High energy absorption (ANNEALED)
Knot strength: fibers don’t damage
each other
processing advantage
+ drapable fabrics
In combination with properties as:
Shielding
Electrical conductivity
Thermal conductivity
Performance curve
SIM-SIBO NANOFORCE
Metal fiber introduces plastic deformation in the composite
20
Plastic deformation of the steel fibers is clearly
shown during tensile test of the composite
offers solution to brittle fracture of carbon, glass
2
Elongation
carbon
glass
steel 30µm
steel 14µm
On composite level
SIM-SIBO NANOFORCE
Exploration of reinforcement with steel fibers
21
High elongation of annealed fibers
higher strain to failure of composite
high energy absorption, even specifically
High stiffness
In combination with properties as:
Shielding,
Electrical conductivity,
Thermal conductivity, ...
Fine fiber (like carbon & glass fibers)
in fine textile structures
Opportunities for high
performance composites!
CO
NC
LU
SIO
NS
Potential for making light, stiff, tough & durable composites
Potential for making light steel sandwich plates
Additional properties can be added to both composites and sandwich plates Electrical and thermal conductivity (Anti-static, EM Shielding, ….)
Sound & vibration absorption ….
SIM-SIBO NANOFORCE
Thank You !