Periodic Reporting for period 3 - LAY2FORM (Efficient Material Hybridization by Unconventional Layup and Forming of Metals and Composites for Fabrication of Multifunctional Structures)
Berichtszeitraum: 2020-10-01 bis 2022-03-31
What is the problem/issue being addressed?
The transport sector is under constant pressure to produce innovative lightweight structural solutions that improve vehicle fuel consumption. Single-material structural components in vehicles can be replaced, advantageously, by layered integrated multimaterial systems. When properly selected and designed these layered composite-metal hybrid materials enable a significant weight reduction and consequently lower CO2 emissions. Transition from an all metal or composite bulk to a multi-layer hybrid metal/composite has already been shown to provide advances in crashworthiness, impact, strength, acoustic and vibrational performance in automotive and aerospace components and assemblies. Despite intensive research and low-volume production, advanced continuous fibre polymer composites still lack truly high-volume applications in the automotive sector. LAY2FORM aims to demonstrate how the integration of novel unconventional technologies, into manufacturing systems provides an efficient, flexible and cost-effective solution for the manufacturing of multifunctional hybrid lightweight materials. The implementation of an end-to-end engineering concept implements a continuous and automated process chain adapted for a mass customisation manufacturing able to handle efficiently a range of material combinations and products (adapted to Industry 4.0 vision).
Why is it important for society?
One of the key societal challenges of today in Europe is its transport-related decarbonisation, from the road transport to the aviation sectors. Over the past few decades, structural design for vehicle structures has been subjected to multiple pressures of different stakeholders focused in decreasing their footprint and in improving their safety towards increased transport efficiency, reduced emissions and life cycle impact of the vehicle on the environment, as well as to improve the safety, performance, functionality, comfort and perceived quality. LAY2FORM results can certainly contribute to the ongoing deep changes on the overall mobility sector, particularly in the current trend of sensor/ actuator-based interaction between the society, the vehicles and the transport infrastructures.
What are the overall objectives?
The main goal of LAY2FORM is to develop a new advanced and highly integrated manufacturing process for forming of layered metal/ thermoplastic-matrix composite hybrid materials, suitable to highly dynamic and competitive manufacturing environments, such as those of the automotive sector. Unconventional technologies (laser and Ultrasound-US) will be integrated into the manufacturing route, for material modification, adhesion, shaping, spot welding and consolidation, as well as for end-of-life material disassembly. The innovative integrated process will be assisted with simulation, cognitive automation, decision support, real-time control and advanced in-line NDT techniques, in a fully automated multi-stage manufacturing system. Forming of metal foil / carbon fibre reinforced thermoplastic hybrids will be demonstrated in industrially relevant conditions.
The transport sector is under constant pressure to produce innovative lightweight structural solutions that improve vehicle fuel consumption. Single-material structural components in vehicles can be replaced, advantageously, by layered integrated multimaterial systems. When properly selected and designed these layered composite-metal hybrid materials enable a significant weight reduction and consequently lower CO2 emissions. Transition from an all metal or composite bulk to a multi-layer hybrid metal/composite has already been shown to provide advances in crashworthiness, impact, strength, acoustic and vibrational performance in automotive and aerospace components and assemblies. Despite intensive research and low-volume production, advanced continuous fibre polymer composites still lack truly high-volume applications in the automotive sector. LAY2FORM aims to demonstrate how the integration of novel unconventional technologies, into manufacturing systems provides an efficient, flexible and cost-effective solution for the manufacturing of multifunctional hybrid lightweight materials. The implementation of an end-to-end engineering concept implements a continuous and automated process chain adapted for a mass customisation manufacturing able to handle efficiently a range of material combinations and products (adapted to Industry 4.0 vision).
Why is it important for society?
One of the key societal challenges of today in Europe is its transport-related decarbonisation, from the road transport to the aviation sectors. Over the past few decades, structural design for vehicle structures has been subjected to multiple pressures of different stakeholders focused in decreasing their footprint and in improving their safety towards increased transport efficiency, reduced emissions and life cycle impact of the vehicle on the environment, as well as to improve the safety, performance, functionality, comfort and perceived quality. LAY2FORM results can certainly contribute to the ongoing deep changes on the overall mobility sector, particularly in the current trend of sensor/ actuator-based interaction between the society, the vehicles and the transport infrastructures.
What are the overall objectives?
The main goal of LAY2FORM is to develop a new advanced and highly integrated manufacturing process for forming of layered metal/ thermoplastic-matrix composite hybrid materials, suitable to highly dynamic and competitive manufacturing environments, such as those of the automotive sector. Unconventional technologies (laser and Ultrasound-US) will be integrated into the manufacturing route, for material modification, adhesion, shaping, spot welding and consolidation, as well as for end-of-life material disassembly. The innovative integrated process will be assisted with simulation, cognitive automation, decision support, real-time control and advanced in-line NDT techniques, in a fully automated multi-stage manufacturing system. Forming of metal foil / carbon fibre reinforced thermoplastic hybrids will be demonstrated in industrially relevant conditions.
During the final review period, the activities went further deep in the implementation of the hybridization methodologies developed so far, by purchasing and assemble the final pilot-line whose viability was proven by manufacturing numerous technological demonstrators.
