Browse Topic: Carbon fibers

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Lightweight Cascade Design Using Type IV Cylinders for Efficient Hydrogen Gas Logistics in India2026-26-0485To be published on 01/16/2026
Hydrogen mobility in India faces a key challenge in the form of high transportation and logistics costs, particularly in tier-II and tier-III cities where dedicated pipelines are not yet feasible. Current methods using traditional steel based cascades are heavy, inefficient, and limit payload capacity. This paper presents a novel lightweight cascade system designed to enhance the efficiency of hydrogen gas logistics using Type IV composite cylinders and an aluminium structural frame. The design adheres to PESO (Petroleum and Explosives Safety Organisation) standards and achieves a structural weight reduction of 52%, owing to the use of carbon fibre composite cylinders and aluminium framework. Field level analysis demonstrates that the gas transport efficiency is improved by a factor of 2.5 compared to conventional steel based systems when used in heavy duty trucks. This innovation offers a significant step forward in enabling economically viable hydrogen distribution for mobility
Parasumanna, Ajeet Babu, Muthusamy, Hariprasad, Ammu, VNSU Viswanath, Kola, Immanuel Raju
Composite Secondary and Tertiary Structure for Landing Gear AIR6827 (Current)11/26/2025
This document will contain guidance and considerations for the use of composite materials on non-primary structure for landing gear systems. Content to include design considerations, conditions and applications where composites are feasible/beneficial, high-level descriptions of various manufacturing processes, and certification/validation considerations.
A-5B Gears, Struts and Couplings CommitteeNEW
Development and Qualification of Composite Landing GearsAIR5552A (Current)11/26/2025
This information report provides general guidance for the design considerations, qualification in endurance, strength and fatigue of landing gear using composite components as principle structural elements. The information discussed herein includes the development and evaluation of design data considering: the potential for imbedded manufacturing defects, manufacturing process variations, the component operating environment, potential damage threats in service, rework and overhaul, and inspection processes. This AIR mainly discusses the use of thick composites for landing gear structural components. Considerations and recommendations provided in this AIR may therefore differ greatly from considerations and recommendations found in widely accepted composite design references such as CMH-17 and Advisory Circulars such as AC 20-107(B).
A-5B Gears, Struts and Couplings CommitteeNEW
Optical Black Coatings On Carbon Fiber Reinforced Composite Sandwich Structure With Aluminum Honeycomb Core For Satellites Applications.2022-26-114105/26/2022
The composite sandwich structure has been in use in space applications as a result of its high strength to weight ratio coupled with excellent compressibility strength. In particular, there has been tremendous demand for honeycomb sandwich structures for satellite application in recent years. Currently, a major problem needs to be addressed concerning reflections from satellite structures which leads to capturing in-accurate data of celestial bodies by ground-based astronomy. In the light of the above, this paper focuses on the development of novel optical black coatings on Carbon fiber reinforced composite sandwich structures with aluminum honeycomb core. A thin layer of Multi-Walled Carbon Nanotubes black coatings was developed on the surfaces of Carbon fiber reinforced composite laminate of the sandwich structure using Chemical Vapour Deposition technique, to provide low scattering and low reflective surface. Three-point bending test are performed for evaluating the Youngs modulus
CS PhD, Ramesh, J, Sudharshan, Chaurasia, P Harsh
Parts Consolidation of Automotive Front Subframe: From Two-Piece CFRP Design to One-Piece Design2022-01-041003/29/2022
As demand for fuel efficiency rises, an increasing number of automotive companies are replacing their existing metal designs with carbon-fiber-reinforced polymer (CFRP) redesigns. Due to the handling and manufacturing processes associated with CFRP materials, engineers have more design freedom to create complex, light-weight designs, which would be infeasible to manufacture using metal. Additionally, it is likely that by redesigning with CFRP, many steel assemblies can be consolidated to significantly fewer parts, simplifying or potentially eliminating the assembly process. When designing a subframe using CFRP materials, designers often aim for a two-piece design (top and bottom), while utilizing reinforcement material where needed. The joining of these two pieces is typically accomplished with many mechanical fasteners and adhesives, significantly increasing the part count and the manufacturing complexity. The objective of this research project is to redesign a CFRP front subframe
