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Tag: carbon fiber

10

Feb

CARBON FIBER CRASH TEST

 
Carbon fiber is a wonderful material. Offering both high strength and low weight, carbon fiber combines two characteristics seemingly at odds with one another to form a very desirable end product, something which is particularly valuable in an automotive application.
 
“In contrast to a steel body where bending helps the integrated crumple zones to reduce the amount of crash energy that reaches the vehicle’s occupants, carbon fiber dissipates the energy by cracking and shattering,” the automaker explains in a press release.
 
This is the first time Volvo and Polestar are experimenting with a carbon fiber reinforced polymer body and researching it in real crash scenarios.With this new testing procedure, Polestar explains, the company wants to prepare its cars for the things that are not planned, such as accidents.
Beyond Materials™ – growing supplier of innovative composite materials.
 
06

Feb

Composite Fabrication Methods

There are numerous methods for fabricating composite components. Some methods have been borrowed (injection molding from the plastic industry, for example), but many were developed to meet specific design or manufacturing challenges faced with fiber-reinforced polymers.

Carbon Fiber and other Composite fabrication processes typically involve some form of molding, to shape the resin and reinforcement. A mold tool is required to give the unformed resin/fiber combination its shape prior to and during cure.

 

Choice of fabrics

Choosing a fabric type is mostly dependant on two factors – weave type and thickness.  Determining the weave type is based upon your aesthetic and conformability requirements.  The most common fabric chosen for aesthetic applications is typically a 3K 2×2 twill for carbon fabric applications.  This fabric provides the most elegant look of all weave types.  One of the most flexible fabrics is generally a twill weave (note that a 4×4 twill will be more flexible than a 2×2).  The least conforming fabric is a plain weave.

 

What thickness you need in a particular fabric is dependent on your application.  For cosmetic purposes using carbon fiber fabric, a 3K carbon is often an ideal choice.  For structural applications, the most cost effective solution is to use the thickest possible fabric.  Thicker fabrics are cheaper per sqm than multiple layers of thinner fabrics, although thinner fabrics will generally conform better to complex curves than thicker fabrics.

 

 

The Overlay Method

The overlay method is the simplest of all the laminating methods.  Generally it involves finding an existing piece and sanding it lightly, then carbon fiber or other composite fabric is laid over the top of this existing piece, and resin is applied.  Finishing such a piece using the overlay method generally involves one of two techniques.  The first is sanding and/or buffing the finished overlay composite piece to a shine.  The second option is to sand the piece smooth, then apply a final coat of resin or add a clear coat, typically of urethane for epoxy, or a polyester clear coat for a polyester based resin.The overlay method is commonly used when one custom piece needs to be made, or a small number of custom pieces need to be made.  The main disadvantage of using the overlay technique is that results can be inconsistent and one often needs to be at least somewhat “crafty” in order to be able to create professional looking pieces.

You can choose one of our laminating carbon fiber kits here  

 

Vacuum Bagging

Vacuum bagging is by far the most complex and expensive of all the methods, but usually results in the best final product.  The first step in vacuum bagging is to create a perfectly designed reverse mold of the final piece which you intend to make.  This mold can be made out of virtually any material, anything from silicon rubber molds to composite.  The second step involves laying your carbon fiber or other composite fabric(s) into your newly created mold, then applying either a release fabric for fairly flat products or a peel-ply for complex and curvy applications.  A release fabric is typically a plain weave nylon treated fabric that allow resin to pass through it, but the release fabric itself will not stick to the composite product.  A peel-ply is a stretchable rubber like membrane with small holes space throughout the membrane, allowing resin to be sucked through those holes.  Behind the peel-ply or release fabric you place a breather fabric.  The purpose of the breather fabric is to absorb the excess epoxy being pulled through the release fabric or peel-ply.  Behind the breather fabric is the vacuum bag itself.  This acts as a permanent barrier and helps create an airtight chamber so that the resin can be sucked away from the product.  Sealing the bag to the mold requires a special sticky tape.  This tape provide an airtight seal between the mold and the vacuum bag itself.  This tape is commonly referred to as sealant tape.