A summary of the main results achieved is listed below:
- final demonstrator was redesigned with a skeleton structure continuous fibre with the aluminium reinforcements, while a Glass Mat Reinforced Thermoplastic completes the remaining part volume; with this concept the necessary tools and moulds were developed and manufactured within the reporting period;
- The integration of CAD/CAM FreeCAD plugin, SAS model and PAM-form simulator was integrated in the decision support system environment;
-On the hybrid digital twin activities: the improvement, validation and test of the XML structure on the cloud infrastructure, the deployment of the OPCUA client towards all partners involved in this digital infrastructure and the testing of the entire communication system;
- The disassembly of hybrid representative samples was performed by LSW, proving the reliability of Lay2form hybridization and consequent material recovery, enhancing the eco-friendliness, end-of-life and sustainability characteristics of the proposed solution;
- The demonstration of Lay2form pilot line manufacturing capabilities by producing several technological demonstrators, following the defined division of the manufacturing line in 4 separated lines;
- The previously developed manufacturing sustainability and cost-effectiveness models and tools were fed with pilot-line collected data leading to the assessment of the ecological and economical assessment of Lay2form parts in long-term;
- Manufactured demonstrators were assessed by means of a set of non-destructive shearographic analyses where debonding in the part and fibre directions were evaluated. Additionally, a set of quality-control evaluation tests were run to the parts;
- The previously developed CAD/CAM system was debugged and tested with the real demonstrators, generating the trajectories that the laser head must travel for the trimming process;
- The trimming of real demonstrators was carried out following the automatic generated trajectories while some corrections were performed in the laser head angle, in order to avoid interactions between the laser beam and parts’ backside features;
- The assembly of the pilot line and modules integration is complete and the data workflow integration works were carried out in the manufacturing process.
A summary of the main results achieved is listed below:
- final demonstrator was redesigned with a skeleton structure continuous fibre with the aluminium reinforcements, while a Glass Mat Reinforced Thermoplastic completes the remaining part volume; with this concept the necessary tools and moulds were developed and manufactured within the reporting period;
- The integration of CAD/CAM FreeCAD plugin, SAS model and PAM-form simulator was integrated in the decision support system environment;
-On the hybrid digital twin activities: the improvement, validation and test of the XML structure on the cloud infrastructure, the deployment of the OPCUA client towards all partners involved in this digital infrastructure and the testing of the entire communication system;
- The disassembly of hybrid representative samples was performed by LSW, proving the reliability of Lay2form hybridization and consequent material recovery, enhancing the eco-friendliness, end-of-life and sustainability characteristics of the proposed solution;
- The demonstration of Lay2form pilot line manufacturing capabilities by producing several technological demonstrators, following the defined division of the manufacturing line in 4 separated lines;
- The previously developed manufacturing sustainability and cost-effectiveness models and tools were fed with pilot-line collected data leading to the assessment of the ecological and economical assessment of Lay2form parts in long-term;
- Manufactured demonstrators were assessed by means of a set of non-destructive shearographic analyses where debonding in the part and fibre directions were evaluated. Additionally, a set of quality-control evaluation tests were run to the parts;
- The previously developed CAD/CAM system was debugged and tested with the real demonstrators, generating the trajectories that the laser head must travel for the trimming process;
- The trimming of real demonstrators was carried out following the automatic generated trajectories while some corrections were performed in the laser head angle, in order to avoid interactions between the laser beam and parts’ backside features;
- The assembly of the pilot line and modules integration is complete and the data workflow integration works were carried out in the manufacturing process.
Current knowledge-based modelling of such materials and processes can be integrated in cognitive systems that monitor and correct production, and that this enhanced manufacturing capability can further increase speed, efficiency and cost savings. Significant technical breakthroughs are still required to meet the targets of project:
- Flexible manufacturing strategies applicable to all kinds of metals and fibre-reinforced polymer composites thin layered materials, replacing complex and low efficient assemblies of different components and materials, insuring the lowest use of energy and resources along the full manufacturing chain and at the end of life.
- Efficient processing techniques, leading to significant time and resources savings during manufacturing. Composite-metal cobonding (adhesive-free), integrated consolidation/ heating of the composite-metal blanks (typically highly energy-consuming) and the extensive use of laser and US (clean and low energy-intensive energy sources) in all the four main processing stations as well as disassembly at the end-of-life.
- Tight quality control and fault tolerance concepts at the material tape/foil, blank and product-level, by foreseeing the real-time detection and solving of defects along the full manufacturing chain, minimizing the waste of all type of resources, while improving quality.
- Tailored Eco-efficiency and LCA approaches and tools embedded in component design and manufacturing. LAY2FORM will assess the feasibility of the multi-material parts production, mostly based on the efficiency of the alternative manufacturing routes to be developed.
- Flexible manufacturing strategies applicable to all kinds of metals and fibre-reinforced polymer composites thin layered materials, replacing complex and low efficient assemblies of different components and materials, insuring the lowest use of energy and resources along the full manufacturing chain and at the end of life.
- Efficient processing techniques, leading to significant time and resources savings during manufacturing. Composite-metal cobonding (adhesive-free), integrated consolidation/ heating of the composite-metal blanks (typically highly energy-consuming) and the extensive use of laser and US (clean and low energy-intensive energy sources) in all the four main processing stations as well as disassembly at the end-of-life.
- Tight quality control and fault tolerance concepts at the material tape/foil, blank and product-level, by foreseeing the real-time detection and solving of defects along the full manufacturing chain, minimizing the waste of all type of resources, while improving quality.
- Tailored Eco-efficiency and LCA approaches and tools embedded in component design and manufacturing. LAY2FORM will assess the feasibility of the multi-material parts production, mostly based on the efficiency of the alternative manufacturing routes to be developed.