Process for applying CFRP patches on steel sheets to be formed
阅读说明：本技术 在待成形的钢板上施加cfrp贴片的工艺 (Process for applying CFRP patches on steel sheets to be formed ) 是由 L·维克斯特罗姆 于 2018-05-17 设计创作，主要内容包括：一种生产复合机动车辆构件的工艺,所述工艺包括以下步骤：将经过表面处理的钢部件(1)加热至奥氏体温度,以在所述钢部件中形成奥氏体；使钢部件成形为期望的形状；使钢部件冷却至低于500℃的温度；将由预浸料纤维增强聚合物制成的贴片(2)施加至钢部件的至少一部分,压制所施加的由纤维增强聚合物制成的贴片(2)以使其粘附至钢部件(1)；和在所述压制工具内至少部分地使所述贴片固化。(A process for producing a composite automotive vehicle component, the process comprising the steps of: heating the surface treated steel component (1) to an austenite temperature to form austenite in the steel component; forming the steel component into a desired shape; cooling the steel component to a temperature below 500 ℃; applying a patch (2) of prepreg fibre-reinforced polymer to at least a portion of the steel component, pressing the applied patch (2) of fibre-reinforced polymer to adhere it to the steel component (1); and at least partially curing the patch within the pressing tool.)
1. A process for producing a composite automotive vehicle component, the process comprising the steps of:
-heating the surface treated steel component (1) to an austenite temperature so as to form austenite in the steel component;
-shaping the steel component (1) into a desired shape,
-cooling the steel component (1) to a temperature below 500 ℃,
-applying a prepreg fibre reinforced polymer part (2) to at least a portion of the steel part,
-pressing a prepreg fibre reinforced polymer part (2) to adhere it to a steel part (1), and at least partially curing the fibre reinforced polymer part (2).
2. A process according to claim 1, wherein the step of shaping the steel component (1) into a desired shape is performed within a shaping tool, and the step of applying the prepreg fibre-reinforced polymer component (2) to the steel component (1) is performed in a pressing tool different from the shaping tool.
3. The process of claim 2, wherein the steel component is transported from the forming tool to the pressing tool on a conveyor line.
4. A process according to any one of the preceding claims, wherein no surface treatment is performed on the steel component (2) between the step of shaping the steel component and the step of applying the prepreg fibre reinforced polymer component (2) to at least a portion of the steel component.
5. A process according to claim 4, wherein the steel component (1) and the prepreg fibre-reinforced polymer component (2) are joined without the use of a further adhesive other than the inherent polymer of the fibre-reinforced polymer component (2).
6. Process according to any of the preceding claims, wherein the pressing tool remains pressed against the fibre reinforced polymer part (2) on the steel part (1) for less than 40 seconds, preferably less than 30 seconds.
7. Process according to any of the preceding claims, wherein the fibre reinforced polymer part (2) is attached to a portion of the steel part (1) that has been deformed during the forming of the steel part, and wherein the fibre reinforced polymer part (2) is arranged to cover at least a part of the deformed portion of the steel part.
8. A process according to any one of the preceding claims, wherein the fibre-reinforced polymer part (2) comprises carbon fibres embedded in an epoxy resin.
9. Process according to any of the preceding claims, wherein the pressing tool is heated to a temperature above 120 ℃ during pressing of the fibre reinforced polymer part (2) to the steel part (1).
10. Process according to any of the preceding claims, wherein the fibre reinforced polymer part (2) is attached to the steel part (1) before the steel part (1) has cooled and still has a temperature of at least 150 ℃ when applied to the steel part.
11. Process according to any of the preceding claims, wherein the steel component (1) is made of steel that has been treated with an oxidation skin inhibiting layer.
12. Process according to claim 11, wherein the steel component (1) is made of steel that has been covered with an Al-Si layer.
13. Process according to any of claims 1-10, wherein the steel part (1) is made of steel that has been surface treated to form an oxide structure to which the fibre-reinforced polymer part (2) can be attached, the formed oxide structure comprising a 1.5-4 μ ι η thick skin formed of iron oxide.
14. Process according to any one of claims 1-10, wherein the steel component (1) is made of stainless steel.
15. Process according to any of the preceding claims, wherein the steel component (1) is formed of austenitic steel forming a martensitic structure by air hardening and the process comprises the step of cooling the steel component with the applied fibre-reinforced polymer component (2) without rapid quenching.