Krsikapa, Daniel, Jalayer, Shayan, Dossett, Wesley, Lee, Young Min, Ko, Kwang Un, Huh, Mong Young, Choi, Byeung Hyeun, Ku, Ja Won, Lee, Keon Chul, Kim, Il Yong
Simultaneous free-size, gauge, and composite optimization for automotive chassis design: A practical case study with CFRP crossmember 2022-01-094303/29/2022
Rising gas prices and increasingly stringent vehicle emissions standards have pushed automakers to increase fuel economy. Mass reduction is the most practical method to increase fuel economy of a vehicle. New materials and CAE technology allow for lightweight automotive components to be designed and manufactured, which outperform traditional component designs. Topology optimization and other design optimization techniques are widely used by designers to create lightweight structural automotive parts. Other design optimization techniques include free-size, gauge, and size optimization. These optimization techniques are typically used in sequence or independently during the design process. Performing various types of design optimization simultaneously is only practical in certain cases, where different parts of the structure have different manufacturing constraints. This paper presents a case where this simultaneous optimization approach is used to redesign an automotive front
Jalayer, Shayan, Dossett, Wesley, Krsikapa, Daniel, Lee, Young Min, Ko, Kwang Un, Huh, Mong Young, Choi, Byeung Hyeun, Ku, Ja Won, Lee, Keon Chul, Kim, Il Yong
Selection of suitable lightweight materials for various Automotive Vehicles and their components through Advanced Computational Investigations 2022-01-040703/29/2022
Generally, most of the fractions are occurred because of a lack of resistivity knowledge in internal structure level at abnormal loading conditions such as shock load, impact load, aerodynamic load, etc. Aforesaid loads drastically affect the structural performance of a component. The detailed pre-defined study about aforesaid loading environments and their side effects can provide the details of withstanding capability at peak loading conditions. This work examined the behavior of composite materials, which are subjected to sudden loading conditions at different real-time applications. Automotive vehicles and their components such as four-wheeler bumper, main bike stand, and automotive passenger bus are predominantly imposed these comprehensive investigations. The three primary different composites such as CFRP [Carbon Fiber Reinforced Polymer], GFRP [Glass Fiber Reinforced Polymer], and KFRP [Kevlar Fiber Reinforced Polymer] are selected and implemented under crash analysis with the
R, Vijayanandh, Gnanasekaran, Raj Kumar, Kulandaiyappan, Naveen Kumar, Raji, Arul Prakash, Madasamy, Senthil Kumar, Kesavan, Kandasamy, Subramaniam, Indira Prasanth
Development of In Mold Coating Clear Coat Paint for Carbon Fiber Sheet Molding Compound Roof.2022-01-041203/29/2022
Carbon Fiber Reinforced Plastics (CFRP) is superior in the specific tensile strength and the specific rigidity which used for various products in aerospace and sports industry. With increasing attention to Carbon Neutral (CN) in the world, the vehicle electrification and the lightweight are expanding. As a result, the application of CFRP to luxury cars, electric cars and sports cars, is increasing. It is also applied by Lexus LC, RC-F and Toyota 86 GRMN. However, there are two technical concerns. First is the durability which caused by CFRP resin characteristic. Second is poor appearance which is caused by CFRP surface pinholes. In order to secure the good durability and surface appearance, CFRP must be required pre-treatment before painting (putty applying a filler for the plastics surface coverage and surface sanding) and the multiple painting. Current painted CFRP is not suitable for the mass production due to long and complicated process. As a result, the applied vehicle is limited
Ito, Katsunori
Moisture absorption behavior and hygrothermal aging life prediction for CFRP adhesive-bonded joints2022-01-038903/29/2022
Effects of moisture absorption on the strength degradation, energy absorption and failure mechanism of CFRP laminates and the adhesive-bonded joints in hygrothermal environment were investigated in this work. Experiments of accelerated moisture absorption, uniaxial tension and three-point bending were performed. SEM observations on the CFRP laminates and the fracture surfaces of the CFRP bonded joints were conducted. Strength degradation and failure mechanism induced by moisture absorption were discussed in detail. The results showed that the strength degradation in tension and in three-point bending of the CFRP laminate due to moisture absorption reached 7.4% and 17.1%, respectively. Different response of CFRP laminate and adhesive layer to the moisture determined the failure mode of the adhesive-bonded joints. Suitable match of CFRP laminate and adhesive was very important to make the failure mode of the joint under control.
