A preform is a 3D fibrous structure, which is the precursor to the manufacture of Carbon Fibre Reinforced Plastic (CFRP) components via Resin Transfer Moulding (RTM). BMW leads the automotive industry in the application of CFRP manufacturing in series production, as applied for the BMW i3 and i8 models. The RTM process involves the manufacture of the fibrous preform, which is placed into a closed mould, and infiltrated with an epoxy resin at high temperatures. New methods and devices are required to non-destructively assess the quality of fibre preforms. An existed BMW funded programme at the Centre for Advanced Composite Materials (CACM) is developing non-destructive measurements for preforms based on force and airflow measurements. This project is focused on the design and implementation of new airflow sensor heads that can be used to detect defects in preforms (i.e. folds, wrinkles). New designs will be developed utilising finite element analysis, and then trialled experimentally. A dynamic, spatial pressure measurement system will be used to verify the flow paths of air through preform samples with defects.
Prof. Bickerton worked for the BMW Group from 2012 to 2014, gaining direct experience within the department responsible for the manufacture of structural carbon fibre composite parts. His group maintains strong links to that department, carrying out funded research in several areas.Undergraduate
The end target for this project will be new designs of airflow sensor heads developed to sense the presence of preform defects. These sensor heads will be integrated into an existing apparatus developed and delivered to BMW in 2016. Student participants will gain knowledge on manufacture of automotive composite structures, and in particular preforming and RTM.
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Lab allocations have not been finalised