 

If producing large numbers of identical units, such as if you intend to go into production making one specific piece or product, vacuum bagging is an ideal method.  The disadvantages of using a vacuum bagging method are that it often requires a great deal of effort to create a perfect mold; it also often requires adjusting of the vacuum bag line(s) and possibly adjusting the individual suction of each line.  Because of this, it is common to go through at least three to five pieces until you perfect your product and are ready to go into production.  Therefore this method is generally not recommended if your intention is to create only a few specific pieces.

 

29

Jul

Volvo carbon fiber panels

Volvo to replace body parts with energized carbon fiber panels

For automobile manufacturers, the electric elephant in the room continues to be bulky and weighty battery packs. This week, Volvo unveiled an innovative potential solution to the problem that it has been working on for the past three and a half years with other European partners; replace steel body panels with carbon fiber composite panels infused with nano-batteries and super capacitors.

The conductive material used around the vehicle to charge and store energy can be recharged via the vehicle’s regenerative braking system or via the grid. When the system and motor requires a charge, the energized panels behave like any traditional battery pack and discharge accordingly. According to Volvo, the material charges and stores faster than a typical system.

Using a Volvo S80 as a test platform, the team replaced the vehicle’s trunk lid and plenum cross member over the engine bay with the new material. Volvo claims the composite trunk lid, which is stronger than the outgoing steel component, could not only power the vehicle’s 12 volt system but the weight savings alone could increase an EV’s overall range and performance as a result.

Under the hood, Volvo wanted to show that the plenum replacement bar is not only capable of replacing a 12 volt system but is also 50 percent lighter than the standard steel cross-member and torsionally stronger. The very much revolutionary concept, chock full of cost and engineering challenges, presents an interesting solution that could not only reduce overall weight but increase charge capacity relative to a vehicle’s surface area.

Volvo says energized carbon fiber body panels are not only stronger and lighter but easily replace...

When it comes to weight savings, the battery pack in Tesla’s Model S for example, not only adds significant cost but also brings with it over 1,000 lb (453 kg), making the electric argument a difficult one for many. With Volvo’s concept, that huge chunk of weight would not only be lighter under this scenario, but would be spread out evenly over a vehicle’s body. In theory, vehicle handling and performance characteristics would thus improve as a result of this revised displacement idea.

But the idea of using body panels as battery packs does come with its share of particular concerns. Lamborghini, McLaren and Pagani charge a hyper-premium for their exotics as a result of extensive carbon fiber use, so for this idea to become reality and make it to mass production would require a significant reduction in the cost of carbon fiber.

Capacitor infused carbon fiber crossmember in place on Volvo S80 test vehicle

Then there’s the issue of broken panels or those damaged in an accident. In the event of an accident not only would body panels be extremely costly to replace but they could present unprecedented problems for emergency crews. Electrical surges coming from broken body panels could be potentially harmful were rescue persons unaware of the underlying electrical issues.

On a fossil fuel-powered note, cars using traditional 12 volt batteries, which weigh anywhere from 45 – 61 lb (20-28 kg), this technology could also prove beneficial by relocating that hefty chunk of lead from the nose of the car out across larger surface areas.

According to Volvo, weight savings of 15 percent or more could be achieved by replacing a vehicle’s traditional body and relevant electrical components with these new nano-infused carbon fiber panels. Volvo is also keen to point out the positive sustainability aspect that comes as a result of such weight reduction.

Source: Volvo

20

Jun

BMW Unveils Exclusive HP4 RACE Motorcycle made with Carbon Fiber

At this year’s Milan Motorcycle Show, BMW Motorrad unveiled an “advanced prototype” of its BMW HP4 RACE, which the company is calling its most exclusive motorcycle ever. Like many BMW vehicles, it features a significant amount of carbon fiber. The 2017 HP4 RACE is the latest version of the HP4 that debuted in 2013 with one of the first semi-active suspension systems on the market.

The HP4 Race will join Ducati’s Superleggera as the only bikes on the market with full featherweight carbon fiber frames. For the HP4 RACE, the use of composites will extend beyond just the frame.

