BASF carbon-fibre plastics study ends
9 Mar 2015
New processes and techniques for manufacturing thermoplastics strengthened by carbon fibres have been developed by a research study that ends today.
The joint project by BASF and carbon composite manufacturer SGL Group developed a system aimed at enhancing the cost-effectiveness of manufacturing thermoplastic carbon-fibre composites, for example through techniques such as an injection procedure known as thermoplastic resin transfer moulding (T-RTM).
Thermoplastics-based carbon-fibre composites combine the properties of carbon fibres such as high rigidity and low weight with the familiar processing advantages of thermoplastics, allowing them to be formed, recycled and welded.
“We are working on the development of robust polyamid 6 carbon-fibre composite systems
BASF’s Josef R. Wünsch
This helps make carbon fibre technology an even more viable proposition for large-scale production in a number of different applications.
The composite developed by BASF and SGL’s research is based on a reactive polyamide system and compatible carbon fibres.
Research around the processes and systems used to produce the composite means that lightweight structural components, such as those for the automotive industry, can now be manufactured quickly and easily.
BASF’s role in this project was to process SGL Group’s newly developed carbon fibres using the T-RTM technique and to characterise them comprehensively both chemically and mechanically.
The BASF research team is continuing to work intensively on the development of caprolactam-based thermoplastic reactive systems.
“In close collaboration with plant manufacturers as well as tiers and automotive OEMs, we are working on the development of robust polyamid 6 carbon-fibre composite systems,” said BASF head of Structural Materials and Systems Research Josef R. Wünsch.
“The mechanical characteristic values arising from the interaction of the fibre and matrix are crucial input parameters for our simulation tool Ultrasim. We are currently working intensively on enhancing our simulation expertise for reactive systems so that we can provide our customers with expert support for part design and optimisation.”
The collaboration between SGL Group and BASF was launched back in October 2012.
Following the completion of the research stage of the project, work is now underway to transfer its findings into specific applications in the automotive industry.
As part of the project, SGL Group developed a new sizing formulation for the carbon fibres.
In addition, special processes for manufacturing carbon-fibre-based textiles such as fabrics and braidings were also developed.
For example, to produce Non-Crimp-Fabrics (NCF), special threads are used that enable processing in the reactive polyamide system.