Xu, Xianghe, Yu, HaiYan, Xing, Ping
Design and Optimization of an Electric Car Chassis and Body using Structural Analysis and CFD 2022-01-033903/29/2022
The transition from traditional gasoline-powered automobiles to electric vehicles (EVs) has taken time, two major challenges of engine- powered vehicles are greenhouse gas emissions and fuel economy. Electric cars require less maintenance. A lot of money can be saved while also helping the environment. In today's world, working with lightweight materials have emerged as a key area for improvement in the automotive industry. The most efficient method for increasing power output is to reduce the weight of vehicle components. Composite materials have benefited greatly from research and development because they are stronger, more recyclable, and easier to integrate into vehicles. The primary goal of this research is to design the body and chassis frame of a two-seater electric car. A CFD analysis was performed to determine the drag coefficient of the body along with structural analysis to obtain the frontal impact and torsional rigidity of the chassis to develop an effective electric car
Aiyan, Mohammed, Raghav S, Sanjay, Sagar, S Sumanth
Performance Optimisation of an Exhaust System for 4 Cylinder Engine by Implementation of Computational Fluid Dynamics, Acoustic and Thermal Analysis2022-01-067703/29/2022
The engine system requirements have changed from being focused only on delivering engine power to now having to meet environmental emission standards. The exhaust system collects exhaust gases from the combustion cylinders, eliminates dangerous pollutants, decreases noise, and discharges the purified exhaust gases at a safe distance from the vehicle's occupants. Designs of lightweight models for exhausts were always aimed at using newer lighter materials. As the design of an exhaust is more or less fixed, this approach is hardly profitable anymore. The most important components of an exhaust system are the exhaust manifold, the catalytic converter, the muffler, the resonator and connecting all of them together are connecting exhaust pipes. In this paper, the optimization of the various elements of 4 cylinder 1.8L engine exhaust system is carried out with the help of analysis software ANSYS 19.2 workbench, by performing ‘Steady State Thermal Analysis’, ‘Acoustic Analysis’ and simulating
Aiyan, Mohammed, Raghav S, Sanjay, Sagar, S Sumanth
Residual Stress Prediction of a Thermoformed Carbon Fiber Reinforced Polymer Structure Through a Novel Manufacturing to Response Pathway2022-01-032103/29/2022
Thermoforming of thermoplastic-based continuous carbon fiber reinforced polymer (CFRP) offers major advantage in reducing cycle times for large scale productions, but it inevitably induces certain undesirable effects in the formed parts. One such effect is residual stress. For a complex CFRP structure, the magnitude and state (tension/compression) of the residual stress could vary at different locations on the part. Several researchers have developed a number of techniques to experimentally measure the magnitude of these residual stresses, which have shown that these residual stresses could have considerable impact on the mechanical performance of complex CFRP structures, especially developed using thick laminates. However, the degree of impact of the residual stresses on the structural performance of the part still represents a knowledge gap. Experimental investigations could be performed to study the impact of residual stresses on mechanical performance but they are tedious and time
Limaye, Madhura, Pradeep, Sai Aditya, Kothari, Anmol, Agha, Akshat, Li, Gang
Evaluating the mechanical behavior of fused deposition modeling parameters of Raster angle and Layer thickness effects on as-built and annealed polymer associated composites2021-28-028310/01/2021
Fused deposition Modeling (FDM) is one of the 3D techniques which are mainly used to fabricate the three-dimensional object directly and it is more economical method. The objective of this investigation is to primarily as-build and annealed polymer associated composites of carbon fiber Polyethylene Terephthalate Glycol (CF-PETG) material by FDM with the effect of different raster angle and layer thickness were consider for the prime parameters. The test specimen was prepared by FDM process with different raster angle (00/900, -450, +450, -450+450) and layer thickness (100, 400 microns) with other parameters were kept constant. The study of the mechanical properties such as hardness, tensile and impact test of the as-built and annealed CF-PETG were studied. The best results obtained for annealed specimens printed with raster angle of 00/900 and layer thickness of 100 microns produced more influence in all the mechanical properties. The high strength printed samples were suggested for
Ari Gowder Ravi Kumar, Sivanesh, R, Soundararajan, Dorai, Arivazhakan, Suresh Kumar, Gopinath, Ramesh, Aravind Kumar
Effect of various synthetic and natural fibers for the production of copper-free automotive brake pads2021-28-027410/01/2021