“The HP4 RACE will feature the full carbon fiber main frame and carbon fiber rims,” said Stephan Schaller, President of BMW Motorrad. “We will reveal more about this model next spring.”

According to sportrider.com, the carbon fiber main frame, self-supporting tail section, and wheels, as well as the bodywork, were likely made in-house by BMW at one of its three manufacturing plants in Landshut, Leipzig, and Dingolfing, Germany. The site adds that BMW was one of the first auto manufacturers to make a significant investment into its own carbon fiber manufacturing capabilities, instead of outsourcing the manufacturing components like most other automakers.

The motorcycle will be manufactured by hand in an exclusive limited series and supplied in the second half of 2017.

 

Buy carbon fiber, fiberglass and other composites online in Australia at Beyond Materials™

According to  http://compositesmanufacturingmagazine.com

20

Jun

Zoltek Carbon Fiber Featured in New Uniti Electric Car

Swedish startup company Uniti recently released its “smartphone car,” a modern electric vehicle that comes with five years of free electricity. The car can cover 186 miles with its 22 kWh battery and charge up to a range of 124 miles in 30 minutes.

According to Lewis Horne, founder and CEO of Uniti, the car’s body is made entirely of Zoltek’s PX35 carbon fiber in order to facilitate the company’s ability to scale up production. Zoltek, a subsidiary of Toray, has the largest global capacity of industrial-grade carbon fiber which can support automotive mass production. Additionally, by utilizing PX35, Uniti was able to create an electric car that is lightweight without sacrificing safety or comfort.

“Uniti is pioneering a new space in the electric vehicle market,” said David Purcell, Executive Vice President of Composite Intermediates and Oxidized Fiber at Zoltek. “We are pleased to support the efforts of this innovative team, and even more pleased that Uniti recognizes Zoltek’s PX35 as a key enabling material on their initial vehicle.”

According to Zoltek, PX35 carbon fiber has superior mechanical properties that are comparable to steel with just 25 percent of the density of steel at a price point competitive with aluminum. In addition to the automotive market, Zoltek is also currently supplying PX35 carbon fiber into wind energy applications.

Uniti will offer a line of two, four and five-seat vehicle models, with first deliveries targeted for 2019. There are already over 1,000 advance orders for the start-up company’s first vehicle. For more information, visit www.uniti.earth.

 

Buy carbon fiber, fiberglass and other composites online in Australia at Beyond Materials

 

According to  http://compositesmanufacturingmagazine.com

20

Jun

PolyOne Develops Carbon Fiber Underbody Brace for C7 Corvette

PolyOne announced its lightweight, carbon fiber-reinforced polymer (CFRP) underbody brace is now offered as a performance upgrade for the current C7 generation of GM’s Chevrolet Corvette Z06. The Corvette Z06 won last year’s Car and Driver Lightning Lap with the fastest speed, which also ranked as the second fastest lap time in the history of the event.

 

 

The company produced the continuous carbon fiber braces using pultrusion technology. PolyOne says the braces reduce weight compared to aluminum. The braces also increasing flexural stiffness for improved structural integrity and long-term fatigue strength.

“Our Glasforms team evaluated several composite types and identified a solution with optimal performance. The carbon fiber-reinforced composite part is 17% lighter than the stock aluminum part, and the composite held up well in GM’s extensive vibration, shake and road test regimen,” said Matthew Borowiec, general manager, PolyOne Advanced Composites – the company’s new platform it created after it acquired Gordon Composites and Polystrand. “We are proud that our team’s expertise in materials and engineering is helping to boost the legendary performance of the Corvette.”

General Motors uses the Corvette as a validation vehicle for many of its new technologies. GM has a 60-year history with composites. In 1953, Molded Fiber Glass launched the first production model of the Corvette with fiberglass body panels. In 1972, the Corvette’s body panels were made with sheet molding compounds (SMC) for the first time. All Corvettes since 1973 have used SMC body panels. As recently as last year, Continental Structural Plastics introduced its TCA Ultra Lite body panel for the Corvette.

