Documents published in Scipedia

• Automation of the dry fibre deposition process to manufacture structural parts for the automotive sector

  L. Carral, A. Gutierrez, L. Mera

  Materiales Compuestos (2025). Vol. 08 - COMUNICACIONES MATCOMP21 (2022) Y MATCOMP23 (2023), (Núm. 8 - Fabricación y Aplicaciones Industriales - Materiales y Estructuras - Modelos Numéricos), 22

  
  

  Abstract

  In recent years, lightweight structures have gained importance due to increasingly stringent environmental legislations. This situation is especially critical for the transport sector and, especially, for the automotive sector where, in parallel, there is a strong competitiveness. In this context, it should be noted that traditionally manufacturing processes for structural composite materials involver high TAKT times, which has limited their implementation. Thus, the resin transfer molding manufacturing process and, more specifically, its recently developed thermoplastic version (TP-RTM) has been identified as a route with great potential for mass manufacturing. Within the framework of the European LEVIS project, the development of a suspension arm made entirely of composite materials has been studied. This study focuses on the development of the process window of the preforming stage, one of the most critical for the development of complex geometries. In this sense, automated taping technology has broken few years ago, allowing the improvement of robustness and productivity. Specifically, a wide range of materials has been studied and important parameters such as fibre deposition pressures and temperatures have been analysed. On the other hand, to optimize the TP-RTM, several aspects have been studied, such as viscosity of the resin, the curing cycle of the resin, the compatibility of the resin, the curing cycle of the resin with the dry fibre and the study of the optimal parameters for the resin injection.

  Abstract
  In recent years, lightweight structures have gained importance due to increasingly stringent environmental legislations. This situation is especially critical for the transport [...]

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• AUTOMATIZATION IN NEW MANUFACTURING APPROACHES FOR BODY SHELL APPLICATIONS

  A. Gutierrez, L. Mera, L. Carral, I. Coto, F. Ansedes, M. Plettig, S. Renner

  Materiales Compuestos (2023). Vol. 07 - COMUNICACIONES MATCOMP21 (2022), (Núm. 3 - Materiales y Estructuras - Modelos Numéricos), 12

  
  

  Abstract

  The transport sector has exerted and continue to be the driving force for the development of new materials and lightweight solutions. The present study focuses on the work developed in a European project (CARBODIN https://carbodin.eu/) where one of the main objectives is to develop innovative and affordable solutions for advanced car body shells. Thus, contributing to the development of the next generation of passenger trains that will be lighter as well as more energy- and cost-efficient. Composite materials appear to be one of the most promising candidates to attain these ambitious targets. Therefore, new strategies to achieve greater automation are presented as novel manufacturing routes and offer a cost-effective industrial solution. This study has allowed the integration of unconventional technologies, such as AFP, within conventional production systems, such as VIP, which is the key to developing sustainable units, overcoming the common difficulties associated with processing and achieving the modularity of the manufacturing process and the reduction of the weight of the final rail structure. For this reason, a comparison of the manufacture of both monolithic composites and sandwich structures have been obtained through the VIP process, manufactured in an automated and manual way. Several automated approaches have been studied, with the choice of the robotized lay up of bindered dry fibers. An out of autoclave manufacturing was assisted through different monitoring technologies such as resin arrival sensors and thermography in order to ensure high quality components.

  Abstract
  The transport sector has exerted and continue to be the driving force for the development of new materials and lightweight solutions. The present study focuses on the work [...]

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• Novel Manufacturing Approaches For Car Body Shell Applications Based On Sandwich Structures

  L. Carral, L. Mera, A. Gutierrez, P. Rodriguez, X. Pérez, M. Pletting, S. Renner

  Materiales Compuestos (2023). Vol. 07 - COMUNICACIONES MATCOMP21 (2022), (Núm. 3 - Materiales y Estructuras - Modelos Numéricos), 3

  
  