In recent years, asbestos and copper free brake pads have attracted researchers due to its adverse environmental risks which make it mandatory for the manufacturers to look for a reliable replacement. It is essential to identify new combination of synthetic and natural fibers for the potential automotive brake pads. Experiments were planned to produce various frictional composites (1) glass fiber (2) carbon fiber (3) basalt fiber (4) hemp fiber with standard additional materials through hot pressing technique. The developed form of brake pads were tested as per ASTM and industrial standard practices like hardness, wear and friction. Also worn surface analysis was performed using a scanning electron microscope. Most noteworthy tribometric operating parameters like load (10-40N), sliding velocity (1-5m/s) were being considered and wear mechanism for various types of composites and their performances are being discussed. In order to prove the application suitability, recovering synthetic
R, Soundararajan, Soundarrajan, Karthik, Rengaraj, Jeyakumar, gopal, Shanthosh
Flexural behavior of hybrid layered composites suitable for automotive structural applications2021-28-021010/01/2021
Electric vehicle is the current trend in automotive industry. A light weight material at affordable cost is preferred for these types of vehicles. Composite is a suitable material for this due to their attractive strength-to-weight ratio. Even though carbon fiber reinforced composites provide very good strength and modulus its usage is limited because of their higher price. Hybrid laminates stacked with glass/carbon/kevlar fiber layer shall provide good strength at lower cost. This work focus on the flexural behaviour of glass fiber reinforced laminates stacked with carbon and kevlar fiber as outer layer. Laminates were prepared by hand lay-up method. Three-point bending test was conducted as per ASTM standard. A significant improvement in flexural modulus and bending resistance was observed for the glass/carbon-epoxy hybrid laminates when compared with the glass-epoxy laminate. The micrographs of the failed specimens are also studied.
A, Arockia Julias, Ponniah Daniel, Jeyakumar, Manohar, D Murali, Muthiah, Thirumurugan, R, Sathish Kumar
Carbon Fiber Fabric and Epoxy Resin Wet Lay-Up Repair Material Part 5 - Carbon Fiber Fabrics, Plain Weave, 193 g/m2, and Epoxy ResinAMS2980/5A (Current)09/24/2021
This Material Specification defines the requirements of carbon fiber fabric and epoxy resin systems used for wet lay-up repair of carbon fiber reinforced epoxy structures, qualified according to AMS2980/1 and AMS2980/2. Unless otherwise specified by the drawing, the order or the inspection schedule, the present specification shall be used in conjunction with the referenced documents.
AMS CACRC Commercial Aircraft Composite Repair Committee
Carbon Fiber Fabric and Epoxy Resin Wet Lay-Up Repair Material Part 0 - IntroductionAMS2980B (Current)09/23/2021
This document (Technical Specification) gives information about qualification rules and the relation between the different specification parts involved, such as Technical Specification (TS), Material Specification (MS), and Purchasing Specification (PS). The link to material qualification and qualified products is presented.
AMS CACRC Commercial Aircraft Composite Repair Committee
Stable, Efficient, Anode-Free Sodium BatteryTBMG-3960508/01/2021
The challenges of energy storage — which require the capacity to bank an intermittent and seasonally variable supply of solar energy — have kept the technology from being economically competitive. Researchers have used low-cost materials to create rechargeable batteries that will make energy storage more affordable. These materials could also provide a safer and more environmentally friendly alternative to lithium-ion batteries that currently dominate the market but are slow to charge and have a knack for catching fire.
Bars, Rods, and Shapes Produced from 30% Carbon Fiber Filled Polyamide-Imide (PAI) MaterialAMS3670/5D (Current)05/19/2021
This specification covers molded or extruded bar, rod, and shapes produced from a polyamide-imide polymer filled with 30% carbon fiber. This is designated as Grade 5 material per AMS3670.
AMS P Polymeric Materials Committee
Carbon Fiber and Fiberglass Epoxy/Prepreg Products with 350 °F (177 °C) Cure for Aerospace Applications: Type 34, Class 4, Grade 294, Style 7781AMS6891/3 (Current)03/10/2021
The intent of this specification is for the procurement of the material listed on the QPL and, therefore, no qualification or equivalency threshold values are provided. Users that intend to conduct a new material qualification or equivalency program must refer to the quality assurance section of this base specification, AMS6891.
AMS P17 Polymer Matrix Composites Committee
Carbon Fiber and Fiberglass Epoxy/Prepreg Products with 350 °F (177 °C) Cure for Aerospace Applications: Type 42, Class 4, Grade 48, Style 108AMS6891/4 (Current)03/10/2021
The intent of this specification is for the procurement of the material listed on the QPL and, therefore, no qualification or equivalency threshold values are provided. Users that intend to conduct a new material qualification or equivalency program must refer to the Quality Assurance section of this base specification, AMS6891.