16. A motor vehicle component comprising a shaped steel part (1) and an applied fibre-reinforced polymer part (2), wherein the motor vehicle component is produced by a process according to any of the preceding claims.
Technical Field
The invention relates to a process for applying a component made of a fibre-reinforced polymer to a steel component. In particular, the present invention relates to a process of applying a CFRP patch to a steel sheet to be formed into a vehicle component.
Background
In the vehicle industry, it is important to provide components with high ductility that deform in a predictable manner when subjected to high strains (e.g., during a collision). It is conventional in the art to reinforce steel components by applying fiber reinforced polymers at critical areas of the vehicle component. This is an advantageous way of locally stiffening the product while keeping the weight of the product to a minimum.
In the art, challenges in applying patches made of fiber reinforced polymers to steel panels include achieving good bonding between steel components and maintaining productivity of the operation.
In EP 1908669B 1 a process for producing a vehicle part is disclosed, wherein two parts are joined to each other by means of an adhesive, wherein a second component, typically a fiber-reinforced polymer, is joined to a steel plate, wherein the residual heat from the hot working process of the steel plate is used to create an adhesive joint between the components.
In order to obtain good adhesion between the steel component and the fibre reinforced polymer patch and to achieve accurate mounting of the reinforced polymer patch, it is desirable to apply the fibre reinforced polymer patch as a prepreg and cure the patch as it adheres to the steel plate. A problem associated with such a step is that curing of the prepreg fibre reinforced polymer typically takes a significant amount of time, which slows down the process.
Therefore, there is a need for a production process for joining prepreg fiber reinforced polymer patches to steel parts.
Disclosure of Invention
It is an object of the present invention to provide an efficient process for producing steel components, in particular for the automotive industry.
This object is achieved by a process for producing a composite motor vehicle component, comprising the steps of:
-heating the surface treated steel component to an austenite temperature to form austenite in the steel component;
-shaping the steel component into a desired shape,
-cooling the steel component to a temperature below 500 ℃,
-applying a prepreg fibre reinforced polymer part to at least a portion of the steel part,
-pressing the prepreg fibre-reinforced polymer part to adhere it to a steel part and at least partially curing the fibre-reinforced polymer part.
The invention also relates to a motor vehicle component comprising a shaped steel part and an applied patch made of carbon fiber reinforced polymer, which has been produced by the process as described above.
The process of the invention has the advantage that productivity can be increased due to the use of tools for shaping and cooling the steel sheet during a shorter time, since the steel sheet can be arranged to be cooled outside the tools.
Other aspects and advantages of the invention will be apparent from the following description and the independent claims.
Drawings
Certain aspects of the invention will hereinafter be described with reference to the accompanying drawings, in which:
FIG. 1 is a schematic diagram of a process according to certain aspects of the present invention.
Detailed Description
In fig. 1, a schematic view of a process for producing a composite automotive vehicle component according to certain aspects of the present invention is shown. The process may be divided into three sub-processes, including a first sub-process comprising a set of steps 101-103 for preparing a steel component for producing a composite vehicle member; a
Referring to the lower left portion of fig. 1, the process comprises: a
In parallel with the preparation of the steel component 1, a fibre-reinforced polymer component 2 is prepared for subsequent adhesion to the steel component 1. In a first providing
In a
The joining of the fibre-reinforced polymer part 2 to the steel part 1 is performed in a press tool different from the forming tool in which the steel part is hot-formed. The steel component is transferred from the forming tool to the pressing tool on a transfer line. Thus, no robot is required to move the steel part from the forming tool to the pressing tool.
The heated steel part 1 and the heated fibre-reinforced polymer part 2 are joined in a tool, typically a forming tool, to form the composite part 3, wherein in an
In the tool, the applied patch of fibre-reinforced polymer is pressed during heating to adhere it to the steel part, thereby at least partially curing the fibre-reinforced polymer part 2 within the tool. Preferably, the steel component 1 and the prepreg fibre-reinforced polymer component 2 are joined without the use of other adhesives than the inherent polymer of the fibre-reinforced polymer.