  Abstract

  The transport sector has exerted and continue to be the driving force for the development of new materials and lightweigth solutions. The present study focuses on the work developed in a recently completed European project (CARBODIN https://carbodin.eu/) where one of the main objectives is to develop innovative and affordable solutions for advanced car body shells. Composite materials appear to be one of the most promising candidates to attain these ambitious targets. However, to overcome the cost barrier as well as meet additional railway requirements, new strategies such as process integration and novel manufacturing routes are needed, which will offer a cost-effective industrial solution. The case study corresponds to a C-Groove insert used as an anchoring point to hang passenger seats off the car body side walls, to fix Interior Panels or luggage racks. To improve this design, a trendsetting design was developed to integrate composite C-Grooves to Composite sidewalls. This work will display the details of such design as well as the optimal manufacturing strategy to achieve it. An out of autoclave (OoA) manufacturing process was assisted through different monitoring technologies such as resin arrival sensors and thermography to ensure high quality components. Additionally, a multi-material approach based on 3D printed technologies has been tackled. A thorough analysis of the joint has been performed and different integration approaches have been explored by designing co-cured and co-bonded manufacturing stages. Finally, several demonstrators have been made and tested to define the most promising integration approach and scaling up yet again to a larger demonstrator.

  Abstract
  The transport sector has exerted and continue to be the driving force for the development of new materials and lightweigth solutions. The present study focuses on the work [...]

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• AUTOMATIZATION IN NEW MANUFACTURING APPROACHES FOR BODY SHELL APPLICATIONS

  A. Gutierrez, L. Mera, L. Carral, I. Coto, F. Ansedes, M. Plettig, S. Renner

  Aitana Gutierrez's personal collection (2022). 2

  
  

  Abstract

  The transport sector has exerted and continue to be the driving force for the development of new materials and lightweight solutions. The present study focuses on the work developed in a European project (CARBODIN https://carbodin.eu/) where one of the main objectives is to develop innovative and affordable solutions for advanced car body shells. Thus, contributing to the development of the next generation of passenger trains that will be lighter as well as more energy- and cost-efficient. Composite materials appear to be one of the most promising candidates to attain these ambitious targets. Therefore, new strategies to achieve greater automation are presented as novel manufacturing routes and offer a cost-effective industrial solution.  This study has allowed the integration of unconventional technologies, such as AFP, within conventional production systems, such as VIP, which is the key to developing sustainable units, overcoming the common difficulties associated with processing and achieving the modularity of the manufacturing process and the reduction of the weight of the final rail structure. For this reason, a comparison of the manufacture of both monolithic composites and sandwich structures have been obtained through the VIP process, manufactured in an automated and manual way. Several automated approaches have been studied, with the choice of the robotized lay up of bindered dry fibers. An out of autoclave manufacturing was assisted through different monitoring technologies such as resin arrival sensors and thermography in order to ensure high quality components.

  Abstract
  The transport sector has exerted and continue to be the driving force for the development of new materials and lightweight solutions. The present study focuses on the work [...]

  • 25
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• REPAIRING OF STEEL STRUCTURES BY COMPOSITE PATCHES ACTING AS A CRACK ARRESTORS

  L. Blanco Salgado, L. Carral, R. Mano, T. González, E. Senín

  Memorias del Congreso Internacional de Ingeniería Mecánica y Mecatrónica Aplicada (2022). 1

  
  

  Abstract

  Today’s merchant and passenger vessels are complex structures that operate in harsh environments with respect to static and cyclic loads and corrosion. Depleting funds for fleet renewal and increasing through-life cost of maintenance and repair are the principal factors that lead to the need to implement new solutions that are easy to apply and low cost. All this added to the growing need for lightening in the transport sector turn the FRP materials into the main candidates as drivers for this change. This present study within RAMSSES is focused on the compare a damage steel structures to repair composite patches. A representative structural detail of a cruise vessel was selected and designed as a demo case. The best patch solution was selected by FEM calculations, which have been fed from the mechanical test results of the composite material combinations, steel, surface treatments and adhesion joint of the one-shot dissimilar joints without adhesive. Fatigue tests have been carried out and monitoring by strain gauges and FBGs positioning and distribution in the high stress areas along the demonstrator. Fatigue tests have been carried out in the six demos to compare crack evolution in cracked Patched and Un-Patched demonstrators. As conclusion after the fatigue tests, composite patch works as crack arrested. Therefore, this behaviour represents an improvement of the 2.6 times of the fatigue life comparing UnPatched and Patched damaged steel.

  Abstract
  Today’s merchant and passenger vessels are complex structures that operate in harsh environments with respect to static and cyclic loads and corrosion. Depleting funds [...]

  • 25
  •  read