AMS P17 Polymer Matrix Composites Committee
Unidirectional Carbon Fiber Tape Epoxy Repair Prepreg, Vacuum Curing Part 5 - Material Specification for Unidirectional Carbon Fiber Tape Epoxy Prepreg for Repair and Film Adhesive for Repair, 120 to 145 °C (250 to 290 °F) CuringAMS6885/5 (Current)02/22/2021
AMS6885/5 is the Material Specification (MS) which defines the requirements of a unidirectional carbon fiber tape epoxy repair prepreg capable of curing under vacuum for repair of carbon fiber reinforced epoxy structures. It also defines the requirements of an epoxy film adhesive to be applied in a co-bonding process with the prepreg for solid laminate and sandwich bonding.
AMS CACRC Commercial Aircraft Composite Repair Committee
Eco-profiling of Bio-epoxies via Life cycle AssessmentSAE-PP-0023102/03/2021
Epoxies, synthesized from bisphenol-A (BPA) and epichlorohydrin (ECH), are predominantly used as coatings, adhesives, and as matrix material in fiber-reinforced composites for body-in-white (BiW) applications in the automotive sector. However, given the production of conventional epoxies from non-renewable petroleum resource and toxicity of BPA, several initiatives have been undertaken by researchers to synthesize alternative epoxies from various bio-sources that are free of BPA and exhibit similar mechanical performance. As a result, such bio-sourced epoxies are almost immediately termed as “eco-friendly”, despite the lack of comprehensive evaluation of their ecological performance that takes into account enhanced natural resource usage and associated impacts accompanying such epoxies. Hence, this work aims at addressing this gap by evaluating the environmental impacts of such bio-sourced epoxies via cradle-to-gate life cycle assessment to determine the genuine credentials of their
Anthony, Lindsay, Jackson, Alyssa
Products of Tomorrow: February 2021TBMG-3852402/01/2021
This column presents technologies that have applications in commercial areas, possibly creating the products of tomorrow. To learn more about each technology, see the contact information provided for that innovation.
3D-Printed Composites for High-Temperature UsesTBMG-3849302/01/2021
Innovators at NASA Glenn Research Center, in collaboration with the University of Louisville and the U.S. Air Force, developed an additive manufacturing technique to produce composite parts with high-temperature capabilities using thermoset polyimide resins. The process uses selective laser sintering (SLS) to melt-process a powdered version of NASA’s novel RTM370 imide resin filled with finely milled carbon fibers.
Carbon Fiber and Fiberglass Epoxy Prepreg Products with 350 °F (177 °C) Cure for Aerospace ApplicationsAMS6891 (Current)12/30/2020
The intent of this specification is for the procurement of carbon fiber and fiberglass epoxy prepreg products with 350 °F (177 °C) cure for aerospace applications; therefore, no qualification or equivalency threshold values are provided. Users that intend to conduct a new material qualification or equivalency program must refer to the production quality assurance section (4.3) of this base specification, AMS6891.
AMS P17 Polymer Matrix Composites Committee
Carbon Fiber and Fiberglass Epoxy Prepreg Products with 350 °F (177 °C) Cure for Aerospace ApplicationsAMS6891-TEST-REC (Historical)12/30/2020
The intent of this specification is for the procurement of carbon fiber and fiberglass epoxy prepreg products with 350 °F (177 °C) cure for aerospace applications; therefore, no qualification or equivalency threshold values are provided. Users that intend to conduct a new material qualification or equivalency program must refer to the production quality assurance section (4.3) of this base specification, AMS6891.
AMS P17 Polymer Matrix Composites Committee
Carbon Fiber and Fiberglass Epoxy/Prepreg Products with 350 °F (177 °C) Cure for Aerospace Applications: Type 40, Class 1, Grade 196, Style 6K-PWAMS6891/2 (Current)12/29/2020
The intent of this specification is for the procurement of the material listed on the QPL; therefore, no qualification or equivalency threshold values are provided. Users that intend to conduct a new material qualification or equivalency program must refer to the Quality Assurance section of this base specification, AMS6891.
AMS P17 Polymer Matrix Composites Committee
Carbon Fiber and Fiberglass Epoxy Prepreg Products with 350 °F (177 °C) Cure for Aerospace Applications: Type 35, Class 1, Grade 191AMS6891/1 (Current)12/29/2020
The intent of this specification is for the procurement of the material listed on the QPL; therefore, no qualification or equivalency threshold values are provided. Users that intend to conduct a new material qualification or equivalency program must refer to the Quality Assurance section of this base specification, AMS6891.
