Characterization and failure study of Chopped

Carbon Fiber Reinforced Polymer (CCFRP)

Composite for automotive applications

Geo Jose

Objective

To develop a Chopped Carbon fiber reinforced PMC

with mechanical properties and processing significantly
superior to current Carbon fiber SMC materials, in
order to expand its application for automotive lightweighting by attaining better strength, serviceability,
durability and cost-effectiveness

Why?

Anisotropic mechanical properties (quasi-isotropic

laminate composites) limit the application

high raw material costs and long cycle times

Reliable material performance and crash modeling

routines need to be developed QUALITY

Recyclability will soon be a need

Composites to be challenged by other lightweight

materials (Mg, Al, HS Steels)

Discontinuous fiber thermoplastics

Discontinuous random 2D fibers

Adapted from Fig.16.8,

Callister 7e.
Mechanical performance vs. production volume vs. manufacturing
process. From an internal report supplied by Hexcel, Duxford.

Features
Mass production with reasonable performance
Reduces cost/part
Isotropic
Complex geometries possible/formability
random nature of the fibers limits the
mechanical properties to 20-40% of an aligned
material [16]
Recyclability

Challenges
Ensure process repeatability (Proper
mixing/orientation)
Consistent mechanical properties over the
bulk of the composite material (Reduce voids
and imperfections)
Cycle time reduction
Improve mechanical performance
Identifying critical fiber length
Retaining mechanical properties after
recycling

Factors affecting the mechanical behavior

Component properties

Interfacial interactions

Resultant composite behavior is a function of the %volume of matrix, fiber and

filler. (Garoushi, Lassila & Vallittu 2006)

Structure

Surface treatments on fibers

Composition

Structure and mechanical behavior of matrix, fiber and filler.

Chemical composition, purity, surface free energy

Orientation (Jules et al.)

Aggregation (Distribution) (Lei, Zhang & Liu 2012)
Length/aspect ratio of fiber (Hashimoto et al. 2012; Fu & Lauke 1996)
Shape of fiber

Processing conditions

Fabrication process (Joseph, Joseph & Thomas 1999)

Process parameter (Kiran et al. 2011; Raunija et al. 2014; Wu et al. 2013)

Key Technical Challenges

Obtain Mechanical Properties for Structural Automotive

applications
Dispersion of Fibers

Fiber-Matrix Compatibility

Chopping fibers
Hybrid blends
Surface treatments?

Moisture Absorption
Ensure process repeatability (Proper mixing/orientation)
Consistent mechanical properties over the bulk of the
composite material (Reduce voids and imperfections)
Cycle time reduction
Retaining mechanical properties after recycling

Addressing the Challenges

Composite - A structural material that gains its
strength from a combination of complementary
materials
1. Modify the reinforcement
2. Modify the resin
3. Modify the manufacturing process

Approach

Investigate the deformation behavior and fiber/matrix adhesion of the

composites at different volume fractions and fiber lengths

Study the effect of process parameters on residual stress of the composite

Influence of these parameters on interfacial shear strength

Effect of fiber/matrix surface treatments on deformation behavior
Identify the affects that leads to inconsistency
Identify various defects and study their effects on deformation behavior and
mechanical properties
Study the effect of these parameters on impact strength, hardness and thermal
properties
Effect on mechanical behavior and failure mechanisms

Effect of process parameters and fiber matrix chemistry on cycle time

reduction
Develop a micromechanical model to predict mechanical properties
based on fiber distribution

Automotive requirements

Reduction in cycle time

Mass production
Comparable mechanical properties
Formability
Apart from tensile properties, energy absorption
(crash worthiness), hardness and vibration
charecterstics

What I am looking at?

Initial work will be carried out at Deakin where

Fiber matrix combination will be identified

Fabrication process will be finalized
Initial property studies will be performed

@ NAL

Facilities for property evaluation

Fabrication facilities
Assistance for micro mechanical modeling and simulation
Other assistance based on research progress

U
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Experiment plan

Microsoft Office
Word 97 - 2003 Document

References

Microsoft Office
Word 97 - 2003 Document