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Manufacture of Green-composite automotive dashboard.

R.Hoto1 a,J.P Torres2 b,J.A. Garca-Manrique1c*

1Instituto de Diseo ! "abricaci#n, $ni%ersidad Po&it'cnica de (a&encia, )ain.

2

Instituto de +iencia ! Tecno&oa de Materia&es, $ni%ersidad ac. de Mar de& P&ata, Arentina.Instituto de Diseo ! "abricaci#n, $ni%ersidad Po&it'cnica de (a&encia, )ain

re/o0doctor.u%.es, btorres0i.3d.edu.ar, cuarcia03c3.u%.es

Keywords:4ist t/e 5e!6ords co%ered in !our aer. T/ese 5e!6ords 6i&& a&so be used b! t/eub&is/er to roduce a 5e!6ord inde7.

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Introduction

owadays" there is a growing need for the production and deelopment of materials synthesi/edfrom renewable sources and to decrease the world0s dependence on petroleum. 1n the fiberreinforced polymer composites (3Ps% manufacturing industry" these tendencies hae recently ledto the inestigation of possible substitutes" both for matrix and reinforcement components. 3ecently"

bio-based matrix materials hae receied considerable attention mainly for being nonpetroleum-dependent. These systems can be obtained from sustainable sources such as egetable oil" cellulose"and soy protein" among others. 1n the case of bio-based thermosetting resins" much research is still

pending since mechanical properties comparable with those of petroleum-based counterparts are erydifficult to achiee 56. 7ne of the main drawbacks of using plant oil as a precursor for bio-basedresins is that its chemistry can lead to a low crosslink density network which produces a polymerwith low glass transition temperature (lower than !)%" poor stiffness (lower than 2 8Pa%" and

inferior thermo-physical properties" compared to the traditional petroleum based polymers. 9oweer"this same feature can lead to a superior toughness by proiding additional deformation mechanismsfor energy absorption before failure in impact loading situations 526. Altogether" a compromisesolution can be the combination of both synthetic and bio-based materials 5:" 46 in such a way that asuperior material is obtained from a cost-performance standpoint. ;ith respect to fiberreinforcements" basalt fibers (

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radiation and seawater resistance. inally" reduction of risk of enironmental pollution like high-toxicmetals and oxides can be achieed by replacing 8s with ue. Cechanical behaior of the proposed material system was assessed bymeans of flexural and uniaxial tensile tests together with DC simulations. To perform numericalsimulations of the processing stage" the fiber permeability was measured using an especially designedcharacteri/ation setup. A case study for the fabrication of a 8reen omposites dashboard was carriedout. The fabrication stage was modelled using the PAC-3TC software along with the permeabilityalues determined experimentally. The load-bearing capability of the part was studied by means of

DC stress analysis" and the part configuration were determined in order to satisfy the maximumallowable stress alues established in the mechanical characteri/ation stage.

2. Materials and Methods

2. Overview on Liquid Composite Molding (LCM) Manufacturing Methods.EC is a manufacturing method that consists in the impregnation of a fabric with a low iscosity

resin. 1t is currently considered as one of the most iable and ecofriendly process in themanufacturing of high >uality parts. Fepending on the characteristics of the mold and the applied

pressure gradient" there are a number of different types of EC process among which are 3esinTransfer Colding (3TC%" acuum Assisted 3esin Transfer Colding (A3TC%" 3eactie 1nBectionColding (31C%" and Gtructural 3eactie 1nBection Colding (G31C%. 7ne disadantage in ECmethods is that defects such as oids and dry spots can be induced during the impregnation stage 5$6.

These defects are considered to be the largest source of >uality and reproducibility problems. Theyare often caused by unbalanced resin flows" which are directly related to the fiber permeability andthe impregnation elocity. As a conse>uence" an accurate prediction of resin flow behaior in thefiber impregnation process is of great importance for the optimi/ation of EC parts >uality.urrently" there are a number of computer simulation tools aailable for the modelling of EC

processes" which proide a remarkable adantage oer the (cost and time consuming% trial-and errormethods traditionally used in the industry. 1n order to perform EC modelling" one of the mostcritical input parameters for the mathematical models is the reinforcement permeability. 1n the past2) years" a number of studies 5!=6 hae focused on the deelopment of a reliable and standardi/ed

procedure for the accurate characteri/ation of fiber permeability.

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