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DOE OSTI · 1600931

Carbon Fiber Reinforced Polyolefin Body Panels

Shewey, Megan·Tibbenham, Patti·Houston, Dan
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Abstract

This project addresses an automotive industry desire for a cost-effective, lightweight material for body panels that offers mass reduction compared to steel and aluminum body panels, and a cost savings compared to incumbent polymer body panels. Inexpensive polypropylene (PP) combined with <10 weight % reclaimed/recycled carbon fiber (rCF) have the potential to meet both performance and affordability targets for lightweight, paintable vertical body panels. This project supports DOE and IACMI technical goals of reducing production cost of CF composites >25% in 5 years on a path to >50% in 10 years and demonstrating technologies for >80% recyclability or reuse of fiber reinforced composites in 5 years on a path to >95% in 10 years. Alternative body panel materials must meet all fit and surface finish requirements, and match the appearance of metal body panels adjacent to them. The PP/rCF materials must maintain exterior dimensional requirements with a low co-efficient of thermal expansion, excellent paintability, and mechanical performance. Thermoplastic injection molding offers significant reduction in tooling costs as injection molding dies are typically less than half the cost of stamping dies. This project utilized rCF compounded with special formulations of PPs to produce automotive components that meet requirements for fit, finish, mechanical performance, and paintability while offering significant mass savings over incumbent metal panels. It will also offer a cost savings versus other composite solutions. Fenders were molded at the IACMI – Corktown facility using an existing fender tool. Ford Motor Company was the industry lead for this project and provided project management, testing, painting and adhesion testing, and developed the cost-model/business case. Ford engaged and aggregated cost share with Borealis who provided materials, technical support for process trials, and participated in coordination meetings. Vehicles Technology Area staff in Corktown assisted in project management, process trials, molded fenders, and benchmarked physical characteristics. Over 450 plaques were molded with two different gating systems to look at processing conditions and specimens were excised for mechanical testing. Plaques were also used for paint trials, surface analysis, and dimensional analysis. Subsequently, over 200 fenders were molded at IACMI – Corktown. These fenders were used for paint trials, surface analysis, and dimensional analysis. The PP/rCF systems met all of the requirements except for paint appearance. Additional development of paint primer and top coat is necessary to fulfill automotive OEM paint surface requirements.

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32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATION36 MATERIALS SCIENCE42 ENGINEERINGcarbon fiberinjection moldinglightweightpaintpolypropylenerecycling

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Shewey, Megan, Tibbenham, Patti, Houston, Dan. 2019-10-23. Carbon Fiber Reinforced Polyolefin Body Panels. https://doi.org/10.2172/1600931

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