Buy carbon fiber, fiberglass and other composites online in Australia at Beyond Materials

According to  http://compositesmanufacturingmagazine.com

03

Jun

Carbon Fiber and fiberglass kits for your all repair needs.

Buy Carbon Fiber Kits. Learn How to do a carbon fiber wrap and make your own custom carbon Fiber parts

 

Here at Beyond Materials we have put together Several Real Carbon Fiber and Fiberglass kits. That you can use to make your first carbon fiber or  fiberglass parts. Our kits only use the best quality 100% real carbon fiber.

These carbon fiber kits includes all of the basic materials you will need to make a small carbon fiber part, make a repair or skin a product in carbon fiber. The best part is that our carbon fiber kits are small and affordable and include everything you need to get started.

These carbon fiber kits have been used to repair or reinforce kiteboards, landboards, carbon fiber lips, carbon fiber hoods, interior pieces, R/C vehicles and more.

 

  

 

For general yachting, the Beyond Materials  fiberglass repair kit is a safety kit that will help you repair or at least temporary mend a crack or a hole in a punctured hull – enabling you to continue your fishing trip or continue your vacations – and without being any kind of composite expert or having to carry on-board scales to weight the resin+hardener, rollers and brushes. Beyond Materials makes composite repairs simple and straightforward.

  

 

Buy carbon fiber, fiberglass and other composites online in Australia at Beyond Materials

29

Nov

Recycled carbon fiber moves into automotive

Chery New Energy Automobile Technology Co. Ltd. in China has pledged to apply recycled carbon fiber from ELG Carbon Fibre to its eQ1 electric vehicle. The ultimate goal is to expand the fiber into higher volume vehicles.

 

ELG Carbon Fibre Ltd. (Coseley, UK) and Adesso Advanced Materials Wuhu Co. Ltd. (Wuhu, China) have concluded a MOU regarding cooperation to develop lightweight composite components for the automotive industry based on ELG’s recycled carbon fiber materials.

 

 

The initial focus of the cooperation is to investigate applications that have been identified by Chery New Energy Automobile Technology Co. Ltd. (Wuhu, China) on the Chery eQ1 electric vehicle. The goal is to further reduce the weight of the eQ1, which already makes extensive use of aluminium technology, through selective use of carbon fiber composites. The longer term intent is to then apply the knowledge gained from these projects in Chery’s conventional vehicles.

Following a preliminary evaluation of ELG’s materials by Professor Fan Guanghong’s team at the Advanced Manufacture Technology Center of China Academy of Machinery Science Technology (CAMTC), Chery has suggested initial applications to be investigated, and providing that technical and commercial targets are achieved.  ELG, Adesso and Chery intend to enter into a definite agreement to start full-scale production of these parts in Wuhu. This agreement would see ELG Carbon Fibre establish a carbon fiber recycling operation in China when sufficient volumes of recycled carbon fiber materials are required.

Frazer Barnes, managing director of ELG Carbon Fibre, says, “The eQ1, through its extensive use of aluminium, already represents a huge advancement in lightweighting for the Chinese car industry. We are pleased to be working with the innovative engineering team at Adesso and Chery to help them take the next step forward and start introducing carbon fibre composites into their vehicles”.

Dr. Bo Liang, president, chairman and CEO of Adesso, says, “Working together in this project enables us to address the barriers preventing large-scale use of carbon fiber composites in automotive applications —namely cost — through the use of recycled materials, design and manufacturing and collaboration with experienced partners. Our vision is that cooperation leads to an automotive composites hub in Wuhu. It also strengthens our vision on sustainability of the composite industry in China.”

Gao Lixin, deputy general manager of Chery Automobile Co. Ltd. and general manager of Chery New Energy Automobile Technology Co. Ltd., says, “There is a strong need to reduce the weight of both new energy and conventional vehicles in order to meet environmental and performance targets. We believe carbon fiber composites have an important role to play in this and through our cooperation with ELG and Adesso on the eQ1 project we will gain a significant learning curve advantage that we can then use in our conventional vehicles.”

 

Buy carbon fiber, fiberglass and other composites online in Australia at Beyond Materials

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