AMS P17 Polymer Matrix Composites Committee
Bioenvironmental Engineering Guide for Composite MaterialsTBMG-3825012/01/2020
The use of composite materials is on the rise. Consequently, this guide was developed to provide base-level Bioenvironmental Engineering (BE) personnel with a comprehensive baseline for identifying, evaluating, and controlling occupational and environmental hazards associated with composite fibers and materials.
Bioenvironmental Engineering Guide for Composite Materials20AERP12_0812/01/2020
Developing a comprehensive baseline for identifying, evaluating, and controlling occupational and environmental hazards associated with composite fibers and materials for base-level Bioenvironmental Engineering (BE) personnel. Air Force Research Laboratory, Wright-Patterson Air Force Base, Ohio The use of composite materials is on the rise. Consequently, this guide was developed to provide base-level Bioenvironmental Engineering (BE) personnel with a comprehensive baseline for identifying, evaluating, and controlling occupational and environmental hazards associated with composite fibers and materials. The expectation from this guide was to assist commanders with risk management decisions when responding to composite materials in (1) aircraft repair and maintenance and (2) crash and recovery operations. BE personnel should be able to identify potential inhalation and dermal hazards, recommend personnel protection options and decontamination procedures, recommend environmental controls
Design, Manufacturing, and Performance Standard for Composite Materials Used on Aircraft Seat StructuresARP6337-TEST-REC (Historical)11/18/2020
This SAE Aerospace Recommended Practice (ARP) defines additional documentation, environmental considerations, in-service damage limits, test and evaluation criteria necessary to support certification of aircraft seats manufactured using composite materials, in addition to requirements in AS8049 and ARP5526. This document is limited to aircraft seat composite parts in the seat primary load path from the occupant to the attachments of the seat to the aircraft. The term “composite” is inclusive of any fiber-reinforced polymer matrix materials such as carbon fiber-reinforced plastics, sandwich panels and bonded structure.
Aircraft SEAT Committee
Design, Manufacturing, and Performance Standard for Composite Materials Used on Aircraft Seat StructuresARP6337 (Current)11/18/2020
This SAE Aerospace Recommended Practice (ARP) defines additional documentation, environmental considerations, in-service damage limits, test and evaluation criteria necessary to support certification of aircraft seats manufactured using composite materials, in addition to requirements in AS8049 and ARP5526. This document is limited to aircraft seat composite parts in the seat primary load path from the occupant to the attachments of the seat to the aircraft. The term “composite” is inclusive of any fiber-reinforced polymer matrix materials such as carbon fiber-reinforced plastics, sandwich panels and bonded structure.
Aircraft SEAT Committee
Hummingbird Robot Uses AI to Maneuver in Tight SpacesTBMG-3761809/01/2020
Flying robots that behave like hummingbirds were developed that are trained by machine learning algorithms based on various techniques the bird uses naturally every day. This means that after learning from a simulation, the robot “knows” how to move around on its own like a hummingbird would such as discerning when to perform an escape maneuver.
CFRP technical resources20AUTP09_0209/01/2020
New 2020 SAE Technical papers detail current carbon-composite material developments. The performance-enhancing attributes of carbon-fiber-reinforced plastics continue to be explored by global automakers as they seek more solutions to vehicle lightweighting, particularly for the new wave of electric vehicles. SAE International's Technical Papers library offers the latest insights into CFRP materials research, engineering, processing, and production technologies. The following papers were among many published in spring 2020; more can be found at https://www.sae.org/publications/technical-papers:
Brooke, Lindsay
Graphene-Reinforced Carbon FiberTBMG-3761709/01/2020
Anew way of creating carbon fibers — which typically are expensive to make — could one day lead to using these lightweight, high-strength materials to improve safety and reduce the cost of producing cars. Using a mix of computer simulations and laboratory experiments, researchers found that adding small amounts of the 2D graphene to the production process both reduces the production cost and strengthens the fibers.
Scaling Low-Cost Carbon Fiber Production with Oxidation TechnologyTBMG-3711006/01/2020
Few materials used in manufacturing today are as versatile and desirable in performance applications as carbon fiber. Also known as graphite fiber and carbon graphite, carbon fiber is made up of thin strands of carbon that vary in diameter from four to ten microns, dependent on manufacturer and use. Do not let the size of these fibers fool you. Carbon fiber is regarded as one of the lightest and strongest materials on Earth. Compared to a unit of steel, carbon fiber is up to ten times stronger, two times stiffer, and 66% lighter.