Preferably, the steel part is not surface treated between the step of shaping the steel part 1 and the step of applying the fibre-reinforced polymer part 2 to a part of said steel part. This is possible because the steel component is a stainless steel component, a coated steel component or a pre-treated steel component. The pre-treatment is performed to produce a surface on the steel part that is free of loose iron oxides that would otherwise impede surface bonding to the fiber reinforced polymer part 2. The heating of the steel component,
In many prior art solutions this is solved by performing a surface treatment on the steel to remove the formed iron oxide when the steel has been cooled before the fibre-reinforced polymer part adheres to the steel part. Such surface treatments may include, for example, shot peening, blasting, and the like. However, such treatment will introduce further steps in the process and slow down the overall process.
According to one aspect of the process of the invention, the steel member is made of steel that has been treated with an scale-inhibiting layer. This has the advantage that no surface treatment of the steel part is required between the heating and forming of the steel part and the adhesion of the fibre-reinforced polymer part to the steel part.
According to one aspect, the steel component is made of steel that has been covered with an Al-Si layer. Alternatively, the steel member is made of steel that has been subjected to a surface treatment prior to being heated, which surface treatment changes the properties of the surface and makes it easier to form an oxide structure to which patches made of fibre-reinforced polymer can be attached. Such surface treatments typically include a 1.5-4 μm thick scale formed from iron oxides (wustite, magnetite and hematite). The steel surface has been chemically pretreated, which results in the formed scale being anchored to the steel during the press hardening.
As a further alternative, the steel component may be made of stainless steel, wherein no surface treatment is required either before or after heating of the steel component. For most applications, the steel components are preferably made of carbon steel.
During the
In the prior art, it is conventional practice to maintain a slight pressure and heat for about 120 seconds to cure the fiber reinforced polymer. As one aspect of the present invention, it has been tested that curing can be accelerated by slightly increasing the curing temperature. Thus, for a typical epoxy, curing may be performed in about 20-30 seconds, rather than in the 120 seconds, thereby significantly speeding up the process.
In one aspect, the prepreg fibre reinforced polymer patch is attached to a portion of the steel component that has been deformed to include at least one curved portion, wherein the prepreg fibre reinforced polymer patch is arranged to cover an inboard portion of the at least one curved portion. Such application of a fibre-reinforced polymer patch will provide local reinforcement, which is often required in areas that have already undergone a bent or shaped portion.
The prepreg fibre-reinforced polymer patch preferably comprises carbon fibres embedded in an epoxy resin. Preferably, the epoxy resin is a fast-setting epoxy resin known as a fast-curing epoxy resin.
During pressing of the patch made of fibre reinforced polymer to the steel part, the tool in which the prepreg fibre reinforced polymer is at least partially cured is preferably heated to a temperature above 150 ℃. The patch made of fiber reinforced polymer is attached to the steel part before the steel part has cooled and still has a temperature of at least 150 ℃. This is advantageous not only because the entire process is accelerated, but also because the residual heat of the steel component is utilized during the curing of the fiber-reinforced polymer. The most suitable temperature for the steel component and the tool depends on the type of epoxy resin used.
Typically, at the beginning of the curing process, the steel component is allowed to have a higher temperature than the tool. As mentioned above, this is advantageous in that the entire process is accelerated and the residual heat of the steel component is utilized during the curing of the fibre-reinforced polymer. Thus, the steel component will be allowed to cool slightly during the solidification of the fiber reinforced polymer.
During heating of a patch made of fibre-reinforced polymer, entrapped air between the layers of the patch will be allowed to escape. The patch may have a temperature above 100 ℃ when it is applied to the steel component.
The steel component may be formed of austenitic steel forming a martensitic structure without quenching, and the process comprises the step of cooling the steel component without quenching with the applied patches of carbon fiber reinforced polymer. Thus, the steel has an alloy that allows the formation of a hardened martensitic structure even at low cooling rates. Cooling in the atmosphere is sufficient. This also contributes to the overall process, since the steel part can be air hardened, so that cooling is a less important step. Typically, the steel is air-hardened Ultra High Strength Steel (UHSS).
The main object of the process of the invention is to produce a motor vehicle component consisting of a shaped steel part and applied patches made of carbon fibre-reinforced polymer, which has been produced by the process as described above.
The present invention has been described above with reference to specific aspects thereof. It will be appreciated by a person skilled in the art that the invention may be varied within the scope of the invention, which is limited only by the following claims.
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