Competitive production processes for multi-material components step 2

Purpose and goal

The main purpose of the project was to raise the TRL level from TRL3 to 5 for a manufacturing methodology for lightweight solutions of multi-material. A process has been developed which seems to enable mass production of carbon fiber-reinforced press hardened parts, which is a cost-effective first step in introducing carbon fiber at a larger scale. This has been demonstrated by an automated process implemented in a manufacturing line at Gestamp. In the future, more work is needed to reduce the price for the composite, which holds the majority of the increased cost.

Expected results and effects

The project contributes to both sustainability and growth, as the components are made lighter with retained mechanical properties and by that increase the competitiveness. The project is a good example of the fact that the ultimate material does not yet exist without future vehicles will probably still contain a mixture of different materials where properties like performance, weight, cost and joining to the surrounding structure will affect the choice of materials. How big impact each property have will probably change over time.

Planned approach and implementation

The project was divided into three work packages, two larger ones which dealt with automated manufacturing of a composite-reinforced press-hardened steel component, and simulations regarding forming and curing. Smaller work packages have contributed with input to the production by, for example, testing surface treatments and process parameters and also developing a material model for the simulations. The third work package, the multi material solution was long-term tested for corrosion and thermal fatigue. Physical and web-based workshops have been continuously held.