Composite Hybrid Automotive Suspension System Innovative Structures (CHASSIS)2020-01-077704/14/2020
The Composite Hybrid Automotive Suspension System Innovative Structures (CHASSIS) is a project to develop structural commercial vehicle suspension components in high volume utilising hybrid materials and joining techniques to offer a viable lightweight production alternative to steel. Three components are in scope for the project:- Front Subframe Front Lower Control Arm (FLCA) Rear Deadbeam Axle
Banks, Alan, Bone, Gareth
Investigation of Mechanical Behavior of Chopped Carbon Fiber Reinforced Sheet Molding Compound (SMC) Composites2020-01-130704/14/2020
As an alternative lightweight material, chopped carbon fiber reinforced Sheet Molding Compound (SMC) composites, formed by compression molding, provide a new material for automotive applications. In the present study, the monotonic and fatigue behavior of chopped carbon fiber reinforced SMC is investigated. Tensile tests were conducted on coupons with three different gauge length, and size effect was observed on the fracture strength. Since the fiber bundle is randomly distributed in the SMC plaques, a digital image correlation (DIC) system was used to obtain the local modulus distribution along the gauge section for each coupon. It was found that there is a relationship between the local modulus distribution and the final fracture location under tensile loading. The fatigue behavior under tension-tension (R=0.1) and tension-compression (R=-1) has also been evaluated. Damage evolution on the free edge of the samples under cyclic loading has been recorded using optical microscopy by
Sun, Xuze, Engler-Pinto, Carlos, Huang, Li, Huang, Shiyao, Tang, Haibin, Cui, Haitao, Su, Xuming
Process Development of Dissimilar Clinch Joints in Cross-Tension Specimens of AA5052 and TP-CFRP Sheets2020-01-022504/14/2020
This paper studied the process development of dissimilar clinch joints in cross-tension specimens of aluminum alloy 5052-H32 (AA5052-H32)/thermoplastic carbon fiber reinforced plastic (TP-CFRP) sheets. The AA5052-H32 and TP-CFRP sheets with a thickness of 1.6 mm were used. The important processing parameters for AA5052/TP-CFRP clinch joints, such as the punching load, heating mode, heating temperature, and die depth, were considered. The failure loads, failure modes, and metallographic micrographs of AA5052/TP-CFRP clinch joints were analyzed to determine an available processing parameter set for fatigue tests. Finally, the fatigue performance and failure mode of AA5052/TP-CFRP clinch joints were obtained.
Lin, Pai-Chen, Fang, Gavin, Lin, Chia-Wei, Ching, Yern Chee
DEVELOPMENT OF AN EPOXY CARBON FIBER REINFORCED ROOF FRAME USING THE HIGH PRESSURE RESIN TRANSFER MOLDING (HP-RTM) PROCESS2020-01-077304/14/2020
Composites technology for the automotive market continues to advance rapidly. Increasing knowledge of composite design, simulation tools, new materials and process equipment are all contributing to make composites better performing and more affordable for mass-produced vehicles. In particular, the high pressure resin transfer molding (HP-RTM) and related liquid compression molding (LCM) processes are enabling manufacturers to produce complex composite parts at shorter and shorter cycle times. This paper describes the development of an epoxy carbon fiber roof frame targeted for future vehicle production. Several composite processes were considered for the roof frame. The case illustrates that when the (product) design, material and process are considered together, a high-performing, cost-efficient part can be produced. The resulting carbon fiber roof frame met all OEM performance requirements and economic targets while weighing 44% less than the original design in magnesium and 32% less
Ball, Cedric A., Greydanus, Stephen, Swentek, Ian, Nara, Kameswara Rao
Composite Suspension Leaf Springs: The Smart Solution2020-01-099104/14/2020
2020 SAE Congress - Technical Paper Abstract "Smart Solutions for Electric Vehicle Suspensions" Session: Steering, Chassis and Suspension Authors: Peter Kuhn, SGL Technologies GmbH, Meitingen, Germany William D. Pinch, SGL Technologies LLC, Charlotte, NC USA Abstract: Battery Electric Vehicles (BEVs) Programs are becoming the vehicle of choice globally. This is driven by heightened vehicle emissions requirements and improved fuel economy performance. Vehicle requirements will be rolled down to Subsystems and Components. Subsystem requirements will be divided into upper and lower control planes with Kinematic performance targets discussed. Various types of front and rear suspensions will be identified and analyzed including MacPherson & Chapman Strut, Short-Long Arm (SLA), and various Multi-link arrangements. At the component level the use of innovative, lightweight composite materials provides a significant advantage. Besides ensuring technical feasibility, implementation on high
