Manufacture of Green-composite automotive dashboard.

R.Hoto
1 a,
J.P Torres
2 b,
J.A. Garca-Manrique
1c*
1
Instituto de Diseo ! "abricaci#n, $ni%ersidad Po&it'cnica de (a&encia, )*ain.
2
Instituto de +iencia ! Tecno&o,a de Materia&es, $ni%ersidad -ac. de Mar de& P&ata, Ar,entina.
.
Instituto de Diseo ! "abricaci#n, $ni%ersidad Po&it'cnica de (a&encia, )*ain
re/o0doctor.u*%.es,
b
1*torres02i.3d*.edu.ar,
c
1u,arcia03c3.u*%.es
Keywords: 4ist t/e 5e!6ords co%ered in !our *a*er. T/ese 5e!6ords 6i&& a&so be used b! t/e
*ub&is/er to *roduce a 5e!6ord inde7.
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Introduction
-owadays" there is a growing need for the production and de.elopment of materials synthesi/ed
from renewable sources and to decrease the world0s dependence on petroleum. 1n the fiber
reinforced polymer composites (23P4s% manufacturing industry" these tendencies ha.e recently led
to the in.estigation of possible substitutes" both for matrix and reinforcement components. 3ecently"
bio-based matrix materials ha.e recei.ed considerable attention mainly for being nonpetroleum-
dependent. These systems can be obtained from sustainable sources such as .egetable oil" cellulose"
and soy protein" among others. 1n the case of bio-based thermosetting resins" much research is still
pending since mechanical properties comparable with those of petroleum-based counterparts are .ery
difficult to achie.e 56. 7ne of the main drawbacks of using plant oil as a precursor for bio-based
resins is that its chemistry can lead to a low crosslink density network which produces a polymer
with low glass transition temperature (lower than !)4%" poor stiffness (lower than 2 8Pa%" and
inferior thermo-physical properties" compared to the traditional petroleum based polymers. 9owe.er"
this same feature can lead to a superior toughness by pro.iding additional deformation mechanisms
for energy absorption before failure in impact loading situations 526. Altogether" a compromise
solution can be the combination of both synthetic and bio-based materials 5:" 46 in such a way that a
superior material is obtained from a cost-performance standpoint. ;ith respect to fiber
reinforcements" basalt fibers (<2s% ha.e been recently studied as sustainable alternati.e for fiber
reinforcement since the earth has practically unlimited basalt reser.es 5(6. <2s are produced from
basalt rock" the most common rock found in the earth crust. Also" basalt is biologically inert" and its
weathering increases the mineral content of soil. <2s are manufactured by melting at :))=#))4
and subse>uent spinning. This manufacturing process re>uires no precursor or additi.es" which
results in a decrease of its en.ironmental impact and production costs 5?6. 3egarding mechanical
performance" it has been reported that <2s ha.e higher modulus and strength than glass fibers (82s%
5#6. 1n addition" basalt has much higher chemical resistance than glass' it can be used for the
transportation and storage of corrosi.e li>uids and gases. 1t also pro.ides much better electrical
insulating properties and thermal stability than glass 5?6. 7ther ad.antages of basalt are its high @A
radiation and seawater resistance. 2inally" reduction of risk of en.ironmental pollution like high-toxic
metals and oxides can be achie.ed by replacing 82s with <2s. All of these features make <2s a
suitable substitute for 82s. 7n the other hand" when comparing <2s against carbon fibers (42s%" <2s
are more attracti.e from an en.ironmental protection perspecti.e since they offer sustainability and
independence from petroleum at significantly lower costs (e.en though they ha.e lower strength and
stiffness%. 2inally" it is important to remark that basalt fiber interface interaction with polymeric resins
is not completely understood 5#6 and a subBect of further in.estigation in order to gain a precise
knowledge of its effect on mechanical properties. The obBecti.e of this paper is to in.estigate the
possibility of using a no.el <23 bio-based epoxy green composite system as a potential substitute
for traditional petroleum-deri.ed composites. 2or this" composite specimens were manufactured
using the AA3TC techni>ue. Cechanical beha.ior of the proposed material system was assessed by
means of flexural and uniaxial tensile tests together with 2DC simulations. To perform numerical
simulations of the processing stage" the fiber permeability was measured using an especially designed
characteri/ation setup. A case study for the fabrication of a 8reen 4omposites dashboard was carried
out. The fabrication stage was modelled using the PAC-3TC software along with the permeability
.alues determined experimentally. The load-bearing capability of the part was studied by means of
2DC stress analysis" and the part configuration were determined in order to satisfy the maximum
allowable stress .alues established in the mechanical characteri/ation stage.
2. Materials and Methods
2. Overview on Liquid Composite Molding (LCM) Manufacturing Methods.
E4C is a manufacturing method that consists in the impregnation of a fabric with a low .iscosity
resin. 1t is currently considered as one of the most .iable and ecofriendly process in the
manufacturing of high >uality parts. Fepending on the characteristics of the mold and the applied
pressure gradient" there are a number of different types of E4C process among which are 3esin
Transfer Colding (3TC%" Aacuum Assisted 3esin Transfer Colding (AA3TC%" 3eacti.e 1nBection
Colding (31C%" and Gtructural 3eacti.e 1nBection Colding (G31C%. 7ne disad.antage in E4C
methods is that defects such as .oids and dry spots can be induced during the impregnation stage 5$6.
These defects are considered to be the largest source of >uality and reproducibility problems. They
are often caused by unbalanced resin flows" which are directly related to the fiber permeability and
the impregnation .elocity. As a conse>uence" an accurate prediction of resin flow beha.ior in the
fiber impregnation process is of great importance for the optimi/ation of E4C parts >uality.
4urrently" there are a number of computer simulation tools a.ailable for the modelling of E4C
processes" which pro.ide a remarkable ad.antage o.er the (cost and time consuming% trial-and error
methods traditionally used in the industry. 1n order to perform E4C modelling" one of the most
critical input parameters for the mathematical models is the reinforcement permeability. 1n the past
2) years" a number of studies 5!=6 ha.e focused on the de.elopment of a reliable and standardi/ed
procedure for the accurate characteri/ation of fiber permeability.
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546 3.W. 7ng" W.T. Fawley and P.8. 4lem' submitted to Wournal of Caterials 3esearch (2)):%
5(6 P.8. 4lem" C. 3odrigue/" W.A. Aoigt and 4.G. Ashley" @.G. Patent ?"2:"???. (2))%
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