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One‐Step Process for Press Hardened Steel–Carbon Fiber Reinforced Thermoset Polymer Hybrid Parts

Tom Taylor, David Penney Orcid Logo, Jun Yanagimoto

Steel Research International, Volume: 91, Issue: 10, Start page: 2000085

Swansea University Author: David Penney Orcid Logo

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DOI (Published version): 10.1002/srin.202000085

Abstract

A new one‐step process for manufacturing press hardened steel–carbon fiber reinforced (thermoset) polymer hybrid parts with potential for reduced cycle time, infrastructure requirements, and energy consumption compared with traditional two‐ and three‐step processes is developed. The process combines...

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Published in: Steel Research International
ISSN: 1611-3683 1869-344X
Published: Wiley 2020
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URI: https://cronfa.swan.ac.uk/Record/cronfa54858
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spelling 2020-10-26T16:15:43.5272795 v2 54858 2020-08-03 One‐Step Process for Press Hardened Steel–Carbon Fiber Reinforced Thermoset Polymer Hybrid Parts 869becc35438853f2bca0044df467631 0000-0002-8942-8067 David Penney David Penney true false 2020-08-03 MTLS A new one‐step process for manufacturing press hardened steel–carbon fiber reinforced (thermoset) polymer hybrid parts with potential for reduced cycle time, infrastructure requirements, and energy consumption compared with traditional two‐ and three‐step processes is developed. The process combines and optimizes the press hardening and prepreg compression molding technologies, traditionally used in isolation for manufacturing press hardened steel and carbon fiber reinforced polymer parts, respectively, to produce hybrid parts in a one‐step, fully integrated process. Heat required for curing and bonding prepreg to steel is provided by residual heat of the steel part immediately following hot forming and interrupted die‐quenching of steel. Thermal conductivity of tool material is investigated to achieve the optimal balance between die‐quenching rate for martensite formation in steel and temperature maintenance for complete curing and bonding of prepreg. Addition of epoxy adhesive and thickness ratio between steel and prepreg are also investigated. Benchmarking is conducted against parts manufactured by the traditional two‐step process, in which the press hardened steel part is formed in isolation before joining with the carbon fiber reinforced polymer part. No sacrifice of part quality is found from the new one‐step process with no loss of mechanical performance, despite clear economic and environmental advantages. Journal Article Steel Research International 91 10 2000085 Wiley 1611-3683 1869-344X 10 7 2020 2020-07-10 10.1002/srin.202000085 COLLEGE NANME Materials Science and Engineering COLLEGE CODE MTLS Swansea University 2020-10-26T16:15:43.5272795 2020-08-03T14:40:35.7652464 Faculty of Science and Engineering School of Engineering and Applied Sciences - Materials Science and Engineering Tom Taylor 1 David Penney 0000-0002-8942-8067 2 Jun Yanagimoto 3 54858__17867__e9f5aad6ab3a4da2abc79868644a142a.pdf 54858.pdf 2020-08-05T13:38:57.8773204 Output 762724 application/pdf Accepted Manuscript true 2021-07-10T00:00:00.0000000 false
title One‐Step Process for Press Hardened Steel–Carbon Fiber Reinforced Thermoset Polymer Hybrid Parts
spellingShingle One‐Step Process for Press Hardened Steel–Carbon Fiber Reinforced Thermoset Polymer Hybrid Parts
David Penney
title_short One‐Step Process for Press Hardened Steel–Carbon Fiber Reinforced Thermoset Polymer Hybrid Parts
title_full One‐Step Process for Press Hardened Steel–Carbon Fiber Reinforced Thermoset Polymer Hybrid Parts
title_fullStr One‐Step Process for Press Hardened Steel–Carbon Fiber Reinforced Thermoset Polymer Hybrid Parts
title_full_unstemmed One‐Step Process for Press Hardened Steel–Carbon Fiber Reinforced Thermoset Polymer Hybrid Parts
title_sort One‐Step Process for Press Hardened Steel–Carbon Fiber Reinforced Thermoset Polymer Hybrid Parts
author_id_str_mv 869becc35438853f2bca0044df467631
author_id_fullname_str_mv 869becc35438853f2bca0044df467631_***_David Penney
author David Penney
author2 Tom Taylor
David Penney
Jun Yanagimoto
format Journal article
container_title Steel Research International
container_volume 91
container_issue 10
container_start_page 2000085
publishDate 2020
institution Swansea University
issn 1611-3683
1869-344X
doi_str_mv 10.1002/srin.202000085
publisher Wiley
college_str Faculty of Science and Engineering
hierarchytype
hierarchy_top_id facultyofscienceandengineering
hierarchy_top_title Faculty of Science and Engineering
hierarchy_parent_id facultyofscienceandengineering
hierarchy_parent_title Faculty of Science and Engineering
department_str School of Engineering and Applied Sciences - Materials Science and Engineering{{{_:::_}}}Faculty of Science and Engineering{{{_:::_}}}School of Engineering and Applied Sciences - Materials Science and Engineering
document_store_str 1
active_str 0
description A new one‐step process for manufacturing press hardened steel–carbon fiber reinforced (thermoset) polymer hybrid parts with potential for reduced cycle time, infrastructure requirements, and energy consumption compared with traditional two‐ and three‐step processes is developed. The process combines and optimizes the press hardening and prepreg compression molding technologies, traditionally used in isolation for manufacturing press hardened steel and carbon fiber reinforced polymer parts, respectively, to produce hybrid parts in a one‐step, fully integrated process. Heat required for curing and bonding prepreg to steel is provided by residual heat of the steel part immediately following hot forming and interrupted die‐quenching of steel. Thermal conductivity of tool material is investigated to achieve the optimal balance between die‐quenching rate for martensite formation in steel and temperature maintenance for complete curing and bonding of prepreg. Addition of epoxy adhesive and thickness ratio between steel and prepreg are also investigated. Benchmarking is conducted against parts manufactured by the traditional two‐step process, in which the press hardened steel part is formed in isolation before joining with the carbon fiber reinforced polymer part. No sacrifice of part quality is found from the new one‐step process with no loss of mechanical performance, despite clear economic and environmental advantages.
published_date 2020-07-10T04:08:40Z
_version_ 1763753611825774592
score 11.01628

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