A preform is a 3D fibrous structure, which is the precursor to the manufacture of Carbon Fibre Reinforced Plastic (CFRP) components. BMW leads the automotive industry in the application of CFRP manufacturing in series production, as applied for the BMW i3 and i8 models. Preforms are commonly assembled from multiple layers of 2D fibre textiles, formed into the 3D shape of the final part. 3D preforms must be stiff enough for handling, and have their layers bonded together. A “binder” is essentially a small amount of adhesive material applied between the layers of textile that serve these purposes. During the process of preforming 2D layers into a 3D preforming, through hot and cold pressing, the binder material flows between and into the textile layers. Previous studies at the CACM have demonstrated that the speed and mode of resin infusion in a Resin Transfer Moulding (RTM) tool are significantly affected by the parameters used during preforming (i.e. pressing thicknesses and temperatures). Such effects may lead to strong variation in mould filling, and possible scrapping of parts. This project will focus on exploring the physical mechanisms that lead to varied filling behaviour, and the establishment of guidelines for reproducible preforming. Both preforming and mould filling experiments will be carried out, and possible methods explored to take advantage of enhanced resin flow via controlled preforming.
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
Deeper understanding will be generated on the role of binder, and preforming parameters, on the subsequent mould filling stage of RTM. Guidelines will be developed to define the recommended operating parameters for preforming. Student participants will gain knowledge on manufacture of automotive composite structures, with a strong focus on the preforming and mould filling stages of RTM.
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Lab allocations have not been finalised