Pinch, William, Kuhn, Peter
AFP Processing of Dry Fiber Carbon Materials (DFP) for Improved Rates and Reliability2020-01-003003/10/2020
Automated fiber placement of pre-impregnated (pre-preg), thermoset carbon materials has been industrialized for decades whereas dry-fiber carbon materials have only been produced at relatively low rates or volumes for large aerospace structures. This paper explores the differences found when processing dry-fiber, thermoset, carbon materials (DFP) as compared to processing pre-preg, thermoset materials with Automated Fiber Placement (AFP) equipment at high rates. Changes to the equipment are required when converting from pre-preg to dry fiber material processing. Specifically, the heating systems, head controls, and tow tension control all must be enhanced when transitioning to DFP processes. Although these new enhancements also require changes in safety measures, the changes are relatively small for high performance systems. Processing dry fiber material requires a higher level of heating, tension control and added safety measures. However, once these are achieved, processing rates and
Assadi, Michael, Field, Tyler
Effects of Helical Carbon Nanotubes on Mechanical Performance of Laminated Composites and Bonded Joints2020-01-002903/10/2020
Most composite assemblies and structures generally fail due to weak interlaminar properties and poor performance of their bonded joints that are assembled together with an adhesive layer. Adhesive failure and cohesive failure are among the most commonly observed failure modes in composite bonded joint assemblies. These failure modes occur due to the lack of reinforcement within the adhesive layer in transverse direction. In addition, the laminated composites fail due to the same reason that is the lack of reinforcement through the thickness direction between the laminae. The overall performance of any composite structures and assemblies largely depends on the interlaminar properties and the performance of its bonded joints. Various techniques and processes were developed in recent years to improve mechanical performance of the composite structures and assemblies, one of which includes the use of nanoscale reinforcements in between the laminae and within the adhesive layer. However
Sritharan, Ramanan, Askari, Davood
Advances in Drilling with PCD (Polycrystalline Diamond)2020-01-003503/10/2020
PCD properties were optimized to drill stacks of CFRP/Ti using an accelerated wear test milling gray cast iron. The optimized PCD was then used to prepare PCD drills. Tests were made to determine the best drilling conditions for the optimized PCD. The results yielded a significant improvement in cycle times as compared to earlier studies using PCD drills. Notched PCD cutting edges were found to eliminate oversizing of the CFRP near the interface of the two materials.
Bunting, Jeremy, Bunting, John
Advances in Drilling with PCD (Polycrystalline Diamond)2020-01-003503/10/2020
PCD properties were optimized to drill stacks of CFRP/Ti using an accelerated wear test milling gray cast iron. The optimized PCD was then used to prepare PCD drills. Tests were made to determine the best drilling conditions for the optimized PCD. The results yielded a significant improvement in cycle times as compared to earlier studies using PCD drills. Notched PCD cutting edges were found to eliminate oversizing of the CFRP near the interface of the two materials.
Bunting, Jeremy, Bunting, John
Conductive Polymer/Carbon Nanotube Structural MaterialsTBMG-3617203/01/2020
Carbon nanotubes (CNTs) show promise for multifunctional materials for a range of applications due to their outstanding combination of mechanical, electrical, and thermal properties. These promising mechanical properties, however, have not translated well to CNT nanocomposites fabricated by conventional methods due to the weak load transfer between tubes or tube bundles.
Precision 3D BioprinterTBMG-3605702/01/2020
nScrypt Inc. Orlando, FL 407-275-4720
Composite Electrical ConnectorsAIR4567B (Current)01/21/2020
This SAE Aerospace Information Report (AIR) establishes guidelines for evaluating composite electrical connectors and accessories.
AE-8C1 Connectors Committee
Thin Heat Shield for Superfast AircraftTBMG-3579101/01/2020
The world of aerospace increasingly relies on carbon fiber-reinforced polymer composites to build the structures of satellites, rockets, and jet aircraft. But the life of those materials is limited by how they handle heat. Researchers have developed a heat shield that better protects those extremely fast machines.
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